IP Library › Granted Patent US 12,296,553
Granted Patent B2
US 12,296,553 · App. 18/507,158 · Granted May 13, 2025

Sound damping gypsum board and method of constructing a sound damping gypsum board

Inventors: Joseph J. Bailey (Charlotte, NC); Eli Stav (Charlotte, NC); Richard Weir (Indian Trail, NC); R. G. Iyer (Charlotte, NC)
Assignee: Gold Bond Building Products, LLC
B32B13/12B32B27/308E04B1/86E04C2/288E04C2/526G10K11/168B32B2307/10B32B2419/04
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Quick Facts
Patent No.
US 12,296,553
App. No.
18/507,158
Granted
May 13, 2025
Kind
B2
Abstract

The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board. The gypsum board comprises a gypsum core including gypsum and a sound damping polymer. The gypsum core includes a first gypsum layer surface and a second gypsum layer surface opposing the first gypsum layer surface. In addition, a first encasing layer is disposed on the first gypsum layer surface and a second encasing layer is disposed on the second gypsum layer surface.

Claims (26)

1. A gypsum board comprising:

a gypsum core including a first gypsum layer surface and a second gypsum layer surface opposing the first gypsum layer surface, the gypsum core including a first gypsum layer comprising gypsum and a sound damping polymer and a second gypsum layer comprising gypsum,

a first encasing layer disposed on the first gypsum layer surface wherein the first gypsum layer is between the first encasing layer and the second gypsum layer, and

a second encasing layer disposed on the second gypsum layer surface.

2. The gypsum board of claim 1 , wherein the sound damping polymer comprises a viscoelastic polymer.

3. The gypsum board of claim 1 , wherein the sound damping polymer comprises an acrylic polymer or copolymer.

4. The gypsum board of claim 1 , wherein the first gypsum layer further comprises a plasticizer, a starch, or a mixture thereof.

5. The gypsum board of claim 1 , wherein the second gypsum layer further comprises a plasticizer, a starch, or a mixture thereof.

6. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.001 wt. % to 10 wt. % based on the weight of gypsum.

7. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.001 wt. % to 2.5 wt. % based on the weight of gypsum.

8. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.1 wt. % to 1.5 wt. % based on the weight of gypsum.

9. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.001 lbs/MSF to 150 lbs/MSF.

10. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.1 lbs/MSF to 15 lbs/MSF.

11. The gypsum board of claim 1 , wherein the second gypsum layer further comprises the sound damping polymer.

12. The gypsum board of claim 1 , wherein the gypsum board is a composite board having a second gypsum board comprising a second gypsum core adjacent the first encasing layer.

13. The gypsum board of claim 1 , wherein the gypsum board exhibits a sound transmission loss of 20% or more in comparison to a board without a sound damping polymer.

14. The gypsum board of claim 1 , wherein the gypsum board exhibits a decay time of 1 second or less.

15. The gypsum board of claim 1 , wherein the gypsum board exhibits a decay time of 0.8 seconds or less.

16. A method of forming the gypsum board of claim 1 , the method comprising:

providing a first encasing layer,

depositing a first gypsum slurry comprising stucco, water, and the sound damping polymer on the first encasing layer for forming the first gypsum layer,

depositing a second gypsum slurry comprising stucco and water on the first gypsum slurry for forming the second gypsum layer,

providing a second encasing layer on the second gypsum slurry, and

allowing the stucco to convert to calcium sulfate dihydrate.

17. The method of claim 16 , wherein the first gypsum slurry further comprises a plasticizer, a starch, or a mixture thereof.

18. The method of claim 16 , wherein the second gypsum slurry further comprises a plasticizer, a starch, or a mixture thereof.

Assignments (5)
SECURITY INTEREST Recorded Nov 3, 2025
From: GOLD BOND BUILDING PRODUCTS, LLC
To: BANK OF AMERICA, N.A., AS COLLATERAL AGENT
Reel/Frame 073476/0358 →
SECURITY INTEREST Recorded Sep 4, 2025
From: GOLD BOND BUILDING PRODUCTS, LLC
To: BANK OF AMERICA, N.A., AS COLLATERAL AGENT
Reel/Frame 072813/0095 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 13, 2023
From: BAILEY, JOSEPH J.; STAV, ELI; WEIR, RICHARD; IYER, R. G.
To: NATIONAL GYPSUM PROPERTIES, LLC
Reel/Frame 065537/0514 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 13, 2023
From: PROFORM FINISHING PRODUCTS, LLC
To: GOLD BOND BUILDING PRODUCTS, LLC
Reel/Frame 065537/0533 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 13, 2023
From: NATIONAL GYPSUM PROPERTIES, LLC
To: PROFORM FINISHING PRODUCTS, LLC
Reel/Frame 065549/0041 →
Continuity (4)
Continuation 18157152 · Jan 20, 2023
Continuation 16705288 · Dec 6, 2019
Provisional Application 62776058 · Dec 6, 2018
Related Publication 20240075708A1 · Mar 7, 2024
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