CN103391843A - 抗下垂的无甲醛涂布的纤维基底 - Google Patents

抗下垂的无甲醛涂布的纤维基底 Download PDF

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CN103391843A
CN103391843A CN2011800656068A CN201180065606A CN103391843A CN 103391843 A CN103391843 A CN 103391843A CN 2011800656068 A CN2011800656068 A CN 2011800656068A CN 201180065606 A CN201180065606 A CN 201180065606A CN 103391843 A CN103391843 A CN 103391843A
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K·G·考德威尔
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Abstract

本发明涉及改进的无甲醛的涂布的纤维基底。该涂层包括当加热固化时形成三维网络的交联粘合剂体系。在涂层施加到纤维基底的背面且固化之后，该涂层能吸湿膨胀，所述吸湿膨胀赋予优良的抗下垂性能。该涂层与具有中性或温和碱性pH的其他涂料体系相容。改进在于粘合剂体系用挥发性碱中和，结果它快速地蒸发，以便没有妨碍交联反应。

Description

抗下垂的无甲醛涂布的纤维基底
技术领域
本发明涉及涂布的面板，和特别地施加到纤维面板的主要外表面上抗下垂的无甲醛的涂层。
背景技术
纤维基底是轻质、多孔的复合材料，它用于许多不同的目的，其中包括在悬浮的(suspended)天花板型系统中的面板。它们由含纤维、粘合剂体系和其他添加剂的水性淤浆混合物生产。纤维(它典型地用作增强材料)包括矿棉，玻璃和纤维素纤维。粘合剂体系(它将纤维和其他添加剂保持在一起)包括淀粉，胶乳，再生纸产品和其他聚合物材料。其他添加剂包括填料，例如膨胀珍珠岩，粘土等。
本领域中广泛已知的是改变前述组分的材料百分数最终影响纤维基底的物理和机械性能，尤其当纤维基底安装在水平延伸的悬浮的天花板系统内时。例如，对于本领域技术人员来说，众所周知的是在安装到悬浮的天花板框架内后，若由于芯基底中的一些组分，例如水溶性聚合物粘合剂(例如淀粉)和纤维素纤维(例如，新闻纸)的亲水性质导致暴露于高湿度环境下时，则纤维基底倾向于下垂。更具体地，在吸收湿气之后，基底丧失其模量并在其重力作用下下垂。因此，常规的选择行为是当这些亲水组分的材料百分数增加时，基底的下垂性能下降。
存在各种尝试来改进或者消除这些常规纤维基底内的下垂。一种已知的方法是施加吸湿涂层到基底的主要外表面之一上。更具体地，这一涂层包括亲水且随着湿度上升能吸收湿气并且随着湿度下降能解吸湿气的粘合剂体系。因此，当湿度上升时，吸湿涂层吸收湿气并且其体积与尺寸膨胀，从而在涂层施加到其上的基底表面上产生膨胀力。本质上，涂层抵消了因湿度条件引起的压缩力。
为了在高相对湿度下抵抗来自下面纤维隔音板的压缩力，不仅背涂层必须吸湿，并产生膨胀力，进一步要求涂层维持高模量。本领域中充分了解的是，需要对亲水聚合物进行聚合物改性，以便在吸收高程度的湿气之后，维持高模量。聚合物改性的一种已知方法是通过交联。一旦聚合物被合适地交联，则聚合物基体的膨胀受到限制，和反过来聚合物软化，即在高湿度条件下的模量损失最小。
另外，存在用作粘合剂的数种已知的无甲醛的组合物以供制造纤维基底。例如，美国专利Nos.6,221,973和6,331,350公开了已知无甲醛的玻璃纤维粘合剂，它包括聚酸，例如聚丙烯酸，和多元醇，例如甘油，二乙醇胺，三乙醇胺，山梨醇或乙二醇。然而，这些无甲醛的粘合剂溶液的主要缺点是它们的pH低，这使得它们常常与其他涂层不相容和/或引起加工设备腐蚀。
因此，需要改进的涂布的纤维基底，它不释放环境刺激物，例如甲醛，抗下垂，且与此同时维持高模量；与其他涂层和填料相容；且避免了腐蚀加工设备。
发明内容
本发明涂布的纤维面板包括纤维基底和施加到该纤维基底的主表面上的无甲醛的涂层。该涂层包括具有中和的聚羧基聚合物和多元醇交联剂的粘合剂体系。该涂层的pH大于或等于6，且能在高湿度下吸湿膨胀抗下垂。改进在于用快速地蒸发的挥发性碱中和涂层，以便没有妨碍交联反应。
具体实施方式
本发明是无甲醛的涂层，它可施加到纤维基底的主表面上使其具有抗下垂性，同时维持高的模量。该涂层具有大于或等于约6的中性或温和的碱性pH，和优选约6-约10，使得该涂层与其他涂层，各种填料和加工设备相容。优选的涂层粘合剂体系包括用挥发性碱中和的至少一种聚羧基聚合物和能交联该中和的聚羧基聚合物的至少一种多元醇。更具体地，多元醇交联聚羧基聚合物，形成三维网络，所述三维网络具有高的模量且能吸湿膨胀抑制下垂。在聚羧基聚合物内的羧基与多元醇内的羟基的摩尔比为约1:0.2-约1:8。
聚羧基聚合物是含有多个羧基的均聚物或共聚物。由其中至少一种单体包含羧基的多个单体合成所述聚羧基聚合物。含羧基的合适单体包括丙烯酸，甲基丙烯酸，马来酸，富马酸，马来酸酐等。不含羧基的合适单体包括苯乙烯，乙烯，丙烯，丙烯酸酯等。优选的聚羧基聚合物是聚丙烯酸，它由仅仅丙烯酸单体合成。
在水溶液中用挥发性碱中和聚羧基聚合物，以便没有妨碍交联反应，和因此避免对下垂性能的任何损害。氨水是挥发性碱的优选的选择，这是因为氨快速地蒸发，且使得能比较快速地固化。另外，该涂料粘合剂应当不含任何单一或多价的金属离子，例如钠，钾，钙等。预料不到的是，发现在涂层内任何显著量的这些离子也妨碍交联反应。涂料粘合剂因此优选具有小于1000ppm，和更优选小于500ppm的金属离子浓度。
来自可再生资源的多元醇是尤其优选的，因为它们具有可再生性，低毒性，和低成本。最有利的可再生多元醇包括甘油，右旋糖，果糖，蔗糖和山梨糖醇等。多元醇是含有两个或更多个羟基的多元醇。多元醇交联剂包括仲烷醇胺(例如，二乙醇胺，乙基二乙醇胺，甲基二乙醇胺等)，叔烷醇胺(例如，三乙醇胺)，甘油，葡萄糖(即，右旋糖)，果糖，蔗糖，山梨糖醇，甲苯二酚，儿茶酚，焦酚，乙醇酸化脲，聚乙烯醇，1,4-环己烷二醇，季戊四醇，乙二醇，二甘醇，三甘醇，羟基封端的聚环氧乙烷，三羟甲基丙烷，或其混合物。
聚羧基聚合物内的羧基与多元醇内的羟基之间的摩尔比影响交联密度，涂层的模量，涂层的吸湿性能，和抗下垂性能。因此，可控制羧基与羟基的摩尔比，优化所需的最终性能。优选的羧基与羟基的摩尔比为约1:0.2-约1:8。
可在填料添加程度下，进一步调节吸湿膨胀和抗下垂性能。填料应当对湿气不敏感，所述湿气然后可在高湿度下抑制吸湿膨胀。填料也优选具有高的模量，所述高的模量本身可改进已固化的涂层的模量。可使用或者有机或者无机的各种填料。合适的无机填料包括石灰石，粘土，砂子，云母，珍珠岩，硅藻土，长石，滑石，玻璃珠等。合适的有机填料包括硬塑料粉末，例如聚碳酸酯，聚酯，尼龙，聚丙烯，聚乙烯等。
实施例
实施例1
按照下述工序制造水性涂层BC#1：将247.0g聚丙烯酸铵(38%w/w)加入到含有521.8g水的混合器内。在混合的同时，按序将102.5g右旋糖，1.0g Tergitol TMN-6(润湿剂),2.6g消泡剂，1.2g杀虫剂和1519.7g填料淤浆加入到混合器中。最终的涂层具有55%的固体含量，Brookfield粘度为3,400cps，pH8.9，且填料与粘合剂(F:B)之比为6:1。
通过喷涂到三类天花板面板的背面上，施加涂层。它们全部含有不同含量的增强纤维(或者矿棉或者玻璃纤维)。面板#3是含额外的粘土的窑炉产品。干燥的施加重量为10g/英尺2。为了平衡因干燥背涂层引起的天花板瓷砖应力，还施加含填料与粘合剂之比为5:1和50%固体的底层涂料(PC#1)到天花板面板的表面上，且干燥施加重量为约10g/英尺2。然后干燥喷涂过的面板，并在烘箱内，在410°F下固化10分钟。然后将涂布的面板切割成24"×3"的长条，测试在82°F和35%至90%至35%的RH循环下共2循环(24小时/循环)的下垂。在第4个循环下的最终下垂是一设计值(projected value)。然后使用经验式，将下垂数据转化成2'x2'和2'x4'的全面板尺寸。
表I中示出了在涂层施加之前，所有三个基础面板的弹性模量(MOE)，断裂模量(MOR)，甲醛释放(CA1350)，和下垂数据。表I表明，断裂模量(MOR)和弹性模量(MOE)随矿棉纤维或玻璃纤维的含量增加而增加。这清楚地表明当增强纤维增加时，面板变得更结实。窑炉面板#3(它含有大多数矿棉纤维和额外的粘土)是所有中最结实的。具有最小增强纤维的裸面板#1的下垂最差。当机械强度得到改进时，裸面板的下垂得到改进。面板#3不下垂，这是因为它基本上不吸湿。因此，具有差的机械性能的面板需要特别的涂层，以改进它们的抗下垂性，同时窑炉面板#4没有这种需求。
表I.实施例1-2和对比例1-2的试验结果概述
Figure BDA00003543217900051
当用BC#1和PC#1涂布面板时，下垂行为取决于增强纤维的含量而变化。与前面一样，随着面板内增强纤维增加，下垂结果改进。表1示出了对于面板#2来说，BC#1涂层对2x2'和2x4'这两种尺寸满足抗下垂性。对于面板#1来说，BC#1涂层对2x2'满足抗下垂性，但对于2'x4'面板尺寸来说，没有提供充足的抗下垂性，这是因为其较宽的跨度导致的。
实施例2
按照下述工序制造水性涂层BC#2：将576.0g聚丙烯酸铵(38%w/w)加入到含387.8g水的混合器内。在混合的同时，按序添加239.3g右旋糖，1.0g Tergitol TMN-6，2.6g消泡剂，1.2g杀虫剂和1187.5g填料淤浆到该混合器内。最终的涂层具有的固体含量55%，Brookfield粘度为1,100cps，pH8.9，和填料与粘合剂(F:B)之比为2:1。紧跟在如实施例1所述的相同的涂层施加，涂层固化和面板下垂测试工序之后，使用这一背涂层评价三种不同的天花板面板。表I中示出了转化的下垂数据。
使用California CA1350方法的甲醛释放试验表明具有BC#2涂层的面板#3和裸面板#3均具有不可检测的释放水平，因此，在这一试验中，BC#2涂层没有增加可检测的甲醛释放。在Collaborative forHigh Performance Schools(CHPS)编码中，这些面板容易满足18.9μg/m2hr的甲醛释放极限。根据表I，可清楚地表明对于2'x4'面板来说，与BC#1配方相比，BC#2配方具有较好的抗下垂性。然而，面板的横向翘曲可能是问题，若BC#2配方用于2'x2'面板尺寸的话。
对比例1
按照下述工序制造水性涂层BC#3：将1557.6g聚丙烯酸铵(38%w/w)加入到含177.4g水的混合器内。在混合的同时，向该混合器内添加647.0g右旋糖，2.6g消泡剂和1.2g杀虫剂。最终的涂层具有的固体含量50%，Brookfield粘度为170cps，pH9.6，和填料与粘合剂(F:B)之比为0:1。紧跟在如实施例1所述的相同的涂层施加，涂层固化和面板下垂测试工序之后，使用这一背涂层评价三种不同的天花板面板。表I中示出了转化的下垂数据。
当在天花板面板#1和#2中使用不具有填料的配方时，填料的增强效果丧失，和该涂层没有提供具有充足面板下垂性能的面板。这显然表明填料非常有助于增强粘合剂的强度。
对比例2
按照下述工序制造水性涂层BC#4：将265.3g Rhoplex GL720胶乳(丙烯酸类基础胶乳,Tg=95°C,50%固体)加入到含有81.2g水的混合器内。在混合的同时，按序向该混合器内添加0.1g聚磷酸四钠，1568.2g高岭土粘土淤浆(70%固体),81.1云母，0.8g杀虫剂，1.0gRhoplex RM232增稠剂和3.2g消泡剂。最终的涂层具有的固体含量65%，Brookfield粘度为520cps，pH6.6，和填料与粘合剂(F:B)之比为约8:1。紧跟在如实施例1所述的相同的涂层施加，涂层固化和面板下垂测试工序之后，使用这一背涂层评价面板#1。在这一对比例中使用新的底层涂料PC#2(16:1F:B之比和50%固体)。表I中示出了转化的下垂数据。
在这两个面板尺寸下，面板#1的下垂试验失败，尽管2'x2'面板的确好于2'x4'面板。因此，在相同的成本基础下，胶乳基背涂层BC#4具有比BC#1和BC#2高的下垂值，且没有充分足够地抗湿度下垂。
表II.在用各种涂层涂布的面板#1上的下垂结果
Figure BDA00003543217900081
实施例3
按照下述工序制造水性涂层BC#5：将328.0g获自Sartomer Co.的SMA-1000H加入到含291.0g水的混合器内。在混合的同时，向该混合器内添加38.0g甘油，1.0g消泡剂，1.0g杀虫剂和340.0g高岭土粘土。所得涂层具有50%的固体，630cps Brookfield粘度和2:1的填料与粘合剂之比。紧跟在如实施例1所述的相同的涂层施加，涂层固化和面板下垂测试工序之后，使用这一涂层测试面板#1(具有约10%增强纤维)。如表II所示，在4个湿度循环之后，涂布的面板具有-198mil的下垂值。
实施例4
按照下述工序制造水性涂层BC#6：将227.2g SMA-1000H加入到含352.7g水的混合器内。在混合的同时，向该混合器内添加76.6g右旋糖(葡萄糖)，1.0g消泡剂，1.0g杀虫剂和340.0g高岭土粘土。所得涂层具有50%的固体，2700cps Brookfield粘度，8.9pH和2:1的填料与粘合剂之比。紧跟在如实施例1所述的相同的涂层施加，涂层固化和面板下垂测试工序之后，使用这一涂层测试面板#1。如表II所示，在4个湿度循环之后，这一涂布的面板具有-188mil的下垂值。
实施例5
按照下述工序制造水性涂层BC#7：将346.8g SMA1000H加入到含377.9g水的混合器内。在混合的同时，向该容器内添加22.1g三乙醇胺(TEA)，1.0g消泡剂和440.9g高岭土粘土。最终的涂层具有2.7:1的填料与粘合剂之比，50%固体，1260cps Brookfield粘度，和8.9pH。紧跟在如实施例1所述的相同的涂层施加，涂层固化和面板下垂测试工序之后，使用这一涂层测试面板#1。如表II所示，在4个湿度循环之后，这一涂布的砖块具有-180mil的下垂值。
实施例6
使用获自Georgia-Pacific,Inc.的基于聚羧基聚合物和多元醇的商业热固性粘合剂GP364G17，如下所述制造水性涂层BC#8：将449.4g GP364G17加入到含445.0g水的混合器内。在混合的同时，向该混合器内添加1.2g消泡剂，1.0杀虫剂，和503.0g高岭土粘土。所得涂层具有2.5:1的填料与粘合剂之比，50%固体，720cps Brookfield粘度，和8.0pH。紧跟在如实施例1所述的相同的涂层施加，涂层固化和面板下垂测试工序之后，使用这一涂层测试面板#1。如表II所示，在4个湿度循环之后，这一涂布的砖块具有-126mil的下垂值。
前面阐明了实践本发明的一些可能性。许多其他实施方案可能在本发明的范围与精神内。例如，尽管本文描述了掺入到天花板瓷砖结构内的涂层，但本领域的技术人员要理解，涂层可具有其他应用，例如在建筑物，家具，或机动车工业中。因此，打算将前述说明视为阐述而不是限制，和通过所附权利要求及其等同的全部范围，给出本发明的范围。

Claims (15)

1.一种涂布的纤维基底，它包括吸收湿气和随着湿度增加将下垂的纤维基底；和施加到该纤维基底的主表面上的无甲醛的涂层，该涂层具有会交联反应的粘合剂体系，其中该涂层的pH大于或等于6，且能吸湿膨胀；其改进包括用挥发性碱中和该涂层。
2.权利要求1的涂布的纤维基底，其中粘合剂体系包括聚羧基聚合物和多元醇交联剂。
3.权利要求1的涂布的纤维基底，其中pH范围为约6-约10。
4.权利要求1的涂布的纤维基底，其中粘合剂体系具有小于1000ppm的金属离子浓度。
5.权利要求4的涂布的纤维基底，其中粘合剂体系具有小于500ppm的金属离子浓度。
6.权利要求1的涂布的纤维基底，其中涂层的填料是无机填料，有机填料或其结合物。
7.权利要求1的涂布的纤维基底，其中涂层中填料与粘合剂之比为1:1-10:1。
8.权利要求2的涂布的纤维基底，其中聚羧基聚合物是由其中至少一种单体含有羧基的单体制造的均聚物和共聚物。
9.权利要求2的涂布的纤维基底，其中聚羧基聚合物是聚丙烯酸，聚(苯乙烯马来酸/酸酐)或其结合物。
10.权利要求2的涂布的纤维基底，其中多元醇交联剂含有至少两个羟基。
11.权利要求10的涂布的纤维基底，其中多元醇是二乙醇胺，三乙醇胺，甘油，右旋糖，蔗糖，果糖，山梨糖醇或其结合物。
12.权利要求2的涂布的纤维基底，其中粘合剂体系中羧基与羟基的摩尔比为约1:0.2-约1:8。
13.权利要求1的涂布的纤维基底，其中挥发性碱是氨水。
14.权利要求5的涂布的纤维基底，其中无机填料包括石灰石粉末，粘土，砂子，云母，珍珠岩，硅藻土，长石，滑石和玻璃珠。
15.权利要求5的涂布的纤维基底，其中有机填料包括硬塑料粉末，例如聚酯，尼龙，聚丙烯，聚碳酸酯和聚乙烯。
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