Methods of manufacturing acoustical sound proofing material

Abstract

A manufacturing process appropriate for use in constructing laminated structures for use in building construction such that the laminating steps to not require elevated drying temperatures or an extended dwell time at any point. This is accomplished using a specially formulated viscoelastic glue and ambient temperature drying apparatus. As a result, the production capacity of the manufacturing process is greatly improved over existing methods.

1 . A method of forming a laminated structure appropriate for use in constructing walls, floor, ceilings or doors, said laminated structure having a selected area, said method comprising:
 providing a first external layer of material including a first surface and a second surface;   applying a layer of viscoelastic glue to said first surface;   flowing gas over said glue for a predetermined time to remove a selected amount of moisture from said glue; and   placing a second layer of material onto the layer of glue wherein the glue is between said first and second layers, thereby joining said first external layer to said second layer.   
     
     
         2 . The method of  claim 1  wherein said second layer of material is an external layer of said laminated structure. 
     
     
         3 . The method of  claim 2  including applying pressure to the laminated structure following the placing of said second layer on said glue. 
     
     
         4 . The method of  claim 1  including drying said gas prior to flowing said gas over said adhesive. 
     
     
         5 . The method of  claim 1  including:
 applying a second layer of viscoelastic glue to an exposed surface of said second layer, and   flowing gas over said second layer of viscoelastic glue for a predetermined time to remove a selected amount of moisture from said glue.   
     
     
         6 . The method of  claim 5  including drying said gas forced over said second layer of viscoelastic glue prior to flowing said gas over said second layer of viscoelastic glue. 
     
     
         7 . The method of  claim 5  including placing a third layer of material on said second layer of viscoelastic glue after said gas has forced over said second layer of viscoelastic glue for said predetermined time thereby to create said laminated structure. 
     
     
         8 . The method of  claim 7  including applying a selected pressure to said laminated structure following the placing of said third layer of material on said second layer of viscoelastic glue. 
     
     
         9 . A method of forming a laminated panel including at least a first layer of material and a second layer of material, wherein each layer of material is bonded to an adjacent layer of material by viscoelastic glue, said method comprising:
 placing viscoelastic glue in a selected pattern on an exposed surface of a layer of material to which another layer of material is to be bonded;   flowing gas over said viscoelastic glue to remove moisture from said glue; and   placing a second layer of material over said viscoelastic glue following the flowing of gas over said viscoelastic glue.   
     
     
         10 . The method of  claim 9  wherein said viscoelastic glue is placed on said exposed surface in a selected pattern. 
     
     
         11 . The method of  claim 9  wherein said viscoelastic glue is placed on said exposed surface as a continuous layer. 
     
     
         12 . The method of  claim 11  wherein said viscoelastic glue has a thickness between one thirty second of an inch ( 1/32″) and one eighth of an inch (⅛″). 
     
     
         13 . The method of  claim 9  wherein said gas is forced over said viscoelastic glue for a sufficient time to bring the moisture content of said viscoelastic glue to below five percent (5%) by weight of the viscoelastic glue. 
     
     
         14 . The method of  claim 9  wherein said gas is forced over said viscoelastic glue for a sufficient time to bring the moisture content of said viscoelastic glue to between thirty percent (30%) and five percent (5%) by weight of the viscoelastic glue. 
     
     
         15 . The method of  claim 9  wherein said gas is air. 
     
     
         16 . The method of  claim 15  wherein said air is at approximately ambient temperature. 
     
     
         17 . The method of  claim 16  wherein said air is forced across said viscoelastic glue at a flow rate between about fifteen thousand cubic feet per second and about fifty thousand cubic feet per second. 
     
     
         18 . A structure made by the method of  claim 9 . 
     
     
         19 . A structure made by the method of  claim 1 .