Board construction assembly for reducing sound transmission and method

Abstract

An underlayment for supplementing one or more mechanical properties of conventional wall, ceiling, or floor board is used to in a wall, ceiling, or floor assembly that may be fabricated on site. The assembly includes a first and second wall, ceiling, or floor boards which each have mechanical properties, and the underlayment which has at least one supplemental mechanical property for supplementing the physical properties of the first and second boards. The second board is secured to the first board with the underlayment sandwiched between the second and first boards to form a wall, ceiling, or floor assembly with the supplemental physical property or properties of the underlayment. The supplemental physical property or properties of the underlayment may include, but are not limited to, sound transmission reduction.

1 . A method for on-site fabrication of a wall, ceiling, or floor construction component/underlayment assembly, comprising: 
 providing a first wall, ceiling or floor construction component; the first construction component having a length, a width, and a thickness; the first construction component having first and second major surfaces that are each defined by the length and the width of the first construction component; the first construction component having mechanical properties;    providing a second wall, ceiling or floor construction component; the second construction component having a length, a width, and a thickness; the second construction component having first and second major surfaces that are each defined by the length and the width of the second construction component; the second construction component having mechanical properties;    providing an underlayment means having a supplemental mechanical property for supplementing the mechanical properties of the first and second construction components;    applying the underlayment means to the first major surface of the first construction component and securing the underlayment means to the first major surface of the first construction component to form an underlayment layer;    overlaying the underlayment means and the first major surface of the first construction component with the second construction component; and    securing the second construction component to the first construction component with the underlayment means sandwiched between the second and first construction components to form a wall, ceiling or floor assembly with the supplemental mechanical property of the underlayment means.    
   
   
       2 . A method according to  claim 1 , wherein the underlayment layer formed by the underlayment means substantially overlies the entire first major surface of the first construction component.  
   
   
       3 . A method according to  claim 2 , wherein the thickness of the underlayment layer is between about 3.0 mm and about 30.0 mm.  
   
   
       4 . A method according to  claim 1 , wherein the underlayment means is flexible and a roll good.  
   
   
       5 . A method according to  claim 1 , wherein the first and second construction components are gypsum boards, cement boards, or wood fiber boards.  
   
   
       6 . A method according to  claim 5 , wherein the first and second construction components are gypsum boards.  
   
   
       7 . A method according to  claim 6 , wherein the first and second construction components are gypsum wallboards.  
   
   
       8 . A method according to  claim 1 , wherein the underlayment means comprises a nonwoven fiberglass mat.  
   
   
       9 . A method according to  claim 8 , wherein the nonwoven fiberglass mat has a thickness of between about 3.0 mm and about 30.0 mm.  
   
   
       10 . A method according to  claim 9 , wherein the nonwoven fiberglass mat has a thickness of about 6.5 mm.  
   
   
       11 . A method according to  claim 1 , wherein the supplemental mechanical property of the underlayment means increases sound transmission reduction.  
   
   
       12 . A method according to  claim 11 , wherein the supplemental mechanical property of the underlayment means increases sound transmission reduction by 1 to 21 percent (1-21%).  
   
   
       13 . A method according to  claim 12 , wherein the supplemental mechanical property of the underlayment means increases sound transmission reduction by 10 to 21 percent (10-21%).  
   
   
       14 . A method according to  claim 1 , wherein the supplemental mechanical property of the underlayment means increases a Sound Transmission Class (hereinafter “STC”) value by about 1 to about 21 percent (1-21%).  
   
   
       15 . A method according to  claim 14 , wherein the supplemental mechanical property of the underlayment means increases the STC value by about 10 to about 21 percent (10-21%).  
   
   
       16 . A method according to  claim 1 , wherein the supplemental mechanical property of the underlayment means satisfies a STC value for multi-family housing as determined by the U.S. Department for Housing and Urban Development for sound transmission from living unit to living unit, in an average noise environment, where the corridor floors are carpeted.  
   
   
       17 . A method according to  claim 1 , wherein the means used to secure the second construction component to the first construction component with the underlayment means sandwiched between the second and first construction components to form the wall, ceiling or floor assembly also secures the second construction component to a structural support member.  
   
   
       18 . A method according to  claim 1 , wherein the means used to secure the second construction component to the first construction component with the underlayment means sandwiched between the second and first construction component to form the wall, ceiling or floor assembly is an adhesive.  
   
   
       19 . A construction component/underlayment assembly, comprising: 
 a first wall, ceiling or floor construction component; the first construction component having a length, a width, and a thickness; the first construction component having first and second major surfaces that are each defined by the length and the width of the first construction component; the first construction component having mechanical properties;    a second wall, ceiling or floor construction component; the second construction component having a length, a width, and a thickness; the second construction component having first and second major surfaces that are each defined by the length and the width of the second construction component; the second construction component having mechanical properties;    an underlayment including a phase change material that for supplementing the mechanical properties of first and second wall, ceiling, or floor construction components; and    the underlayment and first and second construction components forming a layered construction with the underlayment being located between the first and second construction components.    
   
   
       20 . A construction assembly according to  claim 19 , wherein: 
 the first and second construction components are wall, ceiling, or floor construction boards; and    the first and second construction components and the underlayment are permanently secured together.    
   
   
       21 . A construction assembly according to  claim 20 , wherein the first and second construction components are a first and second wall construction components.  
   
   
       22 . A construction assembly according to  claim 21 , wherein the first and second wall construction components comprises gypsum wallboard.  
   
   
       23 . A construction assembly according to  claim 21 , wherein at least one of the first or second wall construction components comprises gypsum wallboard.  
   
   
       24 . A construction assembly according to  claim 23 , wherein the underlayment includes a sound deadening material for supplementing the mechanical properties of the first and second construction components to reduce sound transmission through the assembly.  
   
   
       25 . A construction assembly according to  claim 24 , wherein the underlayment means comprises a nonwoven fiberglass mat.  
   
   
       26 . A construction assembly according to  claim 25 , wherein the nonwoven fiberglass mat has a thickness of between about 3.0 mm and about 30.0 mm.  
   
   
       27 . A construction assembly according to  claim 26 , wherein the nonwoven fiberglass mat has a thickness of about 6.5 mm.  
   
   
       28 . A construction assembly according to  claim 24 , wherein the supplemental mechanical property of the underlayment means increases sound transmission reduction by 1 to 21 percent (1-21%).  
   
   
       29 . A construction assembly according to  claim 28 , wherein the supplemental mechanical property of the underlayment means increases sound transmission reduction by 10 to 21 percent (10-21%).  
   
   
       30 . A construction assembly according to  claim 24 , wherein the supplemental mechanical property of the underlayment means increases a STC value by about 1 to about 21 percent (1-21%).  
   
   
       31 . A construction assembly according to  claim 30 , wherein the supplemental mechanical property of the underlayment means increases the STC value by about 10 to about 21 percent (10-21%).  
   
   
       32 . A construction assembly according to  claim 24 , wherein the supplemental mechanical property of the underlayment means satisfies a STC value for multi-family housing as determined by the U.S. Department for Housing and Urban Development for sound transmission from living unit to living unit, in an average noise environment, where the corridor floors are carpeted.  
   
   
       33 . A construction assembly according to  claim 19 , wherein the means used to secure the second construction component to the first construction component with the underlayment means sandwiched between the second and first construction components to form the wall, ceiling or floor assembly also secures the second construction component to a structural support member.  
   
   
       34 . A construction assembly according to  claim 19 , wherein the means used to secure the second construction component to the first construction component with the underlayment means sandwiched between the second and first construction component to form the wall, ceiling or floor assembly is an adhesive.