Sound attenuation building material and system

• US 9,076,428 B2
• Filed: 05/20/2013
• Issued: 07/07/2015
• Est. Priority Date: 03/21/2007
• Status: Expired due to Fees

• Current Assignee: Microsphere Labs LLC
• Original Assignee: Ashtech Industries, LLC
• Inventors: Kipp, Michael D., Pugh, Dilworth L., Ridges, Michael D., McCarvill, William T.
• Primary Examiner(s): Nguyen, Chi Q
• Application Number:
  US13/898,333
• Publication Number:
  US 20140151152A1
• Time in Patent Office: 778 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: 1/1
• 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 cenospheres and perlite; and

a sodium silicate binder adhering together the cenospheres and perlite to form a porous core matrix;

an acoustically transparent material disposed on the exposed face of the building material; and

wherein the acoustically transparent material is a mesh material.

2. The building material of claim 1, wherein the cenospheres have an outer shell and a hollow interior filled with a gas.

3. The building material of claim 1, wherein the cenospheres have a crush strength between 3000 psi and 5000 psi.

4. The building material of claim 1, wherein the sodium silicate is a solution of sodium silicate in water.

5. The building material of claim 4, wherein the solution comprises a 1:

1 ratio of sodium silicate to water.

6. The building material of claim 1, wherein the cenospheres have a 300 micron to 600 micron diameter size range.

7. The building material of claim 1, wherein the core matrix further comprises a setting agent.

8. The building material of claim 7, wherein the setting agent is Class C fly ash.

9. The building material of claim 1, wherein the core matrix further comprises a water soluble polymer.

10. The building material of claim 9, wherein the water soluble polymer is polyethylene oxide.

11. The building material of claim 1, wherein the core matrix further comprises a surfactant.

12. The building material of claim 1, wherein the core matrix further comprises a foaming agent.

13. The building material of claim 1, 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.

14. The building material of claim 13, wherein the exposed face has a plurality of protrusions extending from the core matrix.

15. The building material of claim 14, wherein the plurality of protrusions are spaced in a predetermined pattern.

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

17. The building material of claim 16, wherein the rigid material is disposed within the core matrix.