CONSTRAINED LAYER FLOOR AND WALL DAMPING SYSTEMS USING HIGH-DENSITY REINFORCED CEMENT PANELS

Abstract

A method is provided for assembling a wall system to an existing frame for a wall, floor or roof, including: attaching a first dense, fiber-reinforced cement panel to the frame, the panel having an interior surface facing the frame, and an exterior surface; applying a layer of acoustic dampening material is applied to the exterior surface; and attaching a second dense, fiber-reinforced cement panel to at least one of the dampening material, the first panel, and the frame. A building panel is provided, including, a first panel of dense, fiber-reinforced cement; an internal layer of acoustic dampening material; and a second panel of dense, fiber-reinforced cement such that the dampening material is sandwiched between the first and second cement panels.

Claims

1. A method for assembling a wall system to an existing frame for a wall, floor or roof, comprises: attaching a first dense, fiber-reinforced cement panel to the frame, the panel having an interior surface facing the frame, and an exterior surface; applying a layer of acoustic dampening material is applied to the exterior surface; and attaching a second dense, fiber-reinforced cement panel to at least one of the dampening material, the first panel, and the frame.

2. The method of claim 1, wherein said acoustic dampening material is an adhesive, and attaching the second dense, fiber-reinforced cement panel includes inserting at least one fastener into at least one of the first dense, fiber-reinforced cement panel and the frame, then once the acoustic dampening material has set, removing the at least one fastener and patching at least one hole created by the fastener.

3. The method of claim 1, wherein said acoustic dampening material is provided in sheet form.

4. The method of claim 1, wherein applying said acoustic dampening material is accomplished through rolling, brushing, spraying or troweling.

5. The method of claim 1, wherein said acoustic dampening material is an adhesive including alkyl abietate, a plant resin and polyvinyl alcohol.

6. The method of claim 1, wherein said acoustic dampening material is an adhesive applied in a layer of 0.02 inch to 0.10 inch and including a polymer having a glass transition temperature (T.sub.g) of −10° C. to about 30° C.

7. The method of claim 6, wherein said adhesive further includes plasticizer.

8. The method of claim 1, wherein each of the first and second dense, fiber-reinforced cement panels have a density of 55 pcf or greater.

9. A building panel, comprising: a first panel of dense, fiber-reinforced cement; an internal layer of acoustic dampening material; and a second panel of dense, fiber-reinforced cement such that said dampening material is sandwiched between said first and second cement panels.

10. The building panel of claim 9, wherein each of said first and second panels have a density of 55 pcf or greater.

11. The building panel of claim 9, wherein said fiber reinforced cement panel includes one of Portland cement based, Magnesium Oxide cement based and polymer cement based panels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 is a fragmentary view of a wall created using the present wall system, with portions removed for clarity;

[0025] FIG. 2 is a cross-section taken along the line 2-2 of FIG. 1 and in the direction generally designated; and

[0026] FIG. 3 is a graphic representative of test data where sound absorption at various frequencies of several panel systems was compared.

DETAILED DESCRIPTION

[0027] Referring now to FIG. 1, the present sound reducing, constrained layer damping system is shown as a wall panel or generally indicated by reference number 10. For the purposes of the present application, since the same panel is usable in floor, wall, ceiling and roof systems, “wall” will be understood to refer to all such applications. The present system 10 is intended for use on a frame 12 including regularly spaced vertical studs 14 held in place by headers 16 and footers 18 using threaded fasteners or the like as are well known in the art. Also as is well known in the art, the frame 12 is made of wood or metal components. Further, the vertical studs 14 are commonly placed at a 16-inch spacing measured from their center, but may be spaced as far apart as 24-inches.

[0028] It is contemplated that the present system 10 is optionally useful in modular construction, whereby the present system either arrives pre-assembled as panels at a modular manufacturing facility, or as components which are then mounted onto the individual building modules. These modules are then completed and transported to an installation site, where they are stacked and connected to each other and then form the final modular building. It is also contemplated that the modular manufacturing site can be on the construction site or at a remote assembly location. Such modular construction is described in commonly-assigned U.S. Pat. No. 10,066,390 which is incorporated by reference.

[0029] Included in the damping system 10 is a first dense, fiber-reinforced, structural cementitious panel 20 as described in U.S. Pat. Nos. 6,986,812; 7,445,738; 7,670,520; 7,789,645; and 8,030,377, which are all incorporated herein by reference. It is also contemplated that the term “fiber-reinforced, structural cementitious panel” also refers to Portland cement-based, Magnesium Oxide cement-based and polymer cement-based panels. The first panel 20 has an interior surface 22 facing the frame 12, and an exterior surface 24. As is known in the art, the first panel 20 is secured to the frame 12 using fasteners 26. It is preferred that the first panel 20 has a density of at least 55 pounds per cubic foot (pcf). It is further preferred that the first panel 20 has a density of at least 80 pcf.

[0030] Applied to the exterior surface 24 is an acoustic dampening material 28 contemplated has having a wide range of compositions, but being resilient and absorbing sound waves. The dampening material 28 is optionally provided as an adhesive-like composition or as a sheet of material, and is also referred to as the adhesive 28 as a coating or a layer. When the former is utilized, the acoustic dampening material 28 is applied to the exterior surface 24 using a roller, a brush, a trowel, or is sprayed upon the panel 20 using conventional spraying equipment. When provided as a sheet of material, the dampening material 28 is secured to the panel 20 using fasteners 26 or adhesive. In the preferred embodiment, the dampening material 28 is applied in a thickness of 0.02 inch to 0.10 inch.

[0031] A second dense, fiber-reinforced, structural cementitious panel 30, preferably identical to the first panel 20, is applied to the dampening material 28 so that that dampening material is sandwiched between the panels 20, 30. In the preferred embodiment, the second panel 30 is attached to at least one of the dampening material 28, the first panel 20, and the frame 12.

[0032] By using two dense fiber reinforced cement panels 20, 30 to sandwich the less-dense acoustic dampening material 28, the resistive acoustic properties of the system 10 are greatly improved when compared to the sum of the material parts alone. The nature of the configuration of using the high density panels 20, 30 with the lower density constrained (sandwiched) material 28 provides the present acoustic insulation system 10, which is also able to support applied floor and wall loads. In a preferred embodiment, instead of being provided as a prefabricated panel, the present system 10 is installed or assembled at the jobsite.

[0033] In applications where the acoustic dampening material 28 is a settable adhesive, attaching the second dense, fiber-reinforced cement panel 30 includes inserting at least one fastener 32 into at least one of the first dense, fiber-reinforced cement panel 20 and the frame 12. Then, once the acoustic dampening material 28 has set, the fasteners 32 are removed and the resulting holes are patched as is well known in the art.

[0034] In applications where the dampening layer 28 is an adhesive, the adhesive layer includes a polymer such as a binder. A suitable adhesive 28 is disclosed in commonly-assigned U.S. patent application Ser. No. 16,356,303, filed Mar. 18, 2019, US 2019/0338516 which is incorporated by reference. The adhesive layer preferably has a balance between tackiness and relaxation time. That is, the adhesive should be pliable and tacky enough to adhere to both the panels 20 and 30. Concurrently, sound dampening is improved with a high viscoelastic relaxation time. That is, the velocity of sound depends on the elastic modulus of the adhesive (Ĕ (ω)). Ĕ (ω) can be expressed as Ĕ (ω)=E′(ω)+ïE″ (ω), where E′(ω) is the storage modulus and E″(ω) is the loss modulus of the adhesive and each can be expressed as EQ. 1 and EQ. 2, where ω is frequency (for STC ω ranges from 100-5000 Hz) and Θ. is the viscoelastic relaxation time of the adhesive.

[00001]$\begin{array}{cc}{E}^{\prime }\left(\omega \right)=\frac{E}{1+{\left(\omega \theta \right)}^2}& \mathrm{EQ}.1\end{array}$$\begin{array}{cc}{E}^{″}\left(\omega \right)=E*\frac{\omega \theta }{1+{\left(\omega \theta \right)}^2}& \mathrm{EQ}.2\end{array}$

[0035] Accordingly,

[00002]$\begin{array}{cc}\frac{E^{″}\left(\omega \right)}{E^{\prime }\left(\omega \right)}=\omega \theta .& \end{array}$

Therefore, for a high θ, the loss modulus is higher as compared to the storage modulus. So, when E″(ω) is greater than E′(ω), the acoustic attenuation in transmission increases. In addition, the adhesive preferably should maintain high viscoelastic relaxation time over time and a range of temperatures.

[0036] In a preferred embodiment, the polymer of the adhesive layer 28 is synthetic latex (i.e., an aqueous dispersion of polymer particles prepared by emulsion polymerization of one or more monomers). The latex is a film-forming polymer. The adhesive coating used to form the adhesive layer comprises an aqueous emulsion or dispersion comprising water, surfactant, and latex polymer selected from the group consisting of acrylics, styrene acrylics, acrylic esters, vinyl acrylics, vinyl chloride acrylic, styrene acetate acrylics, butyl acrylics, ethyl acrylics, ethylene polyvinyl acetate, polyvinyl acetate, styrene butadiene, and combinations thereof. If desired, the adhesive coating can have an absence of one or more of the foregoing polymers. Typical acrylics are polymers made from polymers of acrylic acid or acrylates, for example, polyacrylate, poly butyl acrylate, poly ethyl acrylate.

[0037] Preferably the latex polymer is selected from styrene-butadiene latex, styrene acrylic polymer, or acrylic ester polymer. Preferably, the latex polymer glass transition temperature is in the range from about −10° C. to about 30° C., more preferably from about 5° C. to about 30° C., more preferably from about −10° C. to about 20° C., and more preferably from about 10° C. to about 20° C.

[0038] Typically, the adhesive compositions 28 have at least 10 wt. %, more typically at least 20 wt. % latex polymer. For example, typically 15 to 70 wt. %, 45 to 70 wt. % or 45 to 60 wt. % latex polymer.

[0039] The adhesive compositions 28 may also include a plasticizer. Typically, the adhesive compositions 28 have 0 to 50 wt. % more typically 5 to 50 wt. %, furthermore typically 10 to 30 wt. % plasticizer. However, the adhesive compositions of the invention may have an absence of plasticizer.

[0040] Typical plasticizers may be any of abietates, phthalates, terephthalates, benzoates, and epoxidized oils such as epoxidized soybean oil (ESO), preferably the abietates.

[0041] The plasticizer improves both tack and sound attenuation. The term “tack” refers to the ability of a material to stick to the surface on momentary contact and then to resist separation.

[0042] Typical abietates are alkyl abietate, e.g., methyl abietate or ethyl abietate, or aralkyl abietate, for example benzyl abietate. The abietate is believed to work like a plasticizer and can be used to adjust the softness and tackiness of the adhesive.

[0043] The alkyl portion of the alkyl abietate can be a saturated linear or branched C.sub.1 to C.sub.16, preferably C.sub.1 to C.sub.8, alkyl group. The aralkyl group is typically benzyl.

[0044] Typical abietate plasticizers for use in the present invention are shown in Formula (I).

##STR00001##

wherein R is a saturated linear or branched C.sub.1 to C.sub.18, typically C.sub.1 to C.sub.16 or C.sub.1 to C.sub.8 or C.sub.1 to C.sub.4, alkyl group or an aralkyl group, preferably benzyl.

[0045] A representative of the alkyl abietate family, methyl abietate, is shown in Formula (II).

##STR00002##

[0046] Another representative of the alkyl abietate family, hexadecyl ester of abietic acid (i.e., cetyl abietate), is shown in Formula (III).

##STR00003##

wherein R is a linear alkyl group having the formula C.sub.16H.sub.33.

[0047] The adhesive compositions 28 also optionally include a resin. Typical resins may be any one or more synthetic resins. Typical resins may include any one or more plant resins. For example, typically one or more plant resins such as wood or gum rosin, ester gum, hydrogenated rosin, dammar gum, manila gum, coumarone-indene resin, copal, kauri gum, ethyl cellulose, mastic, and/or sandarac.

[0048] Typically, the adhesive compositions 28 have 0 to 25 wt. %, more typically 5 to 20 wt. % resin. However, the adhesive 28 is contemplated has having an absence of resin.

[0049] The adhesive compositions 28 also optionally include a polyvinyl alcohol.

[0050] Typically, the adhesive compositions 28 have 0 to 20 wt. %, more typically 5 to 15 wt. % poly vinyl alcohol. However, the adhesive compositions 28 optionally have an absence of polyvinyl alcohol.

[0051] A preferred adhesive composition 28 for achieving a balance of properties comprises the above-described polymer and a plasticizer, preferably an alkyl or aralkyl abietate plasticizer.

[0052] A more preferred adhesive composition 28 includes a mixture of acrylic polymer, resin, polyvinyl alcohol and alkyl abietate. The acrylic component, resin, and polyvinyl alcohol can provide tack. Further, the hydrogel nature of polyvinyl alcohol also allows it to retain some water in it, which helps with workability and reduction sound transmission of the adhesive.

[0053] To improve the workability, different inorganic components (e.g., calcium carbonate, anhydrous gypsum, etc.) can be also included.

[0054] If desired particles of sound compliant material and particles of sound-stiff material can also be included in the polymer adhesive layer 28. Such a polymer adhesive layer 28 includes the polymer adhesive as binder and a combination of first particles (the particles of sound compliant material) which are mostly compliant with respect to sound transmission and second particles (the particles of sound-stiff material) which are mostly stiff with respect to sound transmission.

[0055] It will be appreciated that the term “compliant material” is used interchangeably with the term “sound-compliant material” and it is understood broadly in this disclosure to mean a material which is at least partially flexible and able to transfer, dissipate and/or absorb sound waves through its body at least partially. It will be further appreciated that the term “stiff material” is used interchangeably with the term “sound-stiff material” and is understood broadly in this disclosure to mean any material which is likely to reflect most of energy from sound waves rather than transfer, dissipate and/or absorb the sound waves.

[0056] If desired, the sound-compliant particles are larger in size than sound-stiff particles such that each sound-compliant particle is surrounded with several sound-stiff particles. In other embodiments, sound-compliant particles and sound-stiff particles are of about same size. If desired, the sound-compliant particles and sound-stiff particles are used in the equal molar ratios. However, if desired the sound-compliant particles are the main component and sound-stiff particles are used in only much smaller amounts. In other embodiments, this ratio is reversed. For example, the molar ratio of sound-compliant particles to sound-stiff particles in the compliant coating may be from 1:1 to 1:1,000 or the molar ratio of sound-compliant particles to sound-stiff particles is 1,000:1 to 1:1.

[0057] If desired, the polymer adhesive layer 28 includes sound-compliant rubber particles, such as for example tire scrap particles, with sound-stiff nanometric silica particles. It will be further appreciated that any sound-compliant particles are optionally used, including, but not limited to, nitrile rubber, butyl rubber, ethylene propylene diene monomer (EPDM), natural rubber compounds, cotton fibers, organic fibers, inorganic fibers, polypropylene fibers, air-filled glass beads, polystyrene beads or polystyrene foam.

[0058] It will be also appreciated that any sound-stiff particles are usable in the compliant coating 28. Such sound-stiff particles may include, but are not limited to, silica particles, clay particles, calcium carbonate, perlite, gas-filled microspheres, hollow microspheres, cenospheres and inorganic glues. If desired, a combination of several sound-compliant materials can be mixed together with at least one sound-stiff material. If desired, a combination of several sound-stiff materials can be mixed together with at least one sound-compliant material. If desired, a combination of several sound-stiff materials can be mixed together with several sound-compliant materials.

[0059] However, without being limited by theory, sound has a higher transmission velocity through solid particulates. Therefore, to create the sharp discontinuity in velocity of sound at the different layers, the adhesive layer 28 preferably does not include solid particulates. Generally, the polymer adhesive layer 28 has an absence of mineral filler. Generally, the polymer adhesive layer 28 has an absence of gypsum. Generally, the polymer adhesive coating 28 applied has an absence of gypsum. Generally, the polymer adhesive coating 28 applied has an absence of calcium carbonate. Generally, the polymer adhesive coating 28 applied has an absence of magnesium carbonate. Generally, the polymer adhesive coating 28 applied has an absence of pigment. Generally, the polymer adhesive coating 28 applied has an absence of polyurea. Generally, the polymer adhesive coating 28 applied has an absence of inorganic particles. Generally, the polymer adhesive coating 28 applied has an absence of organic particles.

[0060] Generally, the polymer adhesive coating 28 applied has an absence of hydroxyethyl cellulose.

[0061] Generally, the adhesive layer 28 is applied in an amount equal to that to form a polymer coating having a thickness of about 0.02 inches to about 0.06 inches, a thickness of about 0.02 inches to about 0.05 inches.

[0062] In one embodiment, the adhesive layer 28 is applied by at least one method selected from the group consisting of spray coating, dip coating, rill application, free jet application, blade metering, rod metering, metered film press coating, air knife coating, curtain coating, flexography printing, and roll coating.

[0063] Methods for preparing synthetic latexes are well known in the art and any of these procedures can be used. Latexes typically have 1-55 wt. % binder (polymer) and water. Latex is an emulsion with emulsified polymer particles that can vary from 30 nm to 1500 nm. Therefore, the adhesive coating can comprise the emulsified polymer particles with an absence of other particles including solid particles, for example filler particles. Once the adhesive coating is applied and is the adhesive layer in the final inventive product, the latex forms a film (e.g., a continuous film) and is not in particulate form. Therefore, the adhesive layer can have an absence of particulates.

[0064] Referring now to FIG. 3, test results of a small scale STC test are shown. The small scale test method was a table-top arrangement: A material sample (gypsum wallboard or other panel), with approximate dimensions of 4″ wide by 48″ long, is held in place on each of long ends of the sample by silicone rubber padded clamps to mitigate undesirable vibrations. An electrodynamic shaker is placed upon vibration isolation pads and securely fastened to the table. An impedance head is attached to the shaker to measure the input force (frequency and amplitude), which will be used to normalize the frequency response function. The shaker is attached to the material sample at one end and is excited with a random noise signal ranging from 100 to 4000 Hz. Micro-accelerometers are attached equidistant points along the length of the material sample and are used to measure the frequency response function at the equidistant points along the material sample. The output frequency response function (frequency and amplitude) measured by the accelerometers is compared to the input frequency response function (frequency and amplitude) measured by the impedance head at the shaker. The difference between these input and output frequency responses is then correlated to acoustic transmission loss of the material sample.

[0065] Referring again to FIG. 3, it is seen that the preferred constriction of structural panels 20, 30 sandwiching a layer of adhesive 28, shown as Structural Panels with Glue, provided superior sound reduction results at all frequencies compared to a single structural panel alone, a pair of structural panes or conventional gypsum wallboard (NatGyp Board).

[0066] While a particular embodiment of the present constrained layer floor and wall damping systems using high-density reinforced cement panels has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.