Acoustical sound proofing material for architectural retrofit applications and methods for manufacturing same
A laminated structure for use in retrofit building construction (partition, wall, ceiling, floor or door) that exhibits improved acoustical sound proofing characteristics while being optimized for efficient installation. The laminated structure includes a panel with at least one layer of viscoelastic glue, or fire-resistant, viscoelastic glue, which functions both as a glue and an energy dissipating layer. In one embodiment, the laminated structure to be attached to an existing wall in some embodiments includes standard paper-faced gypsum board. In another embodiment the to-be-applied laminated structure includes a cement-based board, and in yet another embodiment the to-be-applied laminated structure includes a cellulose-based board. Once the laminated structure is installed on an existing wall or other partition, the resulting structure greatly attenuates transmitted noise and minimizes the labor required for installation and finishing.
1. A laminated, sound-attenuating structure having a plurality of edges comprising:
a layer of gypsum board having first and second surfaces; and
a layer of viscoelastic glue over the first surface covering an area less than an area of the layer of gypsum board, the viscoelastic glue containing about 60% of acrylate polymer by weight, and
a release layer of a first selected material in direct contact with the layer of viscoelastic glue, wherein said laminated, sound-attenuating structure has a sound attenuation value of about 49.
2. The laminated, sound-attenuating structure according to claim 1 , further comprising a first layer of selected material interposed between the first surface and the layer of viscoelastic glue.
3. The laminated, sound-attenuating structure according to claim 2 , wherein the layer of selected material interposed between the first surface and the layer of viscoelastic glue is selected from the group consisting of paper and fiberglass.
4. The laminated, sound-attenuating structure according to claim 1 , further comprising a second layer of a second selected material interposed between the first surface and the layer of viscoelastic glue.
5. The laminated, sound-attenuating structure according to claim 4 , wherein the second layer of the second selected material is selected from the group consisting of paper and fiberglass.
6. The laminated, sound-attenuating structure according to claim 1 , wherein the layer of viscoelastic glue comprises a layer of fire-resistant, viscoelastic glue.
7. The laminated, sound-attenuating structure according to claim 6 further comprising a first layer of selected material interposed between the first surface and the layer of fire-resistant, viscoelastic glue.
8. The laminated, sound-attenuating structure according to claim 7 , wherein the first layer of selected material is selected from the group consisting of paper and fiberglass.
9. The laminated, sound-attenuating structure according to claim 6 , further comprising a first layer of film of a first selected material over the layer of fire-resistant, viscoelastic glue.
10. The laminated, sound-attenuating structure of claim 9 , further comprising a second layer of a second selected material interposed between the first surface and the layer of fire-resistant, viscoelastic glue.
11. The laminated, sound-attenuating structure according to claim 10 , wherein the second layer of the second selected material is selected from the group consisting of paper and fiberglass.
12. The laminated, sound-attenuating structure according to claim 1 , wherein the release layer of a first selected material comprises a layer of film selected from the group consisting of silicone-coated paper, polycoated liner, plastic film and dry-coated paper.
13. The laminated, sound-attenuating structure according to claim 9 , wherein the first layer of film of a first selected material comprises a layer of film selected from the group consisting of silicone-coated paper, polycoated liner, plastic film and dry-coated paper.
14. A laminated, sound-attenuating structure having a plurality of edges which comprises:
a layer of cement-based board having first and second surfaces; and
a layer of viscoelastic glue over the first surface covering an area less than an area of the layer of cement-based board, the viscoelastic glue containing about 60% of acrylate polymer by weight, and
a release layer of a first selected material in direct contact with the layer of viscoelastic glue, wherein said laminated, sound-attenuating structure has a sound attenuation value that is greater than about 34.
15. The laminated, sound-attenuating structure according to claim 14 , wherein the layer of cement-based board is selected from the group consisting of calcium silicate board, magnesium oxide-based board and phosphate-based board.
16. The laminated, sound-attenuating structure according to claim 14 , wherein the release layer of a selected material is selected from the group consisting of silicone-coated paper, polycoated liner, plastic film and dry-coated paper.
17. The laminated, sound-attenuating structure according to claim 15 , wherein the release layer of a selected material is selected from the group consisting of silicone-coated paper, polycoated liner, plastic film and dry-coated paper.
18. The laminated, sound-attenuating structure of claim 14 , wherein the layer of viscoelastic glue comprises a layer of fire-resistant, viscoelastic glue.
19. The laminated, sound-attenuating structure according to claim 18 , wherein the layer of cement-based board is selected from the group consisting of calcium silicate board, magnesium oxide-based board and phosphate-based board.
20. The laminated, sound-attenuating structure according to claim 18 , wherein the layer of cement-based board is selected from the group consisting of calcium silicate board, magnesium oxide-based board and phosphate-based board.
21. The laminated, sound-attenuating structure according to claim 18 , wherein the release layer of a selected material is selected from the group consisting of silicone-coated paper, polycoated liner, plastic film and dry-coated paper.
22. A laminated, sound-attenuating structure having a plurality of edges which comprises:
a layer of cellulose-based board having first and second surfaces;
a layer of viscoelastic glue over the first surface covering an area less than an area of the layer of cellulose-based board, the viscoelastic glue containing about 60% acrylate polymer by weight; and
a release layer of a first selected material in direct contact with the layer of viscoelastic glue, wherein said laminated, sound-attenuating structure has a sound attenuation value that is greater than about 34.
23. The laminated, sound-attenuating structure according to claim 22 , wherein the layer of cellulose-based board is selected from the group consisting of plywood, medium density fiberboard, oriented strand board and particle board.
24. The laminated, sound-attenuating structure according to claim 22 , wherein the release layer of a selected material is selected from the group consisting of silicone-coated paper, polycoated liner, plastic film and dry-coated paper.
25. The laminated, sound-attenuating structure according to claim 22 , wherein the layer of cellulose-based board is selected from the group consisting of plywood, medium density fiberboard, oriented strand board and particle board; and wherein the layer of film of a selected material is selected from the group consisting of silicone-coated paper, polycoated liner, plastic film and dry-coated paper.
26. The laminated, sound-attenuating structure of claim 22 , wherein the layer of viscoelastic glue comprises a layer of fire-resistant, viscoelastic glue.
27. The laminated, sound-attenuating structure according to claim 26 , wherein the layer of cellulose-based board is selected from the group consisting of plywood, medium density fiberboard, oriented strand board and particle board.
28. The laminated, sound-attenuating structure according to claim 26 , wherein the release layer of a selected material is selected from the group consisting of silicone-coated paper, polycoated liner, polyethylene film and dry-coated paper.
29. A laminated, sound-attenuating structure having a plurality of edges comprising:
a layer of gypsum board having first and second surfaces;
a layer of viscoelastic glue over the first surface having a thickness of 1/32 of an inch and covering an area less than an area of the layer of gypsum board, the viscoelastic glue containing about 60% acrylate polymer by weight, and
a release layer of a first selected material in direct contact with the layer of viscoelastic glue, wherein said laminated, sound-attenuating structure has a sound attenuation value of about 49.
30. The laminated, sound-attenuating structure according to claim 29 , said area of said layer of viscoelastic glue having patterns spaced from one another; and
said spacing between said patterns having a maximum distance of half wavelength of sound frequency of interest for sound attenuation.
31. The laminated, sound-attenuating structure according to claim 30 wherein said patterns are used to improve edge coverage, regardless of the location of the cutting line for the structure.
32. The laminated, sound-attenuating structure according to claim 6 , wherein said layer of fire-resistant viscoelastic glue contains intumescent compounds employing mixtures selected from the group consisting of inorganic foaming mixtures, expandable graphite mixtures, and a combination of inorganic foaming mixtures with expandable graphite mixtures.
33. The laminated, sound-attenuating structure according to claim 18 , wherein said layer of fire-resistant viscoelastic glue contains intumescent compounds employing mixtures selected from the group consisting of inorganic foaming mixtures, expandable graphite mixtures, and a combination of inorganic foaming mixtures with expandable graphite mixtures.
34. The laminated, sound-attenuating structure according to claim 26 , wherein said layer of fire-resistant, viscoelastic glue contains intumescent compounds employing mixtures selected from the group consisting of inorganic foaming mixtures, expandable graphite mixtures, and a combination of inorganic foaming mixtures with expandable graphite mixtures.
35. The laminated, sound-attenuating structure of claim 1 , wherein the release layer of a first selected material is a continuous layer of material.