# US 12,180,700 B2 · Sound damping wallboard and method of constructing a sound damping wallboard

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- Number: US 12,180,700 B2
- Document ID: US12180700B2
- Status: Granted
- Kind: B2
- Application number: 18/178,858
- Filed: 2023-03-06
- Published: 2023-06-29
- Granted: 2024-12-31
- Earliest claimed: 2017-06-03
- Assignees: Gold Bond Building Products, LLC
- Applicants: Gold Bond Building Products, LLC
- Inventors: Jeff Hawk; Tommy Wilson; Michael N. Blades; Joseph J. Bailey; Brian G. Randall
- Web page: https://patentgrep.com/patent/US12180700B2

## CPC

- B32B 15/10: of wood
- E04B 1/8409: {sheet-shaped}
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 7/022: Mechanical properties
- B32B 7/06: permitting easy separation
- B32B 7/08: by mechanical means
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/005: {comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/04: comprising such {particular} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/041: {of metal}
- B32B 9/045: {of synthetic resin}
- B32B 9/047: {made of fibres or filaments}
- B32B 9/06: of paper or cardboard
- B32B 13/04: comprising such {water setting} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06)}
- B32B 13/06: of metal
- B32B 13/08: of paper or cardboard
- B32B 13/12: of synthetic resin
- B32B 13/14: next to a fibrous or filamentary layer
- B32B 15/043: {of metal (B32B15/01 takes precedence)}
- B32B 15/08: of synthetic resin
- B32B 15/085: comprising polyolefins
- B32B 15/12: of paper or cardboard
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 21/04: comprising wood as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/042; next to a bituminous or tarry layer B32B11/042; next to a water setting substance layer B32B13/10; next to a metal layer B32B15/10; next to a glass layer B32B17/062; next to a layer formed of natural mineral fibres or particles B32B19/042; next to a cellulosic plastic layer B32B23/044)}
- B32B 21/06: of paper or cardboard
- B32B 21/08: of synthetic resin
- B32B 21/10: Next to a fibrous or filamentary layer
- B32B 27/08: of synthetic resin
- B32B 27/10: of paper or cardboard
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B32B 29/02: next to a fibrous or filamentary layer
- E04B 1/86: slab-shaped
- E04B 2/7409: {special measures for sound or thermal insulation, including fire protection}
- E04C 2/043: {of plaster (E04C2/049 takes precedence)}
- E04C 2/288: composed of insulating material and concrete, stone or stone-like material
- G10K 11/168: Plural layers of different materials, e.g. sandwiches
- B32B 9/002: {comprising natural stone or artificial stone}
- B32B 2250/04: 4 layers
- B32B 2250/05: 5 or more layers
- B32B 2250/44: Number of layers variable across the laminate
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/12: on paper layer
- B32B 2255/26: Polymeric coating
- B32B 2255/28: Multiple coating on one surface
- B32B 2262/101: Glass fibres
- B32B 2307/10: having particular acoustical properties
- B32B 2307/72: Density
- B32B 2307/732: Dimensional properties
- B32B 2307/748: Releasability
- B32B 2607/00: Walls, panels
- C01F 11/46: Sulfates (dehydration of gypsum {for the production of calcium sulfate cements} C04B11/02)
- E04B 2001/8461: {layered}
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- G10K: SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
- C01F: COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS (metal hydrides {monoborane, diborane or addition complexes thereof} C01B6/00; salts of oxyacids of halogens C01B11/00; peroxides, salts of peroxyacids C01B15/00; sulfides or polysulfides of magnesium, calcium, strontium, or barium C01B17/42; thiosulfates, dithionites, polythionates C01B17/64; compounds containing selenium or tellurium C01B19/00; binary compounds of nitrogen with metals C01B21/06; azides C01B21/08; {compounds other than ammonia or cyanogen containing nitrogen and non-metals and optionally metals C01B21/082; amides or imides of silicon C01B21/087}; metal {imides or} amides C01B21/092, {C01B21/0923}; nitrites C01B21/50; {compounds of noble gases C01B23/0005}; phosphides C01B25/08; salts of oxyacids of phosphorus C01B25/16; carbides C01B32/90; compounds containing silicon C01B33/00; compounds containing boron C01B35/00; compounds having molecular sieve properties but not having base-exchange properties C01B37/00; compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites, C01B39/00; cyanides C01C3/08; salts of cyanic acid C01C3/14; salts of cyanamide C01C3/16; thiocyanates C01C3/20; {double sulfates of magnesium with sodium or potassium C01D5/12; with other alkali metals C01D15/00, C01D17/00})

## Abstract

A sound damping wallboard for installation on an installed wallboard, a sound damping wallboard system, and a method of constructing a sound damping wallboard on a building structure are disclosed. The sound damping wallboard includes a gypsum layer having a gypsum layer inner surface and a gypsum layer outer surface, a first sound damping layer disposed at the gypsum layer inner surface and having a first sound damping layer inner surface opposite the gypsum layer inner surface, a first encasing layer disposed at the gypsum layer outer surface, a second encasing layer disposed at the first sound damping layer inner surface, and a second sound damping layer disposed at the second encasing layer opposite the first sound damping layer inner surface.

## Claims

### Claim 1

A sound damping wallboard, comprising:
a gypsum layer, the gypsum layer being the only gypsum layer of the sound damping wallboard,
a first encasing layer disposed at an outer surface of the gypsum layer;
a first sound damping layer disposed at an inner surface of the gypsum layer and having a first sound damping layer surface opposite the gypsum layer;
a second sound damping layer disposed at the first sound damping layer surface and having a second sound damping layer surface opposite the first sound damping layer; and
a second encasing layer disposed at the second sound damping layer surface, the second sound damping layer being positioned on the second encasing layer, wherein the second encasing layer is a paper encasing layer or a fiberglass encasing layer;
wherein, when attached to an installed wallboard, the first sound damping layer is disposed between the gypsum layer and the installed wallboard.

### Claim 2 (depends on 1)

The sound damping wallboard of claim 1, further comprising a third encasing layer disposed on the first sound damping layer surface, wherein the second sound damping layer is positioned on the third encasing layer.

### Claim 3 (depends on 1)

The sound damping wallboard of claim 1, wherein the first and second sound damping layers comprise different sound damping materials.

### Claim 4 (depends on 1)

The sound damping wallboard of claim 1, wherein the first and second sound damping layers have different thicknesses.

### Claim 5 (depends on 1)

The sound damping wallboard of claim 1, wherein the first and second sound damping layers include the same polymer, wherein the first and second sound damping layers include different additives, wherein the additive in the first sound damping layer has a different density than the additive in the second sound damping layer.

### Claim 6 (depends on 1)

The sound damping wallboard of claim 1, wherein the first sound damping layer, the second sound damping layer, or both include an acrylic polymer or copolymer.

### Claim 7 (depends on 1)

The sound damping wallboard of claim 1, wherein the first encasing layer includes paper.

### Claim 8 (depends on 1)

The sound damping wallboard of claim 1, wherein the second encasing layer is a paper facing material.

### Claim 9 (depends on 1)

The sound damping wallboard of claim 1, wherein the second encasing layer comprises a different material than the first and third encasing layers.

### Claim 10 (depends on 1)

The sound damping wallboard of claim 1, wherein the sound damping wallboard exhibits a sound transmission loss of 20% or more in comparison to a wallboard without a sound damping layer.

### Claim 11 (depends on 1)

The method of claim 1, wherein the gypsum layer of the sound damping wallboard has a density that is higher than a density of the installed wallboard.

### Claim 12

A sound damping wallboard, comprising:
a gypsum layer,
a first encasing layer disposed at an outer surface of the gypsum layer;
a first sound damping layer disposed at an inner surface of the gypsum layer and having a first sound damping layer surface opposite the gypsum layer;
a second sound damping layer disposed at the first sound damping layer surface and having a second sound damping layer surface opposite the first sound damping layer; and
a second encasing layer disposed at the second sound damping layer surface, the second sound damping layer being positioned on the second encasing layer, wherein the second encasing layer is a paper encasing layer or a fiberglass encasing layer;
wherein the gypsum layer is the only gypsum layer having an encasing layer present thereon;
wherein, when attached to an installed wallboard, the first sound damping layer is disposed between the gypsum layer and the installed wallboard.

### Claim 13 (depends on 12)

The sound damping wallboard of claim 12, further comprising a third encasing layer disposed on the first sound damping layer surface, wherein the second sound damping layer is positioned on the third encasing layer.

### Claim 14 (depends on 12)

The sound damping wallboard of claim 12, wherein the first and second sound damping layers comprise different sound damping materials.

### Claim 15 (depends on 12)

The sound damping wallboard of claim 12, wherein the first and second sound damping layers have different thicknesses.

### Claim 16 (depends on 12)

The sound damping wallboard of claim 12, wherein the second encasing layer is a paper facing material.