US2008086957A1PendingUtilityA1

Noise-attenuating laminate composite wallboard panel and methods for manufacturing same

39
Individually held — no corporate assignee on recordPriority: Oct 4, 2006Filed: Oct 4, 2007Published: Apr 17, 2008
Est. expiryOct 4, 2026(~0.2 yrs left)· nominal 20-yr term from priority
Inventors:Ronald Averill
B32B 29/06B32B 13/08E04B 1/86E04B 2001/8461
39
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Claims

Abstract

A laminate composite wallboard panel is disclosed having multiple layers whose cross sections may contain internal and external non-uniformities and whose surfaces may be rough and non-uniform. The wallboard panel is similar in size and weight to a standard gypsum panel and can be handled and installed in a manner similar to such a panel. The wallboard panel also provides high degrees of noise attenuation, thermal insulation, fire resistance, shear strength, mold resistance and moisture resistance.

Claims

exact text as granted — not AI-modified
1 . A laminar, sound-absorbing structure for constructing walls and ceilings, comprising: 
 a plurality of layers wherein one or more of the layers has internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.    
   
   
       2 . The laminar structure of  claim 1  wherein said plurality of layers consists of five layers, comprising: 
 a first layer made of a selected material;    which is contact with a second layer made of a viscoelastic adhesive;    which is in contact with a third layer made of a selected material;    which is contact with a fourth layer made of a viscoelastic adhesive; and    which is in contact with a fifth layer made of a selected material.    
   
   
       3 . The laminar structure of  claim 2  wherein the first layer comprises a gypsum panel.  
   
   
       4 . The laminar structure of  claim 2  wherein the third layer comprises a sheet of absorbent paper.  
   
   
       5 . The laminar structure of  claim 2  wherein the fifth layer comprises an MgO panel.  
   
   
       6 . The laminar structure of  claim 3  wherein the third layer comprises a sheet of absorbent paper.  
   
   
       7 . The laminar structure of  claim 6  wherein the fifth layer comprises an MgO panel.  
   
   
       8 . The laminar structure of  claim 6  wherein the fifth layer comprises a gypsum panel.  
   
   
       9 . The laminar structure of  claim 5  wherein the third layer comprises a sheet of absorbent paper.  
   
   
       10 . The laminar structure of  claim 9  wherein the first layer comprises an MgO panel.  
   
   
       11 . The laminar structure of  claim 3  wherein the fifth layer comprises a gypsum panel.  
   
   
       12 . The laminar structure of  claim 3  wherein the fifth layer comprises an MgO panel.  
   
   
       13 . The laminar structure of  claim 5  wherein the first layer comprises an MgO panel.  
   
   
       14 . The laminar structure of  claim 1  wherein said plurality of layers consists of three layers, comprising: 
 a first layer made of a selected material;    which is contact with a second layer made of a viscoelastic adhesive; and    which is in contact with a third layer made of a selected material.    
   
   
       15 . The laminar structure of  claim 14  wherein the first layer comprises a gypsum panel.  
   
   
       16 . The laminar structure of  claim 14  wherein the first layer comprises an MgO panel.  
   
   
       17 . The laminar structure of  claim 15  wherein the third layer comprises a gypsum panel.  
   
   
       18 . The laminar structure of  claim 15  wherein the third layer comprises an MgO panel.  
   
   
       19 . The laminar structure of  claim 16  wherein the third layer comprises an MgO panel.  
   
   
       20 . The laminar structure in either of claims  1  and  14  comprising three or more layers where: 
 at least one layer has internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform; and    at least one layer is made of a viscoelastic adhesive.    
   
   
       21 . The laminar structure in any of claims  1 ,  14 , and  20  wherein the first layer is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       22 . The laminar structure in any of claims  1 ,  14 , and  20  wherein the third layer is selected from a group consisting of paper, gypsum panels, MgO panels, metal, wood, ceramic, and polymers wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       23 . The laminar structure in either of claims  1  and  2  comprising five or more layers where: 
 at least one layer has internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform; and    at least one layer is made of a viscoelastic adhesive.    
   
   
       24 . The laminar structure in any of claims  1 ,  2 , and  23  wherein the first layer is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       25 . The laminar structure in any of claims  1 ,  2 , and  23  wherein the third layer is selected from a group consisting of paper, gypsum panels, MgO panels, metal, wood, ceramic, and polymers wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       26 . The laminar structure in any of claims  1 ,  2 , and  23  wherein the fifth layer is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       27 . The laminar structure of  claim 1  comprising seven or more layers where: 
 at least one layer has internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform; and    at least one layer is made of a viscoelastic adhesive.    
   
   
       28 . The laminar structure in either of claims  1  and  27  wherein the first layer is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       29 . The laminar structure in either of claims  1  and  27  wherein the third layer is selected from a group consisting of paper, gypsum panels, MgO panels, metal, wood, ceramic, and polymers wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       30 . The laminar structure in either of claims  1  and  27  wherein the fifth layer is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       31 . The laminar structure in either of claims  1  and  27  wherein the seventh layer is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       32 . The method of forming a laminar, sound-absorbing structure for constructing walls and ceilings which comprises: 
 providing a layer of first material having two surfaces;    placing a layer of viscoelastic adhesive onto one surface of said layer of first material;    placing a layer of second material onto said layer of viscoelastic adhesive;    applying selected amounts of pressure on selected portions of the layer of second material for selected amounts of time; and    heating/cooling said layers of laminar structure at selected temperatures for selected amounts of time.    
   
   
       33 . The laminar structure of  claim 32  wherein the layer of first material is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       34 . The laminar structure of  claim 32  wherein the layer of third material is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       35 . The method of forming a laminar, sound-absorbing structure for constructing walls and ceilings which comprises: 
 providing a layer of first material having two surfaces;    placing a layer of viscoelastic adhesive onto one surface of said layer of first material;    placing a layer of second material onto said layer of viscoelastic adhesive;    placing a layer of viscoelastic adhesive onto the exposed surface of said layer of second material;    placing a layer of third material onto said layer of viscoelastic adhesive affixed to said layer of second material;    applying selected amounts of pressure on selected portions of the layer of third material for selected amounts of time; and    heating/cooling said layers of laminar structure at selected temperatures for selected amounts of time.    
   
   
       36 . The laminar structure of  claim 35  wherein the layer of first material is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       37 . The laminar structure of  claim 35  wherein the layer of second material is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.  
   
   
       38 . The laminar structure of  claim 35  wherein the layer of third material is selected from a group consisting of gypsum panels, MgO panels, wood, plywood, metal, fiber glass, polymers, fire retardant panels, and high-density mat materials wherein said materials may be cellular or foamed and have may have internal and/or external non-uniformities and/or surfaces that are rough and/or non-uniform.

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