CN101180441A - 吸音顶棚系统 - Google Patents

吸音顶棚系统 Download PDF

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CN101180441A
CN101180441A CNA2006800177147A CN200680017714A CN101180441A CN 101180441 A CN101180441 A CN 101180441A CN A2006800177147 A CNA2006800177147 A CN A2006800177147A CN 200680017714 A CN200680017714 A CN 200680017714A CN 101180441 A CN101180441 A CN 101180441A
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layer
plate
soft fiber
architectural applications
supporting
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CN101180441B (zh
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B·L·斯平格
J·费莱吉
J·R·沃特斯
G·马丁
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Armstrong World Industries Inc
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Abstract

一种内部建筑系统，包括弯曲的吸音的自支撑复合板，该板区分并强调内部建筑空间，同时提供实质性的声吸收能力。复合板包括两层或更多层非自支撑的软纤维材料，和位于每个所述软纤维层之间的非连续的粘合层。该系统还包括用于将板安装到建筑结构上的安装零件。安装零件具有穿孔板片，该穿孔板片嵌入板中，板将零件的可见度最小化，同时提供了增强的承载能力。

Description

吸音顶棚系统
相关申请的交叉引用
根据美国35U.S.C.§119(e)规定，本申请要求2005年4月4日提交的美国临时申请No.60/667,931的优先权。
技术领域
本发明总体上涉及一种内部建筑系统，尤其是涉及一种具有以最小下垂量来支撑自身的复合软纤维基板系统。
背景技术
办公室、零售店及类似商业设施中的传统吊顶系统一般包括支撑吸音软纤维块的悬挂网。这些系统一般跨越房间长度，即是连续的，并形成相同的外表。尽管这些连续悬挂系统提供了一种舒适和吸音空间，但设计者、建筑师和建筑业主出于各种原因经常反对这些系统的使用，所述原因包括减低了顶棚高度和适应整个跨度的材料成本。因此，越来越多的内部建筑空间具有这样的开放式通风系统或开放式阁楼、天花板设计，在这些设计中硬天花板、HVAC管道、布线等等暴露在外。然而，这种开放式通风系统设计会使空间紊乱，因此不实用、不美观。
在开放式通风系统的内部建筑环境中人们一直努力区划空间并提供审美要求。一个新兴的市场是强调式顶棚(accent canopy)市场。现有强调式顶棚系统的例子包括Armstrong World Industries公司的INFUSIONS强调式顶棚。INFUSIONS强调式顶棚包括柔性板结构和支撑该柔性板结构的悬挂构件。另外，偏置构件与柔性板配合，将柔性板保持在翘曲、通常为弯曲的形状。令人遗憾的是，INFUSIONS板由没有吸音功能的聚合材料制成。
需要一种用于开放式通风系统(open-plenum)设计的产品，其能区分并强调空间，同时包括传统矿物纤维块的吸声功能。
发明内容
本发明的内部建筑系统，包括弯曲的吸音的自支撑的复合板，和用于将该板安装到建筑结构上的安装零件。复合板包括至少两层非自支撑的软纤维材料，和位于每一软纤维层之间的非连续的粘合层。板具有一部分埋入其中的悬挂零件。该系统区分并强调内部建筑空间，同时提供实质性的吸声能力和美观效果。
附图说明
图1是具有本发明的软纤维复合板的内部建筑系统的一个实施例的透视图。
图2A是本发明的软纤维复合板的一个角部的分解透视图，其中一部分被切除以示出板的内部的一个实施例。
图2B是本发明的软纤维复合板的一个角部的分解透视图，其中一部分被切除以示出板的内部的另外一个实施例。
图3是图2A中的一个部分的透视图，显示了本发明的穿孔板片。
图4是用于安装本发明的软纤维复合板的零件系统的一个实施例的分解透视图。
具体实施方式
图1示出了本发明的内部建筑系统的一个实施例。系统10包括一个弯曲的吸音复合板12和用于将板12连接到内部建筑结构上的安装零件14。尽管本发明的板12具有多种弯曲外形，包括山顶状的弧形、山谷状的弧形等，但出于说明目的，整个附图中显示的结构是山顶状的弧形。
前面提到的板12由两层或更多层的软纤维材料构成。每一软纤维层由吸音矿物纤维或中密度玻璃纤维构成。一种满足要求的软纤维材料为湿成形矿物纤维板，Armstrong World Industries有限公司有售，名称为ULTIMA。参考图2A和图2B的优选实施例，板具有四层：第一内层16和第二内层17，第一外层15和第二外层18。每一软纤维层的厚度范围在大约0.125至大约0.40英寸之间，优选为大约0.225至大约0.310英寸之间。软纤维层在这个范围的下端值处更为柔软，因此，所述板可模压成一种半径比在厚度范围上端值处的板的厚度小的板。更特别地，当使用厚度约为0.125英寸的软纤维层时，可获得的半径大约为4英尺，而当使用厚度约为0.40英寸的软纤维层时，可获得的半径大约为15英尺。为便于说明，软纤维层15-18的每一层都具有相同厚度，但是每一层也可以具有不同的厚度。
板12还包括在每一软纤维层之间的非连续的粘合层19。非连续粘合层可包括多种形式，如呈点状、带状等。保持粘合剂的非连续性，对于使粘合剂引起的对板的吸音能力的不利影响最小化是必要的。要指出的是，施加到此处所述的每一板表面上的粘合剂的量为每平方英尺大约10克至大约30克，优选地为每平方英尺大约16克到大约25克。
在一个实施例中，每一粘合层为每平方英尺25克。在一个实施例中，使用穿孔筛子，将胶体型粘合剂液滴涂覆在软纤维层的水平表面上，所述穿孔筛子具有由3/16”直径的孔组成的20％的开口面积，并具有中心间距为0.109”、直径为0.0625”的交错圆孔。满足要求的粘合剂材料类型包括聚乙烯醋酸盐和乙烯基丙烯酸。当液滴具有足够高度而渗透接触层的表面然后将一个软纤维层与另一个软纤维层形成类似焊接的连接时，在保持软纤维层的吸音性能的同时，非连续粘合层19对板提供改进的结构强度。
相反，从WO90/01090的描述中可知一种用于制造弯曲矿物棉板的方法。根据这种方法，一种平的矿物纤维天花板被分成至少两层，并重新组建形成成型吊顶板。所述至少两层通过连续的粘合层被重新连接。连续粘合层据称是用来提供增强效应的，然而由于粘合剂是连续的，因而会对板吸收声音的能力产生实质性的影响。
尽管对板的吸音性能来说并不重要，然而如层15、18这样的每一最外面的纤维板层可选择地包括粘接到裸露表面上的平纹棉麻织物(scrim)30。满足要求的平纹棉麻织物30包括Owens Corning公司的A80EF或YK111玻璃纤维平纹棉麻织物。平纹棉麻织物30使板坚固并改善板的操作性能(handling)。平纹棉麻织物30可涂敷多孔吸音漆，如Armstrong的DURABRITE的吸音透明漆，来完成板。具有连接到外层15、18上平纹棉麻织物的板12具有最大弯曲应力131psi。
如图2B所示玻璃纤维平纹棉麻织物30可选择地使用在内层16、17上。平纹棉麻织物30被粘接到内层16、17之一或全部内层上的优点在于，增强软纤维层并使之易于操作。具有连接到所有软纤维层上的平纹棉麻织物的板12具有最大弯曲应力182psi。
如所有图所示，复合软纤维板12可利用悬挂零件14固定悬挂在天花板或墙上。本发明的悬挂零件14对已有悬挂系统的改进之处在于，零件的主要部分埋入所述复合软纤维板中，除了可见部分较少之外，还提供了增强的承载能力。如图4最佳所示，优选的悬挂零件14包括基本上为平面状的穿孔板片20。由于穿孔板片20对零件14的承载能力有影响，所以穿孔板片20的材料类型和尺寸的选择取决于支撑的基板总重量。
在图3、4所示的实施例中，板片20位于内软纤维层16、17之间。要指出的是，板片20可设置于任意两层之间，这取决于完成的复合板12的重量。因为板片20被穿孔，湿的粘合剂会进入到穿孔中。
软纤维和粘合层以及嵌入的穿孔板片一起形成的叠层，被传送到用夹具关闭的模具上。在模具中，粘合剂会变干。干的粘合层使复合板具有刚性并使其能通过长时间的下垂测试。因为一些粘合剂会在板片20的穿孔内干燥，复合板的承载能力便增强。例如，板片20可更好地分配力，所述力将导致复合板能够承受地震级的力而不拔出悬挂零件。一旦复合板12从模具中移出，完成的复合板的竖直边可以具有与施加到外层15、18的水平面相同的吸音平纹棉麻织物材料和涂料。
从穿孔板片顶部表面延伸有凸起的接收器，接收器例如是用于将悬挂缆线24连接到基板12上的非电镀黄铜圆筒。当安装系统时，零件14的唯一可见部分是接收器的一部分和从其延伸的缆线24。
现在参考附图2A详细描述板12的一个实施例形成。四个标准的高羊毛配比的板15-18，如由Armstrong World Industries.公司生产的、商品名为ULTIMA的湿成形矿物纤维板，被背砂(back sanded)处理成厚度0.310英寸。根据ASTM C423a单独测试每一块板15-18的吸音系数NRC时，每一个板15-18的吸音系数NRC为0.7。
一个水平表面上具有平纹棉麻织物30A的第一软纤维板15设置在平的表面上，平纹棉麻织物30A朝下。相对于平纹棉麻织物30A的板18的水平表面具有施加在其上的非连续粘合层19。然后，第二软纤维板16的一个水平面上具有平纹棉麻织物30B，并在其具有平纹棉麻织物30B的表面的相对表面上具有非连续粘合层19，使平纹棉麻织物的一侧向下，将第二软纤维板16放置在第一板15上。然后将至少一个穿孔板片20放置在第二板16上，使穿孔板片20的平板一侧向下，所述穿孔板片20具有从其上竖直延伸的接收器。如图1所示的一个典型实施例中，穿孔板片设置在第二板16四个角的每一个上。板片20用20GA8”×8”型304不锈钢穿孔。将在一个水平面上具有平纹棉麻织物30C的第三软纤维板17放置在第二板16之上，使其平纹棉麻织物的一侧向上。因此，穿孔板片20位于层16、17之间。第三软纤维层17包括在其中延伸穿过的开口21以容纳接收器。第四软纤维层18的一个水平面上具有平纹棉麻织物30D并在相对的水平面上具有一层粘合剂(未表示)，将第四软纤维层18设置在第三板17上，使平纹棉麻织物的一侧向上。要指出的是，每一粘合层既可先于堆叠操作也可在堆叠操作中施加到软纤维板上。例如，在堆叠之前，较易于将粘合剂丝网印刷到各层之上。
堆叠好的四个板被传送到由具有所需半径的模具形成的底模(bottomform)上，使平纹棉麻织物30A的一侧朝下。具有相同所需半径的顶模设置在堆叠板的顶部。使这些模具夹紧到一起并持续一整夜以使粘合剂干燥。在粘合剂干燥后，板从模具中移出，并且如果需要，板可切成所需尺寸。板的竖直边用预先完成的平纹棉麻织物镶边，以便与表面和背面完成的表面相匹配。板的形状不限制特殊半径，因此可制造具有拉得更直的半径或平的板。
本发明的吸音顶棚提供了比具有同样可视表面的连续天花板更大的声吸收能力，因为它们吸收了来自各个侧面的声音。根据ASTM C 423，本发明的吸音板的整体声音吸收效果以赛宾(Sabin)作为计量单位被适当地报告。该ASTM测试方法区别如本发明的吸音顶棚的“单元吸音物体(unit absorbers)”和通常以NRC报告的连续天花板。NRC代表了每平方英尺材料的吸收百分比，Sabin是良好的用于板的即板的前部、后部和侧部的整体声音吸收效果的计量单位。
上述四层结构的Sabin值的范围为整个板尺寸中每25平方英尺大约25Sabin到大约45Sabin。对四个主要语音频率：500、1000、2000和4000Hz的平均吸收量计算出其Sabin值。要指出的是，不论板安装成如图1所示的山峰状还是安装成山谷状(未示出)，Sabin值不会改变。
以能够教给的目前已知的最好的实施例提供了本发明的上述描述。本领域技术人员可以理解，在仍获得本发明的有益效果的同时可对所述的实施例作出各种改变。同样明显的是，本发明的一些期望效果可通过选择本发明的一些特征而不利用其他特征来实现。因此，本领域技术人员可以理解，可以对本发明作出修改和改变，且在特定环境下这样的修改和改变是需要的，并且是本发明的一部分。因此，提供的以上描述用以阐明本发明的原理但并不限于此，因为本发明的范围由权利要求所限定。

Claims (10)

1.一种内部建筑系统，包括：
复合板，所述复合板具有至少两层非自支撑的软纤维材料和非连续的粘合层，所述粘合层位于所述至少两层非自支撑的软纤维层中的每一层之间，弯曲的所述复合板是自支撑和吸声的。
2.根据权利要求1所述的内部建筑系统，其中所述复合板是弯曲的。
3.根据权利要求2的内部建筑系统，其中，所述至少两层非自支撑的软纤维层中的每一层具有大约0.125英寸到大约0.40英寸范围的厚度。
4.根据权利要求3所述的内部建筑系统，其中，复合板的半径范围为大约4英尺到大约15英尺。
5.根据权利要求4所述的内部建筑系统，其中，所述至少两层非自支撑的软纤维层每个都具有自由定向设置的纤维。
6.根据权利要求1所述的内部建筑系统，其中，连接零件嵌入所述复合板中。
7.根据权利要求6所述的内部建筑系统，其中，嵌入的连接零件是穿孔板片。
8.根据权利要求7所述的内部建筑系统，其中，穿孔板片设于所述至少两层非自支撑的软纤维层中的两层之间。
9.根据权利要求1所述的内部建筑系统，其中，每个所述至少两层非自支撑的软纤维层选自由矿物纤维、玻璃纤维及其组合构成的组。
10.根据权利要求1所述的内部建筑系统，其中，所述粘合层的量为每平方英尺大约10克到大约30克。
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