CN107673659A - 天花板底垫 - Google Patents
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Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/28—Polysaccharides or derivatives thereof
- C04B26/285—Cellulose or derivatives thereof
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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
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
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- 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
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
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- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
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- Civil Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
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- Finishing Walls (AREA)
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- Floor Finish (AREA)
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Abstract
本发明公开了一种用于悬吊式天花板的水毡化底垫，所述水毡化底垫包含按重量计约1/2矿棉、限于约1/8的淀粉粘结剂、限于约1/8的新闻纸和约1/4膨胀玻璃珠。
Description
本案是申请日为2011年12月9日、申请号为201180059345.9、发明名称为“天花板底垫”的专利申请的分案申请。
技术领域
本发明涉及建筑构造材料，具体涉及天花板组合物。
背景技术
对生产建筑材料和产品的环境影响的意识正在增长。减小不利的环境影响并构建可持续性的一种可能方式是循环材料。这类循环材料有时广义上分类为消费后循环材料和工业后循环材料。消费后循环材料尤其受诸如LEED之类的组织推崇。
吊顶中所用的天花板应该具有特定的性能特性，包括吸音能力、相对低的密度、耐燃性和抗下垂性。除了满足这些标准外，原料必须相对能低廉获得并容易加工。这些特性即使用复合材料也可能难以实现。而且，可得循环材料的普适性有限，该循环材料可以提供这些期望特性中的一种或多种，与其它可行材料相容，可以以实用成本获得并且不带来不期望的特性。重要的是找到一种实现这些必要特性、而且与现有生产设备和工艺相容的高循环含量配方。
发明内容
本发明涉及发现成功用于天花板底垫的高循环含量配方。该配方适合用在现有水毡化(water felted)工艺中，并且提供增加这种工艺的能量和材料利用效率的潜能。已发现膨胀玻璃珠可以成功用作湿毡化配方中的填充剂。该填充材料与所选定组分以合适比例使用能实现令人满意的吸音，以及合适的机械性质包括干和湿强度、硬度、刚度和抗下垂性。而且，这些特性可以在具有约15lbs./ft3相对低密度的底垫中实现。此外，这些玻璃珠以合适比例与其它材料一起使用，通过相对于现有技术的垫配方减少水工艺需要和湿垫中的水载量而具有提高能量效率的潜能。有利的是，膨胀玻璃珠可以与工业中常用材料一起使用，从而可以简化供应渠道、原料储存和处理问题。
本发明还涉及以下项目。
1.一种用于悬吊式天花板的水毡化底垫，所述水毡化底垫包含按重量计约1/2矿棉、限于约1/8的淀粉粘结剂、限于约1/8的新闻纸和约1/4膨胀玻璃珠。
2.一种用于悬吊式天花板的水毡化底垫，所述水毡化底垫包含按重量计30至70％矿棉、约3至12％粘结剂、3至12％纤维素纤维和5至30％膨胀玻璃珠。
3.根据项目2所述的水毡化底垫，其中所述玻璃珠的颗粒尺寸为约.1至约.3毫米。
4.根据项目3所述的水毡化底垫，其中所述玻璃珠的堆密度为约25lbs./ft3。
5.根据项目4所述的水毡化底垫，其中所述垫的密度为15lbs./ft3或更低。
6.根据项目5所述的水毡化底垫，其中所述垫的厚度为约7/8”。
具体实施方式
天花板或天花面板常用于制造天花吊顶。该板以长方形格铺设，通常具有2’×2’和2’×4’的标称面尺寸或这些尺寸的等同米制尺寸。根据本发明，本领域已知的一般常规湿毡化工艺用于制造天花板底垫。在这种工艺中，将底垫组分混合在水浆料中，并将该水浆料沉积在运动的丝网上以形成某指定厚度的底垫材料层。该材料层重力排水，并且可以继而在真空作用下排除其它的水含量。这种施加真空和任选的压制步骤可以重复。在这种机械脱水后，可以将材料运送到干燥器，在此剩余的水从垫中蒸发出，并且引起垫配方中的粘结剂凝结或固化。
本发明涉及发现材料组合及其相对比例，它们制造的天花板底垫具有高的循环材料含量，并且除了可接受的材料性质和性能特性之外还具有改进的加工特性。已发现来自消费后循环玻璃的膨胀玻璃珠可以成功用作填充剂，与其它组分一起制造用在天花板中的水毡化底垫。膨胀玻璃珠的合适来源是Poraver North America Ltd.。实验已表明对于本文所公开的产品，标称尺寸为约0.1至约0.3mm且堆密度为约25lbs./ft3的膨胀玻璃珠特别有用。如果被毡化的浆料的稠度相对较高，则可以使用较大的玻璃珠，例如尺寸为约1至2mm且密度为约14至15lbs./ft3，而不存在玻璃珠浮出浆料的风险。该实验还已揭示下面组分按各自重量比例可以产生令人满意的结果。
在以上右侧的配方是优选混合物的例子时，要理解可以在不显著损失性能下变化这些比例。玉米淀粉最常用作粘结剂；如果胶乳用作粘结剂，则其含量百分比一般较低，例如约3％或更高。作为一般性的教导，组分比例应该落在上表所指定的范围内。广义上该表建议，根据本发明的底垫配方可以包含按重量计约1/2矿棉、低于约1/8淀粉粘结剂、低于约1/8新闻纸和约1/4膨胀玻璃珠。实用的底垫例如可以具有约7/8”的标称厚度和15lbs./ft3或更低的密度。
已发现在天花板底垫制造中使用膨胀玻璃珠比常规使用膨胀珍珠岩具有若干出乎意料的优点。这些包括能够以比使用珍珠岩作为填充剂的现有技术配方中常用稠度高的稠度混合组分，所述稠度即用于形成底垫的浆料中固体组分的重量与水重量的比例。这种高稠度减少了用以制造所公开底垫的工艺水的量。而且，水载量，即在真空和压制操作后机械保留在垫预成型物中的水含量低于使用膨胀珍珠岩的典型配方。这种减小的水载量允许以更少能量和提高的生产线速度干燥该垫。
已发现膨胀玻璃珠和新闻纸纤维的组合提高组分的湿强度。该湿强度可以使得制造工艺更加耐受处理力的变化，由此减少制造该产品的废料和时间。尽管膨胀玻璃珠比湿毡化底垫中常用的膨胀珍珠岩填充剂重许多倍，但是膨胀玻璃珠可以制造表现出良好声学性质的低密度产品。这些相对密度使得用膨胀玻璃珠可以形成可行低密度的天花板底垫不符合直觉。但是，所提及组分的配方可以产生密度为约15lbs./立方英尺的具有令人满意特性的底垫。按一般规律，新闻纸含量应该限于约6％；已发现更高比例的新闻纸将趋于降低NRC(减噪系数)。膨胀玻璃珠含量通常应该限于约30％，以避免底垫过脆。
本文所述水毡化玻璃珠填充的底垫产品在干燥后通常用漆状涂料涂布表面，以改善其如常规在工业中作为表面面板或板的反光性和外观。在表面涂布之前，可以研磨底垫以形成相对光滑的表面。此外，底垫的面可以被穿孔或产生裂纹以提高其吸音性能。
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括的教导的合理范围下可以通过增加、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限定的范围外，本发明不限于本公开内容的具体细节。
Claims (4)
1.一种用于悬吊式天花板的水毡化底垫，所述水毡化底垫包含按重量计约1/2矿棉、限于约1/8的淀粉粘结剂、限于约1/8的新闻纸和约1/4膨胀玻璃珠，其中所述玻璃珠的堆密度为25lbs./ft3并且尺寸在1至2毫米之间，以实现具有高稠度的湿毡化而不存在通过浮出湿毡化浆料的珠分离。
2.一种用于悬吊式天花板的水毡化底垫，所述水毡化底垫包含按重量计30至70％矿棉、约3至12％粘结剂、3至12％纤维素纤维和5至30％膨胀玻璃珠，其中所述玻璃珠的堆密度为25lbs./ft3并且尺寸在1至2毫米之间，以实现具有高稠度的湿毡化而不存在通过浮出湿毡化浆料的珠分离。
3.根据权利要求2所述的水毡化底垫，其中所述垫的密度为15lbs./ft3或更低。
4.根据权利要求3所述的水毡化底垫，其中所述垫的厚度为约7/8”。
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| US12/975,501 | 2010-12-22 | ||
| US12/975,501 US8383233B2 (en) | 2010-12-22 | 2010-12-22 | Ceiling tile base mat |
| CN2011800593459A CN103270229A (zh) | 2010-12-22 | 2011-12-09 | 天花板底垫 |
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| EP (1) | EP2655757B1 (zh) |
| JP (1) | JP6328426B2 (zh) |
| KR (1) | KR101952441B1 (zh) |
| CN (2) | CN103270229A (zh) |
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| AU (1) | AU2011349858B2 (zh) |
| BR (1) | BR112013014179B1 (zh) |
| CA (1) | CA2822256C (zh) |
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| WO2013122974A1 (en) | 2012-02-17 | 2013-08-22 | United States Gypsum Company | Gypsum products with high efficiency heat sink additives |
| US8801902B1 (en) * | 2013-09-18 | 2014-08-12 | Usg Interiors, Llc | Water reduction by modulating vacuum |
| US8974925B1 (en) | 2013-10-15 | 2015-03-10 | United States Gypsum Company | Gypsum board |
| US8894811B1 (en) * | 2013-10-16 | 2014-11-25 | Usg Interiors, Llc | Air dispersion of mineral fibers in ceiling tile manufacture |
| KR101471556B1 (ko) * | 2014-09-05 | 2014-12-11 | 황동문 | 유리공예품소재의 제조방법 및 그 소재 |
| US9896807B2 (en) * | 2015-09-25 | 2018-02-20 | Usg Interiors, Llc | Acoustical ceiling tile |
| WO2017175063A1 (en) | 2016-04-04 | 2017-10-12 | Fiberlean Technologies Limited | Compositions and methods for providing increased strength in ceiling, flooring, and building products |
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| US4698257A (en) * | 1982-11-08 | 1987-10-06 | The Celotex Corporation | Wet-end molded product |
| CN1479699A (zh) * | 2000-12-27 | 2004-03-03 | USG�ڲ��ɷ�����˾ | 具有改良的声音吸收值的双层吸音天花板 |
| CN101918651A (zh) * | 2008-01-04 | 2010-12-15 | Usg因堤瑞尔斯公司 | 使用纸加工废料制作的吸音吊顶板材 |
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| US3379609A (en) * | 1964-01-16 | 1968-04-23 | United States Gypsum Co | Water-felted building product including nonfibrous cellulose binder |
| US4062721A (en) | 1976-10-26 | 1977-12-13 | Conwed Corporation | Use of surfactant to increase water removal from fibrous web |
| US5013405A (en) | 1987-01-12 | 1991-05-07 | Usg Interiors, Inc. | Method of making a low density frothed mineral wool |
| US4911788A (en) * | 1988-06-23 | 1990-03-27 | The Celotex Corporation | Method of wet-forming mineral fiberboard with formation of fiber nodules |
| JPH02296951A (ja) * | 1989-05-08 | 1990-12-07 | Takagi Kogyo Kk | 軽量モルタルパネル |
| RU2070870C1 (ru) * | 1993-02-09 | 1996-12-27 | Казанский инженерно-строительный институт | Состав для акустической плиты и способ изготовления акустической плиты |
| JP2935811B2 (ja) * | 1994-07-22 | 1999-08-16 | 大建工業株式会社 | 繊維板の製造方法 |
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| US5964934A (en) * | 1997-12-18 | 1999-10-12 | Usg Interiors, Inc. | Acoustical tile containing treated perlite |
| ATE259922T1 (de) | 1998-03-02 | 2004-03-15 | Wilhelmi Werke Ag | Plattenförmiges brandschutzelement in sandwich- bauweise |
| US20020096278A1 (en) * | 2000-05-24 | 2002-07-25 | Armstrong World Industries, Inc. | Durable acoustical panel and method of making the same |
| JP2004300793A (ja) | 2003-03-31 | 2004-10-28 | Daiken Trade & Ind Co Ltd | 化粧材およびその製造方法 |
| DE10326252A1 (de) | 2003-06-11 | 2005-01-05 | Dennert Poraver Gmbh | Verfahren zur Herstellung eines Formkörpers aus einem Leichtzuschlagstoff-Granulat und einem Bindemittel |
| DE102004012598A1 (de) | 2004-03-12 | 2005-09-29 | Dennert Poraver Gmbh | Verfahren zur Herstellung von Schaumglasgranulat |
| US20090273113A1 (en) * | 2008-04-30 | 2009-11-05 | Baig Mirza A | Wallboard and Ceiling Tile and Method of Manufacturing Same |
| DE102008026650A1 (de) | 2008-06-04 | 2009-12-24 | Lahnau Akustik Gmbh | Plattenelement |
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2010
- 2010-12-22 US US12/975,501 patent/US8383233B2/en active Active
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2011
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- 2011-12-09 CN CN2011800593459A patent/CN103270229A/zh active Pending
- 2011-12-09 RU RU2013130660/03A patent/RU2591865C2/ru active
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- 2011-12-09 WO PCT/US2011/064140 patent/WO2012087611A1/en active Application Filing
- 2011-12-09 KR KR1020137017867A patent/KR101952441B1/ko active IP Right Grant
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- 2011-12-09 MX MX2013006677A patent/MX356605B/es active IP Right Grant
- 2011-12-09 NZ NZ612170A patent/NZ612170A/en unknown
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| US4698257A (en) * | 1982-11-08 | 1987-10-06 | The Celotex Corporation | Wet-end molded product |
| CN1479699A (zh) * | 2000-12-27 | 2004-03-03 | USG�ڲ��ɷ�����˾ | 具有改良的声音吸收值的双层吸音天花板 |
| CN101918651A (zh) * | 2008-01-04 | 2010-12-15 | Usg因堤瑞尔斯公司 | 使用纸加工废料制作的吸音吊顶板材 |
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| Publication number | Publication date |
|---|---|
| CA2822256C (en) | 2019-06-11 |
| US8383233B2 (en) | 2013-02-26 |
| RU2591865C2 (ru) | 2016-07-20 |
| MX2013006677A (es) | 2013-07-29 |
| BR112013014179B1 (pt) | 2021-01-26 |
| MY162591A (en) | 2017-06-30 |
| BR112013014179A2 (pt) | 2018-05-15 |
| MX356605B (es) | 2018-06-05 |
| RU2013130660A (ru) | 2015-01-27 |
| EP2655757B1 (en) | 2016-06-29 |
| US20120164422A1 (en) | 2012-06-28 |
| WO2012087611A1 (en) | 2012-06-28 |
| NZ612170A (en) | 2015-02-27 |
| AU2011349858A1 (en) | 2013-05-02 |
| KR20140075641A (ko) | 2014-06-19 |
| JP6328426B2 (ja) | 2018-05-23 |
| CA2822256A1 (en) | 2012-06-28 |
| AR084313A1 (es) | 2013-05-08 |
| CN103270229A (zh) | 2013-08-28 |
| JP2014506965A (ja) | 2014-03-20 |
| KR101952441B1 (ko) | 2019-02-26 |
| AU2011349858B2 (en) | 2015-07-30 |
| EP2655757A1 (en) | 2013-10-30 |
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