CN103269994B - 使用壳聚糖的声学建材 - Google Patents
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Abstract
浇注天花板及其制备方法引入壳聚糖，其量足以提供增加的强度并增强用于形成板的浆料脱水。
Description
本申请是2011年11月15日提交的美国申请序列号No.13/294,200的部分继续申请，后者又要求2010年12月28日提交的美国临时申请No.61/427,643的优先权。
技术领域
本领域涉及用于建筑的建材，更具体涉及包含均匀分散在板结构内的壳聚糖的天花板。
背景技术
建材或天花板在建筑业中用于提供原天花结构或更换覆盖天花结构。天花板可以直接安装到建筑表面上或它们可以利用固定到建筑结构的网状支承件安装在吊顶式天花布置中。这些板由纤维、填料和粘结剂的浆料制备。
本文特别关注的是使用例如美国专利5,395,438和1,769,519中所公开的那些组合物和浇注程序制备板。根据这些专利教导，制备包含纤维、填料、着色剂和粘结剂，特别是淀粉凝胶的模制组合物用以模制或浇注天花板主体。将该混合物或组合物置于合适的托盘上，接着用刮板或辊将组合物刮至所需厚度。接着将装有组合物的托盘置于烘箱中干燥或固化该组合物。从托盘中取出经干燥的板材，并可以处理一面或双面以提供光滑表面，从而获得所需厚度并防止扭曲。接着将板材切成所需尺寸的板。
壳聚糖或聚-D-葡萄糖胺可作为几丁质脱乙酰化形式商购，其中几丁质是甲壳纲动物外骨和某些真菌的细胞壁中的结构成分。它是类似于纤维素的阳离子聚合物。已发现壳聚糖促进凝血并已用在绷带中。它是杀生物剂并具有增强抗微生物和抗真菌行为的特殊性质。壳聚糖也用作重金属水过滤中的絮凝剂。壳聚糖还被指出吸收甲醛和气味。
发明内容
已发现壳聚糖是可直接引入浆料配方内的纤维板的多功能添加剂。将壳聚糖溶解在酸中并作为稀溶液直接加入浆料中。以此方式，壳聚糖均匀分散通过板结构，并且在制备工艺中无显著变化。
在天花板结构中使用壳聚糖使得所得制品能够具有许多优点。例如，小于约10wt%的壳聚糖浓度提供足以允许减少粘结剂量的结构增强。这带来成本节约，因为粘结剂是纤维板组合物中的昂贵成分。
在板结构中引入壳聚糖的另一优点是它增强并帮助组分粘结，并使得能够增加回收内容物。即可以减少粘结剂的量，并可以使用增加量的回收纤维素。
最出乎意料地，还已发现在板结构中引入壳聚糖以在它们成形时强化从板结构中脱水或除水并减小干燥要求。在浇注工艺中，在烘箱干燥步骤之前改善从板结构中脱水，并减小所需的干燥量。在根据本发明的包括壳聚糖的板结构中，相比除加入壳聚糖外相同的板结构和处理，在烘箱干燥之前在脱水步骤中脱除的水量增加。因此，根据本发明在最后烘箱干燥步骤中待脱除的水量减小。降低的烘箱干燥要求节约能量和花费。
壳聚糖的杀生物性尤其适用在其中高湿度、冷凝或水分的其它来源可能润湿板的天花板应用中。这种环境有利于可能通过空气转移而沉积的微生物和真菌的不合意生长。
据信壳聚糖吸收甲醛的能力降低了工艺和制品的甲醛水平。壳聚糖的去味性能在制品应用中特别有用。
具体实施方式
如上述，已发现壳聚糖作为多功能添加剂为建材，特别是浇注天花板组合物提供期望的特性。为方便起见，下文具体参照浇注天花板描述本发明。
本文关注的天花板包括通常是矿物纤维如矿棉或类似无机纤维的基础纤维。填料通常是珍珠岩、粘土、碳酸钙、玻璃珠、灰泥(半水合硫酸钙)或石膏。粘结剂通常是淀粉、胶乳或类似材料。如上述这些材料或成分通常混合在水性浆料中并按水毡化工艺处理。
在典型组合物中，纤维和填料组分包含主要成分。但是，可以使用宽泛变化的成分。例如，下面图表归纳了典型的浇注天花板组合物。应该认识到组合物可以如下表所列包含一种或多种所示类型的纤维、填料或粘结剂。本文的百分比是基于固体的重量百分比，除非通过注释或上下文另有说明。
以已知方式将纤维、填料和粘结剂组分以约65%至75%固体的含量混合在水性浆料中。将壳聚糖溶解在酸性水溶液中并均匀掺混到该浆料中。例如，可以将粉末或片状形式的壳聚糖溶解在2–4体积%的乙酸溶液中，进而加入浆料中。所加入的壳聚糖溶液的量提供基于浆料中所含固体为1%至6%的最终产物重量基重。
据信壳聚糖中存在的亲水性OH和NH基团增强了壳聚糖的均匀分布和彻底渗透和/或接触纤维和填料浆料成分。而且，据信带阳离子的壳聚糖与淀粉相互作用。而且，壳聚糖看起来形成纤维状结构，它与板的其它纤维组分相互交织和/或以其它方式相互作用以提供结构增强，这使得能够减小粘结剂的量并且板物理性质存在可接受的有限变化。
如上述，向天花板等的板结构中加入壳聚糖减小在该结构烘箱干燥前成形时它所残留的水量。浇注工艺可以包括天然排水、对板施用真空和/或辊压以在烘箱干燥前除水。已发现根据本发明使用壳聚糖在与一种或多种前述预烘箱干燥工艺使用时能有效增强除水。因此，根据本发明含壳聚糖的板在烘箱干燥前包含比具有相同组成但没有加入壳聚糖的相同成形板结构少的水。
下面说明性实施例比较对应于板芯且不包括外涂层、孔或其它表面处理的板。该板组合物包含矿棉、玉米淀粉、灰泥和硼酸。在此改变板组合物以引入不同量的壳聚糖来验证壳聚糖的粘结和增强性质。
所制备的板中包含的组分的绝对量示于下表1中。
表1:配方
板1提供没有加入壳聚糖但具有典型量淀粉的对比板。板2-5包含增加量的壳聚糖。
板1-5的性质示于表2中。
表2：性质
测试板1-5，结果示于上表2中。采用下面测试程序测定表2中给出的测试结果。
挠曲模量MOR测试是3-点弯曲测试。本文的测试程序类似于用于预制结构声学板或嵌入式天花板的强度性质(Strength Properties of Prefabricated ArchitecturalAcoustical Tile or Lay-In Ceiling Panels)的ASTM C367标准测试法。硬度测试说明天花板耐受在安装或后安装过程中可能出现的压痕的能力。本文所用的2”球硬度测试类似于用于预制结构声学板或嵌入式天花板的强度性质的ASTM C367标准测试法。
板1和2的比较显示，如增加的MOR和硬度结果所示，强度和硬度增加。该比较包括相同量的粘结剂，并且在板2中加入1％壳聚糖。因此，壳聚糖提高了这些物理性质。
板3和4如增加的MOR所示表现出强度进一步增加。板5在加入10％后表现出强度和MOR下降。据信强度或MOR增加和/或可接受的物理性质值可以通过加入大于5％且至约10％或更高的壳聚糖来实现。当前优选的壳聚糖范围为约2％至约8％。如本文所用，可接受的物理性质表示所测试的物理性质值至少等于使用相同成分但不加入壳聚糖的相同成形天花板所提供值的约95%。
即使可能导致性质值略低，但应该认识到在实现增加强度或MOR性质和/或硬度的结构中可以减小更昂贵的淀粉成分的量。此外，可以增加回收新闻纸的量来替代减少的淀粉量，由此增加板中回收和工业后/消费后内容物。
板5的特征在于强度和硬度下降大于对比值的5%。当前认为这种下降超过可接受物理性质值。
采用如上述的浇注程序制备下面的板以评估抗霉性。基于总干成分的板组成归纳在下表3中。
表3：基于总干成分的组成
根据前面配方，制备板6–7并基于ASTM D3273-00(2005年经再批准)测试它们的抗霉性。板6是对比板，不含壳聚糖；板7包含5%壳聚糖，板7包含10%壳聚糖。评估两周暴露和四周暴露后的板正面和背面。观察板正面和背面，并评定为0–10的值，其中0表示整个样品表面上连续毁损，10表示样品完全没有被微粒物质毁损。测试结果示出下表4中。
表4：抗霉性
如表4所示，壳聚糖的使用抑制了生霉。板表面基本没有毁损。壳聚糖提高抗霉性，并且强度和MOR值增加。
下文给出另外的对比、5%壳聚糖和10%壳聚糖配方。
应该显然，本公开内容用于举例，并且在不脱离本公开内容所包含教导的合理范围的情况下可以通过添加、修改或省略细节进行各种变化。因此除了下面权利要求必定如此受限的范围外，本发明不限于本公开内容的具体细节。
Claims (21)
1.一种由主要包括纤维、填料、选自淀粉和胶乳的粘结剂和壳聚糖的成分的水性浆料的干燥声学产物形成的浇注天花板，所述壳聚糖均匀分散在整个水性浆料中用以与浆料成分相互作用，由此相比除壳聚糖外的相同浆料成分同样成形的天花板，通过壳聚糖与浆料中的纤维成分相互作用而结构增强通过干燥来自水性浆料中的水而形成的浇注天花板。
2.根据权利要求1所述的浇注天花板，其中所述壳聚糖与所述成分相互作用，以相比由除壳聚糖外的相同浆料成分同样形成的天花板，提供具有增强物理性质的天花板，所述物理性质包括MOR。
3.根据权利要求1所述的浇注天花板，其中所述壳聚糖以基于水性浆料中固体总重量为0.5wt％至10wt％的量存在。
4.根据权利要求1所述的浇注天花板，其中所述壳聚糖溶解在酸溶液中用以加入浆料中。
5.根据权利要求1所述的浇注天花板，其中所述浆料包含对应于壳聚糖加入量而减少量的粘结剂以保持可接受的物理性质，以及对应于粘结剂减少量而增加量的纤维素纤维回收材料，由此提高板的工业后/消费后内容物。
6.根据权利要求5所述的天花板，其中所述可接受的物理性质包括MOR和硬度。
7.根据权利要求1所述的浇注天花板，其中所述壳聚糖与所述浆料成分在脱水过程中相互作用以相比由除壳聚糖外的相同浆料成分同样形成的浇注天花板，从天花板中除去增加量的水。
8.根据权利要求1所述的浇注天花板，其中所述纤维为矿棉，且所述填料选自珍珠岩、碳酸钙、粘土和灰泥。
9.根据权利要求1所述的浇注天花板，其中所述壳聚糖趋于提高天花板的抗霉性。
10.根据权利要求1所述的浇注天花板，其中所述天花板具有包含按重量计如下成分的组合物：
60％至80％的纤维，
15％至70％的填料，
3％至12％的粘结剂，和
0.5％至10％的壳聚糖，
条件是以上成分的含量百分比之和等于或小于100％。
11.一种声学建材，其包含主要包括矿物纤维、填料、淀粉粘结剂和壳聚糖的成分的水性浆料的干燥产物，所述壳聚糖均匀分散在整个水性浆料中，所述壳聚糖与浆料成分相互作用，由此相比除壳聚糖外的相同浆料成分同样成形的声学建材，通过壳聚糖至少与淀粉粘结剂相互作用来结构增强所述声学建材。
12.根据权利要求11所述的建材，其中所述壳聚糖与所述浆料成分相互作用，以相比由除壳聚糖外的相同浆料成分同样形成的建材，提供具有增强机械性质包括MOR的建材。
13.根据权利要求11所述的建材，其中所述壳聚糖以基于水性浆料中固体总重量为1wt％至6wt％的量存在。
14.根据权利要求11所述的建材，其中所述浆料包含对应于壳聚糖加入量而减少量的粘结剂以保持可接受的物理性质，以及对应于粘结剂减少量而增加量的纤维素纤维回收材料。
15.根据权利要求11所述的建材，其中所述壳聚糖与所述浆料成分在脱水过程中相互作用以相比由除壳聚糖外的相同浆料成分同样形成的建材，从建材中除去增加量的水。
16.根据权利要求11所述的建材，其中所述纤维选自矿棉、玻璃纤维和纤维素纤维，所述填料选自珍珠岩、碳酸钙、粘土和灰泥。
17.一种在浇注工艺中由水性浆料的干燥声学材料制备天花板的方法，包括：形成主要包括矿物纤维、填料、淀粉粘结剂和壳聚糖的成分的所述水性浆料，所述填料选自珍珠岩、碳酸钙、粘土和灰泥，将所述壳聚糖均匀分散在所述水性浆料中，将所述浆料脱水并干燥以形成所述声学材料，所述壳聚糖与淀粉粘结剂和/或矿物纤维浆料成分相互作用，由此相比除壳聚糖外的相同成分同样形成的浇注板结构增强所得板。
18.根据权利要求17所述的方法，其中所述壳聚糖溶解在酸溶液中并加入浆料中。
19.根据权利要求18所述的方法，其中所述壳聚糖与所述成分相互作用，以相比由除壳聚糖外的相同成分同样形成的浇注板，提供具有增加MOR和硬度的所述浇注板。
20.根据权利要求17所述的方法，其中将所述浆料脱水的步骤包括相比由除壳聚糖外的相同成分同样形成的浇注板，因存在壳聚糖而除去增加量的水。
21.根据权利要求17所述的方法，其中壳聚糖以基于水性浆料中固体总重量为0.5wt％至10wt％的量存在，并且浆料包含对应于壳聚糖加入量而减少量的粘结剂以保持可接受的物理性质，以及对应于粘结剂减少量而增加量的纤维素纤维回收材料，由此提高建材的工业后/消费后内容物。
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| BR112018069541A2 (pt) | 2016-04-04 | 2019-01-29 | Fiberlean Tech Ltd | composições e métodos para fornecer resistência aumentada em produtos de teto, pavimento e construção |
| AU2018324028B2 (en) | 2017-08-30 | 2021-08-12 | The Fynder Group, Inc. | Edible composition with filamentous fungi and bioreactor system for the cultivation thereof |
| AU2020227820B2 (en) | 2019-02-27 | 2023-08-10 | The Fynder Group, Inc. | Food materials comprising filamentous fungal particles and membrane bioreactor design |
| JP2022538816A (ja) | 2019-06-18 | 2022-09-06 | ザ・フィンダー・グループ・インコーポレイテッド | 真菌織物材料および皮革類似物 |
| KR102244208B1 (ko) * | 2020-08-31 | 2021-04-26 | 이정명 | 축광 타일 제조방법 및 이의 시공방법 |
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