CN105143571B - 具有增强的隔音特性的复合多层建筑面板 - Google Patents

具有增强的隔音特性的复合多层建筑面板 Download PDF

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CN105143571B
CN105143571B CN201480022413.8A CN201480022413A CN105143571B CN 105143571 B CN105143571 B CN 105143571B CN 201480022413 A CN201480022413 A CN 201480022413A CN 105143571 B CN105143571 B CN 105143571B
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composite multi
story building
building panel
polymer
gasket
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CN105143571A (zh
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C·K·阿塔瑞
T·J·加维
P·辛克达
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Certainteed Gypsum Inc
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
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    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
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Abstract

公开一种提供增强的隔音特性的建筑板结构。在一个可能的实施例中，所述板为具有相对表面薄片和中间凝固石膏芯的石膏板。开孔式聚合物薄片形成于所述石膏芯内并且使所得板的吸音作用增强。在替代实施例中，使用个别聚合物泡沫片替代所述聚合物薄片。还公开各种制造方法，由此可以连续方法形成具有增强的隔音特性的板。下文将更详细地描述本发明的各种组件和其相互关联的方式。

Description

具有增强的隔音特性的复合多层建筑面板
技术领域
本发明涉及一种建筑板结构。更确切地说，本发明涉及一种具有隔音泡沫的建筑板。
背景技术
建筑板，又称为墙板、石膏板或干墙，为在当今世界上一种最常用的建筑组件。建筑板在住所内部内频繁使用，其中其充当成品墙壁覆盖物与结构性隔断。建筑板还可以用于住所外部，其中其充当覆板以提供气象保护作用和绝热作用。建筑板同样还可以用作如楼梯井、电梯竖井以及内部管道的其它结构的内表面。
一种特别流行的形式的建筑板称为石膏板。石膏板通过将一层胶结性石膏浆料沉积在两个相对纸质衬垫之间来构建。石膏浆料为半含水形式的硫酸钙并且具有多种物理特性使其适用作建筑组件。举例来说，石膏板通常具有光滑的外表面、一致的厚度并且涂覆精整增强物，如漆。石膏板又为合乎需要的，因为其提供一定程度的耐火性和消音功能。
覆纸性石膏板的实例公开于冯哈兹保(Von Hazmburg)的美国专利第2,806,811号中。冯哈兹保公开了一种主要由包入纤维包封物中的厚石膏芯组成的板，所述纤维包封物由马尼拉薄片与新闻纸薄片组成。这些薄片层可以由常规多缸造纸法制造。
另一流行形式的建筑板称为玻璃增强型石膏(GRG)板。一种此类板的实例公开于贝尔(Baehr)等人的美国专利第4,265,979号中。贝尔公开了一种由具有中间石膏芯的相对玻璃纤维垫片构建的建筑板。这一结构提供硬化的外表面并且相对于先前的纸饰面板有所改进。
另一类型的石膏板公开于皮尔格林(Pilgrim)的共同拥有的美国专利第4,378,405号中。皮尔格林公开了一种用多孔无纺玻璃垫片在一侧或两侧饰面的GRG板。皮尔格林的玻璃垫片完全嵌入到浆料芯中。这通过振动石膏浆料以致使其流经垫片中的多孔开口而实现。如皮尔格林所传授将垫片嵌入在芯内，导致在板材的外表面上形成浆料薄膜。具有这一结构的建筑板称为嵌入式玻璃增强型石膏(EGRG)板。
这些各种建筑板构造提供多种有益的特征。然而，这些构造都不会使隔音特性增加。因此，这些板(如果存在)提供极少吸音作用或绝热作用，其充当声音屏障。当建筑板用作隔断或甚至用作外部建筑组件时，吸音作用或绝热作用尤其重要。因此，在所属领域中存在对隔音特性增加的建筑板的需要。更确切地说，在所属领域中存在对吸收声波的板的需要。本发明旨在实现这些和其它目的。
发明内容
本发明的建筑板具有若干重要优势。确切地说，所公开的建筑板会使吸音作用增加而不会牺牲所述板的任何结构性特征。
另一优势通过经由使建筑板的芯内包含聚合物薄片而使隔音特性增加来实现。
本发明系统的又一可能优势通过经由连续制造方法并入有聚合物薄片来实现，由此使得能够快速并且低成本地制造本发明的建筑板。
本发明系统的另一优势通过在建筑板的芯内包括一系列吸音聚合物方块来达到。
本发明系统的又一可能优势通过经由连续制造方法并入有聚合物方块或粉末状材料来实现，由此使得本发明的建筑板能够快速并且低成本地制造。
另一优势通过经由连续制造方法将吸音材料并入石膏建筑板中而认可。
本发明的各种实施例可不具有、具有一些或具有所有这些优势。本发明的其它技术优势对于所属领域的技术人员将为显而易知的。
附图说明
为了更完全地理解本发明和其优点，现在结合附图参考以下描述，其中：
图1为本发明的建筑板的一种可能制造方法的图。
图2为本发明的建筑板的另一可能制造方法的图。
图3为本发明的建筑板的另一可能制造方法的图。
图4为本发明的建筑板的一实施例的截面视图。
图5为本发明的建筑板的一替代实施例的截面视图。
图6为本发明的建筑板的一替代实施例的截面视图。
具体实施方式
本发明涉及一种具有增强的隔音特性的建筑板。在一个可能的实施例中，所述板为具有相对表面薄片和中间凝固石膏芯的石膏板。开孔聚合物薄片形成于所述石膏芯内并且使所得板的吸音作用增强。在替代实施例中，使用个别聚合物泡沫片代替聚合物薄片。还公开各种制造方法，由此可以连续方法形成具有增强的隔音特性的板。下文将更详细地描述本发明的各种组件和其相互关联的方式。
图1-3说明构筑本发明的建筑板的各种生产线(34a、34b以及34c)。图4-6为本发明的各种板构造(20a、20b、20c)的横截面图。本发明的板通常为凝固石膏芯的芯层22和相对纤维薄片纸24。在图4中所图示的特定实施例中，板20a具有上垫片和下垫片24，其由一系列随机排列的无纺无机纤维形成。这些垫片优选地为多孔的且具有内表面和外表面。还可以使用纸饰面薄片并且同样由元件24表示。
继续参考图4，上垫片和下垫片24各涂布有一层致密凝固浆料26。致密浆料26优选地渗透上垫片和下垫片24。因此，各垫24的外表面实质上覆盖有凝固浆料。凝固石膏的芯层22在上浆料层和下浆料层26之间充分延伸并且与其结合。在一个实施例中，芯浆料层22的密度小于上浆料层和下浆料层26的密度。
增强的隔音特性经由使聚合物薄片28包含于芯浆料层22中来实现。在优选实施例中，薄片28由三聚氰胺树脂形成且形成为开孔泡沫。三聚氰胺树脂为热固性聚合物。适合的泡沫为其由巴斯夫公司(BASF Corporation)制造并销售。泡沫为优选的，因为其提供细长并且容易成形的编织物的三维网络。泡沫又给予所得板吸音作用和耐化学品性和耐火性。然而，其它聚合物泡沫的使用也在本发明的范围内。对于1/2英寸厚的建筑板，1/8英寸聚合物薄片28为优选的。
进入泡沫的泡孔内的声波随后衰减并耗散，由此给予薄片28吸音特征。由此，重要的是在板形成期间泡沫的泡孔内保持无石膏浆料。聚合物薄片28经设计位于芯浆料层22内，但不被其渗透。因为聚合物薄片28并不会吸收浆料层22，并且因为其优选地在板20a的大部分宽度上延伸，所以必须穿过薄片28的厚度形成一系列孔32。孔32允许浆料22延伸穿过薄片28，由此充分集成建筑面板20a。在不存在孔32下，建筑面板20a易于沿薄片28的边界分离。在聚合物薄片28可以吸收浆料层22的情况下，可以消除孔32。在优选实施例中，芯层22的厚度实质上大于聚合物薄片28的厚度。
图1说明已根据本发明修改的石膏板生产线34a。生产线34a包括在建筑面板形成期间支持建筑面板20a的一系列形成平台36。如所属领域中已知，形成面板的垫片通过一系列下游传送带而处于拉伸状态。一旦面板已形成，那么就会将其传送到一系列板干燥器中。干燥器用于驱出过量水分并且致使石膏浆料凝固。这使得形成干燥的复合面板。
如图1中所进一步注意到，石膏板20a由第一和第二纤维垫片24形成，其中一定体积的石膏浆料从混合器38沉积。或者可以使用纸垫片替代纤维垫片。在任一情况下，垫片24最初储存于连续制造方法中退绕的大辊42中。第一辊42在形成平台上在位置1a处退绕。致密浆料层26可以任选地在第一垫片24在第一混合器出口44下方展开之后沉积于所述第一垫片上。滚筒推动致密浆料层在位置1b处穿过垫片。此后自混合器38在第二混合器出口46分配另一浆料以形成芯浆料层22。第二辊42理想地位于第一辊的下游。第二垫片24从这一辊退绕于所沉积的石膏芯22的顶部上以产生夹层或面板。注意到所形成的面板在位置1c处。混合器38包括将致密浆料层26供应于第二垫片24上的第三出口48。聚合物薄片28最初储存于卷绕辊52中并且在第二混合器出口46的下游立即分配。这使得薄片28大约位于芯22的中心。
替代生产线34b公开于图2中。生产线34b在所有方面均与图1的生产线相同；然而，经过辊压的聚合物薄片28被含有多个聚合物方块56或一定体积的颗粒状聚合物的料斗54替代。在优选实施例中，使用大约1/2英寸的方块。还可以使用其它形状和大小替代1/2英寸方块。泡沫可以用以产生聚合物方块56。自料斗54分配方块56到滑槽以将方块56传递到芯浆料层22中。在又一实施例中，将泡沫以碾碎或颗粒形式添加到浆料中。
所得建筑板20b具有如图5中所示的横截面。聚合物方块56或颗粒状材料各包括开孔泡沫。方块56或颗粒随机分布在浆料层22内；然而，浆料22并未渗透个别片或方块56。当芯层22围绕个别聚合物方块56延伸时充分整合复合板20b。在又一实施例中，可以将聚合物泡沫碾碎以形成极小块的泡沫，其会聚结成泡沫绒毛。这一泡沫绒毛接着可以分布到浆料芯22中。
生产线34c的另一实施例描绘于图3中。这一实施例使用聚合物薄片28，其可以具有与结合图1所描述的薄片相同的结构。然而，替代将薄片28递送到浆料芯22中，经由粘合将其固定到下垫片24。更确切地说，聚合物薄片辊58在垫片递送到形成平台36之前分配于垫片24的顶部上。所得建筑板20c的截面视图描绘于图6中。如所图示，薄片28现在与第一垫片26以面对面关系定向。将薄片28直接涂覆于上致密浆料层或下致密浆料层中的一者上也在本发明的范围内。这将避免将薄片28固定到垫片24上。可以结合先前所描述实施例中的任一者使用这些实施例中的任一者。
尽管已经依据某些实施例和大体相关的方法描述本发明，但对于所属领域的技术人员这些实施例和方法的更改和置换应为显而易知的。因此，实例实施例的以上描述并不界定或约束本发明。在不脱离本发明的精神和范围的情况下，其它改变、替代以及更改也为可能的。

Claims (19)

1.一种具有增强的隔音特性的复合多层建筑面板，所述面板包含：
由随机排列的无纺无机纤维形成的共面的相对的上垫片和下垫片，所述垫片为多孔的并且具有内表面和外表面；
涂布所述上垫片和下垫片的凝固浆料的上层和下层，所述上层和下层渗透所述上垫片和下垫片，由此各垫片的所述外表面实质上覆盖有凝固浆料；
厚度在所述上层与下层之间延伸的凝固石膏的芯层，所述凝固石膏的所述芯层的密度小于所述上层和下层的密度；
具有一定厚度的聚合物薄片，所述聚合物薄片位于芯浆料层内，但不被其渗透，所述薄片由三聚氰胺树脂形成并且在整个其厚度中含有多个开孔，所述聚合物薄片具有吸音特征，穿过所述聚合物薄片的厚度形成一系列孔以使得所述聚合物薄片与所述芯层结合，所述芯层的厚度大于所述聚合物薄片的厚度。
2.一种具有增强的隔音特性的复合多层建筑面板，所述面板包含：
共面的相对的上纸质薄片和下纸质薄片，所述薄片具有内表面和外表面；
厚度在所述上纸质薄片和下纸质薄片之间延伸的凝固石膏的芯层；
具有一定厚度的聚合物薄片，所述聚合物薄片位于所述凝固石膏的所述芯层内，但不被其渗透，所述薄片在整个其厚度中含有多个开孔。
3.根据权利要求2所述的复合多层建筑面板，其中所述薄片由热固性聚合物形成。
4.根据权利要求2所述的复合多层建筑面板，其中所述薄片由三聚氰胺树脂形成。
5.根据权利要求2所述的复合多层建筑面板，其中所述聚合物薄片增强所述建筑面板的吸音特征。
6.根据权利要求2所述的复合多层建筑面板，其进一步包含穿过所述聚合物薄片的厚度形成的一系列孔以使得所述聚合物薄片与所述芯层结合。
7.根据权利要求2所述的复合多层建筑面板，其进一步包含涂布所述上纸质薄片和下纸质薄片的上凝固浆料层和下凝固浆料层，其中所述上凝固浆料层和下凝固浆料层的密度大于所述凝固石膏的所述芯层。
8.一种具有增强的隔音特性的复合多层建筑面板，所述面板包含：
共面的相对的上垫片和下垫片，所述垫片具有内表面和外表面；
涂布所述上垫片和下垫片的凝固浆料的上层和下层；
厚度在所述上层和下层之间延伸的凝固石膏芯层；
位于所述凝固石膏的所述芯层内的开孔聚合物。
9.根据权利要求8所述的复合多层建筑面板，其中所述上垫片和下垫片为由随机排列的无纺无机纤维形成的多孔垫片。
10.根据权利要求9所述的复合多层建筑面板，其中所述凝固浆料的上层和下层渗透所述上垫片和下垫片，由此各垫片的所述外表面实质上被覆盖。
11.根据权利要求8所述的复合多层建筑面板，其中所述开孔聚合物为三聚氰胺树脂。
12.根据权利要求8所述的复合多层建筑面板，其中所述开孔聚合物给予所述建筑板吸音特征。
13.根据权利要求8所述的复合多层建筑面板，其中所述凝固石膏的所述芯层的密度通常小于所述上层和下层的密度。
14.根据权利要求8所述的复合多层建筑面板，其中所述聚合物包含多个开孔聚合物片。
15.根据权利要求14所述的复合多层建筑面板，其中所述聚合物片由三聚氰胺树脂形成。
16.根据权利要求14所述的复合多层建筑面板，其中所述芯层围绕个别聚合物片延伸但并不渗透。
17.根据权利要求8所述的复合多层建筑面板，其中所述聚合物包含发泡聚合物覆盖层。
18.根据权利要求17所述的复合多层建筑面板，其中所述覆盖层给予所述建筑板吸音特征。
19.根据权利要求17所述的复合多层建筑面板，其中所述覆盖层由三聚氰胺树脂形成。
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