Utility materials incorporating a microparticle matrix

• US 8,997,924 B2
• Filed: 01/07/2013
• Issued: 04/07/2015
• 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): San Martin, Edgardo
• Application Number:
  US13/735,910
• Publication Number:
  US 20130209782A1
• Time in Patent Office: 820 Days
• Field of Search: 181/293, 181/294, 181/290, 181/286, 181/210, 525/78, 521/44, 521/45, 428/318.4, 428/304.4, 428/323, 428/312.2, 428/313.3, 264/241, 264/261
• US Class Current: 181/293
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: C04B 18/082 Cenospheres
• CPC Class Codes: C04B 20/0036 Microsized or nanosized
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/2092 Resistance against biological degradation
• CPC Class Codes: C04B 2111/27 Water resistance, i.e. waterproof or water-repellent materials
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: C04B 38/10 by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• 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 1/90 slab-shaped
• CPC Class Codes: E04C 2/02 characterised by specified materials translucent E04C2/54
• 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: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• 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 428/249971 : Preformed hollow element-containing
• 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 428/2982 : Particulate matter [e.g., sphere, flake, etc.]

Abstract

A utility material can include microparticles, an organic binder and an inorganic binder. The microparticles can be present in an amount from about 25 wt % to about 60 wt %, based on wet formulation. The inorganic binder can optionally include sodium silicate. The organic binder can optionally include a vinyl acetate. The utility material can be formed into a variety of different products or building materials, such as wallboard, shear panels. In addition, the building material may be particularly used to attenuate sound.

Claims

1. A building material comprising:

a wallboard paper sheet;

a core matrix comprised of a plurality of microparticles having a generally spherical shape and a hollow interior, and at least one binder for adhering said microparticles together, said core matrix defining first and second surfaces, wherein the first surface of the core matrix is disposed on the sheet, wherein the second surface of the core matrix is an exposed rough surface so as to expose a portion of the plurality of microparticles and the at least one binder; and

a multi-elevational surface configuration formed in at least a part of said exposed rough surface of said core matrix that is configured to enhance the sound attenuation properties of said building material.

2. The building material of claim 1, further comprising a reinforcing member disposed within said core matrix, said reinforcing member being configured to reinforce said building material in one or more ways selected from the group consisting of reinforcing against sound transmission, reinforcing against heat transfer, enhancing strength, and any combination of these.

3. The building material of claim 1, wherein said building material comprises a Sound Transmission Class (STC) rating between 35 and 65.

4. The building material of claim 1, wherein said building material comprises a decibel noise reduction value between 55 and 65 dB at 3000 Hz, for a ½

inch thick wallboard.

5. The building material of claim 1, further comprising a plurality of cavities strategically formed throughout said core matrix.