Coating material for achieving sound-dampening and method for the same

Abstract

Sound-dampening material, including a base coat and a top coat, and a method for sound-dampening a surface, are described. The base coat includes about 20-50 percent rubber emulsion, about 10-20 percent carbonate filler, about 3-10 percent fire retardant, about 3-10 percent opacity filler, and about 10-64 percent of other components. The top coat includes about 40-80 percent of a rubber emulsion, about 10-20 percent of a carbonate filler, about 3-10 percent of a fire retardant, about 3-10 percent of an opacity filler, and about 0-44 percent of other components. The method includes applying a base coat to a desired thickness allowing the base coat to dry, then applying a top coat over the base coat to a desired thickness.

Claims

1. A sound-dampening coating material comprising: a base coat material having an applied thickness in the range of from about 25 to about 30 mil, the base coat material having the following formula: 20 to 40 percent by weight of a rubber emulsion; about 10 to about 20 percent by weight of a carbonate filler; about 3 to about 10 percent by weight of a fire retardant; about 3 to about 10 percent by weight of an opacity filler; and about 10 to about 64 percent by weight of other components for affecting characteristics of the base coat material; a top coat material applied over the base coat material to a thickness in the range of from about 7 to about 10 mil, the top coat material having the following formula: about 40 to about 80 percent by weight of a rubber emulsion; about 10 to about 20 percent by weight of a carbonate filler; about 3 to about 10 percent by weight of a fire retardant; about 3 to about 10 percent by weight of a opacity filler; and about 0 to about 44 percent by weight of other components for affecting characteristics of the top coat material.

2. The sound-dampening coating material of claim 1, wherein the other components for affecting characteristics of the base coat material are selected from the group consisting of defoamer, freeze/thaw additive, surfactant, biocide, dispersant, fungicide, tackifier, pigment dispersion, diluent, thickener, pH adjuster and the like.

3. The sound-dampening coating material of claim 2, wherein the freeze/thaw additive is propylene glycol.

4. The sound-dampening coating material of claim 2, wherein the dispersant is potassium tripolyphosphate.

5. The sound-dampening coating material of claim 2, wherein the diluent is water.

6. The sound-dampening coating material of claim 2, wherein the thickener is acrylic emulsion thickener.

7. The sound dampening coating material of claim 1, wherein the other components for affecting characteristics of the top coat material are selected from the group consisting of defoamer, freeze/thaw additive, surfactant, biocide, dispersant, fungicide, diluent, thickener, pH adjuster and the like.

8. The sound-dampening coating material of claim 1, wherein the rubber emulsion is a styrenated butadiene rubber emulsion.

9. The sound-dampening coating material of claim 1, wherein the carbonate filler is calcium carbonate.

10. The sound-dampening coating material of claim 1, wherein the fire retardant is aluminum trihydrate.

11. The sound-dampening coating material of claim 1, wherein the opacity filler is titanium dioxide.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawing figures, embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.

(2) FIG. 1 is a cross section of a substrate coated with an embodiment of the sound-dampening of the present invention. FIG. 2 illustrates some commonly accepted STC ratings for wall constructions.

DETAILED DESCRIPTION

(3) While this invention is susceptible of embodiments in many different forms, there is shown in the drawings, and will herein be described in detail, preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated.

(4) The sound-dampening composition 10 of the present invention is preferably comprised of two coats, a base coat 12 and a top coat 14. With proper application, the disclosed composition 10 has the ability of raising the STC rating of a surface, such as a wall, ceiling, floor, etc., to provide needed sound-dampening. By sound-dampening it is meant that the transmission of noise over the frequency range of 125-4000 Hz, assuming a generally even frequency spectrum, is reduced as measured by a certified sound laboratory.

(5) In independent testing by Riverbank Acoustical Laboratories of Geneva, Ill., an STC of 52 was measured on a wall comprised of two gypsum board on insulated steel studs and properly coated with the disclosed sound-dampening composition. As indicated above, such a surface normally has an STC in the range of 43-44. The preferred composition 10 of the two separate coating layers, 12 and 14, are set forth in TABLE 2 (Base Coat 12) and TABLE 3 (Top Coat 14) below:

(6) TABLE-US-00001 TABLE 2 Base Coat Formula-Preferred Composition Weight Percentage Wt % Material (wt %) Range Commercial Product Styrenated Butadiene 39.170 20-50 CP-501 Emulsion Rubber Emulsion Defoamer 0.500 0-2 FGK Defoamer Freeze/Thaw Additive 0.500 0-2 Propylene Glycol Surfactant 0.250 0-1 Triton X-100 Biocide 0.200 0-1 Nuosept 91 Dispersant 0.100 0-1 Potassium Tripolyphosphate Dispersant 0.150 0-1 Tamol 851 Calcium Carbonate Filler 15.000 5-25 Atomite Fire Retardant 6.000 3-12 Aluminum Trihydrate Opacity Filler 6.500 3-12 2300 Titanium Dioxide Fungicide 0.200 0-1 Fungitrol 404D Styrenated Acrylic 30.000 20-40 SP-405 Emulsion Emulsion-Tackifier Pigment Dispersion 0.250 0-1 8594 Carbon Black Diluent 0.425 0-1 Water Acrylic Emulsion 0.650 0-2 CP-590 Emulsion Thickener pH Neutralization 0.100 0-1 AMP-95 TOTAL 100.00

(7) TABLE-US-00002 TABLE 3 Top Coat Formula-Preferred Composition Weight Percentage Wt % Material (wt %) Range Commercial Product Styrenated Butadiene 67.400 55-75 CP-501 Emulsion Rubber Emulsion Defoamer 0.500 0-2 FGK Defoamer Freeze/Thaw Additive 0.500 0-2 Propylene Glycol Surfactant 0.250 0-1 Triton X-100 Biocide 0.200 0-1 Nuosept 91 Dispersant 0.100 0-1 Potassium Tripolyphosphate Dispersant 0.150 0-1 Tamol 851 Calcium Carbonate Filler 15.000 5-25 Atomite Fire Retardant 6.000 3-12 Aluminum Trihydrate Opacity Filler 6.500 3-12 2300 Titanium Dioxide Fungicide 0.200 0-1 Fungitrol 404D Diluent 2.450 1-4 Water Acrylic Emulsion 0.650 0-2 CP-590 Emulsion Thickener pH Neutralization 0.100 0-1 AMP-95 TOTAL 100.00

(8) Each of the two formulas is preferably comprised of solids in the range of from about 55% to about 70%, most preferably about 62% solids. The composition is mixed together thoroughly with all ingredients, as would be understood by those skilled in the art. While a broader range of the weight percentage of each ingredient is possible to produce a suitable sound-dampening material, the uniquely preferred composition set forth above is believed to provide the greatest sound-dampening when applied to a surface.

(9) For example, a base coat 12 may have the following weight percentage variations while still producing suitable, though not necessarily optimal, sound-dampening characteristics: about 20 to about 50 percent by weight of a rubber emulsion; about 10 to about 20 percent by weight of a carbonate filler; about 3 to about 10 percent by weight of a fire retardant; about 3 to about 10 percent by weight of a opacity filler; and about 10 to about 64 percent by weight of other components for affecting characteristics of the base coat material.

(10) Likewise, the top coat 14 may have the following weight percentage variations while still producing suitable, though not necessarily optimal, sound-dampening characteristics: about 40 to about 80 percent by weight of a rubber emulsion; about 10 to about 20 percent by weight of a carbonate filler; about 3 to about 10 percent by weight of a fire retardant; about 3 to about 10 percent by weight of a opacity filler; and about 0 to about 44 percent by weight of other components for affecting characteristics of the top coat material.

(11) The other components for the base coat 12 include defoamer, freeze/thaw additive, surfactant, biocide, dispersant, fungicide, tackifier, pigment dispersion, diluent, thickener, and a pH adjuster. For the top coat 14, the other components are selected from the group consisting of defoamer, freeze/thaw additive, surfactant, biocide, dispersant, fungicide, diluent, thickener, and a pH adjuster.

(12) FIG. 1 illustrates a surface coated with the present invention. For best results, the base coat 12 is applied to a clean dry surface to a preferred thickness in the range of from about 25 to about 30 mil., and the top or finish coat 14 is applied to a thickness in the range of from about 7 to about 10 mil. The thickness of the coatings should be tested when wet, as shrinkage does occur during drying.

(13) The coatings, 12 and 14, are preferably applied by a commercial airless sprayer having a 3.17 to 3.19 mm spray tip to achieve a quality coverage of the surface, as such coverage may directly affect the sound-dampening quality of the material. However, where such a sprayer is impractical or unusable, each coating may be applied using a roller or brush. The user should be diligent in applying each coating, 12 and 14, across the complete surface and to the desired thickness.

(14) The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.