CN110997826A - 可砂磨的透声涂层 - Google Patents

可砂磨的透声涂层 Download PDF

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CN110997826A
CN110997826A CN201880051538.1A CN201880051538A CN110997826A CN 110997826 A CN110997826 A CN 110997826A CN 201880051538 A CN201880051538 A CN 201880051538A CN 110997826 A CN110997826 A CN 110997826A
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coating
formulation
droplets
substrate
sanding
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S·D·赫尔卡
P·J·古伯兰德森
R·伯里
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Abstract

一种用于吸声衬底上的透声涂层的配制物，其包括水分散性粘合剂和相对大的填料颗粒，并且其特征是高颜料体积浓度、高粘度、高剪切稀化和快速干燥，以使得所述配制物能够以微滴形式喷涂，从而在相互接触时保持它们的特性，并且能够有效地将干燥涂层砂磨平整。

Description

可砂磨的透声涂层
技术领域
本发明涉及一种用于改善吸声衬底的外观的透声涂层。
背景技术
美国专利8,684,134、8,770,345和8,925,677公开了用于构造整体式吸声天花板的干墙板或面板。这些面板是穿孔的并且包覆有薄的多孔半透明网，例如非织造半透明纤维玻璃纱或纱幕。面板之间的接合可以使用胶带和接合剂化合物，按照与根据石膏协会(gypsum association)公告GA-216-2013胶粘普通干墙相同的方式完成。
需要一种涂层，其能够涂覆在干墙面板上，以隐蔽胶粘的接合部和穿过网纱可见的穿孔，并且不会显著减弱面板所提供的吸音作用。重要的是，涂层可以在不需要依赖油漆工或工匠的过多技能的情况下涂覆，并且整个涂层将在有限的时间内干燥，优选小于一个工作日的一半。
发明内容
本发明提供一种用于吸声衬底的饰面或外观涂层，其特征在于高孔隙度和由此产生的高透声度，并且其能够有效的磨砂而得到光滑、均一的外观。所述涂层特别适用于隐蔽被半透明或半透明非织造网纱包覆的干墙板中的穿孔，以及在整体式吸声天花板构造中的此些板之间的胶粘接合部。
所公开的涂层材料适于以微滴形式喷涂成多个层，在涂覆连续层之前，让所述多个层干燥。所得涂层结构是残余微滴和中间空隙或孔隙的三维基质。涂层材料的特征在于相对大的填料颗粒、显著高的颜料体积浓度、实质性的剪切稀化和快速干燥性质。
涂层材料以相对较大的微滴形式喷涂。由于材料的物理性质，因此微滴一旦沉积在衬底或前一个材料层上，就保留了它们各自的特性中的至少一些。微滴由于他们的粘度和快速干燥性质而不会与邻近的微滴完全融合。微滴保持足够的个性以在同一涂层与前一涂层的微滴之间提供开放空间。在天花板应用中小到足以被不经意的观察者的肉眼忽略的开放空间通过单独的涂层互连，从而提供贯穿整个涂层厚度之孔隙度。
所公开的涂料配方，除了提供透声作用外，还能容易砂磨以提供相对光滑的外观。
附图说明
图1是采用本发明的石膏面板整体式吸声天花板的局部示意性等距视图；
图2是图1的整体式吸声天花板的放大的局部横截面图；
图3是展示本发明涂层的正面的扫描电子显微照片；
图4是本发明涂层的配制物的通用粘度图；
图5是本发明涂层的典型气流阻率图；并且
图6是展示首先在右侧干燥且在左侧砂磨之后的本发明涂层的外层的照片。
具体实施方式
现参看图1，示出了整体式吸声天花板装置10的局部示意图。将天花板10的各层剥离一部分以露出构造细节。天花板10是悬挂系统，包含本领域已知的干墙网格11，所述干墙网格包括中心间距为4英尺的主T形件12和中间间距为16英寸或2英尺的交叉十字T形件13。本文中使用的尺寸通常是标称尺寸，并且希望包含工业公认的等价度量标准。与十字T形件13互锁的主T形件12通过附接到上部结构(未示出)的金属丝14进行悬挂。网格11的边界通常通过固定到相应壁16的槽模15形成。
吸声面板20通过自钻螺钉21附接到网格T形件12、13的下侧。所示吸声面板的平面尺寸为4英尺×8英尺，但是根据需要或实际可以更长、更短和/或具有不同的宽度。面板20的尺寸以及网格T形件12和13的间距允许面板的边缘位于网格T形件之下并且直接附接到网格T形件上，从而确保这些边缘得到良好的支撑。
参看图2，吸声面板20的特征在于穿孔石膏芯24。一种提供芯24的方法是如下修改标准的市售干墙板：将其纸正面23、石膏芯24和纸背侧或背面25穿通。穿孔28可以通过钻孔、冲孔或其它已知的制孔技术形成。穿孔28优选地均匀间隔开；举例来说，穿孔可以是中心相距16 mm的8 mm直径圆孔。这种布置使穿孔的总面积基本上等于面板20的整个平面面积的20％。可以使用其它孔尺寸、形状、图案和密度。例如，测试表明，孔密度为总面积的9％可以获得良好的结果。边缘区域以及与板的支撑网格、托梁或螺柱的中心相对应的中间区域可以保持不穿孔，以维持紧固点处的强度。
将板29、30层压到穿孔干墙板的两个完整侧面上，从而至少部分地封闭穿孔28的两端。在干墙的背侧，背衬板或腹板30优选地是吸声天花板面板领域中已知的吸声非织造织物。举例来说，背衬织物可以是Freudenberg Vliesstoffe KG以商标
Figure BDA0002380785620000031
销售的背衬织物。
在干墙板22的正面，用合适的粘合剂附接呈非织造织物纱幕层29形式的板或腹板。面层或板29是多孔的；适用于此应用的材料是商业上用作传统吸声天花板面板的盖或面的材料。这种类型的网纱材料的实例是Owens Corning Veil Netherlands B.V.以产品代码A125 EX-CH02销售的材料。
其它相同面板的面板20以与安装普通干墙相同的方式悬挂在网格11上。类似地，如图1所示，接合部33以与胶粘普通干墙相同的方式胶粘。使用干墙接合剂化合物或类似材料34将胶带或类似材料35粘附到两个邻接面板20的相邻边缘，通过将所述干墙接合剂化合物或类似材料直接涂覆于板29和胶带35上来隐蔽胶带。
在将接合剂化合物34砂磨或擦拭光滑之后，将前板29和剩余的接合剂化合物涂上本发明的透声涂层31。当在本文中使用术语整体式时，表示天花板或墙壁的整个可见表面看起来基本上是无缝展开而无接合部的。
根据本发明，将涂层31喷涂到包覆有纱幕或网纱29的面板20的面向房间的一侧，所述面板构成涂层的衬底。理想地，涂层31具有若干物理性质，包含相对大的填料颗粒、显著高的颜料体积浓度(PVC)、高粘度、剪切稀化和快速干燥性能。当用作天花板结构的外观涂层时，涂层31应该是干燥的白色。
用于合适涂层的配制物包含粘合剂和用作颜料或填料的相对大的颗粒，所述颗粒的尺寸大于常规漆状涂层中通常使用的尺寸。粘合剂可以是树脂或聚合物粘合剂，或可用作水性分散液，例如但不限于丙烯酸类、苯乙烯或乙烯基聚合物乳胶或油基介质，例如醇酸树脂、聚氨酯、聚酯或环氧树脂和其组合。
相对大的颗粒包含但不限于玻璃球、珍珠岩、陶瓷、飞灰、聚合物球、硼硅酸盐、粗砂、二氧化硅和粗碳酸盐。相对大的颗粒呈球形或三维球形，而没有突出的板状特性或没有主要呈柱状的形状。大颗粒的尺寸可以在20与900微米之间的范围内。
下表1列出了适用于本发明可砂磨透声涂层31的配方的实例。
表1
Figure BDA0002380785620000041
不同成分的功能或作用标注于最右列。水、增稠剂、粘合剂和大颗粒填料是必不可少的，且当配制物存在于罐中时，杀生物剂是必不可少的。其余成分可视为任选的。出于参考目的，二氧化钛的平均粒度为约0.6微米；碳酸钙可具有约12微米的平均粒度，并且板状云母可具有约20微米的主要尺寸。
3M K1材料是碱石灰硼硅酸盐的玻璃气泡(空心球)，据报道真实密度通常为0.125克/立方厘米且平均粒度为65微米。3M K1材料在本发明的实践中特别有用。由于其中空球结构使得其密度相对低，因此此材料占据了配制物的大部分体积。另外，根据ASTM D281-84，K1材料的吸油量相对较低，为每立方厘米产品0.2-0.6克油。此外，K1材料具有天然白色，这在天花板应用中是有用的。二氧化钛用作改善不透明性的填料和增白颜料。碳酸钙增加了涂层的固体和密度，以进一步改善干燥涂层的干燥时间和硬度。
基于所有固体，涂层配制物的颜料体积浓度(PVC)相对较高，且理想地在75％与95％之间，而替代配制物将在约50％到约99％的较宽范围内。通常，当涂层干燥时，填充涂层中的颗粒之间空隙的粘合剂不够，以致涂层中存在气隙。相对较大颗粒填料的体积与尺寸通常较小的填料的体积比可在约0.1到约10的范围内。
表1的涂层配制物在室温下具有约190BBU(布拉本德单位(Brabender Units))到约265BBU的相对高粘度。替代配制物在室温下可具有约66BBU到约1450BBU的粘度。
表1的涂层配制物以高剪切稀化率为特征，且替代配制物应以高剪切稀化率为特征。表1配制物的剪切稀化特征概括于图4中，其中测得的粘度下降超过40:1。粘度部分地由配制物的增稠剂组分贡献。所列增稠剂是纤维素，但可以使用已知的合成和天然增稠剂。增稠剂还用于使各成分保持悬浮状态。图4的概括性粘度表是在使用T-bar:C锭子的Brookfield HA粘度计上进行测量。替代的涂层配制物应具有高剪切稀化性质，使得在剪切条件下粘度可降低至少10比1。
表1的涂层或等效物优选在单独喷涂层的喷涂过程中涂覆到胶粘的、网纱包覆的穿孔干墙面板或其它衬底上。在涂覆后续涂层之前，允许每一层或涂层基本上干燥。优选地，使用例如Graco销售的常规漏斗式纹理喷涂器以大微滴喷涂润湿的涂层材料。理想地，调节喷枪和/或其空气供应，使得微滴的尺寸为约1到约4mm，优选尺寸为约2mm。湿涂层的剪切稀化性质(如图4中所表征)让其容易以微滴形式喷涂，尽管其粘度高。单个涂层应涉及在两个垂直方向或操作上喷涂衬底，以便实现层的均匀覆盖。可以涂覆二到七个层，优选四个层，以隐蔽天花板的穿孔和胶粘接合部。总涂层的覆盖率可以是每加仑15到35平方英尺，优选25平方英尺。表1的配制物或类似的配制物具有每加仑4到11磅的密度，优选范围为每加仑5到6.5磅。
图3显示了本发明涂层当涂覆于吸声衬底时的多孔性质。检查图3表明微滴保持个性化性质，而粘合剂将固体粘合到第一层的衬底且粘合到层间和层中的邻近微滴。图3右下角的刻度指示1毫米的量度且可在图中以大于或小于1毫米的量度观察微滴。优选地，干燥微滴的范围在1/2与2-1/2mm之间。当水分蒸发时，原始微滴尺寸将缩小。
随着涂层的沉积，建立了三维微滴基质。图3中的空隙、暗区可以在残留的微滴形式之间观察到。这些空隙通过涂层的厚度互连，从而形成多孔且透声的涂层。图3中的空隙或孔隙尺寸通常小于0.5mm，使得它们在天花板高度处不容易被站在相关地板上的人观察到。在3M K1大颗粒提供的表1配制物中，涂层的主要固体体积的低吸收率确保涂层将快速干燥。湿涂层的剪切稀化性质使其容易以微滴形式喷涂。
高粘度和快速干燥性质的结合使微滴能够有利地保持其个性并避免与邻近微滴完全融合。特定层中应用的表1的公开配制物干燥到其不会转移到手指上的程度，即干燥到可以接触，最优选在75℉和50％相对湿度的环境下，第一涂层在20分钟后且后续涂层在30分钟后干燥到所述程度。优选地，具有快速干燥性质的替代配制物在第一次涂布时、在60分钟后干燥到可以接触。涂层的这种快速干燥性质也很重要，因为它使油漆工能够在同一天完成工作。
图5示出了针对表1材料的每个连续干涂层单独测量的典型气流阻率。在每分钟2升的气流通过3.14平方英寸的表面积的情况下测定阻率。图5中测试的涂层的总干燥厚度是0.031英寸。“0涂层”处的初始阻率读数是网纱29的阻率的测量结果。干涂层的厚度优选在0.03与0.15英寸之间。
图6右侧示出了本发明涂层的顶层(外层)的喷涂和干燥饰面。建筑师、室内设计师、建筑物所有者和/或租户可能更喜欢光滑的饰面。图6左侧所示的较精细纹理能够通过砂磨工艺、使用本发明的涂层配制物获得，而透声无损失。作为显著高的颜料体积浓度配制的结果，本发明的涂层可容易砂磨，同时保持透声性。
在砂磨之前，涂层表面的特征是宏观的山丘和山谷，与喷涂过程中沉积的分隔微滴残留物相对应。当磨平时，如图6左侧所示，本发明的涂层的特征在于其表面区域的主要部分基本上是平坦的，而忽略了非常细的砂纸划痕和相对较小的局部山谷。
举例来说，覆盖有本发明涂层的400平方英尺的天花板区域能够以人工方式、使用杆式砂磨机砂磨45分钟，以获得图6左侧所示的平坦表面。为了参照，可以将其与另一种配制物进行比较，所述另一种配制物需要多达1小时45分钟才能人工砂磨400平方英尺的天花板区域。砂磨过程中未除去的灰尘颗粒能够使用例如鼓风机、喷射器或真空机除去。
为了客观地测量人工砂磨400平方英尺天花板区域需要45分钟的本发明涂层和需要1小时45分钟的参考涂层的可砂磨性，进行砂磨测试。根据ASTM D2486标准(测试方法A)，在适当偏离/修改的情况下进行测试。用180粒度(CAMI量表)的砂纸代替重量比砂纸重1磅的指定刷子，不使用“研磨洗涤介质(液体)”且不使用黄铜垫片。如上所述，将涂层涂覆到吸声衬底上。需要45分钟人工砂磨的本发明涂层按照60-65个循环测试以获得平坦表面(图6左侧所示)，而需要1小时45分钟的参考涂层按照110-115个循环测试以获得平坦表面。基于这些测试和经验，本发明涂层配制物应该依据所述经修改的ASTM D2486标准砂磨平整，优选以约85个循环并且更优选以约60-65个循环砂磨平整。
应显而易见的是，本公开是借助于实例，并且可以通过在不脱离本公开中所含有的传授内容的合理范围的情况下添加、修改或消除细节来进行各种变化。因此，本发明不限于本公开的特定细节，除非所附权利要求书必需如此限定。

Claims (2)

1.一种用于吸声衬底上的透声涂层的配制物，其包括水分散性粘合剂和相对大的填料颗粒，并且其特征是高颜料体积浓度、高粘度、高剪切稀化和快速干燥，以使得所述配制物能够以微滴形式喷涂，从而在相互接触时保持它们的特性，所述颜料体积浓度经选择以提供能够砂磨平整的表面，所述表面能够使用180粒度(CAMI)砂纸、经由约85个循环的经修改的ASTM D2486(方法A)标准测试砂磨平整。
2.一种在吸声衬底上形成透声涂层的方法，其包括：在所述衬底上喷涂多个微滴层，让所述层在后续层涂覆之前至少部分地干燥，所述微滴含有足以使其与邻近微滴不发生接触的部分以提供延伸穿过所述涂层的整个厚度的互连孔隙，让所述涂层完全干燥，然后将所述涂层砂磨平整。
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