CN103328737A - 使用壳聚糖的声学建材 - Google Patents
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Abstract
声学建材包含包括纤维、填料、粘结剂和均匀分散的壳聚糖的成分的水性浆料。壳聚糖增强建材的脱水。
Description
本申请要求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
本领域涉及声学建材或纤维板及其制备方法，更具体涉及包含均匀分散在板结构内的壳聚糖的纤维板。
背景技术
声学建材或纤维板可以呈现建筑产业中公知的天花砖、天花板、壁板或壁砖的形式。这些板由纤维、填料和粘结剂的浆料制备。
这些板通常在本领域已知的水毡化工艺中使用浆料制备。纤维、填料、粘结剂和其它成分的分散体流到运动的多孔载体如Fourdrinier成形机上用以脱水。该分散体首先通过重力脱水，接着通过真空抽吸脱水。干燥湿基垫，并将经干燥的材料切成所需尺寸并任选表面涂覆以产生纤维板或砖。
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。
在纤维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(recycle content)。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。在毡化工艺中，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处理中，增加在烘箱干燥之前在脱水步骤中脱除的水量，由此减小在最后烘箱干燥步骤中待脱除的水量。降低的烘箱干燥要求节约能量和花费。
壳聚糖的杀生物性直接适用在板和壁应用中。这些性质在其中高湿度、冷凝或水分的其它来源很可能润湿板的天花板应用中尤其具有价值。这种高湿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声学建材或纤维板提供期望的特性。为方便起见，下文具体参照可用在悬吊式天花板中的天花板来描述本发明。
本文关注的天花板包括通常是矿物纤维如矿棉或玻璃纤维和有机纤维如纤维素纤维的基础纤维。填料通常是珍珠岩、粘土、碳酸钙或灰泥石膏。粘结剂通常是淀粉、胶乳或类似材料。如上所述，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天花板和壁组合物。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3%至6%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。毡化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、回收新闻印刷纸、玉米淀粉、碳酸钙、珍珠岩和絮凝剂。已经验确定玉米淀粉的量优选约8wt%以提供所需的声学、强度和其它性质。在此改变板组合物以引入不同量的壳聚糖并减少淀粉量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(按干重量计)
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和减少量的粘结剂淀粉。
板1-5的各组分的按份计重量百分比示于表2中。
表2：配方(按份计%)
测试板1-5，结果示于下表3中。采用下面的测试程序测定表3中给出的测试结果。
挠曲模量的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 ofPrefabricated Architectural Acoustical Tile or Lay-In Ceiling Panels)的ASTMC367标准测试法。硬度测试表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。
表3：物理测量、MOR、硬度
板1和2的比较表明，如增加的MOR、断裂载荷和硬度结果所示，强度和硬度增加。该比较包括相同量的粘结剂，并且在板2中加入壳聚糖。因此，壳聚糖提高了这些物理性质。
板2和3中粘结剂的量分别减少1%和2%。粘结剂减少并没有通过壳聚糖加入得到完全补偿。因此，板3和4略微脆和软，但是仍在可接受的物理性质值范围内。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%。
即使导致性质值略低，但应该认识到板2和3结构中更昂贵的淀粉成分的量减小了。此外，可以增加回收新闻纸的量来替代减少的淀粉含量，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。而且，可以增加回收新闻纸的量来替代减少的淀粉含量，由此增加板中回收和工业后/消费后内容物。
测试板1-5的降噪情况，更具体地测定ENRC或估计的降噪系数。ENRC测试基于用于Impedance and Absorption of Acoustical Material by theImpedance Tube Method的ASTM C384标准测试法。该测试用于预测吸声。应该认识到测试结果仅与类似制备的样品可比，例如此处的板不包括进一步的表面涂饰或类似最终处理。
测试结果示于下表4中。
表4:ENRC
如表4所示，使用壳聚糖不会不利影响ENRC，并且壳聚糖的优点可以在该性质没有不可接受地下降的情况下实现。
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 (10)
1.一种由包括纤维、填料、粘结剂和壳聚糖的成分的水性浆料形成的天花板，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，通过壳聚糖至少与粘结剂相互作用来结构增强由水性浆料形成的天花板。
2.根据权利要求1所述的天花板，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所述的天花板，其中所述壳聚糖以基于水性浆料中固体总重量为约1wt%至约6wt%的量存在。
4.根据权利要求1所述的天花板，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所述的天花板，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，所述粘结剂选自淀粉和胶乳。
9.根据权利要求1所述的天花板，其中所述天花板具有包含按重量计如下成分的组合物：
约5%至约65%的纤维，
约3%至约12%的粘结剂，和
约1%至约6%的壳聚糖。
10.一种声学建材，其包含包括矿物纤维、填料、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，通过壳聚糖至少与粘结剂相互作用来结构增强所述声学建材。
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| AU2017227612C1 (en) | 2016-03-01 | 2023-02-16 | The Fynder Group, Inc. | Filamentous fungal biomats, methods of their production and methods of their use |
| US20190242055A1 (en) * | 2016-03-11 | 2019-08-08 | Georgia-Pacific Nonwovens LLC | Blended chitosan-latex binder for high performance nonwoven fabrics |
| AU2017247688B2 (en) | 2016-04-04 | 2020-11-05 | Fiberlean Technologies Limited | Compositions and methods for providing increased strength in ceiling, flooring, and building products |
| MX2020002249A (es) | 2017-08-30 | 2020-10-08 | The Fynder Group Inc | Productos alimenticios comestibles y diseño de biorreactor. |
| SG11202108709PA (en) | 2019-02-27 | 2021-09-29 | 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 |
| KR102376364B1 (ko) * | 2021-04-01 | 2022-03-18 | 주식회사 동아에이블 | 세라믹 축광 타일 제조방법 및 이의 시공방법 |
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