CN108472921A - 基于石膏的声学板 - Google Patents

基于石膏的声学板 Download PDF

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Publication number
CN108472921A
CN108472921A CN201780006684.8A CN201780006684A CN108472921A CN 108472921 A CN108472921 A CN 108472921A CN 201780006684 A CN201780006684 A CN 201780006684A CN 108472921 A CN108472921 A CN 108472921A
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CN
China
Prior art keywords
plate
fabric
methyl
gypsum
thermoplastic polymer
Prior art date
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Pending
Application number
CN201780006684.8A
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English (en)
Inventor
K.楚达
C.德马蒂厄-勒尔特根
V.肖邦
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Saint Gobain Placo SAS
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Saint Gobain Placo SAS
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Application filed by Saint Gobain Placo SAS filed Critical Saint Gobain Placo SAS
Publication of CN108472921A publication Critical patent/CN108472921A/zh
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Abstract

本发明涉及基于石膏的板，其包含位于两个覆盖层之间的由石膏制成的芯，其中包含热塑性聚合物纤维的织物构成所述覆盖层中至少一个和/或所述织物被嵌入在构成芯的石膏中。

Description

基于石膏的声学板
本发明涉及一种具有声学性质的基于石膏的板。这种板尤其可用于获得墙壁砌面，天花板或地板，以及分隔墙。
基于石膏的板通常是复合板，其包含由石膏制成的芯，该芯位于由纸或纸板制成的两个覆盖层之间。这些板具有符合现行标准的机械性质，特别是在负载下具有优良的抗弯曲性。
这样的基于石膏的板不具有特定的声学性质。当希望改善这些性能时，已知将所述板与隔音材料(例如玻璃棉或岩棉或聚合物)结合以形成复合产品。根据目标用途，该复合产品可借助于型材，粘合剂，螺钉或销钉固定而保持在位置上。
最常见的基于石膏的板的平均厚度为12.5毫米，通常以“BA 13”的名称出售。这些板的单位面积质量为9千克/平方米。众所周知，可以通过增加其每单位面积质量(例如最高至12kg/m2)来改善板的声学性质，而不改变其厚度，但这必然体现为在板中的石膏量的提高。
因此，板的成本更高。
每单位面积质量较高的板的安装也存在缺点：由于重量的增加，对板的处理是更棘手的且更困难的，而且由于该板是更致密的，因此当使用螺钉进行支撑固定时更难穿透它。当板在高处被固定时，例如在天花板上或用于产生隔板时，这些缺点变成主要缺点。
本发明的一个目的是提供一种基于石膏的板，其具有改善的声学性质，同时保持优良的机械性质。
这种目的根据本发明通过用包含热塑性聚合物纤维的织物替换所述基于石膏的板的由纸或纸板制成的覆盖层中的至少一个和/或通过将所述织物加入在由石膏制成的芯中来实现。
因此，基于石膏的板包含含有热塑性聚合物纤维的织物，所述织物构成由石膏制成的芯的覆盖层或/或被嵌入在构成芯的石膏中。
“织物”应理解为是指非编织物(也取名为“intissé”)，其特别以纱或毡的形式存在，或编织物。
根据本发明的织物包含至少70重量％的由至少一种热塑性聚合物构成的纤维。
作为这种热塑性聚合物的例子，可以提及聚烯烃，如聚乙烯，聚丙烯，聚(1-丁烯)和聚甲基戊烯；均聚物或共聚物形式的聚酰胺，如Nylon®6-6、6-9、6-12、10、11和12，以及聚酰胺-酰亚胺；丙烯腈的均聚物和共聚物，特别是丙烯腈-苯乙烯，丙烯腈-甲基丙烯酸甲酯，丙烯腈-丁二烯-苯乙烯和丙烯腈-苯乙烯-丙烯酸酯；聚酰亚胺；聚酯，如聚(对苯二甲酸亚烷基酯)，特别是聚对苯二甲酸乙二醇酯(PET)和聚对苯二甲酸丁二醇酯(PBT)，和聚(萘二甲酸亚烷基酯)，特别是聚萘二甲酸乙二醇酯；聚(乳酸)；聚羟基烷酸酯；乙烯基聚合物，如聚(乙烯醇)，聚(乙酸乙烯酯)，聚(氯乙烯)和聚(氟乙烯)；乙烯和乙烯基化合物的共聚物，特别是乙烯和乙酸乙烯酯的共聚物(EVA)以及乙烯和乙烯醇的共聚物(EVAL)；(甲基)丙烯酸聚合物，如聚((甲基)丙烯酸)和乙烯与(甲基)丙烯酸的共聚物；(甲基)丙烯酸烷基酯聚合物，特别是聚甲基丙烯酸甲酯；聚己内酯；聚苯乙烯；苯乙烯和酸酐，特别是马来酸酐的聚合物；烯烃和氟化单体的共聚物，特别是聚(四氟乙烯)，聚(乙烯-四氟乙烯)，全氟乙烯-丙烯和聚(三氟氯乙烯)；聚碳酸酯；聚酮；聚醚酮；聚醚砜；聚酰亚胺；和线性聚氨酯。聚丙烯，(甲基)丙烯酸或(甲基)丙烯酸酯聚合物，聚(乳酸)，聚羟基链烷酸酯，PET，PBT和聚萘二甲酸乙二醇酯是优选的。聚丙烯，(甲基)丙烯酸或(甲基)丙烯酸酯聚合物和PET是特别优选的。
有利地，织物包含至少两种不同的热塑性聚合物纤维的混合物，特别是聚丙烯纤维和(甲基)丙烯酸或(甲基)丙烯酸酯聚合物纤维或聚丙烯纤维和PET纤维的混合物。在这种情况下，聚丙烯纤维的量占热塑性聚合物纤维总重量的10-90％，优选至少等于50％，有利地至少等于70％。
热塑性聚合物纤维可以是单长丝纤维或由多个单长丝组成的复丝纤维。在织物的情况下纤维是连续的，并且在非编织物的情况下可以是连续的或切断的。
这些纤维的线密度通常为1至25分特，优选3至15分特，有利地为5至12分特。切断纤维的长度为0.5至15厘米，优选1至10厘米，有利地2至8厘米。
热塑性聚合物纤维可具有简单或多叶形截面，有利地为三叶形，四叶形或五叶形截面。叶片可呈现浑圆形或包括尖边缘。叶片的形状可以是复杂的，例如T形或Y形，并且每个叶片可以具有多个分支。
已知对于多叶纤维定义改性比(rapport de modification)，其对应于纤维截面的外接圆的直径(R)与内切圆的直径(r)之比。该比率R/r优选在2-7之间，有利地在3-6之间。
多叶片纤维有利地是聚丙烯，PET或Nylon®纤维。
这种多叶片纤维特别描述于EP0201812和EP2272999中。
织物可包括至多30重量％的基于非热塑性聚合物的纤维，特别是未改性的纤维素纤维，例如棉纤维或木纤维，或化学改性的纤维素纤维，例如粘胶纤维或人造丝纤维。该纤维还可以是以直径为5至30μm的单根长丝，包含多根这种玻璃长丝的股线(基线)或多根基线的组合体(粗纱)的形式提供的玻璃纤维。玻璃股线的线密度为30至1500特。
当织物是非编织物时，热塑性聚合物纤维和任选的基于非热塑性聚合物或玻璃的其它纤维通常例如通过机械处理，特别是通过针刺(aiguilletage)或空气喷射，或通过热处理，特别是通过纺粘(其在于在拉丝或挤出后立即通过加热粘合该纤维)彼此粘合在一起。
可以通过使用含有至少一种聚合物的含水粘合剂使机械或热粘合的织物加固，所述聚合物选自烯烃(如乙烯，丙烯，丁烯或异丁烯)和乙酸乙烯酯的共聚物，乙酸乙烯酯和(甲基)丙烯酸或丙烯酸酯的共聚物，(甲基)丙烯酸酯和除乙酸乙烯酯以外的单体，特别是苯乙烯的共聚物，(甲基)丙烯酸或丙烯酸酯的均聚物，乙酸乙烯酯、烯烃和乙烯基酯单体的三元共聚物，和丙烯腈聚合物，特别是丙烯腈和(甲基)丙烯酸酯的共聚物，特别是丙烯腈和甲基丙烯酸甲酯的共聚物，丙烯腈、丁二烯和苯乙烯的三元共聚物。优选(甲基)丙烯酸酯和苯乙烯的共聚物，特别是丙烯酸丁酯和苯乙烯的共聚物。
有利地，参与粘合剂组成的聚合物的玻璃化转变温度(Tg)为-50至+ 80℃，优选-40至+ 60℃，有利地-10至+ 25℃，更好地0至+ 10℃，根据标准ISO 11357-1：2009通过差示扫描量热法进行测量。
粘合剂在织物上的施加可以通过本领域技术人员已知的任何方法进行，例如通过喷雾，浸渍或涂覆。
织物的单位面积质量(masse surfacique)通常为50-800克/平方米，优选60-500克/平方米，有利地为80-300克/平方米。
织物可以由通过机械或热处理粘合在一起的多种相同或不同的织物组成，并且这些织物的组合可以通过水性粘合剂加固，如上所述的那样。
该板的芯由基于石膏的组合物获得，该组合物包含煅烧石膏和任选的添加剂。
因此，芯可以按以下重量比例包含下列添加剂，以每100重量份石膏的份数进行表示：
- 0.1至25份粘合剂，其作用是增加覆盖层(当覆盖层由纸或纸板制成时)与石膏的粘合性，优选最多15份，
- 0.001至10份凝固促进剂，例如硫酸钙水合物或硫酸钾，
- 0.001至10份缓凝剂，
- 0至10份杀菌剂，例如奥麦丁钠，
- 0.0001至1份发泡剂，其作用是产生气孔以降低最终产品的密度。举例来说，可以提及烷基醚硫酸钠和十二烷基硫酸钠，
-0至10份至少一种防水剂，例如硅氧烷或聚硅氧烷，
-0至20份至少一种阻燃剂，例如蛭石，二氧化硅，特别是微米尺寸二氧化硅，粘土或金属纤维，
-0至20份至少一种增强剂，例如聚合物纤维，矿物纤维，特别是热塑性聚合物纤维，以及动物或植物纤维。
优选地，粘合剂是淀粉，其特别是用酸进行预处理，糊精，植物粉，特别是小麦粉或玉米粉，纤维素衍生物，例如甲基纤维素或羟甲基纤维素，乙烯基聚合物，例如聚乙烯醇，聚乙酸乙烯酯或乙烯-乙酸乙烯酯共聚物，(甲基)丙烯酸或(甲基)丙烯酸烷基酯聚合物，例如聚甲基丙烯酸甲酯，聚乙烯吡咯烷酮，特别是用聚苯乙烯磺酸盐交联的聚乙烯吡咯烷酮，苯乙烯-丁二烯胶乳，聚酯树脂或环氧树脂。
还优选地，增强剂由至多5份，优选至多3份热塑性聚合物纤维组成，所述热塑性聚合物纤维的长度为3至12.5mm，直径为5至50μm。
基于石膏的板根据本身已知的方法形成，其在于将粉末状煅烧石膏(硫酸钙半水合物)与水混合以形成浆料，其连续沉积在两张纸或纸板之间。
将所形成的产品压制，以获得所需的厚度，然后在传送机上连续输送一段距离，该距离允许浆料达到足以能够被切断成预定长度的板的硬化水平。随后将板在干燥炉中干燥以除去过量的水。
由此获得的板的厚度可以为6至25毫米，并且优选地为约12.5毫米。
传统地，硫酸钙半水合物(CaSO4·0.5H2O；煅烧石膏)，无论是天然的还是合成的，即特别是由热电厂气体的脱硫而产生的，在水的存在下经历水合反应并转化为硫酸钙二水合物(CaSO4·2H2O：石膏)。
用于形成糊剂的所使用的煅烧石膏的量通常为每100重量份水有50至150重量份，优选60至120份。
如上所述，根据本发明的织物代替覆盖该基于石膏的板的主面的由纸或纸板制成的覆盖层的至少一个覆盖层，和/或所述织物被结合在由石膏制成的芯中。
根据第一种变型，基于石膏的板包含织物，该织物被设置在由石膏制成的芯的主面中之一上或嵌入石膏中。
根据第二种变型，基于石膏的板包含被设置于由石膏制成的芯的两个主面上的两个织物，或者一个在这些面之一上的织物，另一个嵌入在石膏中的织物。
根据第三种变型，基于石膏的板包含两个被设置于由石膏制成的芯的两个主面上的织物和嵌入石膏中的第三织物。
在所有上述变型中，使结合在该板的芯中的织物与覆盖该芯的主面的纸层，纸板层或织物层平行地设置，并且优选地，织物位于与芯的主面相等的距离处。两个覆盖层。
但是，不应从本发明中排除在由石膏制成的芯中加入多种相同或不同的织物，这些织物可能以均匀或不均匀的方式分布在石膏的厚度中，特别是这些织物可以是并置的。
本发明的另一主题涉及如上所述的包含热塑性聚合物纤维的织物的用途，用于改善基于石膏的板的声学性质，特别是隔音性质，该基于石膏的板包括位于两个覆盖层之间的由石膏制成的芯，其中所述织物构成一个或多个覆盖层和/或被嵌入在由石膏制成的芯中。本发明还涉及用于改善基于石膏的板的声学性质的方法，包括：提供如上所述的包含热塑性聚合物纤维的织物，和将所述织物并入在基于石膏的板中，其中织物构成覆盖层和/或被嵌入由石膏制成的芯中。
本发明的另一主题涉及根据本发明的基于石膏的板用于改善在建筑物中的隔音的用途。本发明还涉及一种改善在建筑物中隔音的方法，包括安装根据本发明的基于石膏的板，以形成墙壁砌面，假天花板，地板和/或分隔墙。
根据本发明的基于石膏的板可以原样进行使用或与其它材料(例如矿物棉或木棉，或聚合物)结合进行使用，以形成声学和/或热学面板，或者与用于提供在两个基于石膏的板之间的粘合的夹层聚合物膜结合进行使用，以形成复合面板。
该板可用于形成墙壁砌面，假天花板，地板和分隔墙壁。
以下实施例使得可以说明本发明，但不限制本发明。
实施例1至7
在以下条件下制造了根据本发明的包含一种或两种织物的基于石膏的板：
a)通过引入1000g硫酸钙半水合物，5g淀粉，0.1g凝固促进剂(用蔗糖处理的石膏)，0.05g缓凝剂(Plast Retard L，由Sicit 2000出售)和750g水加入混合器中以制备石膏组合物。该混合器设有三叶片搅拌器，速度为650rpm，时间为15秒，然后为1850rpm，时间为45秒。
b)通过将138.5g水和1.4g发泡剂(Militsoam®，由Huntsman出售)引入装有三叶片搅拌器的混合器中来制备泡沫，搅拌器速度为3300rpm，时间为1分钟。
c)将在步骤a)中获得的石膏组合物和30g在步骤b)中获得的泡沫引入混合器中以获得糊剂，该混合器设有行星桨，其以250rpm的速度操作50秒。
d)将浆料倒入黄铜模具中，该黄铜模具包括4个平行六面体腔室(长度：300mm；宽度：30mm；深度：13mm)，其内壁涂有一层油，其底部覆盖有一个纸板片材或根据本发明的织物片材。
当将根据本发明的织物加入浆料中时，首先将浆料倒入模具中，厚度为6mm，然后沉积被切断成模具尺寸的织物，并用浆料将模具填满。
将具有模具尺寸的纸板或织物片材沉积在浆料上，并用一块板封闭模具，在该板上放置两个每个重量为5kg的重物。
20分钟后使板脱模，在露天放置10分钟，然后置于180℃的第一个干燥箱中35分钟，并在第二个100℃的烘箱中放置25分钟。将板储存在40℃的干燥室中。
实施例1在板的一个面上包括由聚丙烯纤维(80重量％)和聚(丙烯酸)纤维(20重量％)组成的非编织物，单位面积质量等于100g/m2(由Fibertex Nonwoven公司以名称Fibertex F-80 Extra出售)，在另一个面上是纸板片材(V5，由Saint-Régis公司出售)。
实施例2包括在板的每个面上的非编织物(Fibertex F-80 Extra，由FibertexNonwoven公司销售)。
实施例3在板的一个面上包括由多叶片PET纤维组成的非编织物(由FiberInnovationTechnology以商标号4DG®出售)，单位面积质量等于50g/m2，另一面上，纸板(V5，由Saint-Régis出售)。
实施例4在板的一个面上包括由多叶片PET纤维组成的非编织物(由FiberInnovation Technology公司以商标号4DG®出售)，单位面积质量等于150g/m2，和在另一个面上，包括纸板片材(V5，由Saint-Régis出售)。
实施例5在由石膏制成的芯中包括由聚丙烯纤维(80重量％)和PET纤维(20重量％)组成的非编织物，其单位面积质量等于100g/m2(由Fibertex Nonwoven公司销售)，和在纸板的每个面上包括纸板片材(V5，由Saint-Régis出售)。
实施例6在由石膏制成的芯中包括由聚丙烯纤维(80重量％)和PET纤维(20重量％)组成的并包含4至6重量％的炭黑的非编织物，其单位面积质量等于100g/m2(由Fibertex Nonwoven公司销售)，和在板的每个面上包含纸板片材(V5，由Saint-Régis公司出售)。
作为对比，在相同条件下制备包含两个纸板片材(V5，由Saint-Régis公司销售)并且在由石膏制成的芯中不包含根据本发明的任何织物的板(对比例7)。
通过在标准ISO 16940：2008(E)的条件下测量它们的机械阻抗MIM(Measurementof Mechanical Impedance)来评估板的声学性质。动态杨氏模量(以GN/m2表示)和损耗因子η(以％表示)是由作为频率(Hz)函数的加速度频率(dB)曲线计算出来的。还计算相对于(比较)实施例7的板的声学增益。
结果如在表1中所示。
Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 (对比)
单位面积质量(kg /m²) 9.30 9.00 10.00 9.80 9.40 9.13 9.11
动态杨氏模量(GN /m²) 2.95 2.61 3.17 2.01 0.90 2.11 3.58
损耗因子η(％) 0.75 1.01 0.88 3.72 7.59 4.70 0.30
声学增益(％) 17.60 27.09 11.45 43.85 74.86 48.60 -

Claims (15)

1.一种基于石膏的板，其包含位于两个覆盖层之间的由石膏制成的芯，其特征在于它包含含有热塑性聚合物纤维的织物，所述织物构成所述一个或多个覆盖层和/或被嵌入由石膏制成的芯中。
2.如权利要求1所述的板，其特征在于，所述织物是非编织物或编织物。
3.如权利要求1或2所述的板，其特征在于，所述织物包含至少70重量％的由至少一种热塑性聚合物组成的纤维。
4.如权利要求1至3中任一项所述的板，其特征在于，所述热塑性聚合物选自聚烯烃，聚酰胺，丙烯腈的均聚物和共聚物，聚酰亚胺，聚酯，聚(乳酸)，聚羟基链烷酸酯，乙烯基聚合物，乙烯和乙烯基化合物的共聚物，(甲基)丙烯酸聚合物，(甲基)丙烯酸烷基酯聚合物，聚己内酯，聚苯乙烯，苯乙烯和酸酐的聚合物，烯烃和氟化单体的共聚物，聚碳酸酯，聚酮，聚醚酮，聚醚砜，聚酰亚胺和线性聚氨酯。
5.如权利要求4所述的板，其特征在于，所述热塑性聚合物选自聚丙烯，(甲基)丙烯酸或(甲基)丙烯酸酯的聚合物，聚(乳酸)，聚羟基链烷酸酯，PET，PBT和聚萘二甲酸乙二醇酯。
6.如权利要求5所述的板，其特征在于，热塑性聚合物是聚丙烯，(甲基)丙烯酸或(甲基)丙烯酸酯的聚合物或PET。
7.如权利要求1至6中任一项所述的板，其特征在于，所述织物包含至少两种不同的热塑性聚合物纤维的混合物，特别是聚丙烯纤维和(甲基)丙烯酸或(甲基)丙烯酸酯聚合物纤维的混合物，或聚丙烯纤维和PET纤维。
8.如权利要求7所述的板，其特征在于，聚丙烯纤维的量占热塑性聚合物纤维总重量的10-90％，优选至少等于50％，有利地至少等于70％。
9.如权利要求1至8中任一项所述的板，其特征在于，所述纤维的线密度为1至25分特，优选3至15分特，有利地5至12分特。
10.如权利要求1至9中任一项所述的板，其特征在于，所述纤维是切断的并且它们的长度为0.5至15cm，优选1至10cm，有利地2至8cm。
11.如权利要求1至10中任一项所述的板，其特征在于，所述热塑性聚合物纤维具有简单或多叶形截面。
12.如权利要求1至11中任一项所述的板，其特征在于，所述织物可包含最多30重量％的基于非热塑性聚合物的纤维或玻璃纤维。
13.如权利要求12所述的板，其特征在于，所述织物通过含水粘合剂进行加固，所述含水粘合剂含有至少一种聚合物，该聚合物选自烯烃和乙酸乙烯酯的共聚物，乙酸乙烯酯和(甲基)丙烯酸或丙烯酸酯的共聚物，(甲基)丙烯酸酯和除乙酸乙烯酯以外的单体的共聚物，(甲基)丙烯酸或丙烯酸酯的均聚物，乙酸乙烯酯、烯烃和乙烯基酯单体的三元共聚物，以及丙烯腈聚合物。
14.如权利要求1至13中任一项所述的板，其特征在于，所述织物具有为50-800g/m2，优选为60-500g/m2，有利地为80-300g/m2的单位面积质量。
15.如权利要求1至14中任一项所述的板，其特征在于，所述板具有为6至25毫米，优选为约12.5毫米的厚度。
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