CN102046895B - Sound attenutation building material and system - Google Patents
Sound attenutation building material and system Download PDFInfo
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- CN102046895B CN102046895B CN2008801293055A CN200880129305A CN102046895B CN 102046895 B CN102046895 B CN 102046895B CN 2008801293055 A CN2008801293055 A CN 2008801293055A CN 200880129305 A CN200880129305 A CN 200880129305A CN 102046895 B CN102046895 B CN 102046895B
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Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
- E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
- E04B2/7409—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts special measures for sound or thermal insulation, including fire protection
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8414—Sound-absorbing elements with non-planar face, e.g. curved, egg-crate shaped
- E04B2001/8419—Acoustical cones or the like, e.g. for anechoic chambers
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8461—Solid slabs or blocks layered
Abstract
A building material configured to enhance sound attenuation and reduction in dB across a walled partition, the building material comprising a facing membrane, a core matrix disposed about the facing membrane, the core matrix comprising a plurality of microparticles and a binder solution configured to support the microparticles, the building material comprising at least a substantially exposed face, wherein a side of the core matrix is at least partially exposed to increase sound attenuation by reducing reflections from sound waves impinging on the building material as compared to a control building material lacking an exposed face. Two building materials may be used in conjunction with one another about a building structure, such as a stud wall, to create and define a sound trap that functions to reduce sound transmission across the partition formed by the stud wall and building materials.
Description
Related application
The application requires the U.S. Patent application No.12/077 in submission on March 21st, 2008; 951 rights and interests; This U.S. Patent application requires the U.S. Provisional Patent Application No.60/919 that submits on March 21st, 2007, and 509, the U.S. Provisional Patent Application No.60/961 that submits on July 17th, 2007,130 and the U.S. Provisional Patent Application No.61/002 that submits on November 7th, 2007; 367 rights and interests, said application is all incorporated this paper into as a reference.The application also requires the U.S. Provisional Patent Application No.61/081 that submits on July 18th, 2008, and 949 and the U.S. Provisional Patent Application No.61/081 that submits on July 18th, 2008,953 rights and interests.
Technical field
The present invention relates to constructional materials, and relate more specifically to comprise the wallboard and other constructional materials of acoustic attenuation characteristic.
Background technology
Multiple constructional materials has been considered acoustic attenuation or absorption characteristic when design, because hope to minimize or reduce at least the transaudient amount through separator usually.About building structure, think that the constructional materials such as wallboard, interlayer and lacquer is to help to reduce transaudient material.
Wallboard is a kind of Applied Materials or constructional materials of routine, and it has many different types, design and size.Wallboard can be constructed with many different characteristic or characteristics, for example different sound absorptions, heat transfer and/or fire performance.Up to now, the wallboard of common type is dry wall plate or gypsum plank.The dry wall plate comprises the gypsum inner core, and this gypsum inner core is the calcium sulfate (CaSO of half water form
4 1/
2H
2O), be arranged between two facing barrier films that are generally paper or fiberglass packing.The dry wall plate can comprise that various additives and filler are to change its characteristic.
The thickness of the dry wall plate that the most generally uses is 1/2nd inches, but thickness range can be from 1/4th inches (6.35mm) to one inch (25mm).For sound insulation or fire prevention, sometimes two-layer dry wall plate is mutually squarely and arranges.The dry wall plate is that 3/8ths inches plates provide 0.32 thermal resistance or R value, is that half inch plate provides 0.45 R value, is that 5/8ths inches plates provide 0.56 R value, and 0.83 R value is provided for inch board.Except that the R value increased, thicker dry wall plate had high slightly transaudient grade (STC) rank.
STC is the part of ASTM IC E413 and E90, is a kind of widely used standard of constructional materials to the attenuation degree of airborne sound that be used to identify.The STC number is derived by the acoustic attenuation value that under 16 standard frequencies from 125Hz to 4000Hz, records.Then these transmission loss values are plotted on the sound pressure level figure and with a result curve and a standard basis outline line and contrast.Acoustic engineers fits to a suitable TL (or transmitting loss) curve to confirm the STC rank with these values.Can think that STC is that the available noise decibel of wallboard or other separator descends.DB is with the logarithm system, but wherein reduces when roughly the reduce by half sound of Shi Rener perception 10dB of volume.Therefore, any dB (magnitude) to reduce all be clearly.Reduce to depend on transaudient frequency for identical materials with dB (magnitude).The STC rank is high more, and dividing plate is just effective more aspect the transmission that reduces modal audio frequency.
Common interior wall has the relative multi-disc dry wall plate that is installed on column frame or the stud wall/dagger wall in house or the building.In this arrangement, be that the STC of interior wall is about 33 under 1/2 inch the situation at dry wall plate plate thickness.Adding the glass fiber interlayer has certain help, but STC is increased to 36-39 according to the type of interlayer and quality and column and double-screw bolt spacing.Because wallboard is made up of several plates or panel usually, so any other seam or gap in crack between the panel or gap or the wall construction are called " side path ", they more freely transmit permission sound, therefore cause lower overall STC rank.Therefore, key is to eliminate or reduces all potential side paths as much as possible.
Similarly, outdoor-indoor transmission grade (OITC) is widely used transaudient other standard of level that is used to show between the exterior space and the interior space.The OITC test is considered to be low to moderate the frequency of 80Hz and more to lay particular emphasis on lower frequency usually.
Summary of the invention
Therefore, the present invention is provided for acoustic attenuation constructional materials, the system and method for attenuate sound.On the one hand, for example, a kind of acoustic attenuation constructional materials is provided.This constructional materials can comprise the core matrix (core matrix) that is arranged on the finish material; Wherein this core matrix comprises a large amount of particulates and the adhesive that is configured to support particulates; Thereby and the face that exposes at least basically of a side of its SMIS matrix exposure formation constructional materials, to increase acoustic attenuation through compare the reflection that reduces the sound wave of impact on constructional materials with the contrast that lacks exposure (control) constructional materials.This constructional materials also can comprise the acoustic window material on the exposure that is arranged on constructional materials.This acoustic window material can comprise screen cloth or Web materials.In addition, in some aspects, constructional materials also can comprise the rigid material related with the core matrix phase.A particular aspects, this rigid material is arranged in the core matrix.
Imagine in the core matrix of the present invention and comprise various particulate.On the one hand, microballon is a hollow.On the other hand, microballon is filled with inert gas.Again on the other hand, littlely very process by flying dust.
The exposure of constructional materials can comprise various configurations, from opposite planar shape configuration to obvious non-planar shaped configuration.For example, on the one hand, the mask that exposes basically has a plurality of protuberances that extend from core matrix.This protuberance can change according to the desired characteristic of constructional materials, and still, on the one hand, said protuberance separates with predetermined pattern.
The present invention also provides a kind of system that is used to use the constructional materials attenuate sound.This system can comprise first constructional materials, second constructional materials; Second constructional materials is arranged on and makes win constructional materials and second constructional materials separate certain distance forming the sound trap space in the orientation that is arranged essentially parallel to first constructional materials, and wherein first constructional materials comprises the core matrix that is arranged on the finish material.Core matrix can comprise a large amount of particulates; And the adhesive that is configured to support particulates; Wherein thereby the first constructional materials core matrix exposes the face that exposes at least basically that forms first constructional materials towards a side of second constructional materials, to increase acoustic attenuation through compare the reflection that reduces the sound wave of impact on first constructional materials with the contrast constructional materials that lacks exposure.One more particularly aspect, building structure can be positioned at the sound trap space.Another more particularly aspect, first constructional materials is supported on around first side of building structure/near and second constructional materials is supported on around second side of building structure.Again another more particularly aspect, first constructional materials, second constructional materials and building structure form partition wall.In some aspects, can in the sound trap between first constructional materials and second constructional materials, interlayer/isolated material be set.
The many configurations that are used for second constructional materials have been imagined.For example, on the one hand, second constructional materials comprises the core matrix that is arranged on the finish material, and its SMIS matrix comprises a large amount of microballons and the adhesive that is configured to support microballon.One special aspect; The second constructional materials core matrix exposes and forms the face that exposes at least basically of second constructional materials towards a side of first constructional materials, to reduce the reflection of impacting the sound wave on second constructional materials and increase acoustic attenuation through comparing with the contrast constructional materials that lacks exposure.Alternatively, the second constructional materials core matrix can be covered towards a side of first constructional materials basically.
The present invention also provides a kind of method of using the constructional materials attenuate sound.This method can comprise in the sound trap described in introducing sound wave as indicated, thereby sound wave is attenuated through at least one of passing at least in part in the first constructional materials core matrix and the second constructional materials core matrix.Another aspect, the two is attenuated sound wave through passing the first constructional materials core matrix and the second constructional materials core matrix at least in part.Again on the other hand, sound wave reduces owing to the reflection of comparing the sound wave of impact on the exposure of first constructional materials with the contrast constructional materials that lacks exposure and is attenuated at least in part.
Description of drawings
The present invention will become obvious fully from description and the accompanying claims below in conjunction with accompanying drawing.Should be understood that these accompanying drawings only illustrate exemplary embodiment of the present invention, therefore should not think that they have limited scope of the present invention.Can easily be understood that, can be arranged and designed into various structure with the member of the present invention that illustrates like big volume description in the accompanying drawings.But, will through use accompanying drawing concrete more with describe and explain the present invention in detail, in the accompanying drawings:
Fig. 1 illustrates the detailed perspective view according to the constructional materials of one exemplary embodiment of the present invention;
Fig. 2 illustrates the detailed perspective view according to the constructional materials of another exemplary embodiment of the present invention;
Fig. 3 illustrates the local side cross-sectional view of form for the exemplary acoustic attenuation system of the partition wall that forms according to exemplary embodiment, and its mid-board is formed by relative exemplary constructional materials, and its mid-board formation and limit a sound trap;
Fig. 4 illustrates the local side cross-sectional view of form for the exemplary acoustic attenuation system of the partition wall that forms according to another exemplary embodiment, and its mid-board is formed by relative exemplary constructional materials, and its mid-board formation and limit a sound trap;
Fig. 5 illustrates the local side cross-sectional view of form for the exemplary acoustic attenuation system of the partition wall that forms according to another exemplary embodiment, and its mid-board is formed by relative exemplary constructional materials, and its mid-board formation and limit a sound trap;
Fig. 6 illustrates the detailed perspective view according to the wallboard building material of one exemplary embodiment of the present invention, and wherein constructional materials comprises core matrix based on particulate, is formed on many projections (multi-elevational) surface configuration in the surface of core matrix and is arranged in the facing plate on the apparent surface of core matrix;
Fig. 7-A illustrates the detailed perspective view according to the wallboard building material of another exemplary embodiment of the present invention, and wherein constructional materials comprises core matrix based on particulate, arranges or be interposed in the intramatrical lath of core (lath), is formed on the many protrusion surfaces configuration in the surface of core matrix and is arranged in the facing plate on the apparent surface of core matrix;
Fig. 7-B illustrates the detail drawing of the constructional materials of Fig. 7-A;
Fig. 8 illustrates according to the vertical view of the constructional materials of an exemplary embodiment more of the present invention, and wherein constructional materials comprises pillow (patterned pillow-like) many protrusion surfaces configuration of the formation pattern in the exposed surface that is formed on core matrix;
Fig. 9 illustrates the cross sectional side view of the constructional materials of Fig. 8;
Figure 10 illustrates the section end view of the constructional materials of Fig. 8;
Figure 11 illustrates the detailed side view of the constructional materials of Fig. 6;
Figure 12 illustrate according to another exemplary embodiment, have a detailed side view of the constructional materials of many protrusion surfaces configuration;
Figure 13 illustrate according to another exemplary embodiment, have a detailed side view of the constructional materials of many protrusion surfaces configuration;
Figure 14 illustrates the cross sectional side view according to the constructional materials of another exemplary embodiment, and wherein constructional materials comprises cavity or the cavity that strategically forms and locate in a large number; And
Figure 15 illustrates the constructional materials that is structured as the ornament materials on the structural outer.
The specific embodiment
Below to detailed description of illustrative embodiments of the present invention with reference to accompanying drawing, but accompanying drawing forms the part of said explanation and the exemplary embodiment of embodiment of the present invention is shown through diagram.Though enough described these exemplary embodiments in detail to enable those skilled in the art to embodiment of the present invention; But should be understood that, also can realize other embodiment and can under the prerequisite that does not deviate from the spirit and scope of the present invention, make various changes the present invention.Therefore; Below be not the of the present invention scope of intention restriction to the more detailed description of embodiments of the invention according to claim; And just unrestricted purpose proposes from explanation, thereby describes characteristic of the present invention and characteristics, illustrates optimal operation mode of the present invention and be enough to enable those skilled in the art to embodiment of the present invention.Therefore, scope of the present invention only is defined by the following claims.
In manual of the present invention and claim, according to use corresponding term to give a definition.
" one " and " being somebody's turn to do/said " that mentions singulative comprises plural, is not like this only if in context, spell out.Therefore, for example mention " wallboard " and comprise one or more these type of wallboards, comprise one or more this type of adhesives and mention " this adhesive ".
In order to explain and explain the claim of being illustrated; Be to be understood that to being combined with the various dissimilar product or the material of particulate (for example microballon) matrix that at this used term " constructional materials " said particulate utilizes one or more compositions to adhere to---such as certain type of adhesive---or be bonded together.This constructional materials can comprise other additive, composition or component, for example hardener, blowing agent or surfactant, water soluble (CO) polymers and other.This constructional materials can comprise many different types, embodiment etc., and can be used in many different application.
As used at this, term " particulate " is interpreted as any natural formation, manufacturing or synthetic particle, and this particle has external surface, has the inside of hollow in some cases.Usually, comprise having the spherical of hollow or spherical basically geometry, be called little different at this particulate of mentioning.The particulate of other type can comprise the particulate that those are processed by timber, ground rubber, the plastics that grind, sawdust etc.
As used at this, term " core matrix " is interpreted as particulate and in order to the combination of other composition of the support matrix that forms constructional materials.Particulate can with combinations such as one or more adhesives, additive, hardener.
Term " many projections " is to be understood that at least one surface for the core matrix that is used to describe constructional materials, is formed with a series of peak and paddy (or protuberance and depression) in wherein should the surface so that the configuration of the integral surface with the different surfaces that is positioned at differing heights and/or direction to be provided.The surface configuration of many projections can form or form pattern arbitrarily.In addition, many protrusion surfaces can be limited with recessed composition the outstanding of any or geometrical figuration.
As used at this, term " basically " is meant action, characteristic, characteristic, state, structure, article or result's completion or the approaching degree of accomplishing.For example, the object of " basically " sealing is meant that object is by complete closed or near complete closed.But in some situations, depend on specific context with the accurate tolerance level of the deflection of absolute completion.But, generally speaking, completion near having and definitely and fully accomplishing identical total result.When being used to the implication of negating, the use of " basically " is used for representing fully or approaching action, characteristic, characteristic, state, structure, article or the result of lacking fully equally.For example, the composition of " not having basically " particle will lack particle fully, or near lacking particle so that effect fully and to lack particle fully identical.In other words, the composition of " not having basically " component or element in fact still can contain this article, only otherwise exist its measurable effect to get final product.
As used at this, term " about " be used for through make a set-point can " a little more than " or " a little less than " end points of number range makes this end points have flexibility.
As used, can in a common list, list a large amount of clauses and subclauses/products, structural member, element and/or material for ease at this.Yet these tabulations should be interpreted as: each parts of tabulation all are regarded as that separate, unique parts separately.Therefore, under the situation of not having explanation on the contrary, the separate part in this type of tabulation should be only owing to the actual equivalent that is listed in any other parts that are interpreted as same tabulation in the public group.
Concentration, amount and other numeric data can be with the formal representation or the propositions of scope at this.Should be understood that; This type of range format is just used for ease with concisely; Therefore should be interpreted as neatly and not only comprise the numerical value of clearly listing as range limit; And comprise all independent numerical value or the subrange that is included in this scope, treat as and clearly listed each numerical value and subrange.For example, number range " about 1 to about 5 " should be interpreted as and not only comprise the value of clearly listing about 1 to about 5, and is included in independent value and the subrange in the pointed scope.Therefore, comprise in this number range independent value as 2,3 and 4 and subrange as from 1 to 3, from 2 to 4 and from 3 to 5 etc., and independent 1,2,3,4 and 5.This same principle is applicable to enumerates a numerical value as minimum value or peaked scope.In addition, no matter the amplitude of described scope and characteristics how, this type of explanation all should be suitable for.
The present invention proposes the Applied Materials that a large amount of particulates of multiple use are constructed.The present invention also proposes the multiple method that is used to produce or make different Applied Materials, and the various application of this type of Applied Materials.The disclosed Applied Materials of this paper, relevant wallboard embodiment and relevant manufacturing and the method for using this type of Applied Materials and Applied Materials of the prior art---like wallboard product, especially dry wall plate---are compared has several significant advantages, and the some of them advantage is pointed out and spreaded all in following more detailed explanation at this.The first, this wallboard building material provides the thermodynamic property that has improved.For example, on the one hand, this wallboard building material has much bigger heat transfer impedance.The second, on the other hand, this wallboard building material has the acoustical behavior of raising.For example, the disclosed wallboard building material of this paper has obviously better transaudient grade (STC) rank.The 3rd, wallboard building material of the present invention is firmer and lighter.These advantages also limit never in any form.In addition, one skilled in the art will understand that and when embodiment of the present invention, can realize being different from other advantage in this advantage of specifically listing.
The disclosed Applied Materials of this paper is strong to various application adaptability.This Applied Materials is because its composition or composition and can be controlled to realize different performance characteristics according to desired use.For example, porosity and the density that can control particulate are to realize the level of any hope.This is in many application---for example when needing sound insulation or heat insulation Applied Materials---in be useful.
For example, on the one hand, the present invention provides a kind of constructional materials of comparing transaudient rating with raising and other beneficial characteristics (for example, high heat transfer impedance) with the dry wall plate of routine.This constructional materials can be used as shear panels or as the wallboard panel structure; Include core matrix; This core matrix comprises a large amount of microballons and at least a adhesive or binder solution, said microballon hollow or solid, inertia, lightweight, is natural formation or synthetic, and this adhesive or binder solution are configured in order to microballon (is for example supported; Bonding or adhere to) together, and form and spread all over a large amount of cavities of core matrix.Particulate thereby quilt disperse and are suspended in the composition, and said composition comprises adhesive at least, possibly also comprise other composition such as surfactant or blowing agent.Adhesive can comprise the mixture of solution of inorganic binder, organic or latex bonded agent solution or solution of inorganic binder and organic bond solution.Core matrix also can comprise various additives, filler, reinforcement material etc.Depend on selected composition, can this Applied Materials be configured to except the acoustic attenuation characteristic, also to have specific physical characteristic and Performance Characteristics, for example intensity, flexibility, hardness, and thermodynamic property, fire performance etc.
In the situation of wallboard panel; Core matrix can be arranged in around the finish material on the side or face around; The opposite side or the face of wallboard panel are not capped, and perhaps part is not capped at least, so that coarse, the porous surface that is limited the composition of core matrix and structure to be provided.In other words, this constructional materials is configured with the core matrix of part exposure at least.In the situation of shear panels, the mode that core matrix can opposite side exposes is arranged in around the finish material.Finish material can be any useful material, like paper, cloth, polymer, metal etc.Be described in more detail below each composition of acoustic attenuation constructional materials of the present invention and system, and further feature and system.
At present found that the exposed surface of core matrix has greatly improved the acoustic attenuation characteristic of constructional materials.The sound wave of impact on exposed surface compared the acoustical reflection that is minimizing with the constructional materials that lacks this exposed surface.As a result, sound wave is comprised that the material of the core matrix of constructional materials more effectively absorbs and decays.
With reference to Fig. 1, show detailed perspective view according to the constructional materials of illustrative aspects formation according to the present invention.As stated, constructional materials comprises that exposure or side are to provide surface coarse, porous.As shown in the figure, constructional materials 10 is for being similar to the panel-form of wallboard panel, have wide about 4 feet, be about 8 feet size, this size is identical with the wallboard product of most conventional.Certainly, also can consider to be different from 4 feet constructional materials sizes of taking advantage of 8 feet, and different thickness.Near shown constructional materials 10 comprises core matrix 14, and this core matrix is arranged in single facing plate or finish coat---being finish material 34---.The exposed side 18 permission sound of core matrix 14 are by the decay of particulate and adhesive, and acoustical reflection all is covered than the both sides of constructional materials 10 and lacks under the situation that is stamped finish material.On the one hand, in the time of on constructional materials being installed or be assembled to such as the works of stud wall, the exposed side 18 of core matrix 14 can be towards the inboard, and facing barrier film 34 is towards the outside.On the other hand, when constructional materials being installed or be assembled on the works, the exposed side 18 of core matrix 14 can be towards the outside, and facing barrier film 34 is towards the inboard.
Imagination can comprise that at the particulate of this use many dissimilar, sizes, shape, one-tenth grade.On the one hand, particulate can be microballon.On the one hand, the particulate that is used in the constructional materials of the present invention can have the average-size of scope between about 10 microns and about 1500 microns.On the other hand, particulate can have the average-size of scope between about 10 microns and about 1000 microns.Again on the other hand, particulate can have the average-size of scope between about 200 microns and about 800 microns.Again on the other hand, particulate can have scope from about 300 microns to about 600 microns average-size.Another aspect, particulate can have scope from about 350 microns to about 450 microns average-size.In addition, particulate can have the bulk density of about 0.4g/ml to about 0.6g/ml, thereby the product that provides is than conventional constructional materials, light like dry wall plate or oriented structure chipboard (OSB) based on gypsum.Therefore the size of particulate can be depending on the performance characteristics of using and hoping.Yet particulate should be excessive so that be caused flowing away or losing efficacy of layout any adhesive above that.
The size of particulate also works the infiltrative effect that influences constructional materials.Particulate should be compatible with any adhesive, additive and/or facing plate.In the situation of hollow minute particle, can the outer casing thickness of particulate be remained on minimum value, as long as particulate keeps structural integrity as hoping in the core host material.On the one hand, particulate can have about 30% outer casing thickness less than mean particle dia.For aspheric particulate, can calculate the diameter of particle based on the effective diameter of particle, wherein utilize the gross area of particle cross section and make this area equal an area of a circle and confirm diameter from this value.Another aspect, outer casing thickness can be less than about 20% of mean particle dia.
An illustrative aspects, particulate can comprise that geometry is essentially the glass particle of the hollow of sphere, inertia, lightweight, natural formation.A kind of particular type little very with trade mark Extendospheres
TMSell, it is by Sphere One Corporation produce and market.In some aspects, hollow can be used for alleviating the weight of constructional materials valuably, and the good isolation characteristic is provided.On the one hand, particulate can be that hollow, inertia, the glass of the natural formation that obtains from the flying dust accessory substance is little different.This type of microballon often is called and floats pearl.Floating pearl can and further be handled with other accessory substance component separating of existing in the flying dust, for example is cleaned and is separated in the size range of hope.Float pearl and mainly form, and can have the hollow that is full of air and/or other gas by silica (silica) and alumina (alumina).Float pearl and have the characteristic of many hope, for example 3000psi is to compressive resistance between the 5000psi and low-gravity, and characteristic that can withstand high temperatures (1800 ° more than the F).Be essentially spherical although float the overall shape of pearl, many is not real sphere, because many crushed or comprise because the unsmooth surface that extra silica and/or alumina cause.
As stated, particulate or microballon can comprise air in certain amount or other gas in hollow.Under possible situation, the composition that can select gaseous material in the microballon alternatively is so that provide the enhancing characteristics of Applied Materials.For example, hollow can comprise rare gas or other known separation gas, like argon gas to improve the isolation characteristic of whole Applied Materials.
On the other hand, particulate can comprise hollow, the spherical structure of being made by synthetic materials.Adopting an advantage of synthetic materials is the uniformity between the microballon, thereby makes their performance of performance and formed core matrix and constructional materials more measurable.But in some cases, these advantages maybe be inadequately obviously to confirm its purposes, because it is very expensive usually to make synthetic microballon.Use the microballon of natural formation to replace synthetic microballon to form constructional materials and can be depending on several different factors, intended application for example, and/or the Performance Characteristics and the characteristics of hoping.In some applications, the microballon of natural formation possibly be preferred, and in other is used, possibly more hope synthesis type.
Core host material of the present invention can comprise the particulate of any amount according to the expected characteristics of the Applied Materials that obtains.On the one hand, for example, the amount of the particulate that exists in the core matrix can be between about 25% and about 60% (by weight) of total core matrix with the form of wet mixture.On the other hand, the amount that exists of particulate can between about 30% and about 40% (by weight) between.Also can imagine other amount, particularly comprise those aspects of other additive or filler in the core matrix, for example perlite, or hardener, for example C class flying dust.The flying dust that should be pointed out that any kind capable of using is as packing material and/or alternatively as floating Zhu Yuan.On the one hand, C class flying dust can be a source or unique source of microballon.The amount of the C class flying dust that is comprised in the core matrix on the one hand, can be at about 0.5wt% in the scope of about 50wt%.On the other hand, C class flying dust can exist with synthetic microballon combination of making, and wherein the ratio of C class flying dust and synthetic microballon is about 1: 15 to about 15: 1.Again on the other hand, the amount of C class flying dust can be less than about 1/3 of microballon amount.Employed C class flying dust can comprise the aluminosilicate calcium salt (calcium aluminate silicate) greater than about 80wt% alternatively, and less than the lime of about 2wt%.
As stated, the present invention also comprises and can operate particulate is linked together and help forming one or more adhesives of porous core matrix.Particulate can be bonding by any way, comprises physical bond structure, chemical adhesion particulate, merges the border of particulate etc.One special aspect, the mode that particulate can physical bond is bonding, as in the matrix of adhesive, particulate being kept together, wherein adhesive adheres to or fixing particulate physically, but can not form covalent bond or other chemical bond with microballon.Adhesive can adhere to each other microballon, if wherein adhesive is water-based adhesive then allow drying, if or for non-water-based adhesive then allow in hot environment, to solidify.On the one hand, can make adhesive crosslinked, wherein the effect of adhesive is that particulate is combined and improves the water proofing property of constructional materials.
The ratio of adhesive and particulate can change according to the constructional materials that will form.Adhesive is firmer and closely knit with the higher constructional materials situation more less than this ratio that make of the ratio of particulate.The less constructional materials porous more that makes of the ratio of adhesive and particulate.
Imagining many adhesive materials is used in the each side of the present invention.Should be noted in the discussion above that any adhesive that can in core matrix, a large amount of particulates be bonded together all should be considered within the scope of the invention.Can select different adhesives as the part of composition helping the composition of constructional materials, and help to provide constructional materials with particular physical characteristics and Performance Characteristics.Can imagine and use water-based adhesive and non-water-based adhesive.The example of common adhesive classification is including, but not limited to thermoplastic, epoxy resin, vulcanizing agent, urethanes, thermosetting plastics, silicones etc.
In one exemplary embodiment, adhesive comprises that this organic bond is such as polyvinyl acetate ester copolymer or ethylene vinyl acetate with the inorganic bond of organic bond combination, as being the silicate of soda of a kind of form or another kind of form.The variable-scaleization of these adhesives.On the one hand, the ratio of inorganic bond and organic bond can be about 7: 1 to about 10: 1.More generally; (adhesive comprises a certain amount of water to inorganic bond at hygrometric state; Or mix with a certain amount of water) amount that exists down by weight between the gross weight of core matrix 50% and 60% between (or about 20wt% extremely the dried inorganic bond of about 36wt%), the amount that organic bond exists under hygrometric state by weight between the gross weight of core matrix 5% to 15% between (or about 2wt% extremely the dried organic bond of about 6wt%).Listed amount can be based on the form (weight percent in described in the text whole core matrix of adhesive is reduced between 40% and 60%) of pure adhesive material; For example based on pure silicate of soda, perhaps can be based on comprising optional water, the similar binder combination of chemical species such as silicate etc. and other additive.As a non-limiting example, the sodium silicate binder solution sold of merchant comprises the silicate of soda of about 35wt% in the solution of 40wt%.In addition, can adopt the inorganic and/or organic bond of more than one types simultaneously.
According to the desired characteristic of the Applied Materials that obtains, imagination is formed the multiple composition of the material of core matrix.In a particular embodiment, the core base composition can comprise 400g to the microballon between the 600g, and this microballon mixes to the ethylene vinyl acetate between the 100g to sodium silicate binder solution between the 800g and 60g with 600g.Certainly, also be possible according to other scope of application scenario.For example, possibly hope 200g is mixed, mixes to the EVAc between the 180g with 20g to the microballon between the 800g with 300g to the silicate of soda between the 1500g or other adhesive.Each composition that also can imagine various prescriptions has other ratio and scope.In addition, can use, also can use more than a kind of inorganic bond more than a kind of organic bond.
In a concrete example, the amount that solution of inorganic binder exists in wet mixture is gross weight about 55.5% of core matrix by weight, and wherein this binder solution comprises silicate of soda and water.More specifically, the amount of the silicate of soda that solution of inorganic binder comprises is by weight between about 40% and about 60%, and the amount of water is by weight between about 40% and about 60%.In many cases, solution of inorganic binder comprises that ratio is 1: 1 silicate of soda and a water.Silicate of soda can provide solution by premix and with liquid form, and perhaps silicate of soda can be powder type and mix with water subsequently.
On the one hand, the amount that latex or organic bond exist in wet mixture is about 7.4% of core matrix gross weight by weight, and comprises (EVA) emulsion of ethylene polyvinyl acetate (ethylene polyvinyl acetate).Latex adhesive helps forming flexible porous composition, and said composition forms the core matrix of wallboard subsequently.A particular example of employed latex adhesive is the ethylene vinyl acetate of selling down at trade mark Airflex (for example, Airflex 420) (water-based adhesive), and it is by Airproducts manufactured and sale.This special adhesive can be used to promote flowing and plastic formation of core matrix, and flexible or semirigid composition is provided.Latex adhesive can be liquid form with the water premixed.Latex adhesive comprises the EVA of its amount about by weight 40% and the water of its amount about by weight 60%.On the one hand, latex adhesive account for wet mixture SMIS matrix the scope of gross weight for from about 2.5wt% about 30wt% extremely.Another aspect, the scope of latex adhesive can be about 5wt% to about 20wt%.The non-limiting example of latex adhesive comprises product (specifically comprising 323,401,420,426), the product (being specially 154s, 163s) that UCAR produces, the bonding adhesive of routine and product (comprising XX210) and their mixture and the composition that paste, Vinac produce that Airflex produces.
In the prescription of core matrix, can comprise water-soluble polymer.This water-soluble polymer can be added to the core base composition, and this core base composition has been dissolved in the water or has been dried forms.The function of water-soluble polymer is with acting on any surfactant that exists in the mixture or the stabilizing agent of blowing agent.Particularly, water-soluble polymer helps stable composition up to adhesive curing or crosslinked.The nonrestrictive example that can be included in the water-soluble polymer in this prescription comprises the water-soluble polymer that Airflex sells, for example PEO (like WSR 301).Water-soluble polymer also can be used as thickener and anti-sealing flows out from mixture during the core matrix-forming.This base polymer can be used for controlling rigidity, flexibility, tearing toughness and other physical characteristic of constructional materials, and stablizes any surfactant (if existence).In certain embodiments, possibly hope to eliminate or at least significantly reduce the amount of organic principle in the core base composition.In that to hope that constructional materials comprises under the situation of fire performance of further enhancing especially true.Therefore the amount that is retained in the organic principle in the core base composition can be depending on concrete application.
As stated, and depend on employed type, adhesive can only solidify and be not crosslinked, perhaps crosslinkable.Through making adhesive crosslinked, between adhesive and microballon, form more by force, more lasting physical connection.Equally, the present invention imagines and uses one or more measures to come to make effectively adhesive crosslinked.In one exemplary embodiment, can come cross-linked binder, thereby realize polymerization and combination through in a reasonable time section, the temperature of adhesive being brought up to a proper temperature.The radiation heating method of this routine capable of using is accomplished, and perhaps also can utilize continuous action or accomplishes with the microwave of different interval actions and the microwave of varying strength.Use microwave obviously faster, and cost is lower.In addition, using the crosslinked effect of microwave is to produce firmer constructional materials, because increased the amount of actual crosslinked adhesive.In addition, according to employed concrete adhesive, can adopt chemical cross-linking agent.This type of chemical cross-linking agent is well-known in the art.
Compare with the constructional materials with uncrosslinked composition, crosslinked in the constructional materials has significant advantage.For example, adhesive is firmer under crosslinked situation, and they can not absorb water easily, and the connection between the microballon is stronger.In addition, As time goes on constructional materials weakens less usually.Those skilled in the art will appreciate that other advantage.But, should be noted in the discussion above that to exist and wherein do not hope crosslinked and the wherein application of preferred not bonding composition.
The present invention also imagines and utilizes surfactant or blowing agent, and it mixes with adhesive and microballon to realize having more low-density constructional materials.About foaming process,, carry out drying then in case them just can beaten or stir to each batching combination so that air is introduced in the mixture.Mechanical agitation capable of using or compressed air are physically introduced air in the mixture and are produced foaming process.Compare with the composition that does not have foaming, foaming process causes particulate to be supported on the position of separating more each other effectively.Exist under the situation of foam, particle suspension also therefore can be dry with the configuration that more disperses.On the other hand, but, the microballon that exists blowing agent to cause can be used to also guarantee that the core base composition has higher flowable or pumping because suspending, and formability.The suitable surfactant or the example of blowing agent include but not limited to anion foaming agent such as Steol FS406 or Bio-terge AS40, cation blowing agent and nonionic blowing agent etc.
As a special example, the core host material based on wet prescription can comprise particulate (wherein the size of particulate is between about 10 microns and about 1000 microns) from about 25wt% to about 60wt%, from about 20wt% silicate of soda of about 36% and extremely from about 5wt% vinylacetate of about 15wt% extremely.On September 25th, 2008 submit to and be entitled as the relevant common unsettled U.S. Provisional Patent Application No.__________ of " Wallboard Materials Incorporating a Microparticle Matrix (wall board material that combines matrix of microparticles) " (the reel number No.2600-32683.NP.CIP2 of agency) and the relevant common unsettled U.S. Provisional Patent Application No.___________ that submits on September 25th, 2008 and be entitled as " Shear Panel Building Material (shear panels constructional materials) " (the reel number No.2600-32683.NP.CIP3 of agency) in the more details relevant with the wallboard building material have been described, said application is all incorporated this paper into as a reference.
Finish material can comprise many dissimilar materials or have the combination of the material of different qualities.An illustrative aspects, finish material comprises paper material, and it is similar in aforesaid various wallboard product---like the dry wall plate or incorporate the application's wallboard as a reference into---goes up existing paper material.In another illustrative aspects, finish material can be cloth, polymer or metal or metal alloy.
With reference to Fig. 2, show the constructional materials that another exemplary embodiment according to the present invention forms.Constructional materials 110 is similar with constructional materials 10 above-mentioned with shown in Figure 1 in many aspects.But constructional materials 110 comprises netted barrier film 154, and it is arranged in around the exposed side 118 of core matrix 114, and is relative with facing barrier film 134.Netted barrier film 154 comprises a plurality of cross portions that form a large amount of grid-like openings.Netted barrier film 154 is used for providing support and stability to core matrix 114 similarly with facing barrier film 134, but still a sizable part that stays the core matrix 114 that is exposed on this side is with the surface of coarse, the porous of keeping constructional materials 110.Netted barrier film 154 can be many dissimilar materials, and grid-like opening can have many different sizes and configuration.
On the one hand, netted barrier film 154 can comprise glass fiber or plastic wire or Web materials.The Web materials of this reinforcement is that constructional materials 110 provides flexural strength, and when exposing on the side of particulate at constructional materials 110 so that reach further support particulates when absorbing the specific purpose that sound wave and damped vibration receive and disperse.According to concrete application and needs, netted barrier film 154 can be processed by glass, plastics (for example, extrusion plastic) or other material.Netted barrier film 154 can be similar with facing barrier film 134 mode or be bonded on the core matrix 114 through any other method as known in the art.
A remarkable advantage of comparing with conventional products is the ability of constructional materials decay of the present invention or absorption sound.Found for the transaudient rating of constructional materials (thickness is 1/2 inch) that forms with similar mode illustrated in figures 1 and 2 between 40 and 60, depend on core matrix composition, wallboard panel thickness and whether have reinforcement material.Thickness also is that the dry wall plate of 1/2 inch routine has about 33 STC rank.During based on the constructional materials of embodiment mentioned above, illustrated in figures 1 and 2, discovery can reach the sound absorption about .89 ± .10 in test.In addition, under 3000Hz, noise reduces between 55dB and 65dB.At 2000Hz, noise reduces between 35dB and 45dB.At 1000Hz, noise reduces between 10dB and 20dB.By contrast, the dry wall plate is reduced to 40dB at the noise of 3000Hz; Noise at 2000Hz is reduced to 28dB; Noise at 1000Hz is reduced to 3dB.Can find out that this constructional materials is obviously better aspect sound absorption.
Except the acoustic attenuation characteristic of its improvement or raising, constructional materials such as dry wall plate, the gypsum plank of constructional materials of the present invention and routine, OSB compares that many additional improved characteristic and characteristics are provided.For example, constructional materials of the present invention has than the significantly lower heat transmission of the constructional materials of routine.For example, in constructional materials above-mentioned and illustrated in figures 1 and 2, can realize 400 ℃ temperature gradient.In a special test, a side of constructional materials of the present invention is heated to 100 ℃, on opposite side after 2 hours, does not have obvious intensification.This temperature gradient can change because of the composition XOR of composition, the for example existence of the type of the ratio of microballon and adhesive, employed adhesive, reinforcement material etc., as indicated described in.Therefore can find out that constructional materials of the present invention shows good thermodynamic property.The ASTM test of use standard finds that the heat transmission of this constructional materials is littler 20 ℃ than dry wall plate under identical test condition (for example, time and temperature).Test shows is compared with the dry wall plate that absorbs about .54BTU, and this constructional materials absorbs about .11BTU.Thus, use core matrix to improve heat capacity, i.e. what of absorbed heat based on microballon.Found with for thermal resistance or the R value of comparing identical constructional materials for the dry wall plate of .45 for 1/2 inch thick panel for 1/2 inch thick panel between 2 and 3.
Find that also above-mentioned identical constructional materials is than between the dry wall plate light about 20% to 30%.For example, the heavily about 39lbs of 4 * 8 panels, the similar great about 51lbs of dry wall plate panel of size by contrast.The great about 80lbs of 4 * 12 dry wall plate panels, the heavily about 60lbs of wallboard building material of the present invention by contrast.
Except that weight is lighter, find that also identical constructional materials is than dry wall plate firm 10% to 20%.In one example, this constructional materials of various test shows will rupture between 170lbs and 180lbs in bending strength test.By contrast, the dry wall plate ruptures about 107lbs usually.The panel that uses in these tests has suitable size and thickness.In the hardness test, the average of this constructional materials is about 15lbf, is 11lbf and test out the dry wall plate on the edge of.Be in one's hands in the nail test, the average that tests out this constructional materials is 99lbf, is 77lbf and test out gypsum plank.
Constructional materials of the present invention also can comprise rigid material or strengthening part, and it is configured to compare the characteristic that raising is provided with the exemplary constructional materials of Fig. 1 and Fig. 2 in one or more zones.In one exemplary embodiment, this constructional materials can comprise and is arranged in the core matrix (being folded in wherein) or at the external surface of core matrix and the rigid material between the finish material.This rigid material can be configured to strengthen or improve one or more characteristic or the characteristic of constructional materials.For example, this rigid material can be configured to strengthen to transaudient, conduct heat or their opposing (or improving impedance) of combination.This rigid material also can be configured to improve the bulk strength of constructional materials.Rigid material can comprise various types of materials, for example metal, weaving or non-woven fibre or fiberboard, plastic foil etc., and the thickness that can have any necessity.
The present invention also is provided for using the sound trap improvement and improving the system and method through the noise minimizing of partition wall.This sound trap can form around constructional materials of the present invention being arranged in building structure such as column or other wall, and wherein relative constructional materials forms and is configured to absorb sound and significantly reduce the transaudient sound trap through this wall.In this configuration, relative exposed surface will be positioned to face one another.The acoustic attenuation system can be formed by the constructional materials of the present invention of the multiple suitable location with multiple configuration.Thus, be not to be intended to limit by any way at this special material that proposes.
Generally speaking, the sound wave that gets into sound trap is had the relevant constructional materials decay of different acoustical reflection degree, depends on the configuration and the employed constructional materials of sound trap.As stated, the exposed surface of core matrix has greatly improved the acoustic attenuation characteristic of constructional materials.The sound wave of impact on exposed surface compared the acoustical reflection that is minimizing with the constructional materials that lacks this exposed surface.As a result, sound wave is comprised that the material of the core matrix of constructional materials more effectively absorbs and decays.For the sound trap that the constructional materials that is had exposure centers on, increase acoustic attenuation through all constructional materialss in the sound trap.For the sound trap of first constructional materials that has exposure on being employed in a side and second constructional materials with finish material relative with the exposure of first constructional materials; Sound can mainly be decayed by the exposure of first constructional materials, and the finish material of second constructional materials is used for acoustic reflection in the exposure of first constructional materials.Therefore, for two kinds of configurations, sound wave is trapped between constructional materials and effective attenuation.
In an optional embodiment, can use two kinds of facing constructional materials panels to constitute sound trap, described in all comprising as indicated, each panel is sandwiched between two core host materials between the veneer material bed of material.The veneer material bed of material can be processed by various materials, describes for example paper, cloth, metal and metal alloy, polymeric material and their combination in as indicated.
With reference to Fig. 3, show acoustic attenuation system 200 according to one exemplary embodiment of the present invention, wherein this acoustic attenuation system forms and limits outside partition wall 204.This acoustic attenuation system 200 and outside partition wall 204 comprise first constructional materials 210 around first side that is supported on building structure such as outside stud wall (not shown), and are supported on second constructional materials 310 around second side of the building structure relative with first constructional materials 210.In this case, second constructional materials is the shear panels with rigid material disposed therein.According to embodiment well known in the art first and second constructional materialss are supported or are installed in the building structure.
First constructional materials 210 comprises the wallboard panel, and has the core matrix 214 that is arranged in around the facing barrier film 234, and a side 218 of core matrix exposes, or exposes at least basically.The exposed side 218 of core matrix is towards the inboard, and is arranged to lean against on the member of forming stud wall, and facing barrier film 234 is towards the outside.Second constructional materials 310 comprises shear panels, and has the core matrix 314 between the second facing barrier film 354 that is arranged in the first facing barrier film 334 that formed by metal such as aluminium and is formed by paper material.Alternatively, wallboard building material 210 and/or shear panels constructional materials 310 can comprise the rigid material 374 between the core matrix 314 that is interposed in shear panels constructional materials 310.
After under this configuration, being installed on the stud wall, wallboard building material 210 and shear panels constructional materials 310 are used to provide and limit the space or the sound trap 284 of certain volume jointly, extend between the inner surface of its every kind of constructional materials in building structure.This sound trap is intended to stop that sound wave passes partition wall 204 transmission along any direction, because under the help of the exposure rough surface 218 of wallboard building material 210, these sound wave core matrix 214 more effectively absorb.Come from indoor and pass the sound wave that wallboard building material 210 propagates towards shear panels constructional materials 310 and partially absorbed and partial reflection by shear panels constructional materials 310.The sound wave of those deflections is propagated towards the exposed side of the core matrix 214 of wallboard building material 210 218, and wherein they run into the surface of coarse, the porous of exposed side 218.Because this configuration coarse, porous, most of sound is absorbed in the core matrix and is attenuated.The core matrix 314 of shear panels constructional materials 310 also helps the absorption and the decay of sound.Thus, and compared with the outside partition wall that the OSB material forms by the dry wall plate of routine, acoustic attenuation system 200 and particularly partition wall 204 provide higher STC and OITC grade.In partition wall of the present invention, increasing the isolation part can make STC compare further raising with the OITC grade with the partition wall of dry wall plate, OSB and interlayer.
Fig. 4 illustrates the acoustic attenuation system 400 according to one exemplary embodiment of the present invention, and wherein this acoustic attenuation system forms and limit inner partition wall 404.This acoustic attenuation system 400 comprises first side, first constructional materials 410 on every side that is supported on building structure such as internal upright wall (not shown) with inner partition wall 404; And be supported on second constructional materials 510 around second side of the building structure relative, thereby limit sound trap 484 with first constructional materials 410.First constructional materials 410 is similar to first constructional materials 210 of Fig. 3, is incorporated into this with describing more than it.Second constructional materials 510 also is similar to first constructional materials 210 of Fig. 3, comprises the core matrix 514 that is arranged between the first facing plate 534 and the second facing plate 554 but difference is wallboard building material 510.In other words, the side of the core matrix 514 of second constructional materials 510 is not exposure, but is capped.Directly improving of the sound absorption of acoustic attenuation system 400 and the attenuation characteristic exposed side 418 through penetrating the first wallboard building material 410 with the sound wave of deflection, wherein their core matrix 414 bufferings also partially absorb at least, and sound wave is trapped within the sound trap 484.
Fig. 5 illustrates the acoustic attenuation system 600 according to one exemplary embodiment of the present invention, and wherein this acoustic attenuation system 600 also forms and limit inner partition wall 604.This acoustic attenuation system 600 comprises first side, first constructional materials 610 on every side that is supported on building structure such as internal upright wall (not shown) with inner partition wall 604; And be supported on second constructional materials 1710 around second side of the building structure relative, thereby limit sound trap 684 with first material 610.First constructional materials 610 and second constructional materials 1710 are similar each other, comprise core matrix 614 and 1714 respectively, and have exposed side 618 and 1718 respectively.Two exposed side 618 and 1718 are all operated receiving and absorption sound, thereby quite a few sound wave is trapped in the sound trap 684, and prevent that them from spreading out of sound trap 684.Thus, this acoustic attenuation system comprises than the obvious higher STC rank of the partition wall of standard dry wall plate.
In above each exemplary acoustic attenuation system, sound is designed to penetrate the skin or the barrier film of various constructional materialss and be trapped within the sound trap of formation, thereby has obviously reduced and passed the transaudient of partition wall, no matter partition wall is interior wall or exterior wall.Should be noted in the discussion above that this sound trap also can form and be limited to around ceiling or any other separator, as persons skilled in the art will recognize that.At least a exposed side that the sound wave of entering sound trap acts on and penetrates through them in the constructional materials is attenuated.The surface coarse, porous of the core matrix that exposes is used for reducing the deflection and the transmission of sound wave, and core matrix overall operation is to partially absorb and the undeflected sound wave of damping at least.The thickness of the core matrix of constructional materials will influence noise reduction or transaudient characteristic, and the composition of core matrix, density and configuration are too.
What it is contemplated that is, the combination in any of constructional materials of the present invention can be used on the either side of building structure and limits a sound trap, comprises disclosed various embodiment in the application of incorporating this paper by reference into.In addition, what it is contemplated that is that constructional materials of the present invention can be according to the content manufacturing of instructing in the application of incorporating this paper into.
In some aspects, core matrix can be configured to further improve the acoustic attenuation characteristic of constructional materials.On the one hand, constructional materials of the present invention comprises that exposure or exposed side are to provide surface coarse, porous.In addition, constructional materials of the present invention comprises the core stromal surface of the exposure with the many protrusion surfaces configuration that is formed at wherein.
As shown in Figure 6, constructional materials 710 is for being similar to the panel-form of wallboard panel, have wide about 4 feet, be about 8 feet and thick about 1/2 inch size, this size is identical with the wallboard product of most conventional.Certainly, can consider that 4 feet are taken advantage of other size outside 8 feet the size, and different thickness.Near shown constructional materials 710 comprises core matrix 714, and it is arranged in single facing plate or finish coat---being finish material 734---.The opposite side 718 of core matrix 714 exposes, thereby exposes the part of the configuration of particulate and adhesive.The exposed surface of core matrix provides and defines surface one coarse, porous, and this surface design is used for attenuate sound better.On the one hand, in the time of on constructional materials being installed or be assembled to such as the works of stud wall, the exposed side 718 that should make core matrix 714 is towards the inboard, and facing barrier film 734 is towards the outside.On the other hand, when constructional materials being installed or be assembled on the works, the exposed side 718 of core matrix 714 should be towards the outside, and facing barrier film 734 is towards the inboard.
The exposed side 718 that Fig. 6 also illustrates core matrix comprises the surface configuration of projection more than.The purpose that is provided near the many protrusion surfaces configuration that forms surface, the especially exposed surface of core matrix has 2 points at least: 1) further strengthen the acoustic attenuation or the damping characteristic of constructional materials significantly, promptly guarantee sound insulation and sound absorption in a very wide frequency range; 2) through eliminating the flexural strength that shear line strengthens constructional materials.To describe as following, imagine many different many protrusion surfaces configurations at this.Person of skill in the art will appreciate that to be provided with from the teeth outwards that a series of peak and paddy are positioned at the different surfaces of differing heights with formation and, especially to the benefit of the specific purpose of attenuate sound with the benefit of the directed different surfaces of different gradients.The sound wave that is incident on these height and/or the directed different surface is more effectively decayed.
Shown in specific embodiment in, the surface configuration of many projections has with the grid pattern of a large amount of ledges 718 (waffle pattern), ledge 718 has square or rectangular cross section and limits a large amount of recesses 726.This a series of peak and paddy form the exhibiting high surface (being horizontal surface 730 and 734 in this example) that is arranged in differing heights effectively on the whole surface of core matrix 714.In addition, ledge 718 can be configured in order to provide with the directed surface (in this example, ledge 718 also limits the surface 738 of several vertical orientations) of different angles.
Also imagine on many protrusion surfaces of the exposure of core matrix 714 and can be provided with or not be provided with independent netted facing plate.If use netted facing plate, then netted facing plate preferable configuration becomes to have flexible with consistent with the surface configuration of many projections.
Fig. 6 and Figure 14 further illustrate constructional materials 710 and comprise a large amount of cavitys or air pocket 746; Said cavity or air pocket spread all over core matrix 714 and strategically form and locate, and be designed in order to the gross weight that reduces constructional materials not can the appreciable impact constructional materials intensity or other characteristic.Preferably, cavity 746 is random position in whole core matrix 714, but cavity also can be arranged to a predetermined pattern.Cavity 746 can form according to any known method during the manufacturing of constructional materials.In essence, the effect of cavity 746 is in core matrix 714, to limit a large amount of cavities or air pocket with different positions.The size of cavity 746 can be set for has about 0.2cm
3To about 200cm
3Volume, preferred about 5cm
3To about 130cm
3Volume.These not only help weight reduction, and owing to still air/dacker space helps to increase whole R value.In addition, these help further attenuate sound, because these provide and have been used for absorbing sound wave but not transmit their additional surface.
With reference to Fig. 7-A and Fig. 7-B, show the constructional materials that another exemplary embodiment according to the present invention forms.Constructional materials 810 is similar with constructional materials 810 above-mentioned with shown in Figure 6 in many aspects.Yet constructional materials 810 comprises arranges or is interposed in the lath 854 in the core matrix 814.Lath 854 comprises a large amount of cross sections 856 that form grid, and said grid has a large amount of openings 858.The effect of lath 854 is to provide support with stability and enhanced strength is provided for core matrix 814.In addition, lath 854 has increased the quality of constructional materials 810, and this point has reduced the possibility of vibration, therefore helps the acoustic attenuation characteristic of constructional materials 810.Lath 854 can comprise many different types and configuration, and wherein grid and opening are of different sizes and configuration.Lath 854 shown in Figure 7 is not to be intended to limit by any way.
On the one hand, lath 854 can comprise metal, glass fiber or plastic wire or Web materials.This stiffener strip material is that constructional materials 810 provides intensity, and further supports microballon.According to concrete application and needs, lath 854 also can be processed by glass, plastics (for example, extrusion plastic) or other material.
With reference to Fig. 8-10, show the constructional materials 910 that another exemplary embodiment according to the present invention forms.In this embodiment, constructional materials 910 comprises the core matrix 914 with first surface 918.In first surface 918, be formed with many projections or nonplanar surface configuration, the form of this surface configuration is the pillow projection pattern of repetition, thereby with a plurality of different projections a plurality of different surface or surf zone is provided.Protuberance can have size, configuration and the height of any hope.Therefore, only be exemplary shown in the figure.
With reference to Figure 11, illustrate the lateral view of the constructional materials 710 of Fig. 6, this constructional materials 710 has many protrusion surfaces configuration that form is the grid pattern of repetition.The configuration of grid-like extends between the periphery of constructional materials, and limits a large amount of protuberance 722 and recess 726.Figure 14 illustrates the sectional drawing of constructional materials, and wherein constructional materials 710 comprises cavity or the cavity 746 that strategically forms and be positioned in a large number in the core matrix 714.
Figure 12 illustrates the detailed side view of another kind of exemplary constructional materials 1010; This constructional materials 1010 comprises the core matrix 1014 with first surface 1018; Wherein be formed with the surface configuration of many projections in the first surface 1018; The surface configuration of these many projections comprises that form is the repeat patterns of first protuberance 1022 of rib vertebra or circular cone, and the repeat patterns with second protuberance 1024 of arbitrary shape.Show second protuberance 1024 and comprise the secondary protuberance 1025 of main base portion protuberance, upper secondary protuberance 1023 and sidepiece with square cross section, all have rib vertebra or cone shape.First protuberance 1022 and second protuberance 1024 limit recess 1026.Though the present invention is not intended to be confined to the protuberance of any given shape, Figure 12 shows that arbitrary shape all can be susceptible at least.
Figure 13 illustrates the detailed side view of another kind of exemplary constructional materials 1110; This constructional materials 1110 comprises the core matrix 1114 with first surface 1118; Wherein be formed with many protrusion surfaces configuration in the first surface 1118; This many protrusion surfaces configuration comprises the repeat patterns of first protuberance 1122 and recess 1126, and wherein these protuberances and recess form the pattern of egg packaging boxlike (egg carton-type).
Therefore Fig. 8-13 illustrates several different many protrusion surfaces configurations.Yet these should not limit by any way.In fact, those skilled in the art can expect can be used to realize other configuration and/or the pattern of design of the present invention.
Example
Following example illustrates current known embodiments of the invention.Therefore, these examples should not be regarded as restriction of the present invention, and only are suitable for instructing composition how to make best understanding and based on the form of the present invention of current experimental data.In addition, comprise that at this some test data of experiment are to provide the guidance to optimal combination thing and Applied Materials form.Thus, at this composition of representational number and their manufacturing approach are disclosed.
Example 1-floats the test of the Applied Materials of pearl and silicate of soda
With Extendospheres
TMThe pearl mixture that floats of form combines with silicate of soda and allows it dry and form the fire prevention isolated material.The Extendospheres that with the diameter dimension scope is the 300-600 micron combines with sodium silicate solution (the O type of Pq Corp.) with 1: 1 part by weight.Wet pulp is injected the cavity around the turbine and allowed its drying.It forms the lump of Extendospheres and silicate of soda.Use this material of Ipro-Tek single-rotor gas turbine test.This material of test shows has high isolating power and temperature capacity.Interlayer is exposed to the temperature up to 1200 ℃.Yet, find that material cracking and foaming also begin to lose physical strength when material directly being exposed to flame and surpassing the cycle of a few minutes.
Example 2-is in order to the formation of the mould of formation wallboard
On the one hand, Applied Materials can be the wallboard panel.Panel can randomly form through uncured wallboard being exposed to microwave.The formation of this type of formation and common wallboard mould capable of using.The example of mould can be made up of the vinyl ester resin mould with overhead and bottom member.At first build wooden model in order to form the vinyl ester resin mould.
In order to form the vinyl ester resin mould, use two-sided tape that one outer wooden model is attached on the wooden model base portion.Alternately use any releasable adhesive or attachment structures.Resin compound is formed by the vinyl ester resin with the 97.5wt% of methyl ethyl ketone peroxide (MEKP) catalyst mix of 2.5wt%.Add the microballon and the resin compound of Extendospheres form with 1: 1 ratio, to form the core mixture.Use is installed in the mixing plant in the rig mixing plant of compo---as be used for---mixed core mixture well.Incorporation time is about 3 minutes.The core mixture is injected in the ready wooden model and is allocated to the covering entire die and comprises all corners.Though be not to be pressed in the mould, use short distance drippage, hand, mechanical oscillation and spreading instrument, leniently make mixture level and smooth like perching knife.Mixture is not to be pressed in the wooden model, thereby because the porosity that can reduce the vinyl ester resin mould that obtains to its pressurization can make it unavailable.Mixture at room temperature solidify up to its when contact hard and firm till.Usually be about three hours hardening time.Take off porous ethylene base ester resin die then carefully.The vinyl ester resin mould that obtains has 11.625 inches * 15.25 inches * 0.5 inch dark cavity, around outer rim, has 0.375 inch wall.Use identical method to form the overhead of vinyl ester resin mould, and in being of a size of 12.375 inches * 16 inches * 0.5 inch dark rectangle, form mould.
Example 3-uses mould to prepare wallboard
As stated, the form of Applied Materials can be the wallboard panel.Panel can be randomly through using porous ethylene base ester resin die to form.At first, use the lining paper template to cut the wallboard lining paper.Although show specific lining paper shape, be to be understood that Any shape or size that lining paper can have is enough to form one section wallboard.Finishing paper is cut into size just less than the rectangle of the large-size of lining paper.In the present embodiment, finishing paper is cut into 11.625 inches * 15.25 inches rectangle.Folding lining paper also is placed in the porous mold.Can use following material to form the wallboard mixture:
700g is to the 900g microballon;
1100g is to the 1300g sodium silicate solution, the sodium silicate solution of for example selling with " O ";
300g is to the 500g latex adhesive;
20cc is to the 30cc blowing agent.
Particularly, at first add to blowing agent in the sodium silicate solution and use the squirrel-cage blender (squirrel mixer) of 540RPM to mix 2 minutes.Latex adhesive added in the mixture and with identical setting mixed for 30 seconds again.When mixing, slowly add microballon more than 1 to 2 minute, even up to mixture.
The wallboard mixture is injected the lining mould and uses perching knife or paint stick (paint stick) makes it to flatten.Should be pointed out that and to use any instrument or method to come smooth mixture at this moment.Through the next further leveling mixture that shakes of exerting oneself.The facing cardboard is placed in the top of mixture, and is covered by the top panel of vinyl ester resin mould.Mould is placed microwave, and with desired time amount radiant panel.Preferably, often rotate mould so that panel is drier.Should not make panel in any long time quantum, receive continuous radiation with big cavity in minimizing or the prevention wallboard core.Can set the time quantum of the power level of microwave radiation with the unlatching of control microwave.The time of microwave opening and closing can be according to table 1:
Table 1
| Power level | Opening time (second) | Shut-in time (second) |
| 1 | 3 | 19 |
| 2 | 5 | 17 |
| 3 | 7 | 15 |
| 4 | 9 | 13 |
| 5 | 11 | 11 |
| 6 | 13 | 9 |
| 7 | 15 | |
| 8 | 17 | 5 |
| 9 | 19 | 3 |
| 10 | 22 | 0 |
In case, just can take out the wallboard panel that obtains from mould carefully by suitably heating.
Example 4-bending strength test
A flexural strength that key character is a plate of wallboard.Comprise the core host material of table 2 ingredients listed through formation, mixture is distributed in the mould cavity and makes it smooth each sample panel for preparing.Thick 0.50 inch of the sample that obtains, wide 2 inches.Each sample is dry till confirming drying through the Aquant hygrometer in being in 100 ℃ stove.Sample is suspended between two support members that separate 6 inches makes the 1-1.5 inch be shelved on the either side of support member.Place the also slow water filling in the center that hangs sample till sample fractures the paint can of quart sized, in the weight of this (fractureing) point measurement and record jar.Flexural strength is important for processing, installation and the use of routine.For the purposes of the gypsum wallboard of the alternative routine of its deadlight, hope that intensity equals the intensity of gypsum wallboard at least.Each wallboard comprises the different components listed like table 2.
Table 2
With the combination of components in each row then machinery beat to produce a foamed product.In mould, make this foamed product moulding then.The adhesive of all uses is the silicate of soda based adhesive.O type adhesive is the viscous sodium silicate solution from Pq Corp..RU type adhesive is also from Pq Corp. and be sodium silicate solution similar with the O type but that viscosity is so not strong.The RU type moisture more, have a lower solid content.BW-50 type adhesive is also from Pq Corp..BW-50 also is a sodium silicate solution, and wherein silica and oxidation disodium (disodium oxide) ratio is lower.Shown in table, the amount that can optimize adhesive and the flexural strength of type with the formation wide region.
Example 5-bending strength test II
Carry out bending strength test according to example 4 on the sample panel of listed step at seven.The composition of each sample panel and bending strength test weight record are in table 3.
Table 3
Shown in table, binder content makes sample strength higher usually in increase sample rate and the increase sample.The content that increases water in the sample mixture reduces the density of mixture usually and causes the intensity of sample to reduce.In the sample that comprises the test that utilizes Manila folder and/or cardboard, said material is placed on the both sides of sample.Under the situation of core material by the paper product side joint, this type of setting equals to conventional gypsum wallboard.Shown in table,---either side all be shown in Manila folder or cardboard form---significantly increased the intensity of sample on both sides, to comprise cardboard.
Example 6-bending strength test III
Form the sample panel of some according to method listed in example 4, the paper tape of different is said thickness is that 2 inches wide * 11 are inch long.Before injecting the core host material, a slice paper tape is placed mould cavity.After injection and smooth mixture, another sheet paper tape that thickness is identical places on the top of mixture.With the wire gauze covering mixture and force down so that it during drying is held in place.For following listed result, paper can suitably not adhere on the core matrix, so test result has reflected the only attached sample that a slice paper is arranged.Under the situation under the paper side direction, carry out bending strength test.Infer and comprise that the sample result of two facing plates should be higher.
The core host material of each sample comprises 250g Extendospheres, 40g water, 220g adhesive, 10g blowing agent.The dry weight of each sample is 334.9.For thickness is 0.009 " paper, the weight that fractures is 6.6kg.For thickness is 0.015 " paper, the weight that fractures is 7.5kg.For thickness is 0.020 " paper, the weight that fractures is 5.2kg.
Example 7-is to the additional testing of sample panel
Form the sample panel of some according to listed method and composition in the above-mentioned example.Usually, mixture, like mixture given above in die for molding, this mould comprises the paper that is arranged in the core above and below and around the framework of sample circumference, to hold wet core material when solidifying in that mixture is dry.Behind dry and heating wallboard sample, can test its mechanical property.The composition of each sample and correlated results are shown in the table 4.
Bending strength test-" bending "
With 2 inches wide * 6 to 8 inches long, thickness is that 0.5 inch sample places on the test fixing device, make it to be suspended between two supporting legs.Two supporting legs separate about 4.25 inches.Testing equipment is equipped with the crooked test annex, and the bar on the annex is parallel to the test specimen location.The anti-bending test annex is centered in the mid point between two supporting legs of test fixing device.One can hook is hung on the end of testing equipment, the weight that slowly increases bucket was till specimen lost efficacy.The weight of measuring bucket is to obtain the bending resistance result.
Hold the nail strength test
, thickness inch long 6 inches wide * 6 be on 0.5 the sample boring in sample, to be formed centrally one 5/32 inches pilot holes.Sample being placed hold on the nail fixing device, is on 2.5 inches the hole be in one's hands diameter in the nail fixing device of pilot hole centering.One nail is inserted in the pilot hole.The diameter of nail shank should be about 0.146 inch, and the diameter of nail head should be about 0.330 inch.Screw rod inserted make it stretch out about 2 inches distance in the indicator hole on the testing equipment.Screw head should be less than the head of employed nail in the test.Sample and fastening devices are positioned at the equipment below makes the center line of nail and screw rod align.One can hook is hung on the end of testing equipment.The weight that slowly increases bucket was till test sample book lost efficacy.Measure the weight of bucket.
Curing, end and edge hardness test
With 2 inches wide * 6 to 8 inches long, thickness is that 0.5 inch specimen holder is held on the anchor clamps of testing equipment.Screw rod inserted make it stretch out about 1.5 inches distance in the indicator hole on the testing equipment.The diameter of screw head should be 0.235 inch.Anchor clamps and sample are positioned at the testing equipment below, make screw head be centered on 0.5 inch edge of sample.One can hook is hung on the end of testing equipment.The weight that slowly increases bucket is thrust in the sample till 0.5 inch up to screw rod at least.If screw rod is from the sidepiece landing and tear and wear paper, then abandon this sample and retest.
Table 4
Example 8-test result II
The wallboard sample comprises 50g Extendospheres and 2cc surfactant.First kind of wallboard being tested comprises the sodium silicate binder mixture of 100g.Second kind of wallboard being tested comprises 75g sodium silicate binder mixture and 25g latex adhesive.The thickness range of test board is from 0.386 inch to 0.671 inch.Test is accomplished according to ASTM 473-3,423, E119 and D3273-00 standard.
Based on three samples, be that first kind of wallboard test and definite flexural strength are average 170lbf (on the white side direction).Based on three samples, find that second kind of wallboard is average 101lbf (under the white side direction).The highest measurement result of six specimen is 197lbf.Conventional gypsum wallboard as a comparison is 107lbf.
Confirm that edge hardness is average 15lbf.The average minimum edge hardness of gypsum wallboard is 11lbf.Sample demonstrates and compares 36% raising with gypsum samples.
Based on the average of 3 samples, measurement hold the nail intensity be 99lbf.On the other hand, measure gypsum wallboard hold the nail intensity be 77lbf.
Tested the thermal resistance of sample wallboard.Wallboard one side is raised to 100 ℃ and continues two hours, and the temperature rise that can survey do not occur at the cold side of sample.
Example weight and conventional gypsum are compared, find that sample is lighter by about 30% than gypsum plank.
The moulding of example 9-wallboard
As another example of wallboard moulding, form the silicate of soda wallboard through following steps.At first make the silicate of soda foaming through the Steol FS 406 that in 100g sodium silicate solution (O of Pq Corp. type adhesive), adds 2cc.It is 6 inches container for paint that mixture is placed diameter.Use one " Squirrel (squirrel-cage) " blender to come blend mixture, drilling machine, diameter that this blender is attached to the 540rpm operation are 3 inches.The operator is along rotating container for paint with the direction of the direction of rotation of blender.Mixture was foamed about one minute and 15 seconds.The volume of silicate of soda doubles during foaming process at least.Extendospheres with 50g
TM(having 300 microns to 600 microns size) adds in the mixture, and mixes one minute with " Squirrel " blender again.Then the finished product mixture is injected in the mould and also makes it smooth with being coated with charge bar.
In case the mixture of foaming is flattened in mould, just mould is placed the stove that is set in 85 ℃.Allow mixture under this temperature dry about 12 hours.
Fully after the drying lining paper is added on the core at core.Thin silicate of soda coating is coated in the back side of paper, and paper is placed on the core matrix.Core and paper are all covered by the polyester gas permeable material in all sides, are placed in then in the vacuum bag.Vacuum bag is placed the stove that is set in 85 ℃, to this parts effect vacuum.Allow these parts in stove dry 45 minutes to one hour.Take out component end item and be trimmed to the size of hope from stove then.Can randomly in core composition, add various materials to add speed.
Example 10-wallboard moulding II
Produce another wallboard according to the method in the example 9.The change part of the composition of wallboard is to use sodium silicate binder solution and the 25g organic bond of 75g.Before foaming, organic bond is added in the sodium silicate binder solution with Steol.
Example 11-wallboard moulding III
Produce another wallboard through at first hiding mould.With FEP lining one substrate.FEP is packed tightly to reduce lip-deep wrinkle.Fringeware (boarder piece) with Blue Flash Tape coating mould.Using Killer Red Tape that fringeware is attached to base. member is 14 inches * 18 inches border to form inside dimension.
Measure and reserve 500g microballon (being of a size of the 300-600 micron), 750g " O " type adhesive, 250g organic bond and 20cc blowing agent.About 2 minutes of the Squirrel mixer mixing O type adhesive of use 540RPM and blowing agent.Add organic bond to mixture and mixed for 30 seconds again.When mixing, slowly add microballon.When all microballons have all added, mixture is mixed 30 seconds or even up to mixture again.Mixture is injected mould and utilizes perching knife to make it smooth.It is further smooth to carry out effectively to shake mould again.Place 100 ℃ dry 12 to 18 hours of stove till finish-drying on mould.Through at first cutting a slice lining paper and a slice finishing paper that are a bit larger tham panel paper is attached on the sample.Uniform sodium silicate solution coating is coated to a side of paper.Paper is placed on the end face and bottom surface of panel, exert pressure equably from the teeth outwards.Can come randomly to exert pressure through packed this panel in vacuum ground.Can panel be put back in 100 ℃ stove till about surface that adhered to panel in 15 minutes up to paper fully.
Example 12-sound trap acoustical testing
Configuration structure with as indicated contrasts sound trap, and wherein first and second constructional materialss all have the core matrix of particulate in adhesive, on the both sides of first and second constructional materialss, all have finish material.Similarly constructing the test sound trap under the configuration, but wherein first constructional materials is lacking finish material on a side of second constructional materials.Two sound traps are further tested as follows:
Each sound trap is placed a sound attenuation room, and speaker phone is on a side of sound trap, and sound pressure meter is positioned on the opposite side of sound trap.Being 110Hz with scope sequentially transmits towards sound trap from speaker phone at about 100dB to a series of tones of 8000Hz, and on the opposite side of sound trap, writes down sound pressure level.For the contrast sound trap, the average sound pressure level that arrives the tone of 8000Hz to 110Hz is about 58.5dB.For the test sound trap, the average sound pressure level that arrives the tone of 8000Hz to 110Hz is about 51.5dB.Therefore, from one of constructional materials parts remove finishing paper cause crossing over sound trap about 7.0dB sound falls.
The present invention will be described with reference to concrete exemplary embodiment in above-mentioned detailed description.Yet should be appreciated that not deviating under the prerequisite that the present invention likes the scope that claim illustrates enclosed, can make various modification and change.Should to be regarded as with accompanying drawing be illustrative and nonrestrictive with describing in detail, all these type of modification and change (if existence) all should fall within this description and the scope of the present invention illustrated in.
More specifically; Though described illustrative exemplary embodiment of the present invention at this; But the present invention is not limited to these embodiment; But comprise any or all embodiment that has modification, omission, combines (for example, striding the combination of the aspect of each embodiment), adaptation and/or change that those skilled in the art can expect based on above-mentioned detailed description.Qualification in the claim should broadly explain based on the language that is adopted in the claim, and is not limited to above-mentioned detailed description or in the application's the term of execution described example, will be understood that these example right and wrong are exclusive.For example, in the present invention, term " preferably " is non-exclusive, and wherein this term is intended to the meaning of expression " preferably, but be not limited to ".Any step cited in any method or the technology claim can be carried out with any order, and is not limited to the order that in claim, proposes.The qualification of device+function or step-plus-function will only be adopted under these circumstances, promptly in specific claim limits, have all following conditions: a) clearly stated " be used for ... device " or " be used for ... step "; And b) clearly stated corresponding function.Structure, material or the action of supportive device+function in the description of this paper, have clearly been stated.Therefore, scope of the present invention should only be confirmed by accompanying claims and their legal equivalent, rather than confirmed by above description that provides and example.
Prescription with the content of expectation patent certificate protection does.
Claims (23)
1. acoustic attenuation constructional materials comprises:
Be arranged on the core matrix on the finish material, said core matrix comprises:
A large amount of particulates, between about 25% to about 60%, wherein each particulate has the inside of external surface and hollow to the amount of said particulate by weight, and has the average-size between about 10 microns to about 1500 microns; And
Be configured to support the sodium silicate binder of said particulate, the amount of said adhesive is by weight between about 40% to about 60%;
Wherein, Thereby a side of said core matrix exposes the face that exposes at least basically that forms said constructional materials at least in part, to increase acoustic attenuation through compare the reflection that reduces the sound wave of impact on said constructional materials with the contrast constructional materials that lacks exposure.
2. according to the constructional materials of claim 1, it is characterized in that the said exposed side of part at least of said core matrix exposes basically.
3. according to the constructional materials of claim 1, it is characterized in that said particulate is filled with inert gas.
4. according to the constructional materials of claim 1, it is characterized in that said particulate is processed by flying dust.
5. according to the constructional materials of claim 1, it is characterized in that the said mask that exposes basically has a plurality of protuberances that extend from said core matrix.
6. according to the constructional materials of claim 5, it is characterized in that said a plurality of protuberances are spaced apart with predetermined pattern.
7. according to the constructional materials of claim 1, also comprise the acoustic window material on the said exposure that is arranged on said constructional materials.
8. according to the constructional materials of claim 1, it is characterized in that said acoustic window material is a Web materials.
9. according to the constructional materials of claim 1, also comprise and the related rigid material of said core matrix phase.
10. according to the constructional materials of claim 9, it is characterized in that said rigid material is arranged in the said core matrix.
11. a system that is used to use the constructional materials attenuate sound comprises:
First constructional materials;
Second constructional materials, said second constructional materials be arranged on the substantially parallel orientation of said first constructional materials in make said first constructional materials and said second constructional materials separate certain distance to form the sound trap space;
Wherein, said first constructional materials comprises the core matrix that is arranged on the finish material, and said core matrix comprises:
A large amount of particulates, between about 25% to about 60%, wherein each particulate has the inside of external surface and hollow to the amount of said particulate by weight, and has the average-size between about 10 microns to about 1500 microns; And
Be configured to support the sodium silicate binder of said particulate, the amount of said adhesive is by weight between about 40% to about 60%;
Wherein, Thereby the said first constructional materials core matrix exposes the face that exposes at least basically that forms said first constructional materials at least in part towards a side of said second constructional materials, to increase acoustic attenuation through compare the reflection that reduces the sound wave of impact on said first constructional materials with the contrast constructional materials that lacks exposure.
12., also comprise the building structure that is positioned at said sound trap space according to the system of claim 11.
13. the system according to claim 12 is characterized in that, said first constructional materials is supported on around first side of said building structure and said second constructional materials is supported on around second side of said building structure.
14. the system according to claim 13 is characterized in that, said first constructional materials, said second constructional materials and said building structure form partition wall.
15. the system according to claim 11 is characterized in that, said second constructional materials comprises the core matrix that is arranged on the finish material, and said core matrix comprises:
A large amount of particulates; And
Be configured to support the adhesive of said particulate.
16. system according to claim 15; It is characterized in that; Thereby the said second constructional materials core matrix exposes the face that exposes at least basically that forms said second constructional materials towards a side of said first constructional materials, to increase acoustic attenuation through compare the reflection that reduces the sound wave of impact on said second constructional materials with the contrast constructional materials that lacks exposure.
17., also comprise the interlayer material in the said sound trap that is arranged between said first constructional materials and said second constructional materials according to the system of claim 11.
18. the system according to claim 11 is characterized in that, at least one in said first constructional materials or said second constructional materials also comprises and the related rigid material of said core matrix phase.
19. the system according to claim 17 is characterized in that, said rigid material is arranged in the said core matrix.
20. a method of utilizing the constructional materials attenuate sound comprises:
Sound wave is introduced in the said sound trap according to claim 11, thereby said sound wave is attenuated through in said first constructional materials core matrix and the said second constructional materials core matrix at least one through part at least.
21. the method according to claim 20 is characterized in that, the two is attenuated said sound wave through the said first constructional materials core matrix and the said second constructional materials core matrix through part at least.
22. the method according to claim 20 is characterized in that, said sound wave reduces owing to the reflection of comparing the said sound wave of impact on the said exposure of said first constructional materials with the contrast constructional materials that lacks exposure and is attenuated at least in part.
23. a partition wall comprises:
Braced structures;
First building panel, this first building panel are arranged on first side of said braced structures; And
Second building panel; This second building panel is arranged on second side of said braced structures; And be arranged on the substantially parallel orientation of said first building panel in make said first building panel and said second building panel separate certain distance to form sound trap
Said first and second building panels include based on the about 25wt% of wet prescription and arrive the inorganic bond of about 36wt% and the organic bond that about 2wt% arrives about 6wt% to the particulate of about 60wt%, about 20wt%.
Applications Claiming Priority (7)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US12/077,951 | 2008-03-21 | ||
| US12/077,951 US20090004459A1 (en) | 2007-03-21 | 2008-03-21 | Utility materials incorporating a microparticle matrix |
| US8194908P | 2008-07-18 | 2008-07-18 | |
| US8195308P | 2008-07-18 | 2008-07-18 | |
| US61/081,949 | 2008-07-18 | ||
| US61/081,953 | 2008-07-18 | ||
| PCT/US2008/077757 WO2009117019A1 (en) | 2008-03-21 | 2008-09-25 | Sound attenutation building and material system |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201210154074.1A Division CN102767245B (en) | 2008-03-21 | 2008-09-25 | Sound attenuation building material and system |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN102046895A CN102046895A (en) | 2011-05-04 |
| CN102046895B true CN102046895B (en) | 2012-07-04 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN2008801293055A Active CN102046895B (en) | 2008-03-21 | 2008-09-25 | Sound attenutation building material and system |
| CN201210154074.1A Expired - Fee Related CN102767245B (en) | 2008-03-21 | 2008-09-25 | Sound attenuation building material and system |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201210154074.1A Expired - Fee Related CN102767245B (en) | 2008-03-21 | 2008-09-25 | Sound attenuation building material and system |
Country Status (5)
| Country | Link |
|---|---|
| EP (2) | EP3309313B1 (en) |
| CN (2) | CN102046895B (en) |
| CA (1) | CA2719087A1 (en) |
| MX (2) | MX358300B (en) |
| WO (1) | WO2009117019A1 (en) |
Families Citing this family (3)
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| RU2658925C2 (en) * | 2015-07-27 | 2018-06-26 | Анна Михайловна Стареева | Single piece spherical sound absorber for mobile vehicles |
| US9903116B2 (en) * | 2015-09-21 | 2018-02-27 | United States Gypsum Company | Acoustical gypsum wallboard |
| CN109457889A (en) * | 2018-11-26 | 2019-03-12 | 江苏标榜装饰新材料股份有限公司 | Microballon decorative panel and microballon decorating structure |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6251979B1 (en) * | 1998-11-18 | 2001-06-26 | Advanced Construction Materials Corp. | Strengthened, light weight wallboard and method and apparatus for making the same |
| JP2002144468A (en) * | 2000-11-16 | 2002-05-21 | Toyo Aluminium Kk | Composite sheet, method for manufacturing the same and panel equipped with composite sheet |
| CN1381420A (en) * | 2001-04-18 | 2002-11-27 | 张梅清 | Microgranular composition |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| DE3100626C2 (en) * | 1981-01-12 | 1985-05-15 | Schmittmann, Hans-Bernd, Dipl.-Chem. Dr.Rer.Nat., 5620 Velbert | Flame-retardant plastics, especially those which can be used as building materials or the like, processes for their production and their use as components |
| US4960184A (en) * | 1989-11-09 | 1990-10-02 | Bruce Woodward | Sound absorbing structure |
| KR960007958B1 (en) * | 1993-12-10 | 1996-06-17 | 재단법인 한국전자통신연구소 | Routing information management method in signaling network operations system |
| US5600930A (en) * | 1995-04-10 | 1997-02-11 | Drucker; Ernest R. | Construction system using lightweight fire-resistant panels |
| JPH09156010A (en) * | 1995-12-11 | 1997-06-17 | Yokohama Rubber Co Ltd:The | Manufacture of sound absorbing panel |
| US5796055A (en) * | 1997-01-13 | 1998-08-18 | Ppg Industries, Inc. | Sound absorbing article and method of making same |
| DE19839973A1 (en) * | 1998-09-02 | 2000-03-23 | Fraunhofer Ges Forschung | Plate-shaped component |
| GB2375358B (en) * | 2001-04-24 | 2004-05-26 | Sound Reduction Systems Ltd | Sound attenuating board |
| JP3918699B2 (en) * | 2002-09-20 | 2007-05-23 | ヤマハ株式会社 | Hollow panel |
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2008
- 2008-09-25 CN CN2008801293055A patent/CN102046895B/en active Active
- 2008-09-25 CN CN201210154074.1A patent/CN102767245B/en not_active Expired - Fee Related
- 2008-09-25 MX MX2013013476A patent/MX358300B/en unknown
- 2008-09-25 WO PCT/US2008/077757 patent/WO2009117019A1/en active Application Filing
- 2008-09-25 EP EP17187078.5A patent/EP3309313B1/en active Active
- 2008-09-25 MX MX2010010289A patent/MX2010010289A/en active IP Right Grant
- 2008-09-25 CA CA2719087A patent/CA2719087A1/en not_active Abandoned
- 2008-09-25 EP EP08873511.3A patent/EP2262959B1/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6251979B1 (en) * | 1998-11-18 | 2001-06-26 | Advanced Construction Materials Corp. | Strengthened, light weight wallboard and method and apparatus for making the same |
| JP2002144468A (en) * | 2000-11-16 | 2002-05-21 | Toyo Aluminium Kk | Composite sheet, method for manufacturing the same and panel equipped with composite sheet |
| CN1381420A (en) * | 2001-04-18 | 2002-11-27 | 张梅清 | Microgranular composition |
Also Published As
| Publication number | Publication date |
|---|---|
| CN102046895A (en) | 2011-05-04 |
| MX358300B (en) | 2018-08-14 |
| CN102767245B (en) | 2014-11-26 |
| WO2009117019A1 (en) | 2009-09-24 |
| EP2262959A4 (en) | 2014-07-30 |
| EP2262959B1 (en) | 2017-08-23 |
| MX2010010289A (en) | 2010-11-05 |
| EP3309313B1 (en) | 2024-04-03 |
| EP3309313A1 (en) | 2018-04-18 |
| CA2719087A1 (en) | 2009-09-24 |
| EP2262959A1 (en) | 2010-12-22 |
| CN102767245A (en) | 2012-11-07 |
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