CN101263269B - 具有不均匀粘合剂成分的天花板 - Google Patents
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Abstract
一种天花板制品和方法,其中,主要包括矿物棉和粘合剂的浆料形成的毡在其表面设有粘合剂增强区域。粘合剂增强区域能够减少乳胶的总体需求量,减少实现市场可接受颜色所需的涂装或漆的量,并能提高噪音降低性。
Description
技术领域
本发明涉及一种天花板,特别涉及这样一种天花板结构,该结构能够通过关键性的乳胶粘合剂沿天花板厚度的不均匀分布,提供改进的耐久性并降低制造成本。
背景技术
通常,通过用由水基浆料制造瓦或板的制毡工艺来制造天花板。浆料通常包括构成天花板的板体的所有原材料的均匀混合。将被粘合的浆料材料层压制成毡并使其干燥以形成板。一些天花板是由在完全干燥前被压花或形成图案的板构成的,而另一些则是由先干燥、随后研磨以获得理想厚度和平滑光洁度的板制成的。通常,原材料包括粘合剂,如乳胶或淀粉或两者的合成物,它们在使板干燥时能够使其它材料固定在一起。通常,虽然粘合剂在板的总重量中占有较小的百分比,但却表现出不相称的高材料成本。粘合剂的成分会影响板的强度和表面硬度。传统地,在浆料混合物中,粘合剂的含量应保持一定水平以获得令人满意的表面硬度,从而获得可接受的耐久性。
发明内容
本发明提供了一种天花板结构,其中,粘合剂材料沿板的厚度具有不均匀的分布,同时,在板的最终或可视表面附近具有较高的浓度。所披露的粘合剂的分布能够降低制造成本,同时提供具有满意或非常优越的硬度和耐久性以及改善的噪音吸收能力。可通过将材料的浆料或混合物中粘合剂成分降至前面提到的配方之下,并且在至少预先形成毡或天花板之后,从而在毡与板的将来可视表面相关的侧面包括一层补充水基乳胶粘合剂,由此能够形成本发明的板。所涂覆的粘合剂优选为在浆料配方中使用的相同材料以固定或粘合制造天花板的其它材料。在板的可视侧的粘合剂增强区域能够增强产品在该侧的硬度和强度,同时允许减少总体粘合剂焊料,降低最后完工涂层或涂漆的需求,并增强吸音能力。
本发明还提供了一种天花板,其包括由浆料制成的标称厚度为大约1/2英寸~大约3/4英寸的毡并具有重量为至少75%的矿物棉含量以及3%的粘合剂,粘合剂大致分布在贯穿大部分毡厚度的范围内并且在毡的表面侧上具有粘合剂增强区域,该区域中单位厚度的粘合剂含量明显大于毡的主体部分的单位厚度的粘合剂含量,从而该区域的硬度大于毡的主体部分的硬度,以便增强天花板抵抗物理损坏的耐久性,同时能够减小天花板的总粘合剂含量,并能够相应地降低天花板的成本。
优选地,粘合剂增强区域由漆型涂层覆盖,与粘合剂增强区域呈现出的颜色相比,该漆型涂层的颜色更接近纯白色。
具体实施方式
本发明包括矿物棉基天花板,其部分以传统的水制毡工艺制造。在本发明的说明书中,浆料固体通常包括大致90%的矿物棉,固体的剩余物主要包括呈乳胶或乳胶和淀粉形式的粘合剂。同时,浆料中的固体为浆料总重量的大约5%;即,5%的浓度。乳胶是众所周知的并广泛用作市场上可得到的粘合剂。通常,在分离水时,将乳胶作为水乳剂分配并聚结为固体。可以根据所希望或必需的那样,使用各种浆料配方。以下的表格大致给出了根据浆料成分的总固体重量百分比的大致范围:
矿物棉 75~95%
珍珠岩 0~15%
纤维素纤维 0~10%
粘合剂(淀粉) 0~5%
粘合剂(乳胶) 0~10%
粘合剂(总共) 5~12%
在制毡工艺中,浆料被放置在运动筛网上,并且通常通过重力、压力辊、真空装置和加热而干燥。浆料中的固体通常均匀地混合和分配,并通常保存或者打算保存于在筛网上形成毡并将其逐渐干燥的状态下。优选地,在浆料中使用的乳胶为在较高温度下固化的高Tg粘合剂材料,例如,通过使毡暴露于热空气(例如,在大约350°F)和/或红外线加热。在提供充足的芯体强度和硬度的情况下,可使用低Tg粘合剂。
本发明包含一种工艺和产品,其中,可以对贯穿毡厚度的粘合剂分布加以改进,使得在天花板的表面或其最终房间侧附近具有更大的粘合剂浓度。已发现:在实现本发明时,即使在减小了其总粘合剂含量时,仍能全部改善天花板的耐久性、其噪音降低系数(NRC)和末道油漆要求,因此,能够降低其制造成本。
通过传统的涂覆技术,如通过喷涂、辊涂、刷涂等,能够在乳胶粘合剂增强区处增大乳胶粘合剂的浓度。在使浆料形成的毡(mat)干燥和/固化之前、期间或者之后,可以对在通过涂覆工艺制造时的粘合剂增强区进行涂覆。毡的在先局部或完全固化可以减少或防止施加用于在毡的表面侧形成加强区的粘合剂材料的自由移动。通常,通过暴露于相对较高温度空气(例如,大约350°F),使加强区的乳胶粘合剂从其水载体中干燥而固化。
浆料粘合剂总体上可包括淀粉,或更为优选地以例如大致等于乳胶成分重量的量使用。乳胶粘合剂增强区或层优选地使用与浆料中使用的相同的乳胶材料,如果需要,也可以不同。在使毡充分固化后,可以应用增强层,并且如果对毡或板进行研磨或砂纸打磨,在所述研磨或砂纸打磨之后,可以应用增强层。
通过允许从传统配方含量中减小浆料的乳胶含量,乳胶粘合剂增强区能够降低制造天花板的成本。根据本发明,成品天花板表面的有效表面硬度远大于现有技术的制品,而总体或净乳胶使用量则小于现有技术的制品。通过在天花板上涂覆或固化的任意最终材料或涂漆测量天花板表面的有效硬度。在绝对值或与现有技术制品的比较中,外表面区域的硬度增大反映在安装期间或在其寿命期间被处理时天花板具有更高的耐久性。
与毡的剩余部分相比,乳胶增强区域在例如基于每单位厚度的克数方面上更大。例如,如果浆料承载的乳胶粘合剂含量以毡重量的大约4或5%分布在毡体的厚度上,则涂覆在毡顶部上的增强区可以大约为整个毡重量的1%。换句话说,在该例子中,在通过涂覆工艺形成乳胶粘合剂增强区时,成品板中的乳胶粘合剂含量的大约1/4~1/5存在于毡的一侧。通常,毡垫的顶侧为形成有辅助乳胶粘合剂增强区的一侧,因为在传统的制毡或处理中,其为最易接近的一侧。在毡生产线上通过喷射、辊涂或类似加工,容易在毡的顶部形成该区域。在通过独立的涂覆工艺形成乳胶增强区时,上述使用的乳胶材料优选与形成毡浆料所使用的材料相同。这种通用性在相关的购买、储存和使用中能够提供便利并降低成本。
对此处所考虑的天花板通常进行涂覆或涂漆以便实现接近真实白色的颜色。这种涂层通常包括为快速低温固化的涂料型乳胶配方的底层涂层和表面涂层。本发明能够以较少的涂漆涂覆所述板,同时,能够实现相同或更高的白度。这种效果是由于存在于根据本发明的原理制成的毡外表面的增强区域中的乳胶粘合剂的高浓度获得,其中,与天然矿物棉的颜色相比,乳胶粘合剂具有更接近白色的颜色。因此,减少了在干燥的板毡或板体的表面上用于隐蔽矿物棉明显的灰白色的所需的涂漆。
已发现:根据本发明制造的天花板还可表现出改进的噪音吸收性,有时在技术上称为噪音降低系数(NRC)。相信这种现象是因使用了较少的涂漆或涂层形成的,使用较少的涂漆或涂层明显会减小毡的多孔表面的净堵塞,因此,能够大大提高声音吸收能力。
以下的表格给出了由标签AControl@标识的传统现有技术板的固体配方的例子和由标签ATrial@标识的本发明的板的配方的例子。
配方/结构:
棉% | 淀粉% | 芯体中的乳胶% | 乳胶喷射% | 整个乳胶% | |
Control | 92.3 | 3.0 | 6.7 | 0.0 | 6.7 |
Trial | 92.3 | 3.0 | 4.7 | 1.0 | 5.7 |
通过以下测试,测量具有配方/结构(Control)和(Trial)的板:
涂层覆盖率,实验值和测定的NRC值:
测试1
测试2
测试3
物理数据:
测试1
测试2
测试3
Trial1,Trial2等为具有本发明的配方/结构的独立试样。
以不同量的底层涂层和表面涂层、利用涂装材料(乳胶基涂漆)涂覆根据本发明制造的板(Trial)。根据机械强度和耐磨性,涂漆级乳胶易于区别于粘合剂型乳胶材料。
对上述表格中记录的值的研究发现:与具有常规配方(Control)的天花板相比,在根据本发明的毡的表面上形成乳胶增强区但具有更少总乳胶含量的的天花板更白,能够更大地降低噪音,并且更具耐久性。
Hunter测量计(HunterG硬度=s值的来源)为在市场上用于测量材料(如壁板)的表面硬度的装置。通常,Hunter测量计读数越高,制品的表面就越硬,并且耐久性越高。
值L,a,b表示评价表面颜色的颜色空间方法,其中,表示纯白色的值为100,a,b值的绝对值越小,从白色向原色的偏差就越小。NRC记录的数值越大,板就越能吸收噪音。
除了此处所披露的方法以外,还可以研发其它方法在天花板中形成乳胶增强区。例如,可以预想在毡体形成之前通过特意允许乳胶沉积或,通过使高乳胶含量加至筛网上,从而在筛网附近,以制毡工艺形成该区域。通常,根据本发明制造的板具有大约1/2~大约7/8″的厚度,并且将具有相对多孔的内部。
显然,本说明书是通过例子给出的并且通过在不脱离说明书中所包含的启示的合理范围的情况下,通过增加、改进或省略细节,可作出各种改进。因此,除了以下权利要求必须限制必须限定的范围以外,本发明不应局限于说明书的特定细节。
Claims (14)
1. 一种制造矿物棉基天花板的方法,其包括:按其中矿物棉的量在重量基位上远大于粘合剂的量的比例,将一定量的矿物棉和粘合剂混合到这样一个程度,即大致均匀地使粘合剂分布在矿物棉上,然后,用在均匀混合状态下的矿物棉和粘合剂形成毡,使粘合剂固化,以便以所得到的材料体呈相对多孔状的方式使矿物棉硬化,在毡的一侧形成粘合剂含量增大的区域,该区域中单位厚度的粘合剂含量明显大于在毡的大部分厚度范围上的单位厚度的粘合剂含量,从而在所述粘合剂增强区域的表面上的毡的硬度大于由在大部分毡的厚度范围上存在的粘合剂含量所形成的毡表面上产生的硬度。
2. 根据权利要求1所述的方法,其中用于粘合剂增强区域的粘合剂为乳胶,并且与同矿物棉混合的至少一些粘合剂相同以便制成毡。
3. 根据权利要求2所述的方法,其中通过利用所述粘合剂涂覆毡,制造粘合剂增强区域。
4. 根据权利要求3所述的方法,其中通过将所述粘合剂喷射至所述毡上来完成用粘合剂对毡的所述涂覆。
5. 根据权利要求3所述的方法,其中通过将所述粘合剂辊涂在所述毡上,在所述毡上形成粘合剂涂层。
6. 根据权利要求1所述的方法,其中用涂装材料涂覆粘合剂增强区域,以使其颜色接近纯白色。
7. 一种天花板,其包括由浆料制成的标称厚度为大约1/2英寸~大约3/4英寸的毡并具有重量为至少75%的矿物棉含量以及3%的粘合剂,粘合剂大致分布在贯穿大部分毡厚度的范围内并且在毡的表面侧上具有粘合剂增强区域,该区域中单位厚度的粘合剂含量明显大于毡的主体部分的单位厚度的粘合剂含量,从而该区域的硬度大于毡的主体部分的硬度,以便增强天花板抵抗物理损坏的耐久性,同时能够减小天花板的总粘合剂含量,并能够相应地降低天花板的成本。
8. 根据权利要求7所述的天花板,其中粘合剂增强区域由漆型涂层覆盖,与粘合剂增强区域呈现出的颜色相比,该漆型涂层的颜色更接近纯白色。
9. 根据权利要求8所述的天花板,其中粘合剂增强区域包括乳胶粘合剂,并且与毡的主体部分的颜色相比,该区域的颜色更接近纯白色,从而与如果没有粘合剂增强区域并且将漆型涂层应用于毡的表面时所需的漆型涂层相比,只需更少的漆型涂层就能在天花板面上获得理想的白色色度。
10. 根据权利要求7所述的天花板,其中,粘合剂增强区域被涂覆在毡上。
11. 一种天花板,其包括由均匀混合的矿物棉和粘合剂构成的水浆料形成的基底毡,矿物棉形成天花板的大部分重量,所述毡具有相对小的密度并且呈相对多孔状,在毡表面侧上的粘合剂增强区域作为涂层形成在水浆料中的矿物棉和粘合剂的主体上,在粘合剂增强区域中的单位厚度的粘合剂浓度明显大于在毡中的单位厚度的粘合剂的浓度。
12. 根据权利要求11所述的天花板,其中涂覆在毡上的粘合剂与混合在浆料中用以形成所述毡的粘合剂材料相同。
13. 根据权利要求11所述的天花板,其中粘合剂增强区域由使天花板的颜色趋向于白色的材料涂覆。
14. 根据权利要求11所述的天花板,其中粘合剂增强区域中的粘合剂为高Tg粘合剂型乳胶。
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US11/227,014 US7732043B2 (en) | 2005-09-15 | 2005-09-15 | Ceiling tile with non uniform binder composition |
US11/227,014 | 2005-09-15 | ||
PCT/US2006/031857 WO2007037820A1 (en) | 2005-09-15 | 2006-08-15 | Ceiling tile with non uniform binder composition |
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JP (1) | JP5294113B2 (zh) |
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US7862687B2 (en) * | 2007-11-20 | 2011-01-04 | United States Gypsum Company | Process for producing a low density acoustical panel with improved sound absorption |
US8182652B2 (en) * | 2010-03-23 | 2012-05-22 | United States Gypsum Company | Method of making a coating and a coated acoustical panel using degraded fibers |
US9040153B2 (en) * | 2012-06-07 | 2015-05-26 | Usg Interiors, Inc. | Method of reducing ceiling tile sag and product thereof |
US9376810B2 (en) | 2014-04-25 | 2016-06-28 | Usg Interiors, Llc | Multi-layer ceiling tile |
US10696594B2 (en) | 2017-08-11 | 2020-06-30 | Usg Interiors, Llc | High noise reduction coefficient, low density acoustical tiles |
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JP2009509068A (ja) | 2009-03-05 |
WO2007037820A1 (en) | 2007-04-05 |
EP1945872A1 (en) | 2008-07-23 |
KR101393731B1 (ko) | 2014-05-13 |
JP5294113B2 (ja) | 2013-09-18 |
CN101263269A (zh) | 2008-09-10 |
US20070056705A1 (en) | 2007-03-15 |
KR20080036221A (ko) | 2008-04-25 |
HK1120582A1 (en) | 2009-04-03 |
TWI386538B (zh) | 2013-02-21 |
EP1945872A4 (en) | 2014-12-03 |
CA2622486C (en) | 2013-04-02 |
NO20081747L (no) | 2008-04-09 |
EP1945872B1 (en) | 2020-06-10 |
RU2008114523A (ru) | 2009-10-20 |
RU2434102C2 (ru) | 2011-11-20 |
TW200724757A (en) | 2007-07-01 |
CA2622486A1 (en) | 2007-04-05 |
US7732043B2 (en) | 2010-06-08 |
ZA200802256B (en) | 2009-09-30 |
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