Noise-attenuating laminate composite wallboard panel and methods for manufacturing same

Abstract

A laminate composite wallboard panel is disclosed having multiple layers whose cross sections may contain internal and external non-uniformities and whose surfaces may be rough and non-uniform. The wallboard panel is similar in size and weight to a standard gypsum panel and can be handled and installed in a manner similar to such a panel. The wallboard panel also provides high degrees of noise attenuation, thermal insulation, fire resistance, shear strength, mold resistance and moisture resistance.

Description

FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT STATEMENT [0001] This invention was not developed in conjunction with any Federally sponsored contract. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] This invention relates generally to building materials and, more particularly, to a laminate composite panel for use in residential and commercial buildings. [0004] 2. Prior Art [0005] Gypsum-based panels were first used to construct the interior walls of buildings nearly 100 years ago. Since then, the standard design of such panels has consisted of a gypsum core sandwiched between two layers of paper. Commercially available panels generally have gypsum cores ranging in thickness from ¼″ to ¾″, while the panels' large surfaces typically have widths of 48″ or 54″ and lengths ranging from 8′ to 12′ in one-foot increments. Within the construction trade, gypsum-based panels are interchangeably referred to as “drywall,”“wallboard,”“gypsum wallboard,” and “gypsum panels,” whi...

AI Technical Summary

Benefits of technology

[0021] The present invention is a composite laminate wallboard panel for use in place of standard gypsum panels. The invention is similar in weight to a standard gypsum panel and can be handled and installed in a manner similar to such panels. However, the invention also provides superior noise attenuation, thermal insulation, fire resistance, shear strength, mold resistance, and moisture resistance.

[0022] Noise attenuation in the current invention is enhanced over panels constructed from the prior art, since laminated layers of the current invention have rough, non-uniform surfaces and / or section properties. Surface non-uniformity may be accomplished by embossing, debossing, dimpling, scoring, kerfing, grooving, boring, perforating, scalloping, corrugating, routing, and / or performing other actions that produce surface non-uniformities, such as bonding or attaching in some manner patches of the same or different materials to the surface of the layer. The sizes, shapes, and spatial distribution of these surface features are generally non-uniform, and different types of features can be combined to yield the desired effect. Non-uniformity of the section properties of a layer may be accomplished by embedding one or more different materials and / or voids non-uniformly within the layer, or by constructing the layer as a patchwork of different materials. The sizes, shapes, material types, and spatial distribution of these embedded materials or voids are generally non-uniform, and different embedded features can be combined to yield the desired effect. Further, surface and section non-uniformity may be employed together in the same layer to yield the desired effect.

Problems solved by technology

Further, surface and section non-uniformity may be employed together in the same layer to yield the desired effect.

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