巴西专利BR112014032257B1 acoustic monolithic ceiling for plasterboard

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专利摘要:
ACOUSTIC MONOLITHIC CEILING OF PLASTER PANEL. An acoustic panel to form a monolithic ceiling or wall, the panel extending across a rectangular area and having a core made primarily of plaster, the core being essentially coextensive with the panel area such that it has two opposite sides, each of an area substantially equal to the area of the panel, the core having a multitude of perforations, generally extending between its sides, the perforations being distributed substantially uniformly across the total area of the core and being open on both sides of the core, the side of the core face being covered by a porous layer, the perforations being optionally restricted on a rear side of the core, the porous layer on the side of the core being suitable for the adhesion of conventional drywall joint compound and a non-blocking paint Water based.
公开号:BR112014032257B1
申请号:R112014032257-0
申请日:2013-06-24
公开日:2021-01-19
发明作者:Erin Dugan；Mark Miklosz；Rafael Bury；Lee K. Yeung；William A. Frank
申请人:Usg Interiors, Llc；
IPC主号:

专利说明:

[0001] This order is partly a continuation of Serial Number Order 13 / 534,454, filed on June 27, 2012. BACKGROUND OF THE INVENTION
[0002] The invention relates to construction materials and systems and, in particular, to an acoustic panel for interior walls and monolithic ceilings for construction. TECHNICAL STATUS
[0003] Sound absorption in buildings is commonly achieved with ceiling tiles made from a suspended grid. Generally, the sound absorbing capacity of the tiles is achieved by the selection and / or characteristics of the surface materials facing the room. Ceiling tile installations have the advantage of providing immediate access to the space above the ceiling, but the divisions between the tiles, even when the grid is hidden, remain visible. Architects and interior designers have long sought a texture-free, monolithic look on an acoustic ceiling, particularly when there is no expected need for access to the space above the ceiling. Common plasterboard drywall ceiling construction does not achieve a sufficiently high noise reduction coefficient (NRC) that would qualify as acoustic. Perforated plaster panels can reach an acceptable NRC level, but they are not monolithic in appearance. SUMMARY OF THE INVENTION
[0004] The invention lies in the discovery that plasterboard panels, such as drywall sheets, can be modified to build an acoustic ceiling or wall with a monolithic planar face and interesting acoustic properties. Such panels can achieve an NRC of 0.70 or more.
[0005] In accordance with the invention, the plaster core is made with an infinite number of perforations or holes distributed throughout its planar area. Perforations or holes are restricted, preferably with a porous non-woven scrim fabric or veil painted on the front face and, optionally, a non-woven porous acoustic fabric on the back side.
[0006] The plaster panel can be made, for example, by perforating standard drywall sheets and thereafter, covering the perforated sides of the sheet with additional laminated sheets or layers. These drilling and lamination steps can be performed by the original manufacturer of the drywall sheets or by a separate and independent entity from the original manufacturer of the drywall.
[0007] Variations in the construction of the plaster panel are contemplated. Common among these variations is a panel with a perforated plaster core and a face covered by a structure that is porous, while appearing essentially imperforate to the naked eye.
[0008] The disclosed plaster-based panels can be installed in the same way or in a similar way as ordinary drywall. For ceiling applications, the acoustic panels of the invention can be screwed to a conventional "t" grade drywall suspension system or "hat channels", conducted in black iron channels, normally used in commercial applications or they can be attached the shaping of wood most often used in residential construction. Acoustic walls can be built by attaching the inventive acoustic panels to vertical struts, serving as spaced support elements. It will be seen that the inventive panels can be easily engraved and painted like ordinary drywall, using the same or similar materials, equipment, tools and skills, to produce a flat monolithic ceiling or wall. BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 is a fragmentary, schematic, isometric view of a monolithic acoustic ceiling;
[0010] FIG. 2 is a fragmented, cross-sectional view, on an enlarged scale, of the monolithic roof;
[0011] FIG. 3 is a fragmentary, enlarged, cross-sectional view of a modified form of an acoustic panel of the invention;
[0012] FIG. 4 illustrates a modified panel conjunction construction;
[0013] FIG. 5 illustrates an aspect of the invention where the veil or scrim attached to a rectangular panel is scaled to overlap the conjunctions of the panel with two adjacent panels.
[0014] FIG. 6 is an edge view of the panel of FIG 5; and
[0015] FIG. 7 shows a plurality of panels FIG. 6 in a mounted interface. DESCRIPTION OF PREFERENTIAL MODALITIES
[0016] Referring now to FIG. 1, a partial schematic view of a monolithic acoustic ceiling installation 10 is shown. Portions of ceiling layers 10 are peeled out to reveal constructional details. Ceiling 10 is a suspension system including a drywall grid 11, known in the art, comprising major T's 12 spaced at 4-foot centers and intersecting crossed T's 13 spaced at 16 inches or 2-foot centers. Dimensions used in this document are generally nominal dimensions and are intended to include industry-recognized metric equivalents. The main T's 12, for the crossed T's 13 are interconnected, are suspended by wires 14 attached to a superstructure (not shown). A perimeter of the grid 11 is conventionally formed by the molding channel 15 attached to the respective walls 16.
[0017] Acoustic panels 20 are attached to the lower sides of grid T's 12, 13 with self-drilling screws 21. The illustrated acoustic panels are 4 feet by 8 feet in their planar dimensions, but can be larger, shorter and / or of different width as desired or practical. The panel size of 20 and the spacing of the grid T's, 12 and 13, allows the edges of the panel to build the base of and be directly connected to a grid T, ensuring that these edges are well supported.
[0018] Referring now to FIG. 2, the acoustic panel 20 of the invention is characterized with a perforated plaster core 24. One method of providing the core 24 is to modify a commercially available standard sheet of drywall, perforating it through a front paper face 23, the core of plaster 24 and a side or back side of paper 25. Perforations 28 can be formed by perforation, punching, or with other known hole making techniques. The perforations 28 are preferably evenly spaced; for example, perforations can be round holes 8 mm in diameter at 16 mm centers. This arrangement produces a total perforation area substantially equal to 20% of the total planar area of a panel 20. Other hole sizes, shapes, patterns and densities can be used. For example, tests have shown that a hole density of 9% of the total area can achieve good results. Marginal areas, as well as intermediate areas corresponding to the support grid centers, beams, or nails, of a sheet can be left unperforated to maintain strength at firming points.
[0019] Sheets 29, 30 are laminated to both full sides of the perforated drywall sheet, thus, at least partially, closing the two ends of the perforations 28. On a back side of the drywall, the backing sheet or canvas 30 is preferably an acoustically absorbent non-woven fabric known from the acoustic ceiling panel technique. As an example, the backing fabric can be marketed under the trademark SOUNDTEX ® by Freudenberg Vliesstoffe KG. It has a nominal thickness of .2 to .3 mm and a nominal weight of 63 g / m2. Specifically, the main components of this example of non-woven fabric are cellulose and glass-e with a synthetic resin binder such as polyacrylate, poly (ethylene-CO-vinylacetate). Alternatively, for example, backing sheet 30 may be a layer of porous paper. The sheet 30 can be provided with a suitable adhesive to bond it to the rear paper side 25 of the modified drywall sheet 22.
[0020] On a front side of the drywall sheet 22, a sheet or canvas in the form of a scrim layer of nonwoven fabric 29 is attached with a suitable adhesive. The coating layer or sheet 29 is porous; a material suitable for this application that is used commercially as a cover or face for conventional acoustic ceiling panels. An example of this type of veil material is marketed by Owens Corning Veil Netherlands B.V., under product code A125 EX-CH02. This scrim fabric comprises hydrated alumina glass fiber filaments, polyvinyl alcohol and acrylate copolymer. The unpainted scrim 29 has a nominal weight of 125 g / m2 and an air porosity, at 100 Pa, of 1900 l / m2 sec. To avoid blocking the face scrim 29, the adhesive can be applied initially to the panel or sheet 22. The coating sheet 29 must be sufficiently robust to withstand field finishing operations described below. It must also be compatible with similar material or composite of drywall and commercially available paints, normally water-based paints like those described below.
[0021] Other usable veils 29 include non-woven fiberglass products, marketed by Owens-Corning Veil Netherlands BV as A135EX-CY07 (nominal weight 135 g / m2, air porosity at 100 Pa of 1050 l / m2sec) and A180EX-CX51 (nominal weight 180 g / m2, air porosity at 100 Pa of 600 l / m2sec). All the veils described are translucent and are unable to visually hide the perforations, 28 unless painted or coated with a coating as disclosed in this document.
[0022] Panel 20 with other identical panels is hung on grid 11 in the same way as regular drywall is installed. Likewise, as shown in FIG. 1, conjunctions 33 are engraved in the same way as regular drywall is engraved. Composite drywall or similar material 34 is used to adhere a tape or similar material 35 to adjacent edges of the two adjacent panels 20 by applying it directly to the sheets 29 and the tape 35 to hide the tape. Typically, the long edges of the panels 20 are etched to receive the conjunction tape 35 below the plane of most of the panel faces. Conjunction compound 34 may be composed of conventional drywall conjunction and tape 35 may be conventional drywall paper or mesh tape. The screws 21 securing the panels 20 to the spaced support elements 12, 13, forming the grid 11 are recessed, as is conventional in the construction of drywall and are concealed with joint compound 34 applied with a knife or engraving spatula in the same way as if applied to ordinary drywall. The panels 20 can be adhesively attached to the vertical beam supports when building a wall. When dry, the composite set 34 can be sanded or wetted with a sponge to mix it with the plane of the face sheet surface, 29.
[0023] After the conjunction compound 34 has been sanded or washed gently, the front sheets 29 and remaining conjunction compound are painted with a commercially available acoustic paint 31 used to paint acoustic tile. An example of a suitable water-based paint, sometimes referred to as a non-blocking paint, is available from ProCoat Products, Inc. Holbrook, Maine USA, sold under the ProCoustic brand. An acoustically non-blocking or non-bridge forming transparent paint or coating alternative 31 may have the following formulation:

[0024] The ideal perlite aggregate particle size distribution for this coating is centered around 10-100 mesh for between 60% - 80% of its volume, packing density can vary from 6 to 8 lbs / feet cubic. The coating 31 can be applied in two coats, in a total of 40 to 160 g / square feet, wet with a coverage of about 80 g / square foot being ideal.
[0025] The particles of this coating formulation can produce a slightly textured appearance equal to the average of coarse sandpaper, between about 30 and about 60 gravel (by CAMI and FEPA standards). This low texture can serve to visually hide the conjunctions between panels. To improve the uniformity of the finished appearance of the ceiling, the engraved conjunctions can be covered with strips of veil fabric 29, wide enough to cover the conjunction compound, before painting. The application of the paint should leave as much porosity through the layer 29 as is desired, but leave the appearance of an essentially imperforate surface to the naked eye, so that the perforations 28 are not seen. More specifically, the paint or coating 31 must be of a bridge-forming or non-blocking type capable of wetting the veil fibers 29 but not creating a film that forms bridges from fiber to veil fiber. Alternatively, where high NRC is not required, satisfactory results can be obtained using a conventional primer and an interior latex paint coating 31 to complete the installation of the ceiling 10. When the term monolithic is used in this document, it is to denote that essentially the entire visible surface of a ceiling or wall appears to be a seamless extension without conjunctions.
[0026] A 1/2 or 5/8 inch drywall-based panel. 20, having the drilling arrangement described and rear and front leaves 29, 30 and the usual space behind the panel can exhibit NRC values up to and above 0.70, a classification equal to the performance of the best grade acoustic ceiling tile.
[0027] Currently, the preferred characteristics of the plaster-based core 24 are: Thicknesses: 0.5 - 0.625 in. preferred, optional 3/8 in. to 1 in. Open area: 9.6-27.7% Hole diameter: 6 - 12 mm. Hole spacing: 15-25 mm.
[0028] The following are the airflow characteristics of the backing layer 30 of non-woven SOUNDTEX ® material described above and the face layer 29 of the first non-woven scrim material described above before and after painting with a proprietary acoustic coating and the ProCoustic acoustic coating.

[0029] The tables printed below show NRC values for the table and inventive tables of other constructions for comparison purposes. As in the previous table, unless otherwise indicated, the backer is the SOUNDTEX ® material and the face is the first scrim identified above. TEST I: * Perforated panel = 5/8 in. FC30 (drywall) with 3/8 "diameter perforations, 16mm oc spacing - 27.7% open area

* Perforated panel = 1/2 in. Ultralight (drywall), with 6mm diameter perforations, 15mm oc spacing, 1.5 inch edges. - hole pattern = 12.6% open area, global panel = 9.6% open area

[0030] Panel A (small holes) = 1/2 in. Knauf 8 / 18R with round perforations of 8mm round diameter, spacing of o.c. 18mm & borderless - 15.5% Open area
[0031] Panel B (large holes) = 1/2 in. Knauf 12 / 25R with 12 mm round diameter round perforations, 25 mm oc spacing & borderless - 18.1% Abra area

[0032] Panel E of test I had a face of heavy manila paper with a weight base of 263.50 gm / m2, a caliper of 17.22 mils, a density of 0.60 c / m3 and a porosity of 58.97 seconds. This test sample illustrates that a face, although porous, but with a very high airflow resistivity is not suitable for use with the invention. BB test panel: indicates that a face with a higher airflow resistivity (see table above) than a painted scrim face can achieve a satisfactory NRC.
[0033] The acoustic panel of the invention can be manufactured in other additional ways and with different constructions, but keeping the perforations effectively restricted at least on the side (fourth) face of a complete panel. For example, where high NRC values are not required, the back layer 30 can be omitted. Porous paper can be replaced by any of the non-woven layers 29, 30.
[0034] It has been found that additionally NRC can be measurably increased by orienting the perforations obliquely towards the panel plane. Such a construction is illustrated in FIG. 3. The perforations 28 can, for example, be oriented at 20 degrees outside a line perpendicular to the plane of the panel. The reason or reasons for this improved acoustic performance is not currently fully understood, but it could be the result of a higher volume of perforation and / or internal reflection of sound waves due to the oblique angle, and / or a larger effective open area for the face. .
[0035] Referring now to FIG. 4, an alternative conjunction construction is illustrated where edges 36 of two adjacent panels 40 are shown in cross section. The same reference numbers are used in FIG. 4 as used in FIG. 2 for identical elements. Panels 40 are the same as panels 20, except that they are of the "square edge" type where the edges of the long panel edges are not etched to receive a tape as they are on panels 20. The fiberglass veil 29 , which is adhered to the paper side 23 with a suitable adhesive such as a polyvinyl acetate emulsion, marketed under the ELMERS ® brand name by Elmer's Products, Inc. Theveil 29 is sized so that it is spaced, for example, 1 inch, from the edge of a panel, leaving a margin 42. Any narrow gap 41 that exists between panels 40 that is unavoidable or intentional can be partially or substantially completely filled with withdrawal of conjunction compound 34 preferably, it is an adjustment, not or low shrinkage, of the airy type as disclosed in the following patents: EU 6,228,163; U.S. 5,746,822; U.S. 5,725,656; U.S. 5,336,318; and U.S. 4,661,161. The gap 41 is filled by the joint compound 34 flush with the outer surface of the front paper face 23. Alternatively, the gap 41 can be left without partially or fully engaging with the joint compound.
[0036] A tape 43 made of the same material as the veil 29 can advantageously be used to extend the conjunction or gap 41 between the panels 40. The width of the tape 43 is less than the combined width of the marginal areas 42 of the panels. Where the panel edges 42 discovered by the web 29 are 1 inch wide, the web tape 43 can be, for example, 1-1 / 4 inch wide. The tape 43 can be adhered, for example, by the same adhesive used to join the veil 29 on the face of paper 23 or with the joint compound.
[0037] Use of 40 square edge drywall panels and non-shrinkable defensible joint reduces the time and labor involved in building a roof or wall of the invention. The spaces between the longitudinal edges of the tape 43 and edges 44 of the panel veils 29 can be filled with the conjunction compound, preferably of the quick-drying, non-shrinking type. The veil, 29, 43, covering the panels 40 is then coated, preferably by spraying, with one of the paints or coating materials 31 described above.
[0038] FIGS. 5 to 7 illustrate a modified acoustic panel 50 that differs only from the panel 40 described in connection with FIG. 4 by the size and position of the veil 29. The veil 29 is slightly smaller in its planar dimensions than the corresponding planar dimensions of the main rectangular or remaining body 51 of the panel 50 to which it is adhered. In addition, the veil 29 is moved from the main body 51 along two intersecting edges 52, 53, so that these edges are supported or free from and not directly adhered to the main body.
[0039] Panel 50 is assembled with identical panels to build a wall, ceiling or similar sound barrier. Cross conjunctions associated with the edges 52 can be staggered in relation to the adjacent panels, arranged together with the edges 53. It will be seen that the cantilevered part or edge 52 and 53 of the veil 29 bridges the actual conjunction existing between the main bodies 51 of panels adjacent, containment. Prior to placing a panel 50 which will provide an overlying veil edge 52, 53, marginal areas 54 not covered by the veil 29 of a previously placed panel 50 are coated with an appropriate adhesive, as discussed above. After placing this next panel 50, its free veil edges, 52, 53 can be pressed onto the adhesive on the edges 54 of the previously placed panels 50. The displacement veil arrangement of the panel 50 can eliminate the work of embossing conjunctions between panels and has the potential to produce conjunctions that are invisible or almost invisible to the eye of an observer. Only a very small gap, usually equal to the small difference selected in the size of the veil 29 in relation to the main body 51, will be present between the adjacent edges of the veils of panels arranged together 50. While the various FIGS. illustrating rectangular panels that are larger in a planar dimension than a perpendicular dimension, it should be understood that square panels are intended to be covered within the meaning of the term "rectangular".
[0040] Previous disclosures involve modifying a conventional drywall sheet to convert them to the acoustic panel of the invention. However, the inventive acoustic panel can be originally manufactured with perforations in the plaster core while it is being originally formed or immediately after it is formed and before the bonding of one or both sheets or layers, if any, to its front and side rear. Perforations, for example, can be converted to the plaster body. The cross section of the perforated in the various disclosed modalities can be circular when not perforated.
[0041] It should be evident that this disclosure is by way of example and that several changes can be made by adding, modifying or deleting details without departing from the fair scope of the teaching contained in this disclosure. The invention, therefore, is not limited to particular details of disclosure except to the extent that the following claims are necessarily so limited.

权利要求:
Claims (5)
[0001]
1. Acoustic panel to form a ceiling or wall, the panel has a core (24) made mainly of plaster, the core (24) being coextensive with the panel area so that it has two opposite sides each of an area equal to area of the panel, the core (24) having a multitude of perforations (28), generally extending between its sides, the perforations (28) being evenly distributed across the total area of the core (24) and being open on the front and the core (24), the perforations (28), being restricted by a porous acoustic non-woven fabric or by a layer of porous paper (30) on the rear side of the core, characterized by the fact that the panel (20) extends by a rectangular area with a nominal thickness of at least 1.27 cm (1/2 inches), where the front side of the core (24) is covered by a visually effective imperforated porous layer (29) when the porous layer is painted (29 ) on the front side of the core and is suitable for adhesion by combination of conventional drywall and a non-blocking water-based paint, the panel (20), after the porous layer (29) on the front side of the core and the composite, are painted with the said non-blocking paint being adapted for exhibiting an NRC of 0.50 or more and wherein the porous layer (29) on the front side of the core (24) comprises a sheet or canvas of translucent veil material.
[0002]
Acoustic panel according to claim 1, characterized by the fact that the long edges of the panel (20) are slightly etched to receive the conjunction tape (35) and the conjunction compound (34).
[0003]
Acoustic panel according to claim 1, characterized by the fact that it has a nominal width of 1.22 m (4 feet) and a nominal length of at least 2.43 m (8 feet).
[0004]
4. Acoustic panel, according to claim 1, characterized by the fact that the front and rear sides of the core are covered with the respective layers of paper (23, 25) with perforations in the register with the perforations of the core.
[0005]
5. Monolithic acoustic ceiling or wall construction, characterized by the fact that it comprises a generally planar grid of spaced parallel support elements (12), a plurality of acoustic panels (20), as defined by claim 1, fixed on their rear sides to the support elements (12), so that such panels (20) each bridge with spaces between the support elements (12), the panels (20) forming conjunctions (33) between adjacent panels, the conjunctions (33 ) being overlying the respective support elements (12), the conjunctions (33) between the panels in their front parts being hidden by the tape (35) and the conjunction compound (34) in the porous layer (29) and by a coating without continuous blocking of paint (31) on the total faces of the panels (20) including the tape (35) and the conjunction compound (34) in their conjunctions.

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法律状态:
2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

2020-01-28| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

2020-11-17| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

2021-01-19| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 24/06/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

申请号 | 申请日 | 专利标题

US13/534,454|US8770345B2|2012-06-27|2012-06-27|Gypsum-panel acoustical monolithic ceiling|

US13/534,454|2012-06-27|

US13/832,107|US8684134B2|2012-06-27|2013-03-15|Gypsum-panel acoustical monolithic ceiling|

US13/832,107|2013-03-15|

PCT/US2013/047280|WO2014004360A1|2012-06-27|2013-06-24|Gypsum-panel for acoustical monolithic ceiling|

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