Utility materials incorporating a microparticle matrix

Abstract

A utility material can include microparticles, an organic binder and an inorganic binder. The microparticles can be present in an amount from about 25 wt % to about 60 wt %, based on wet formulation. The inorganic binder can optionally include sodium silicate. The organic binder can optionally include a vinyl acetate. The utility material can be formed into a variety of different products or building materials, such as wallboard, shear panels. In addition, the building material may be particularly used to attenuate sound.

1 . A utility material comprising:
 from about 25 wt % to about 60 wt % of microparticles based on wet formulation, the microparticles having a size of from about 200 to about 800 microns;   from about 20 wt % to about 36 wt % sodium silicate; and   from about 5 wt % to about 15 wt % of a vinyl acetate,   wherein a cured core matrix material formed therefrom is resistant to substantially all mold growth.   
   
   
       2 . The utility material of  claim 1 , wherein the utility material is a wallboard building material and further comprises:
 a first facing membrane; and   a second facing membrane, wherein the core matrix is disposed between said first and second facing membranes,   wherein the wallboard building material is at least about 20% lighter than gypsum wallboard of the same size and shape.   
   
   
       3 . The wallboard building material of  claim 2 , wherein the vinyl acetate includes vinyl acetate/ethylene copolymer. 
   
   
       4 . The wallboard building material of  claim 2 , wherein the microparticles are present in an amount from about 30 wt % to about 40 wt % of the wet mixture. 
   
   
       5 . The wallboard building material of  claim 2 , wherein the wallboard has an R value, when installed on a stud wall, of at least 15. 
   
   
       6 . The wallboard building material of  claim 2 , wherein the wallboard having ½ inch thickness has a noise attenuation of greater than about 40 db. 
   
   
       7 . The wallboard building material of  claim 2 , wherein the wallboard has a flexural strength of greater than 50% of that of gypsum wallboard of the same size and shape. 
   
   
       8 . The wallboard building material of  claim 2 , further comprising a coupling system integrally formed in said core matrix, said coupling system operating to facilitate coupling of a first wallboard panel to a second wallboard panel, and to at least partially seal said first and second wallboard panels. 
   
   
       9 . The utility material of  claim 1 , wherein the core matrix includes cross-linking. 
   
   
       10 . The utility material of  claim 1 , wherein the core matrix further includes at least one additive selected from the group consisting of water soluble polymers, setting agents, foaming agents, and combinations thereof. 
   
   
       11 . A method for manufacturing a wallboard of  claim 2 , comprising:
 forming the utility material of  claim 1  by mixing together the microparticles, sodium silicate, and vinyl acetate;   disposing said utility material between opposing facing membranes; and   heat curing said formable composition to sufficient to form a core matrix, said facing membranes configured to adhere to said core matrix.   
   
   
       12 . A method for manufacturing a wallboard building material comprising:
 combining a plurality of microspheres with at least one binder solution to produce a formable composition;   disposing said formable composition onto a surface;   situating said formable composition between opposing facing membranes; and   heat curing said formable composition to sufficient to form a core matrix, said facing membranes configured to adhere to said core matrix.   
   
   
       13 . The method of  claim 12 , wherein the step of producing a formable composition further includes first mixing sodium silicate and vinyl acetate, and subsequently adding a plurality of microspheres. 
   
   
       14 . The method of  claim 13 , wherein the sodium silicate is sodium silicate 38 wt % solution, the vinyl acetate is vinyl acetate/ethylene copolymer 40-60 wt % solution, and wherein the formable composition includes:
 about 30 wt % to about 38 wt % microspheres,   about 5 wt % to about 15 wt % vinyl acetate solution, and   about 50 wt % to about 65 wt % sodium silicate solution.   
   
   
       15 . The method of  claim 12 , further forming cross linking in at least a part of the core matrix material. 
   
   
       16 . A building material comprising:
 a core matrix comprised of a plurality of microparticles having a generally spherical shape and a hollow interior, and means for adhering said microparticles together, said core matrix defining first and second surfaces; and   a multi-elevational surface configuration formed in at least a part of said second surface of said core matrix that is configured to enhance the sound attenuation properties of said building material.   
   
   
       17 . The building material of  claim 16 , further comprising a reinforcing member disposed within said core matrix, said reinforcing member being configured to reinforce said building material in one or more ways selected from the group consisting of reinforcing against sound transmission, reinforcing against heat transfer, enhancing strength, and any combination of these. 
   
   
       18 . The building material of  claim 16 , wherein said building material comprises a Sound Transmission Class (STC) rating between 35 and 65. 
   
   
       19 . The building material of  claim 16 , wherein said building material comprises a decibel noise reduction value between 55 and 65 dB at 3000 Hz, for a ½ inch thick wallboard. 
   
   
       20 . The building material of  claim 16 , further comprising a plurality of cavities strategically formed throughout said core matrix.