OPTIMIZED PATTERN OF A DAMPING LAYER FOR WALL, FLOOR, AND CEILING CONSTRUCTIONS

Abstract

An acoustic damping article includes a substrate, wherein the substrate has a surface area S. The acoustic composition further includes a polymer resin. The polymer resin coats partially the surface area with a set of areas. The ratio of the coated areas over the surface area S is less than 1 and the polymer resin coverage is not greater than about 500 g/m2.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS)

The present application claims priority from U.S. Provisional Patent Application No. 61/542,140, filed Sep. 30, 2011, entitled “OPTIMIZED PATTERN OF A DAMPING LAYER FOR WALL, FLOOR, AND CEILING CONSTRUCTIONS,” naming inventors Sylvain Payot, Georges Moineau, Benjamin Mardaga, and Ahmet Comert, which application is incorporated by reference herein in its entirety.

FIELD OF THE DISCLOSURE

This disclosure, in general, relates to acoustic damping articles, construction materials formed using such acoustic damping articles, and methods of using acoustic damping articles.

BACKGROUND

Noise control has long been an issue in residential and business settings. With increasing urbanization and an increasing cost of real estate, individuals are living and working in closer proximity, increasing the need for noise reduction, particularly in high rise and apartment settings. To combat noise in such urban settings, several cities have implemented noise control building codes. Further, many building owners specify noise tolerance in construction specifications during construction.

However, many traditional methods for controlling noise are either cumbersome to install or ineffective. Particularly in the case of walls, traditional techniques include the use of resilient members disposed between a wall panel and a support. Such resilient members are often difficult to install and are expensive. Other traditional methods include the instillation of thick insulative members which have limited effectiveness and add additional steps to the installation and construction of walls or ceilings. Another method for modal damping factor includes laminating a viscoelastic material, such as QuietGlue® or Green Glue® between two constructions panels, e.g., drywall. However, one disadvantage for these materials is a long drying time the viscoelastic material as well as the cost associated with the amount of material to cover a panel.

As such, an improvement for acoustic damping article would be desirable.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 includes and illustration of an exemplary construction panel.

FIG. 2 includes a graph displaying damping factor dependency from the Patterned Interlayer Stiffness (PIS).

FIG. 3 includes a graph displaying damping performances for various stripe patterns over an audible frequency range.

FIG. 4 includes an illustration of viscoelastic polymer applied to a surface of a construction panel as a pattern of stripes.

FIGS. 5a through 5c include an illustration of viscoelastic polymer patterns applied to a surface of a construction panel.

The use of the same reference symbols in different drawings indicates similar or identical items.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

In one aspect, an acoustic damping article includes a substrate. The substrate has a surface area S_t. The damping article further includes a polymer resin. The polymer resin coats partially the surface area S_t with a set of n areas, S_c1 . . . , S_cn, wherein n>1. The ratio of the coated areas S_c over the surface area S_t can be less than 1. The acoustic damping article has a polymer resin coverage on the surface area of not greater than about 500 g/m².

In an example, the polymer resin coverage may not be greater than about 450 g/m², such as not greater than about 400 g/m², not greater than about 350 g/m², not greater than about 300 g/m², not greater than about 250 g/m² not greater than about 200 g/m², not greater than about 180 g/m², not greater than about 150 g/m², or even not greater than about 120 g/m².

In another embodiment, the polymer resin coverage may be at least about 20 g/m², such as at least about 30 g/m², at least about 40 g/m², at least about 50 g/m², at least about 60 g/m², at least about 70 g/m², at least about 80 g/m², at least about 90 g/m², at

least about 100 g/m², at least about 150 g/m², or even at least about 200 g/m².

In another aspect, an acoustic damping article includes a substrate. The substrate has a surface area S_t. The acoustic damping article further includes a polymer resin. The polymer resin coats partially the surface area S_t with a set of n areas, S_c1 . . . , S_cn, wherein n≧1. The ratio of the coated areas S_c over the surface area S_t is less than 1. The acoustic damping article has a modal damping factor in the range between 50 to 850 Hz of at least about 10%.

In an example, the acoustic damping article has a modal damping factor in the range between 50 to 850 Hz of at least about 20%, such as at least about 25%, at least about 30%, at least about 35%, at least about 40%, or at least about 45%.

In an example, the acoustic damping article has a modal damping factor in the range between 700 to 1500 Hz of at least about 10%, such as at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, or at least about 45%.

In another example, the acoustic damping article has a modal damping factor in the range between 1500 to 4500 Hz of at least about 10%, such as at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, or at least about 45%.

The modal damping factor can be estimated by means of a Mechanical Impedance Measurement (MIM). The MIM is a small scale test method directly inspired by a method developed for laminated glass and standardized in ISO 16940:2008. A beam sample having dimensions about 1 foot by 1 inch is cut out of the specimen to be tested and glued to a shaker at its center point. The FRF (frequency response function) of this free-free beam system is analyzed by measuring the punctual velocity and the input force. The application of the 3 dB rule to the anti-resonances of the mechanical impedance enables to determine the modal damping factor of the specimen at different frequencies.

In another embodiment, an acoustic damping article includes a substrate. The substrate has a surface area S_t. The acoustic damping article further includes a polymer resin. The polymer resin coats partially the surface area S_t with a set of n areas, S_c1 . . ., S_cn, wherein n>1. The ratio of the coated areas S_c over the surface area S_t is less than 1. The acoustic damping article can further include that a first shortest distance d1 between edges of two coated areas is not greater than about 35 mm.

In an example, the acoustic damping article may have a first shortest distance not greater than about 30 mm, such as not greater than about 28 mm, not greater than about 25 mm, not greater than about 23 mm, not greater than about 20 mm, not greater than about 18 mm, not greater than about 15 mm, not greater than about 13 mm, not greater than about 10 mm, not greater than about 8 mm, or even not greater than about 5 mm.

In another example, the acoustic damping article can have a second shortest distance between edges of two coated areas. The second shortest distance may not be greater than about 40 mm, such as not greater than about 35 mm, not greater than about 30 mm, not greater than about 28 mm, not greater than about 25 mm, not greater than about 22 mm, not greater than about 20 mm, not greater than about 18 mm, or even not greater than about 15 mm.

In yet another example, the acoustic damping article can have a third shortest distance between edges two coated areas. The third shortest distance may not be greater than about 45 mm, such as not greater than about 42 mm, not greater than about 40 mm, not greater than about 38 mm, not greater than about 35 mm, not greater than about 33 mm, not greater than about 30 mm, not greater than about 28 mm, or even not greater than about 25 mm.

In an example, the polymer resin is formed from a monomer, such as an acrylic acid, an acrylate, a methyl methacrylate, ethyl methacrylate, methacrylate, methyl acrylate, ethyl acrylate, vinyl acetate, derivatives thereof, or any combination thereof.

In another example, the polymer resin may be an acrylic resin. The acrylic resin may have an alkyl group having from 1-4 carbon atoms, a glycidyl group or a hydroxyalkyl group having from 1-4 carbon atoms. Representative acrylic polymers include polyacrylate, polymethyl methacrylate, polyethyl methacrylate, polybutyl methacrylate, polyglycidyl methacrylate, polyhydroxyethyl methacrylate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polyglycidyl acrylate, polyhydroxyethyl acrylate, or any combination thereof. In a particular example, the acrylic resin is in the form of an emulsion, such as a water-based emulsion. For example, the acrylic resin may be an adhesive acrylic resin, such as a pressure-sensitive adhesive acrylic resin.

In yet another example, the polymer resin may include polyvinyl chloride, plasticized polyvinyl chloride, polyvinyl acetate, a derivative thereof, or a copolymer thereof. In a further example, the polyvinyl acetate may be modified, such as through hydroxylization to form a copolymer poly(vinyl acetate-co-vinyl alcohol).

In even one further example, the polymer resin may include a polyurethane, an ethylene vinyl acetate, a polyolefin, a silicone, or any combination thereof.

In one embodiment, the polymer resin can include a filler. The filler can be a liquid filler, a solid filler, or an elastic filler. In an example, the filler can be selected from rubber, barium carbonate, barium sulfate, calcium sulfate, alumina, or silica. The filler can be in form of fibers, granules, or random particles. The size of these particles can be chosen in order to match the desired final thickness of the polymer resin layer.

In another embodiment, an acoustic damping article includes a substrate. The substrate has a surface area S_t. The acoustic damping article further includes a polymer resin. The polymer resin has a shear modulus G′ at 1000 Hz at room temperature and a thickness t. The polymer resin coats partially the surface area S_t with a set of n areas, S_c1 . . . , S_cn, wherein n>1. The ratio of the coated areas S_c over the surface area S_t is designated p and p is less than 1. The acoustic damping article can further include a Patterned Interlayer Stiffness (G′×p)/t is at least about 0.7 GN/m³.

The Patterned Interlayer Stiffness (PIS) is the product of shear modulus and coverage divided by the thickness of the polymer resin layer. In a construction panel, the PIS can correlate to the modal damping factor. A constant PIS can correlate to a constant damping factor. The unit of PIS can be expressed in giganewton (GN) per cubic meters.

In another embodiment, the acoustic damping article has a PIS of at least about 1 GN/m³, such as at least about 2 GN/m³, at least about 4 GN/m , at least about 6 GN/m³, at least about 8 GN/m³, at least about 10 GN/m³, at least about 12 GN/m³, at least about 14 GN/m³, or even at least about 16 GN/m³.

In another embodiment, the acoustic damping article has a PIS which is not greater than about 25 GN/m³, such as not greater than about 22 GN/m³, not greater than about 20 GN/m³, not greater than about 18 GN/m³, not greater than about 16 GN/m³, not greater than about 14 GN/m³, not greater than about 12 GN/m³, not greater than about 10 GN/m³, or even not greater than about 8 GN/m³.

In yet another embodiment the percent coverage p is at least about 0.1, such as at least about 0.2, at least about 0.3, at least about 0.4, at least about 0.5, at least about 0.6, at least about 0.7, at least about 0.8, or at least about 0.9.

In another embodiment the percent coverage p is not greater than about 0.95, such as not greater than about 0.9, not greater than about 0.85, not greater than about 0.8, not greater than about 0.75, not greater than about 0.7, not greater than about 0.65, not greater than about 0.6, not greater than about 0.55, not greater than about 0.5, not greater than about 0.45, or not greater than about 0.4.

In one embodiment, the thickness t is at least about 50 microns, such as at least about 75 microns, at least about 100 microns, at least about 150 microns, at least about 200 microns, at least about 250 microns, at least about 300 microns, at least about 350 microns, at least about 400 microns, at least about 450 microns, or at least about 500 microns.

In another embodiment, the thickness t is not greater than about 5000 microns, such as not greater than about 4000 microns, not greater than about 2000 microns, not greater than about 1000 microns, not greater than about 800 microns, not greater than about 600 microns, not greater than about 500 microns, not greater than about 450 microns, not greater than about 400 microns, not greater than about 350 microns, or not greater than about 300 microns.

In particular, the polymer resin has a low glass transition temperature. For example, the glass transition temperature of the polymer resin may be not greater than about 40° C. In an example, the glass transition temperature is not greater than about 35° C., such as not greater than 30° C. Further, the glass transition temperature of the polymer resin may be not greater than 25° C.

In one embodiment, the shear modulus G′ of the polymer resin can be not greater than about 100 MPa at about 1000 Hz and at room temperature, such as not greater than about 80 MPa, not greater than about 70 MPa, not greater than about 60 MPa, not greater than about 50 MPa, or even not greater than 40 MPa.

In another example, the shear modulus G′ of the polymer resin can be at least about 0.2 MPa, such as at least 0.5 MPa, at least about 1 MPa, at least about 2 MPa, at least about 5 MPa, at least about 10 MPa, at least about 20 MPa, or even at least about 40 MPa,

In another example, the acoustic damping article includes a polymer resin that has an inherent damping loss factor of at least about 0.4, such as at least about 0.5, at least about 0.6, at least about 0.7, at least about 0.8, at least about 0.9, or even at least about 1.

In one further example, the acoustic damping article includes a polymer resin coating at least one area of the coated areas is in the shape of a rectangle, a square, a triangle, a pentagon, a hexagon, a circle, a circular section, a ring , a section of a ring, a half ring, or a combination thereof. For example, the coated areas can be a rectangle abutting to a half ring, the half ring abutting to another rectangle, thereby the coated areas displaying a U-shape.

The rectangle is defined by sides a and b, wherein a proportion of length (a)/length (b) can be greater than about 1, such as greater than about 2, greater than about 5, greater than about 10, greater than about 20, greater than about 50, greater than about 100, greater than about 500, greater than about 1000, or even greater than about 5000.

In another example, the acoustic damping article includes a set of coated areas which forms a pattern of stripes. The pattern can be straight stripes, wavy stripes, zig-zag stripes, parallel stripes, or any combination thereof.

In another example, the acoustic damping article has a ratio of coated area S_c over total surface area S_t which is not greater than about 0.8, such as not greater than about 0.6, not greater than about 0.5, not greater than about 0.4, not greater than about 0.3, not greater than about 0.25, not greater than about 0.2, not greater than about 0.15, or even not greater than 0.1.

In one example, the substrate is selected from a wall panel, a ceiling panel, a dry wall, a tile, a subfloor, or a plastic sheet. In another example, the damping article includes a second substrate overlying the polymer resin.

In a fifth aspect, a method of preparing a construction panel includes coating a first major surface of a first rigid panel with a polymer resin in a set of areas. The coverage of the polymer resin cannot be greater than about 500 g/m².

In a sixth embodiment, a method of preparing a construction panel includes coating a first major surface of a first rigid panel with a polymer resin in a set of areas. The coated areas can have a first shortest distance d1 between edges of two coated areas of not greater than about 25 mm.

In another embodiment, an acoustic damping article includes a substrate. The substrate has a side with a total surface area S_t. The substrate further includes a polymer resin. The polymer resin has a shear modulus G′ at 1000 Hz and at room temperature. The shear modulus can be measured with a rheometer or a viscoanalyzer when the polymer resin is dried. The polymer resin has further a thickness t. The polymer resin can partially coat the side of the substrate in a set of n areas, S_c1, . . . , S_cn, wherein n>1. The percentage coverage p is the ratio of the sum of coated areas S_c over the surface area S_t. The percentage coverage p can be less than 1. The property of (G′xp)/t is at least 0.7 GN/m³.

In an example the polymer resin can be coated by spraying, brushing, plating, trowelling or stenciling. The coating can be conducted with a tool selected from a brush, a roller, a trowel, a spray gun, a caulking gun, wherein the tool is adapted for coating the surface in the set of areas and not coating the surface other than the set of areas. For example, the brush can have gaps to avoid coating a specific area between two coated areas. Likewise, a roller can have imprints, embossments, or sculptural reliefs on its surface that allows for partial coverage of a surface or coating a surface with a certain pattern. Moreover, it is contemplated that the brush can have varying bristle density along the brush's ferrule. Varying bristle density allows for applying the polymer resin at different amounts. Likewise, the roller can be prepared from various materials, such as foam polymers, that allow for different coverage of polymer resin across the length of the roll.

In another example, the trowel can have specifically designed notches. In another example, the spray gun can have a modified nozzle that allows for spraying a pattern of coated areas and uncoated areas. For example, such modification can include a set of divergent or convergent jets directing the polymer resin in certain areas while omitting other areas of the substrate.

In yet another example, the partial coating of the substrate can be done using a stencil technique. A stencil, e.g., a polymer sheet, includes cut outs of various shapes. The cut outs can be in forms of stripes, rectangles, squares, triangles, pentagons, hexagons, or any other polygons. The stencil is placed on a substrate and polymer resin is applied. After the polymer resin has been applied, the stencil is removed leaving a set of coated areas on the substrate.

In even one further example, a substrate can be coated with a polymer resin using a peel-off sheet. The peel-off sheet includes a polymer or paper backing sheet onto which a pattern of coated areas has been applied with polymer resin. The coated areas further can include an adhesive layer. The peel-off sheet is applied onto a substrate wherein the adhesive layer or the coated areas contact the substrate. The polymer resin is sandwiched between the substrate and the backing sheet. Afterwards, the backing sheet is removed. In another example, a second substrate can be placed on the coated area, thereby sandwiching the polymer resin between two substrates.

Moreover, the polymer resin can be coated on two liners having different release formulations between the coating and each liner. That way a pattern can be stored on a roll for custom-made use on construction sites or for customer-specified sale. Measured strips can be taken from the role, one liner removed and the pattern can be applied to a construction panel, while preserving the opposing side with a liner until the second construction panel is mounted to the wall. The polymer resin can also be coated on one liner having different release formulations between the coating on each side of the liner.

The polymer resin may be disposed between two relatively flat rigid members. For example, the polymer resin may be laminated between two rigid panels to form a construction panel for use in forming walls, ceilings, or floors. For example, the rigid panels may include wood, plywood, gypsum board, oriented strand board, cement board, plaster board, fiberboards, wallboard, gyproc, sheetrock, or any combination thereof. In an example, the acoustic damping article may be used to form a laminate for manufacturing walls. In another example, the acoustic damping article may be disposed between subflooring and flooring. In a further example, the acoustic damping article may be disposed between rigid members of a ceiling panel.

For example, as illustrated in FIG. 1, an acoustic damping article comprises a polymer resin 102 which is partially disposed between a first rigid panel member 104 and a second rigid panel member 106. Since the resin is partially disposed, there are polymer resin-free spaces 108 between the two panels 104 and 106. In particular, when disposed between the two rigid panels (104 and 106), the polymer resin may have a thickness in a range of 25 micrometers to 5 millimeters, such as a range of 100 micrometers to 5 millimeters, a range of 500 micrometers to 5 millimeters, or even a range of 1 millimeter to 5 millimeters. The thickness of the resin-free spaces can be equal to the thickness of the polymer resin as illustrated in FIG. 1. In other embodiments the thickness of the resin-free spaces can be different from the thickness of layer 102. For example, the resin-free spaces can have higher thickness than the layer 102. This can be accomplished, for example, by a rigid panel that has a pretreated surface with embossed channels or indentations in areas where the resin-free spaces are located.

In another embodiment, it is also contemplated to fill the resin-free spaces 108 with material. Such material can be material such as polymers, foams, or fabrics. These materials can have the same function as the polymer resin, such as they can be sound absorbing or sound reducing, e.g., soft foam, fiberglass, or mineral wool. In another embodiment, the material filling the resin free space can have another function, e.g., heat insulation.

Alternatively, an additional discontinuous layer (not illustrated) of polymer resin may be applied to the second major surface of the rigid panel 106. Another rigid panel (not illustrated) may be applied in contact with the additional discontinuous layer of polymer to form a three rigid member panel with two acoustic composition layers.

The width of the layer 102 can vary and is dependent from the shape and/or pattern of the areas covered by the polymer resin. Likewise the width or volume of the resin-free spaces 108 can vary as well depending from the pattern or shapes used for the polymer resin coated areas. Therefore, one option for quantifying the of polymer resin applied to a rigid panel is by determining the percentage of area of the rigid panel coated and/or the mass of polymer resin covered per square meter (m²).

In an embodiment, the percentage of area that coats a rigid panel is the sum of all coated area S_c over the surface area S_t of the side of the rigid panel or substrate that receives the coating. Any percentage can be obtained. For example, the substrate or rigid panel can be covered at about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 60%, about 70%, about 80%, or even about 90%.

The coverage or the mass of polymer resin covered per m² can be determined, e.g., by determining the weight difference of the uncoated rigid panel or substrate and the coated rigid panel or substrate and dividing the weight difference by the total surface S area of the one or more sides that received coating. In a practical manner, the polymer resin is generally applied as a liquid or gel. The coverage is determined after the polymer resin has dried and all volatile additives, such as solvents, emulsifier, lubricants, etc. have dissipated until the weight of the coated panel or substrate is constant. Any coverage conceivable can be obtained. For example, the coverage can be at least 50 g/m², at least 75 g/m², at least 100 g/m², at least 125 g/m², at least 150 g/m², at least 175 g/m², at least 200 g/m², at least 250 g/m², at least 300 g/m², at least 350 g/m², at least 400 g/m², or even at least 500 g/m². In another embodiment, the coverage can be not greater than 600 g/m², not greater than 500 g/m², not greater than 400 g/m², not greater than 350 g/m², not greater than 300 g/m², not greater than 250 g/m², or even not greater than 200 g/m².

The damping article as illustrated in FIG. 1 comprising rigid panels 104 and 106, discontinuous polymer resin layer 102, and polymer resin-free spaces 108 form a resonating system, wherein resin-free space 108 is designed to serve to geometrically reduce the interlayer stiffness

In another example, preformed laminates may be formed with the polymer resin. For example, the polymer resin may be applied to a surface of a first rigid panel. The surface of the second rigid panel is placed in contact with the acoustic damping article that is in contact with a major surface with the first rigid panel to form the laminate.

Particular embodiments of the above described acoustic damping article exhibit technical advantages. In particular, embodiments of the above described exhibit desirable high modal damping factors and short drying time.

EXAMPLES

Example 1

As mentioned above, Mechanical impedance measurement (MIM) is a small scale test method for assessing the damping performance and the dynamic stiffness of a multilayer panel. It is directly inspired from a similar method developed for laminated glass and standardized in ISO 16940:2008 (Glass in building—Glazing and airborne sound insulation—Measurement of the mechanical impedance of laminated glass).

The FRF (frequency response function) of this free-free beam system is analyzed by measuring the punctual velocity and the input force. The application of the 3 dB rule to the anti-resonances of the mechanical impedance enables to determine the modal damping factor of the specimen at different frequencies.

FIG. 2 displays the correlation of the Patterned Interlayer Stiffness with the damping factor. For example, taking a frequency of about 1000 Hz, the graph indicates that a maximum damping factor can be achieved using a PIS of about 3 GN/m³, while maximum damping factors can be achieved at higher frequencies with higher PIS values. Since the PIS value is a property depending from the shear modulus of the glue, the percentage coverage, and the thickness, there are three variables that can be adjusted to achieve a improved damping across a construction panel.

FIG. 3 displays such effect on an example of stripes between drywall panels. Commercially available acoustic damping articles are tested for comparison with a sample formed in a manner similar to the samples of Example 1. The samples are tested by placing parallel stripes of Green Glue® formulations in various amounts at various distances on a panel of drywall and measuring the modal damping factor at various frequencies. Green Glue® is available from Green Glue Company of Granville, N.Y. Nine samples were prepared, each sample having an amount of Green Glue® of 140 g/m², 280 g/m², or 410 g/m²; and each sample having stripes in a distance of 20, 30, or 40 mm. A tenth sample with a full coverage of Green Glue® was prepared. As illustrated in FIG. 3, the 20 mm spacing of the 140 g/m² (S20—140 g/m²) coverage shows the highest damping of about 70% at about 1000 Hz. Also interesting, damping of the 30 mm spacing at the 140 g/m² (S30—140 g/m²) coverage was better at higher frequencies, while coverage of samples higher than 140 g/m shows better damping at frequencies lowest frequencies. From this example, it is shown that combining parallel stripes in various distances, e.g., combining S20 with S30 can result in an improved modal damping factor.

Such combination of stripes are disclosed in FIG. 4, where the surface of a construction panel 404 is covered with parallel stripes 402, wherein the distance between stripes vary. Furthermore, FIG. 4 shows that in a process step, the parallel stripes can be applied to the surface in one process step as a continuous stripe with U-turn or half ring 408 at the bottom or top (not disclosed).

FIGS. 5a, 5b, and 5c even further disclose that various distances between resin edges can be applied in different pattern. For example, as disclosed in FIG. 5a, if the resin is applied as squares 512, then a pattern can unfold with at least two distances d1, and d2 between two edges of squares. The basic pattern 510 displays the elemental unit for the pattern. As another example, as disclosed in FIG. 5b, if the resin is applied as triangles 522, then a pattern can unfold with at least three distances d1, d2, and d3 between two edges of squares. The basic pattern 520 displays the elemental unit for the pattern. An as even one further example, as disclosed in FIG. 5c, if the resin is applied as pentagons 532, then a pattern can unfold with at least five distances d1, d2, d3, d4, and d5 between two edges of squares. The basic pattern 530 displays the elemental unit for the pattern.

It is also contemplated to combine resin shapes, e.g. squares with triangles, depending from the desired damping to be achieved at various frequencies.

In summary, an acoustic damping article can include a substrate, the substrate having a side, the side having a total surface area S_t. The acoustic damping article further includes a polymer resin, wherein the polymer resin partially coats the side in a set of n areas, S_c1, . . . , S_cn, wherein n≧1 and a ratio of the sum of coated areas S_c over the total surface area S_t is less than 1, wherein the acoustic damping article has a polymer resin coverage of not greater than about 500 g/m².

In one example, the polymer resin coverage is not greater than about 400 g/m², not greater than about 300 g/m², not greater than about 200 g/m², not greater than about 180 g/m², not greater than about 150 g/m², or not greater than about 120 g/m².

In another example, an acoustic damping article can include a substrate, the substrate having a side, the side having a total surface area S_t. The acoustic damping article further includes a polymer resin, wherein the polymer resin partially coats the side in a set of n areas, S_c1, . . . , S_cn, wherein n≧1 and a ratio of the sum of coated areas S_c over the surface area S_t is less than 1, wherein the acoustic damping article has a modal damping factor in the range between 50 to 850 Hz of at least about 10%.

The modal damping factor can be at least about 20%, at least about 30%, or at least about 40%. In another example, the acoustic damping article can have a modal damping factor in the range between 700 to 1500 Hz of at least about 10%. For example, the modal damping factor can be at least about 20%, at least about 25%, at least about 30%, or at least about 40%.

The modal damping factor in the range between 1500 to 4000 Hz can be at least about 10%. For example, the modal damping factor can be at least about 20%, at least about 25%, at least about 30%, or at least about 40%.

In yet one further example, an acoustic damping article includes a substrate, the substrate having a side, the side having a total surface area S_t, a polymer resin, wherein the polymer resin partially coats the side in a set of n areas, S_c1, . . . , S_cn, wherein n≧1 and a ratio of the sum of coated areas S_c over the surface area S_t is less than 1, wherein a first shortest distance d1 between edges of two coated areas is not greater than about 35 mm.

In an example, the first shortest distance can be not greater than about 25 mm, not greater than about 23 mm, not greater than about 20 mm, not greater than about 18 mm, not greater than about 15 mm, not greater than about 13 mm, not greater than about 10 mm, not greater than about 8 mm, or not greater than about 5 mm.

In another example, a second shortest distance d2 between edges of two coated areas can be not greater than about 40 mm, not greater than about 35 mm, not greater than about 30 mm, not greater than about 28 mm, not greater than about 25 mm, not greater than about 22 mm, not greater than about 20 mm, not greater than about 18 mm, or not greater than about 15 mm.

In even one further example, a third shortest distance d3 between edges two coated areas can be not greater than about 45 mm, not greater than about 42 mm, not greater than about 40 mm, not greater than about 38 mm, not greater than about 35 mm, not greater than about 33 mm, not greater than about 30 mm, not greater than about 28 mm, or not greater than about 25 mm.

In yet another example, the polymer resin can include an acrylate, a methacrylate, a plasticized polyvinyl-chloride, a polyurethane, an ethylene vinyl acetate, a polyolefin, a silicon, or a combination thereof.

In another example, the acoustic damping article according to any one of the preceding claims, wherein the polymer resin includes a filler. The filler can be selected from an elastic filler or a solid filler. For example, the filler can be selected from rubber, barium carbonate, calcium carbonate, barium sulfate, calcium sulfate, alumina, or silica.

In yet another example, an acoustic damping article can include a substrate, the substrate having a side, the side having a total surface area S_t, a polymer resin, the polymer resin having a shear modulus G′ at 1000 Hz and at room temperature and a thickness t, wherein the polymer resin partially coats the side in a set of n areas, S_c1, . . . , S_cn, wherein n>1 and a percentage coverage p is the quotient of the sum of coated areas S_c over the surface area S_t is less than 1. A Patterned Interlayer Stiffness (G′×p)/t is at lea st about 0.7 GN/m³.

In another example, the Patterned Interlayer Stiffness (G′×p)/t is at least about 1 GN/m³ at least about 2 GN/m³, at least about 4 GN/m³, at least about 6 GN/m³, or at least about 8 GN/m³. The (G′×p)/t is not greater than about 20 GN/m³, not greater than

about 18 GN/m³, not greater than about 16 GN/m³, not greater than about 14 GN/m³, or not greater than about 12 GN/m³.

In another example, the coverage p can be at least about 0.1, such as at least about 0.2, such as at least about 0.3, at least about 0.4, at least about 0.5, at least about 0.6, at least about 0.7, at least about 0.8, or at least about 0.9.

In yet another embodiment, p is not greater than about 0.95, such as not greater than about 0.9, not greater than about 0.85, not greater than about 0.8, not greater than about 0.75, not greater than about 0.7, not greater than about 0.65, not greater than about 0.6, not greater than about 0.55, not greater than about 0.5, not greater than about 0.45, or not greater than about 0.4.

In yet another example, the thickness t can be at least about 50 microns, such as at least about 75 microns, at least about 100 microns, at least about 150 microns, at least about 200 microns, at least about 250 microns, at least about 300 microns, at least about 350 microns, at least about 400 microns, at least about 450 microns, or at least about 500 microns.

In another example, the tickness t is not greater than about 5000 microns, such as not greater than about 4000 microns, not greater than about 2000 microns, not greater than about 1000 microns, not greater than about 800 microns, not greater than about 600 microns, not greater than about 500 microns, not greater than about 450 microns, not greater than about 400 microns, not greater than about 350 microns, or not greater than about 300 microns.

In yet another example, the polymer resin has a glass transition temperature not greater than about 40° C, not greater than about 35° C, not greater than about 30° C, or not greater than about 25° C.

In even another example, the polymer resin has a shear modulus G′ of not greater than about 100 MPa at about 1000 Hz and at room temperature. For example, the shear modulus G′ can be not greater than about 80 MPa, such as not greater than about 70 MPa, not greater than about 60 MPa, not greater than about 50 MPa, or even not greater than about 40 MPa.

In another example, the shear modulus G′ is at least about 0.2 MPa, such as at least about 0.5 MPa, at least about 1 MPa, at least about 2 MPa, at least about 5 MPa, at least about 10 MPa, or at least about 20 MPa.

In another example, the polymer resin has an inherent damping loss factor of at least about 0.4 at about 1000 Hz and at room temperature. For example, the polymer resin has an inherent damping loss factor of at least about 0.5, at least about 0.6, at least about 0.7, at least about 0.8, at least about 0.8, or at least about 1, at about 1000 Hz and at room temperature.

For example, the area of the set of coated areas can be in the shape of a rectangle, a square, a triangle, a pentagon, a hexagon, a circle, a circular section, a ring, a half ring, or any combination thereof. For example, the rectangle can be defined by sides a and b, wherein a proportion of length (a)/length (b) is greater than about 1, greater than about 2, greater than about 5, greater than about 10, greater than about 20, greater than about 50, greater than about 100, greater than about 500, greater than about 1000, or greater than about 5000. In another example, the set of coated areas forms a pattern of stripes. In another example, the pattern can be at least one of straight stripes, wavy stripes, zig-zag stripes, parallel stripes, or a combination thereof.

In another example, the ratio of the sum of coated areas S_c over the total surface area S_t can be not greater than about 0.8, not greater than about 0.6, not greater than about 0.5, not greater than about 0.4, not greater than about 0.3, not greater than about 0.25, not greater than about 0.2, or not greater than about 0.1.

The substrate can be selected from a wall panel, a ceiling panel, a dry wall, a tile, a subfloor panel, or a plastic sheet. A second substrate can overlie the polymer resin.

In yet another example, a method of preparing a construction panel includes coating a first major surface of a first rigid panel with a polymer resin in a set of areas, wherein the amount of the polymer resin is not greater than about 500 g/m².

The amount can be not greater than about 400 g/m², not greater than about 300 g/m², not greater than about 200 g/m², not greater than about 180 g/m², not greater than about 150 g/m², or not greater than about 120 g/m².

In another example, a method of preparing a construction panel includes coating a first major surface of a first rigid panel with a polymer resin in a set of areas, wherein a first shortest distance d1 between edges of two coated areas is not greater than about 25 mm.

In another example, the first shortest distance is not greater than about 22 mm, not greater than about 20 mm, not greater than about 18 mm, or not greater than about 15 mm. The coating can further include a second shortest distance d2 between edges of two coated areas, wherein d2 is not greater than about 35 mm, not greater than about 32 mm, not greater than about 30 mm, not greater than about 28 mm, or not greater than about 25 mm.

In another example , a method of preparing a construction panel includes coating a first major surface of a first rigid panel with a polymer resin in a set of areas, the polymer resin having a shear modulus G′ at 1000 Hz and at room temperature and a thickness t, wherein the polymer resin partially coats the surface in a set of n areas, S_c1, . . . , S_cn, wherein n≧1 and a percentage coverage p is the quotient of the sum of coated areas S_c over the surface area S_t is less than 1. The Patterned Interlayer Stiffness (G′×p)/t is at least about 0.7 GN/m³.

The coating can include spraying, brushing, trowelling, plating, or stenciling. In another example, the coating is conducted with a tool selected from a brush, a trowel, a roller, a spray gun, wherein the tool is adapted for coating the surface in the set of areas and not coating the surface other than the set of areas.

Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which they are performed.

In the foregoing specification, the concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of invention.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

After reading the specification, skilled artisans will appreciate that certain features are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, references to values stated in ranges include each and every value within that range.

Claims

1. (canceled)

2. (canceled)

3. An acoustic damping article comprising:

a substrate, the substrate having a side, the side having a total surface area St;

a polymer resin, wherein the polymer resin partially coats the side in a set of n areas, Sc1,..., Scn, wherein n≧1 and a ratio of the sum of coated areas Sc over the surface area St is less than 1; wherein the acoustic damping article has a modal damping factor in the range between 50 to 850 Hz of at least about 10%.

4. (canceled)

5. The acoustic damping article according to claim 3, wherein the acoustic damping article has a modal damping factor in the range between 700 to 1500 Hz of at least about 10%.

6. (canceled)

7. The acoustic damping article according to claim 3, wherein the acoustic damping article has a modal damping factor in the range between 1500 to 4000 Hz of at least about 10%.

8. (canceled)

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. (canceled)

15. (canceled)

16. (canceled)

17. An acoustic damping article comprising:

a substrate, the substrate having a side, the side having a total surface area St;

a polymer resin, the polymer resin having a shear modulus G′ at 1000 Hz and at room temperature and a thickness t, wherein the polymer resin partially coats the side in a set of n areas, Sc1,..., Scn, wherein n≧1 and a percentage coverage p is the quotient of the sum of coated areas Sc over the surface area St is less than 1;

wherein a Patterned Interlayer Stiffness (G′×p)/t is at least about 0.7 GN/m2.

18. (canceled)

19. (canceled)

20. The acoustic damping article according to claim 17, wherein p is at least about 0.1.

21. The acoustic damping article according to claim 17, wherein p is not greater than about 0.95.

22. The acoustic damping article according to claim 17, wherein t is at least about 50 microns.

23. (canceled)

24. The acoustic damping article according to claim 17, wherein the polymer resin has a glass transition temperature not greater than about 40° C.

25. The acoustic damping article according to claim 17, wherein the polymer resin has a shear modulus G′ of not greater than about 100 MPa at about 1000 Hz and at room temperature.

26. (canceled)

27. The acoustic damping article according to claim 25, wherein the shear modulus G′ is at least about 0.2 MPa.

28. The acoustic damping article according to claim 17, wherein the polymer resin has an inherent damping loss factor of at least about 0.4 at about 1000 Hz and at room temperature.

29. (canceled)

30. The acoustic damping article according to claim 17, wherein at least one area of the set of coated areas is in the shape of a rectangle, a square, a triangle, a pentagon, a hexagon, a circle, a circular section, a ring, a half ring, or any combination thereof.

31. The acoustic damping article according to claim 30, wherein the rectangle is defined by sides a and b, wherein a proportion of length (a)/length (b) is greater than about 50.

32. The acoustic damping article according to claim 17, wherein the set of coated areas forms a pattern of stripes.

33. The acoustic damping article according to claim 32, wherein the pattern is at least one of straight stripes, wavy stripes, zig-zag stripes, parallel stripes, or a combination thereof.

34. (canceled)

35. The acoustic damping article according claim 17, wherein the substrate is selected from a wall panel, a ceiling panel, a dry wall, a tile, a subfloor panel, or a plastic sheet.

36. (canceled)

37. (canceled)

38. (canceled)

39. (canceled)

40. (canceled)

41. (canceled)

42. A method of preparing a construction panel, the method comprising: coating a first major surface of a first rigid panel with a polymer resin in a set of areas, the polymer resin having a shear modulus G′ at 1000 Hz and at room temperature and a thickness t, wherein the polymer resin partially coats the surface in a set of n areas, Sc1,..., Scn, wherein n≧1 and a percentage coverage p is the quotient of the sum of coated areas Sc over the surface area St is less than 1;

wherein a Patterned Interlayer Stiffness (G′×p)/t≧0.7 GN/m3

43. The method according to claim 42, wherein the areas are selected from a rectangle, a square, a triangle, a pentagon, a hexagon, a circle, or a ring.

44. The method according to claim 42, wherein the areas form a pattern of stripes.

45. (canceled)

46. The method according to claim 42, wherein the coating includes spraying, brushing, trowelling, plating, or stenciling.

47. (canceled)