CN107206745A - 消声系统 - Google Patents

消声系统 Download PDF

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Publication number
CN107206745A
CN107206745A CN201580072557.9A CN201580072557A CN107206745A CN 107206745 A CN107206745 A CN 107206745A CN 201580072557 A CN201580072557 A CN 201580072557A CN 107206745 A CN107206745 A CN 107206745A
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Prior art keywords
plate
layer
polymer
monomer
aqueous dispersion
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Inventor
U·C·德赛
I·佩利纳斯库
赵天杰
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PPG Industries Ohio Inc
PPG Industries Inc
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PPG Industries Inc
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  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Ceramic Engineering (AREA)
  • Architecture (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)

Abstract

公开了一种层合板，其包括具有内表面和外表面的第一层，具有内表面和外表面的第二层，和在它们之间延伸的胶合层。该胶合层是由聚合物型丙烯酸类微粒的含水分散体来生产的。

Description

消声系统
发明领域
本发明涉及适于消声和减振的层合板。
发明背景
住宅和工业建筑中的墙壁，天花板和地板的隔音性是建筑工业中持续经济和公共政策关注点(concern)。许多建筑物需要具有降低了声音的传播的墙壁、天花板和地板的房间，由此使得对于相邻房间中的人的干扰最小化或者得以消除。同样，在娱乐场合例如剧院和音乐练习室，录音室等中，减少噪音是令人期望的。类似地，健康护理设施例如医院需要安静的环境。
环境隔音性的一个度量是声音传播等级(Sound Transmission Class)(STC)分级，其可以根据ASTM标准E413来测定。STC是基于隔离物(partition)所吸收的声音来计算的，称作声音传播损失(STL)，典型地以分贝(db)来测量。STC是建筑物结构能够多好地衰减空气传播声音的分级。25的STC表示讲话可以经由隔离物而容易地理解，而60或更大的STC分级表示大部分声音经由隔离物是无法听见的。
发明内容
本发明包括一种层合板，其包含具有内表面和外表面的第一层，具有内表面和外表面的第二层，和在第一和第二层的内表面之间延伸，并且至少部分地覆盖第一和第二层的内表面的胶合层。该胶合层是由聚合物型微粒的含水分散体来生产的，并且可以进一步包括松香。还包括在本发明中的是一种层合板，其包含：包含粘弹性材料的约束层的第一部分和包含粘弹性材料的延伸层的第二部分。
附图说明
图1是根据本发明的层合板的横截面；
图2是根据本发明的层合板的横截面；
图3是针对几个板比较作为线性插值频率的函数的阻尼损耗因子(DLF)的图；
图4是针对几个板比较的作为第三倍频带中心频率的函数的声音传播损失(STL)的图；和
图5是针对几个板比较声音传播等级(STC)的图。
具体实施方式
为了下面详细描述的目的，应理解本发明可采用各种替代变化和步骤顺序，除了其中明确有相反的规定之外。另外，除了在任何操作实施例中，或其中另外说明，所有表达，例如说明书和权利要求中使用的成分的量的数字，应被理解为在所有情况下由术语“约”来修饰。因此，除非有相反指示，下述说明书和附加的权利要求中陈述的数字参数是近似值，其可根据本发明获得的期望性能而变化。最起码，并且不试图限制将等同原则应用到权利要求范围，每个数字参数应至少按照所报告的有效数字的位数并通过应用普通的四舍五入方法来解释。
虽然陈述本发明宽广范围的数字范围和参数是近似值，但在具体实施例中称述的数值是尽可能精确地报告的。然而，任何数值必然固有地包含在它们各自测试方法中发现的标准偏差必然造成的一定误差。
同样，应当理解的是，本文中引用的任何数值范围旨在包括全部包括在其中的子范围。例如，“1至10”的范围旨在包括所述的最小值1和所述的最大值10之间(并且包括端值)的全部子范围，也就是说，具有最小值等于或大于1，和最大值等于或小于10。
在本申请中，单数的使用包括复数，和复数涵盖单数，除非另有具体规定。此外，在本申请中，“或”的使用表示“和/或”，除非另有具体规定，即使某些实例中可明确地使用“和/或”。进一步，本申请中，“一”或“一种”的使用表示“至少一种”，除非另有具体规定。例如，“一”芳香族一元酸，“一”多元酸，“一”多元醇，“一”脂肪族多元酸等指一种或多种的任意的这些物质。
如本文中使用，过渡术语“包含”(和其他相当的术语，例如“含有”和“包括”)是“开放式的”，并且涉及本发明必要的组合物，方法及其各自的组分来使用，且是开放的以包括未指明的物质。术语“实质上(essentially)由……组成”指的是给定的特征所需的那些组分，并且允许存在不对该特征的性能或功能特性产生实质性影响的组分。术语“由……组成”指的是这样的组合物和方法，其排除了在特征的说明中没有提及的任何其他组分。
本发明包括如图1所示的层合板10。图1所示结构中的层显示为水平定向的。应当理解的是本发明的层合板可以水平定向使用或者当置于垂直墙壁或者门上时可以垂直定向或者当置于天花板或者地板上时处于一定角度。第一层12和第二层14可以由常规石膏材料来生产，并且可以是大约1/4英寸厚。其他材料和厚度可以根据期望用于所述层。例如第一和第二层12，14可以是基于水泥的板，木材，基于氧化镁的板或者硅酸钙板等。层合板包括胶合层(约束层)16，其在第一层12的内表面18和第二层14的内表面20之间延伸，并且至少部分地覆盖其内表面。胶合层16包括聚合物型丙烯酸类微粒(下述)和添加剂(包括填料，增粘剂，增塑剂等)的含水分散体。用于改进涂层的减振和消声能力的合适的填料包括云母，粉末板岩，蒙脱石薄片，玻璃薄片，金属薄片，石墨，滑石，铁氧化物，粘土矿物，纤维素纤维，矿物纤维，碳纤维，玻璃或聚合物型纤维或者珠，铁氧体，碳酸钙，钙，碳酸镁，重晶石，研磨天然或者合成橡胶，二氧化硅，氢氧化铝，氧化铝粉末及其混合物。增粘剂是低分子量化合物，其可以增加粘结剂的粘性和表面的刚度。增粘剂的例子包括植物基化合物例如脂松香和淀粉，和合成聚合物型分散体例如Aquatec 6025。可以包括增塑剂来确保脂松香的溶解。合适的增塑剂包括邻苯二甲酸酯，己二酸酯，戊二酸酯(gluterate)，癸二酸酯，苯甲酸酯或者通常用于PVC密封剂配方中的任何其他增塑剂。可选择地，可以使用溶剂例如二醇，但是当用于建筑工业时，由于不期望的挥发性而会被避免。一种合适的生物基增塑剂是衣康酸酯，基于溶解在溶剂例如2-乙基己醇和/或二甘醇中的衣康酸(例如由马铃薯所生产的那些)。
本发明的组合物可以包括多种任选的成分和/或添加剂，其在某些程度上取决于组合物的具体应用，例如染料或者颜料例如炭黑或者石墨，增强剂，触变胶，加速剂，表面活性剂，填充剂，稳定剂，腐蚀抑制剂，稀释剂，发泡剂和抗氧化剂。
胶合层16的厚度可以根据层合板所需的期望的声音衰减来变化。该层合板可以通过将胶合层16以厚度0.2mm-0.6mm施用到第一层12来生产。将胶合层16施用到第一层12的底部表面18的期望的区域上。可以使用不同的施用技术，例如：使用来自桶的抹子，将珠子挤压出管，或者将胶压力泵送穿过喷嘴。如果需要，可以使用刮涂棒，随后来产生更均匀和受控的膜厚度。然后将第二层14置于第一层12的顶上，其中顶部表面20是与胶合层16接触的。然后使该组装的板静置，放置于水平表面上持续最少2-3小时。
如图2所示，层合板100可以包括第一和第二层12，14以及约束(胶合)层16和进一步包括在第一层12的外表面54上的延伸层52。如此处使用的，“约束层”指的是这样的胶合层，其在其任一侧上具有阻挡结构，如图1所示。如此处使用的，延伸层指的是这样的胶合层，其在其仅仅一侧上具有结构层，如图2所示。
约束(胶合)层16和延伸层(涂层)52可以由聚合物型丙烯酸类微粒的含水分散体来生产。该微粒可以由反应混合物来制备，该反应混合物包含(1)羟基官能单体例如(甲基)丙烯酸羟烷基酯和/或其己内酯加合物，(2)酸官能单体例如烯属不饱和羧酸单体，和(3)另一种烯属不饱和单体例如(甲基)丙烯酸酯单体。可以使用用于聚合物型丙烯酸类微粒的其他组合物，如美国专利No.6531541第3栏第49行-第7栏第40行及其中的实施例所公开的，通过参考并入本文。
提出下面的实施例来证实本发明的基本原则。本发明不应当认为局限于所提出的具体实施例。实施例中的全部份数和百分比是重量单位的，除非另有指示。
实施例
实施例1A-1B：用于胶中的胶乳组合物
胶乳组合物(实施例1A和实施例1B)是使用表1所列材料在装备有温度计、机械搅拌器、冷凝器、氮气鼓泡器(sparge)和加热罩的四颈圆底烧瓶中制备的。将水和小部分的预乳液(在5％的总预乳液以下)与少量ALIPAL表面活性剂和过硫酸铵自由基引发剂一起加入该反应器中来形成种子(seed)。将其余单体、表面活性剂和水的预乳液与引发剂经规定的时间(3小时)在80-85℃的反应温度使用氮气层一起供给。将该胶乳用二甲基氨基乙醇中和到pH大约8，并且加入抗菌剂。每个格子的最终pH是大约7.5-8.5，非挥发物含量是35-40％，布氏粘度是50-200cps(#1转子，50rpm)和粒度是1000-2000埃。
表1
1(PEG)甲基丙烯酸甲酯
2壬苯醇醚-4-硫酸铵
3壬基酚乙氧基化物
4来自于BASF的专有烃
5来自于Arch Chemicals，Inc.的抗菌剂
实施例2：用于胶的增塑剂
一种生物基增塑剂是使用装备有用于收集水的总蒸馏装置(distillation)、温度计、机械搅拌器、冷凝器、氮气鼓泡器和加热罩的四颈圆底烧瓶来制备的。将表2所列的全部组分加入该烧瓶中，并且将温度设定到130℃。在该反应完成和混合物透明后，以10℃的阶段升温到180℃，直到酸值达到10-15mg KOH/g。
表2
组分 Wt％
亚磷酸三苯酯 0.20
对甲苯磺酸 0.1
衣康酸 33.8
紫罗兰醇(Ionol) 0.23
2-乙基己醇 64.29
二甘醇 1.38
实施例3A-3C–胶组合物
在实施例3A-3C的每个中，将表3所列组分使用高速混合器DAC600FVZ(市售自FlackTek，Inc.)进行混合。在配制涂料组合物之前制备了两种预混物。稠合(condensed)的磺化萘的钠盐的第一预混物是通过与水在2350转/分钟(rpm)混合大约3分钟来制备的。第二增塑剂预混物是如下来制备的：通过将巴西脂松香与实施例2的增塑剂组合物混合，并且将混合物加热到80℃，直到溶解，然后在使用之前冷却。
在制备了所述预混物之后，将组分1-7，12和16在DAC混合杯中称重，并且在2350rpm混合1分钟。然后将组分8-11以表3所列的量加入该混合物中，并且在DAC混合器中在2350rpm混合1分钟。其后，将组分13-15加入该混合物，并且在2350rpm混合另外1分钟。在混合方法过程中，用刮刀检查该混合物来确保均匀，如本领域技术人员将理解的那样。混合方法的最终步骤包括将该混合物用空气发动机桨叶(prop)在真空密封设备中在28-30英寸的真空压力混合1分钟。在用空气发动机桨叶的最终混合步骤之后，该涂料组合物准备好用于测试。
表3
6用乙酸乙烯酯-乙烯稳定的聚(乙烯醇)，作为460由WackerPolymers获得。
7Darvan#1，稠合的磺化萘的钠盐，获自R T Vanderbilt。
8来自于BASF的专有烃。
9来自于Arch Chemicals的抗菌溶液。
10炭黑含水分散体，来自于Emerald Performance Material。
11碳酸钙镁，来自于Specialty Minerals。
12Microglass 9132，获自Fibertec。
13硼酸锌，来自于Polymer Additives Group。
14水合非晶二氧化硅，来自于PPG Industries Inc。
15流变改性剂水溶性丙烯酸类聚合物，获自Rohm&Haas。
16流变改性剂水溶性丙烯酸类乳液，获自Elementiz。
17合成的沉淀二氧化硅，来自于PPG Industries，Inc。
18表面活性剂磷酸酯聚醚酯，获自Dow Chemical。
实施例4A-4E：隔音板
使用实施例3A，3B和3C的胶组合物制备五个板，并且具有表4详列的层化结构。
表4
声音测试是在所述五个板上进行的，来测定每个板的阻尼损耗因子(DLF)，声音传播损失(STL)和声音传播等级(STC)。
减振性能是通过测定测试梁(beam)样品的阻尼损耗因子(DLF)来测量的。该测试梁样品是大约30英寸长和1英寸宽，并且是通过施加到测试梁中心(即，梁长度的中间)的振动力输入来激励(excite)的。除了中心点(其中梁是同时支撑和激励的)之外，所述测试梁是以其他方式自由悬挂的，因此形成中心-中点平衡的测试梁排列。激振器(也称作振动器)在所关注的期望的频率范围以不同频率来振动所述测试梁，其包括测试梁的最少四种振动模式。所施加的力和加速响应二者是使用阻抗头传感器在梁中心点处(在这里施加力)测量的。频率响应函数(FRF)曲线是在驱动点，使用双通道信号采集和光谱分析仪硬件-软件系统(通常用于振动测试实验室)测定的。在FRF曲线中，在某些频率(称作共振频率)观察到峰值振幅值，其对应于测试梁的每个振动模式。阻尼性能是使用半功率带宽方法(也称作3dB向下方法(SAE J1637和ASTM E756))在FRF曲线图上所观察的每个共振频率测定DLF来评价的。在所关注的期望频率的DLF然后通过针对两个共振频率所测量的阻尼损耗因子的值之间的线性插值来测定，其是连续地并且分别地低于和高于所关注的期望的频率。DLF是无量纲量，并且值是0-1，其中1对应于最高阻尼和0对应于最低阻尼。测量是在22-26℃的温度进行的，其代表了典型的室温条件。
空气传播声音传播损失(STL)也是根据ASTM E2249测定的，并且用于根据ASTME413计算声音传播等级分级(STC)。
为了测量STL，使得在源室所产生的扩散空气传播噪音场穿过测试样品进入接收室。源室是混响室，并且接收室是半消声室。该测试样品是作为地板-天花板隔离物来组装的。该隔离物的整体尺寸是5英尺乘5英尺，等于两个室之间的测试窗的尺寸。“地板”侧(其面朝着源室)由工程化木板组成，该工程化木板作为安装在1/2英寸厚胶合板底层地板上的浮式地板层固定在一起。该胶合板底层地板用钉子固定到由2英寸乘4英寸木立柱制成的托梁框架上，并且在测试窗的全部周边周围构建，紧紧填充窗开口。另外2英寸乘4英寸木立柱(间隔16英寸)也横跨该架子安装。测试样品隔离物的地板侧，胶合板底层地板和托梁框架在全部测试过程中保持不变。测试样品隔离物的“天花板”侧(其面朝着接收室)是由经测试的板制成，其是用干式墙钉子固定到托梁框架与胶合板底层地板相对的侧。在胶合板底层地板，天花板层排列和木立柱之间存在着密闭空间，其保持是空的。
STL是在全部第三倍频带测量的，并且中心频率是100Hz-10000Hz。测量了声音强度，并且在面朝源室的测试样品的整个面积上平均化。每个配置的测试重复五次，并且在每个第三倍频带的平均STL数据是作为算数平均值来计算的。测量是在22-26℃的温度进行的。随后使用在第三倍频带测量的平均声音传播损失数据值计算STC分级，并且中心频率是125Hz-4000Hz。
测试结果在表5-7中给出，并且显示在图3-5中。与单独的干式墙(对比例4A)和仅仅具有延伸胶合层的干式墙(对比例4B和4C)相比，对层合结构来说，将约束胶合层(本发明实施例4D)或者约束胶合层与延伸胶合层的组合(本发明实施例4E)添加到干式墙明显改进了(增加了)阻尼损耗因子，声音传播损失和声音传播等级。
表5-阻尼损耗因子(DLF)
表6–声音传播损失(STL)
表7–声音传播等级(STC)
本发明进一步包括下面的条款的主题。
条款1：一种层合板，其包含：具有内表面和外表面的第一层；具有内表面和外表面的第二层；和胶合层，其在所述第一和第二层的所述内表面之间延伸，并且至少部分地覆盖所述第一和第二层的所述内表面，所述胶合层是由聚合物型丙烯酸类微粒的含水分散体来生产的。
条款2：条款1的板，其中所述聚合物型丙烯酸类微粒是由这样的反应混合物来制备的，该反应混合物包含(i)羟基官能单体，(ii)酸官能单体，和(iii)不同于单体(i)的烯属不饱和单体。
条款3：条款1-2的板，其中所述羟基官能单体(i)包含(甲基)丙烯酸羟烷基酯或者其己内酯加合物或者前述二者。
条款4：条款2-3的板，其中所述酸官能单体(ii)包含烯属不饱和羧酸单体。
条款5：条款2-4的板，其中所述烯属不饱和单体(iii)包含(甲基)丙烯酸酯单体。
条款6：条款1-5的板，其中所述含水分散体进一步包含增塑剂。
条款7：条款6的板，其中所述增塑剂包含衣康酸酯增塑剂。
条款8：条款1-7的板，其中所述含水分散体进一步包含松香。
条款9：条款1-8的板，其进一步包含提供在所述外表面的至少一个的至少一部分上的涂料组合物，所述涂料组合物包含另一种聚合物型丙烯酸类微粒的含水分散体。
条款10：条款1-9的条款，其中所述第一层或者所述第二层或者前述二者包含石膏。
条款11：一种层合板，其包含：第一部分，其包含粘弹性材料的约束层；和第二部分，其包含粘弹性材料的延伸层。
条款12：条款11的板，其中所述第一部分进一步包含一对约束构件，所述约束层接纳(receive)在所述约束构件之间。
条款13：条款11-12的板，其中所述约束层包含聚合物型材料，其是由聚合物型丙烯酸类微粒的含水分散体生产的。
条款14：条款13的板，其中所述聚合物型丙烯酸类微粒是由这样的反应混合物来制备的，该反应混合物包含(i)羟基官能单体，(ii)酸官能单体，和(iii)不同于单体(i)的烯属不饱和单体。
条款15：条款13-14的板，其中所述含水分散体进一步包含增塑剂。
条款16：条款15的板，其中所述增塑剂包含衣康酸酯增塑剂。
条款17：条款13-16的板，其中所述含水分散体进一步包含松香。
条款18：条款12的板，其中所述约束构件包含石膏。
条款19：条款11-18的板，其中所述延伸层包含：由聚合物型丙烯酸类微粒的含水分散体生产的聚合物型材料，和占涂层组合物的20-90重量％的填料。
条款20：条款19的板，其中所述聚合物型丙烯酸类微粒是由这样的反应混合物制备的，该反应混合物包含(i)羟基官能单体，(ii)酸官能单体，和(iii)不同于单体(i)的烯属不饱和单体。
虽然已经参考其某些特征的具体细节来描述了本发明，但是并非旨在将这样的细节认为是对于本发明范围的限制，除了它们包括在附加的权利要求中之外。

Claims (20)

1.一种层合板，其包含：
具有内表面和外表面的第一层；
具有内表面和外表面的第二层；和
胶合层，其在所述第一和第二层的所述内表面之间延伸，并且至少部分地覆盖所述第一和第二层的所述内表面，所述胶合层是由聚合物型丙烯酸类微粒的含水分散体来生产的。
2.权利要求1的板，其中所述聚合物型丙烯酸类微粒是由反应混合物来制备的，该反应混合物包含(i)羟基官能单体，(ii)酸官能单体，和(iii)不同于单体(i)的烯属不饱和单体。
3.权利要求1的板，其中所述羟基官能单体(i)包括(甲基)丙烯酸羟烷基酯或者其己内酯加合物或者前述二者。
4.权利要求2的板，其中所述酸官能单体(ii)包括烯属不饱和羧酸单体。
5.权利要求2的板，其中所述烯属不饱和单体(iii)包括(甲基)丙烯酸酯单体。
6.权利要求2的板，其中所述含水分散体进一步包含增塑剂。
7.权利要求6的板，其中所述增塑剂包含衣康酸酯增塑剂。
8.权利要求2的板，其中所述含水分散体进一步包含松香。
9.权利要求1的板，其进一步包含提供在所述外表面的至少一个的至少一部分上的涂料组合物，所述涂料组合物包含另一种聚合物型丙烯酸类微粒的含水分散体。
10.权利要求1的板，其中所述第一层或者所述第二层或者前述二者包含石膏。
11.一种层合板，其包含：
第一部分，其包含粘弹性材料的约束层；和
第二部分，其包含粘弹性材料的延伸层。
12.权利要求11的板，其中所述第一部分进一步包含一对约束构件，所述约束层接纳在所述约束构件之间。
13.权利要求11的板，其中所述约束层包含聚合物型材料，该聚合物型材料是由聚合物型丙烯酸类微粒的含水分散体生产的。
14.权利要求13的板，其中所述聚合物型丙烯酸类微粒是由反应混合物来制备的，该反应混合物包含(i)羟基官能单体，(ii)酸官能单体，和(iii)不同于单体(i)的烯属不饱和单体。
15.权利要求14的板，其中所述含水分散体进一步包含增塑剂。
16.权利要求15的板，其中所述增塑剂包括衣康酸酯增塑剂。
17.权利要求14的板，其中所述含水分散体进一步包含松香。
18.权利要求12的板，其中所述约束构件包含石膏。
19.权利要求11的板，其中所述延伸层包含：由聚合物型丙烯酸类微粒的含水分散体生产的聚合物型材料，和占涂层组合物的20-90重量％的填料材料。
20.权利要求19的板，其中所述聚合物型丙烯酸类微粒是由反应混合物制备的，该反应混合物包含(i)羟基官能单体，(ii)酸官能单体，和(iii)不同于单体(i)的烯属不饱和单体。
CN201580072557.9A 2014-12-01 2015-11-23 消声系统 Pending CN107206745A (zh)

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