CN105358753B - 用于吸声天花板砖的湿铺底垫 - Google Patents

用于吸声天花板砖的湿铺底垫 Download PDF

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CN105358753B
CN105358753B CN201480038092.0A CN201480038092A CN105358753B CN 105358753 B CN105358753 B CN 105358753B CN 201480038092 A CN201480038092 A CN 201480038092A CN 105358753 B CN105358753 B CN 105358753B
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W·A·弗兰克
T·L·罗森斯蒂尔
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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/38—Inorganic fibres or flakes siliceous
    • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/37—Polymers of unsaturated acids or derivatives thereof, e.g. polyacrylates
    • D21H17/375—Poly(meth)acrylamide
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
    • D04H1/08—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres and hardened by felting; Felts or felted products
    • D04H1/10—Felts made from mixtures of fibres
    • D04H1/14—Felts made from mixtures of fibres and incorporating inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63—Inorganic compounds
    • D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
    • D21H17/675—Oxides, hydroxides or carbonates
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
    • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
    • D21H23/04—Addition to the pulp; After-treatment of added substances in the pulp
    • D21H23/06—Controlling the addition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249925—Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249986—Void-containing component contains also a solid fiber or solid particle

Abstract

本发明提供了用于吸声天花板砖的湿铺底垫，其包含在干重基础上的50％或更多的矿棉纤维，包括渣球，小于9％粘合剂，和5‑20％短切玻璃纤维，以及任选的少量其他组成成分，由此所述短切玻璃纤维作用于促进和/或维持垫中的空隙，使得干燥底垫具有约120‑168kg/m3(7‑1/2至约10‑1/2磅/立方英尺)的密度和基本上大于0.55的NRC(噪声降低系数)。

Description

用于吸声天花板砖的湿铺底垫
技术领域
本发明涉及特别适用于吊顶的吸声砖。
背景技术
基于矿物纤维的天花板砖长久以来已是可获得的。此类砖或面板通过矿棉的水毡化稀释水性分散体进行常规制备。在该过程中，矿棉、粘合剂以及需要或必要时的少量其他成分的水性浆料流动到移动多孔支撑线，例如Fourdrinier或Oliver垫成型机的那种上，用于脱水。浆料可首先通过重力进行脱水，且随后通过真空抽吸进行脱水，以形成底垫；随后将湿润底垫在辊或架空移动线和支撑线之间按压至所需厚度，以去除另外的水。随后使按压的底垫在加热干燥烘箱中干燥，并且将干燥的材料切割至所需尺寸且任选喷砂和/或顶部涂覆，或用粘附附着的纤维玻璃纱覆盖且最终涂抹，以产生成品吸声天花板砖或面板。
虽然由于低原料成本，水毡化基于矿棉的吸声天花板砖是相对经济生产的，但它们显示出约.55的相对低的NRC(噪声降低系数)值。长久以来希望产生具有改善的NRC(噪声降低系数)值的基于矿物纤维的吸声天花板砖。
发明内容
本发明提供了基于矿棉的水毡化吸声天花板砖构造，其达到改善的NRC(噪声降低系数)值且可在现有设施中且使用常规加工进行生产。
本发明在于下述发现：优选具有某些特征的普通湿润使用的短切、WUCS、纤维玻璃可以小比例数量取代在通常产品配方中的矿物纤维。取代的结果是底垫中令人惊讶的蓬松增加。这种蓬松代表密度中的显著减少以及孔隙率和因而声吸收中的相应增加。
本发明允许产生相对低密度、相对厚的吸声面板，其能够达到基本上大于.55且最高达.95或更高的NRC(噪声降低系数)值，从而将这些砖的性能置于在吸声砖频谱的高端处。
本发明面板的本体的特征在于空隙的存在，与复合纤维之间的平均间质间隙相比较，所述空隙很大，在面板本体各处随机分布。通过尚未完全理解的一些机制，空隙通过玻璃纤维的存在而制备。空隙群看起来与底垫配方中的玻璃纤维数量成比例。纤维长度和纤维直径看起来是空隙的成功制备中的另外因素。
附图说明
图1是标准配方的吸声面板的横截面的显微照片；
图2是具有包括5％短切纤维玻璃纤维的修改配方的吸声砖的横截面的显微照片；
图3是具有包括10％短切纤维玻璃纤维的修改配方的吸声砖的横截面的显微照片；和
图4是具有包括20％短切纤维玻璃纤维的修改配方的吸声砖的横截面的显微照片。
具体实施方式
根据本发明的吸声砖或面板底垫通过将其组成成分在稀释水浆料中充分混合进行生产。一般常规过程中的浆料分布在活动筛或支撑线上，以形成底垫层。将层通过筛且通过应用抽吸真空而排干水。垫随后在叠压辊或活动筛和运输筛之间轻轻按压。其后，使按压的底垫在烘箱中进行干燥，且切割至成品矩形大小。底垫的面可用常规技术例如研磨、层压和/或涂抹进行完工。
本发明通过用短切纤维玻璃取代一部分标准量的矿棉纤维，而脱离常规基于矿物纤维的底垫配方。短切纤维玻璃可例如具有商购可得的湿润使用的短切(WUCS)材料。
图1显示了用一般常规的基于矿物纤维的配方制备的吸声天花板砖的部分的横截面。下表反映该常规配方的组成成分。
表1
现有技术一般底垫配方
图2-4显示了具有修改配方的吸声砖底垫的横截面的一部分。图2是含有按重量计5％短切玻璃纤维的配方的举例说明，图3显示了具有10％短切玻璃纤维组成的底垫，并且图4显示了具有20％短切玻璃纤维组成的底垫的横截面。在图2-4中所示的组成中，短切玻璃纤维为标称长度6.4mm(1/4英寸)和直径16.5微米。
下文是用于体现本发明的吸声砖的基于矿物纤维的底垫的配方。
表2
本发明的示例性底垫配方
表1和2中所示的百分比是重量百分比。
图1与其余图2-4的比较显示了底垫本体中的空隙的存在，其中空隙数目随着短切玻璃纤维含量百分比而增加。纤维玻璃纤维的直径基本上大于矿物纤维的直径。以底垫的kg/m(磅/立方英尺)计的堆密度与特定体积中的空隙数目成比例减少。随着堆密度减少，如预期的，底垫孔隙率增加，并且它的声音吸收能力即NRC(噪声降低系数)评级增加。
短切纤维产生或至少与基于矿物纤维的底垫本体各处的空隙出现相关的原因尚未完全理解。个别玻璃纤维至少在一些情况下看起来使周围矿物纤维保持在空隙空间之外，打个比方就像伞弓。与短切玻璃纤维如何制备和/或维持空隙无关，与其质量成比例的短切玻璃纤维减少堆密度且增加NRC(噪声降低系数)。
在含有短切玻璃纤维的底垫形成期间，在输送至干燥烘箱之前，在湿润底垫通过顶部筛带或辊轻轻按压之前和之后，湿润底垫经历蓬松增加。短切纤维优选可为标称长度6.4-12.7mm(1/4至1/2英寸)，并且优选具有约13.5微米至16.5微米的直径。依照本发明制备的成品面板可具有120-168kg/m(7-1/2至10-1/2磅/立方英尺)的密度和例如25.4-38.1mm(1英寸至1-1/2英寸)的垫厚度。
底垫通常具有本领域已知的其由非织造纤维玻璃纱覆盖的面或室内侧，其粘附附着且当涂抹或涂覆时保持透气性。
应显而易见的是本公开内容作为例子，并且可通过添加、修饰或消除细节作出各种变化，而不背离本公开内容中包含的教导的合理范围。本发明因此并不限于本公开内容的特定细节，除了下述权利要求必须如此限制的程度之外。

Claims (4)

1.一种用于吸声天花板砖的湿铺底垫，所述湿铺底垫包含在干重基础上的(1)50％或更多的矿棉纤维，包括渣球，(2)小于9％的粘合剂，和(3)5-20％的短切玻璃纤维，以及(4)任选的少量其他组成成分，由此所述短切玻璃纤维作用于促进和/或维持所述垫中的空隙，使得干燥后的底垫具有7.5至10.5磅/立方英尺的密度和大于0.55的NRC(噪声降低系数)。
2.根据权利要求1所述的湿铺底垫，其中所述短切玻璃纤维为标称长度1/4英寸至1/2英寸。
3.根据权利要求2所述的湿铺底垫，其中所述短切玻璃纤维具有13.5微米至16.5微米的标称直径。
4.根据权利要求1所述的湿铺底垫，所述湿铺底垫具有0.95的NRC。
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