Acoustical sound proofing material for architectural retrofit applications and methods for manufacturing same

Abstract

A laminated structure for use in retrofit building construction (partition, wall, ceiling, floor or door) that exhibits improved acoustical sound proofing characteristics while being optimized for efficient installation. The laminated structure includes a panel with at least one layer of viscoelastic glue, or fire-10 resistant, viscoelastic glue, which functions both as a glue and an energy dissipating layer. In one embodiment, the laminated structure to be attached to an existing wall in some embodiments includes standard paper-faced gypsum board. In another embodiment the to-be-applied laminated structure includes a cement-based board, and in yet another embodiment the to-be-applied laminated 15 structure includes a cellulose-based board. Once the laminated structure is installed on an existing wall or other partition, the resulting structure greatly attenuates transmitted noise and minimizes the labor required for installation and finishing.

What is claimed: 
     
         1 . A method for manufacturing a laminated, sound-attenuating structure comprising:
 providing a first cement-based board, the first cement-based board having first and second surfaces;   applying a layer of viscoelastic glue to the first surface; and   applying a release layer to the single layer of viscoelastic glue.   
     
     
         2 . The method according to  claim 1 , further comprising:
 removing the release layer from the single layer of viscoelastic glue; and   attaching the same single layer of viscoelastic glue to a second cement-based board after removing the release layer from the single layer of viscoelastic glue.   
     
     
         3 . The method according to  claim 1 , wherein applying a layer of viscoelastic glue to the first surface comprises:
 applying the layer of viscoelastic glue to provide continuous coverage of the first surface.   
     
     
         4 . The method according to  claim 1 , wherein applying a layer of viscoelastic glue to the first surface comprises:
 applying the layer of viscoelastic glue to less than all of an area of the first surface.   
     
     
         5 . The method according to  claim 1 , wherein applying a layer of viscoelastic glue comprises:
 applying the layer of viscoelastic glue in strips.   
     
     
         6 . The method according to  claim 1 , further comprising:
 flowing a gas over a surface of the layer of viscoelastic glue prior to applying the release layer to the single layer of viscoelastic glue.   
     
     
         7 . The method according to  claim 6 , wherein the gas is comprised of air or dry nitrogen. 
     
     
         8 . The method according to  claim 1 , further comprising applying pressure to the combined gypsum panel, viscoelastic glue and the release layer. 
     
     
         9 . The method according to  claim 1 , wherein the first cement-based board is calcium silicate board, magnesium oxide-based board, or phosphate-based board. 
     
     
         10 . The method according to  claim 1 , wherein applying a layer of viscoelastic glue to the first surface comprises:
 applying a layer of fire-resistant, viscoelastic glue to the first surface.   
     
     
         11 . The method according to  claim 10 , wherein applying a layer of fire-resistant viscoelastic glue to the first surface comprises:
 applying the layer of viscoelastic glue to provide continuous coverage of the first surface.   
     
     
         12 . The method according to  claim 10 , wherein applying a layer of fire-resistant, viscoelastic glue to the first surface comprises:
 applying the layer of viscoelastic glue to less than all of an area of the first surface.   
     
     
         13 . The method according to  claim 10 , wherein applying a layer of fire-resistant viscoelastic glue comprises:
 applying the layer in strips.   
     
     
         14 . The method according to  claim 10 , further comprising:
 flowing a gas over a surface of the layer of fire-resistant, viscoelastic glue prior to applying the release layer to the single layer of viscoelastic glue.   
     
     
         15 . A laminated, sound-attenuating structure comprising:
 a first cement-based board, the first cement-based board having first and second surfaces;   a layer of viscoelastic glue applied to the first surface; and   a release layer applied to the single layer of viscoelastic glue.   
     
     
         16 . The laminated, sound-attenuating structure according to  claim 15 , wherein:
 the layer of viscoelastic glue is applied to provide continuous coverage of the first surface.   
     
     
         17 . The laminated, sound-attenuating structure according to  claim 15 , wherein:
 the layer of viscoelastic glue is applied to less than all of an area of the first surface.   
     
     
         18 . The laminated, sound-attenuating structure according to  claim 15 , wherein:
 the layer of viscoelastic glue is applied in strips.   
     
     
         19 . The laminated, sound-attenuating structure according to  claim 15 , wherein the first cement-based board is calcium silicate board, magnesium oxide-based board, or phosphate-based board. 
     
     
         20 . The laminated, sound-attenuating structure according to  claim 15 , wherein:
 the viscoelastic glue is fire-resistant.