Sound damping gypsum board and method of constructing a sound damping gypsum board
The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board, and a method of making such gypsum board. For instance, the method comprises: providing a first encasing layer and a first sound damping layer on the first encasing layer wherein the sound damping layer includes at least 50 wt. % of a first sound damping polymer; depositing a gypsum slurry comprising stucco and water on the sound damping layer to form a gypsum core; providing a second encasing layer on the gypsum slurry; and allowing the stucco to convert to calcium sulfate dihydrate.
1. A method of forming a gypsum board, the method comprising:
providing a first encasing layer and a first sound damping layer on the first encasing layer wherein the sound damping layer includes at least 50 wt. % of a first sound damping polymer,
depositing a gypsum slurry comprising stucco and water on the sound damping layer to form a gypsum core,
providing a second encasing layer on the gypsum slurry, and
allowing the stucco to convert to calcium sulfate dihydrate.
2. The method of claim 1 , further comprising providing a second sound damping layer between the gypsum slurry and the second encasing layer.
3. The method of claim 1 , wherein the gypsum core includes a first gypsum layer and a second gypsum layer, the first gypsum layer having a density greater than the second gypsum layer.
4. The method of claim 1 , wherein the first sound damping polymer comprises a viscoelastic polymer.
5. The method of claim 1 , wherein the first sound damping layer includes rubber, cork, or a mixture thereof.
6. The method of claim 1 , wherein the first sound damping layer includes a cellulosic material, glycerin, or a mixture thereof.
7. The method of claim 1 , wherein the sound damping layer includes an additive also included in the gypsum slurry.
8. The method of claim 1 , wherein the first sound damping polymer comprises an acrylic polymer or copolymer.
9. The method of claim 1 , wherein the sound damping layer includes at least 90 wt. % of the first sound damping polymer.
10. The method of claim 1 , wherein the gypsum core further comprises a starch.
11. The method of claim 1 , wherein the first sound damping polymer is present in an amount of from 0.001 lbs/MSF to 150 lbs/MSF based on the weight of the gypsum board.
12. The method of claim 1 , wherein the gypsum slurry further includes a second sound damping polymer.
13. The method of claim 1 , wherein the sound damping layer is directly between the first encasing layer and the gypsum slurry.
14. The method of claim 1 , wherein the sound damping layer comprises gypsum.
15. The method of claim 1 , wherein the sound damping layer comprises a pigment.
16. The method of claim 1 , wherein the sound damping layer comprises calcium carbonate.
17. The method of claim 1 , wherein the sound damping layer comprises magnesium carbonate.
18. The method of claim 1 , wherein the sound damping layer comprises an inorganic particle.
19. The method of claim 1 , wherein the gypsum board exhibits a sound transmission loss of 20% or more in comparison to a board without the sound damping layer.
20. The method of claim 1 , wherein the first sound damping polymer is provided in a formulation having a viscosity of from 500 cps to 15000 cps.