Sound attenuation building material and system

• US 8,445,101 B2
• Filed: 09/25/2008
• Issued: 05/21/2013
• Est. Priority Date: 03/21/2007
• Status: Active Grant

• Current Assignee: Akamai Materials Incorporated
• Original Assignee: Ashtech Industries, LLC
• Inventors: Kipp, Michael D., Pugh, Dilworth L., Ridges, Michael D., McCarvill, William T.
• Primary Examiner(s): Michener, Joshua J
• Assistant Examiner(s): Nguyen, Chi Q
• Application Number:
  US12/238,399
• Publication Number:
  US 20090107059A1
• Time in Patent Office: 1,699 Days
• Field of Search: 521/44, 521/45, 521/678, 428/318.4, 428/304.4, 428/323, 428/340, 156/39, 181/290
• US Class Current: 428/318.4
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/082 Cenospheres
• CPC Class Codes: C04B 20/0032 characterised by the gas filling pores, e.g. inert gas or air at reduced pressure
• CPC Class Codes: C04B 2111/52 Sound-insulating materials
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: E04B 1/8209 sound absorbing devices E04B1/8218, E04B1/8227 take precedence
• CPC Class Codes: E04B 1/84 Sound-absorbing elements
• CPC Class Codes: E04B 1/8409 sheet-shaped
• CPC Class Codes: E04B 1/86 slab-shaped
• CPC Class Codes: E04B 2001/8419 Acoustical cones or the like, e.g. for anechoic chambers
• CPC Class Codes: E04B 2001/8423 Tray or frame type panels or blocks, with or without acoustical filling
• CPC Class Codes: E04B 2001/8461 layered
• CPC Class Codes: E04B 2001/8476 with acoustical cavities, with or without acoustical filling
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/16 of fibres, chips, vegetable stems, or the like
• CPC Class Codes: G10K 11/165 Particles in a matrix
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249967 : Inorganic matrix in void-containing component
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/27 : Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]

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.

Claims

1. A sound attenuating building material, comprising:

a core matrix disposed on a facing material, the core matrix comprising;

a plurality of microparticles, wherein the microparticles are cenospheres;

wherein at least a portion of the plurality of microparticles are filled with an inert gas; and

about 25 wt.% to 60 wt.% of the cenospheres based on wet formation, from about 20 wt.% to about 36 wt.% of an inorganic binder and from about 2 wt.% to about 6 wt.% of an organic binder; and

a binder adhering together the microparticles to form a porous core matrix;

wherein a side of the core matrix is at least partially exposed to create an exposed face of the building material 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.

2. The building material of claim 1, wherein the at least partially exposed side of the core matrix is substantially exposed.

3. The building material of claim 1, wherein the substantially exposed face has a plurality of protrusions extending from the core matrix.

4. The building material of claim 3, wherein the plurality of protrusions are spaced in a predetermined pattern.

5. The building material of claim 1, further comprising an acoustically transparent material disposed on the exposed face of the building material.

6. The building material of claim 1, wherein the acoustically transparent material is a mesh material.

7. The building material of claim 1, further comprising a rigid material associated with the core matrix.

8. The building material of claim 7, wherein the rigid material is disposed within the core matrix.

9. A system for attenuating sound using a building material, comprising

a first building material;

a second building material disposed in a substantially parallel orientation to the first building material such that the first building material and the second building material are separated by a distance to create a sound trap space;

wherein the first building material comprises a core matrix disposed on a facing material, the core matrix comprising;

a plurality of microparticles, wherein the microparticles are cenospheres;

wherein at least a portion of the plurality of microparticles are filled with an inert gas; and

about 25 wt.% to 60 wt.% of the cenospheres based on wet formation, from about 20 wt.% to about 36 wt.% of an inorganic binder and from about 2 wt.% to about 6 wt.% of an organic binder; and

a binder adhering together the microparticles to form a porous core matrix;

wherein a side of the first building material core matrix facing the second building material is exposed to create an at least substantially exposed face of the first building material to increase sound attenuation by reducing reflections from sound waves impinging on the first building material as compared to a control building material lacking an exposed face.

10. The system of claim 9, further comprising a building structure located within the sound trap space.

11. The system of claim 10, wherein the first building material is supported about a first side of the building structure and the second building material is supported about a second side of the building structure.

12. The system of claim 11, wherein the first building material, the second building material, and the building structure form a walled partition.

13. The system of claim 9, wherein the second building material comprises a core matrix disposed on a facing material, the core matrix comprising:

a plurality of microparticles, wherein the microparticles are cenospheres; and

a binder adhering together the microparticles to form a porous core matrix.

14. The system of claim 13, wherein a side of the second building material core matrix facing the first building material is exposed to create an at least substantially exposed face of the second building material to increase sound attenuation by reducing reflections from sound waves impinging on the second building material as compared to a control building material lacking an exposed face.

15. The system of claim 9, further comprising an insulation material disposed within the sound trap between the first building material and the second building material.

16. The system of claim 15, wherein the rigid material is disposed within the core matrix.

17. The system of claim 9, wherein at least one of the first building material or the second building material further includes a rigid material associated with the core matrix.

18. A method of attenuating sound with a building material, comprising:

introducing sound waves into the sound trap of claim 9, such that the sound waves are attenuated by passing at least partially through at least one of the first building material core matrix and the second building material core matrix.

19. The method of claim 18, wherein the sound waves are attenuated by passing at least partially through both the first building material core matrix and the second building material core matrix.

20. The method of claim 18, wherein the sound waves are at least partially attenuated as a result of reduced reflections from the sound waves impinging on the exposed face of the first building material as compared to a control building material lacking an exposed face.

21. A walled partition comprising:

a support structure;

a first building panel disposed on a first side of said support structure; and

a second building panel disposed on a second side of said support structure, and in a substantially parallel orientation to the first building panel such that the first building panel and the second building panel are separated by a distance to create a sound trap,

said first and second building panels each comprising from about 25 wt % to about 60 wt % of cenospheres based on wet formulation, from about 20 wt % to about 36 wt % of an inorganic binder, and from about 2 wt % to about 6 wt % of an organic binder.