CN116145882A - 矿物纤维类吊顶板 - Google Patents

矿物纤维类吊顶板 Download PDF

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Publication number
CN116145882A
CN116145882A CN202310303232.3A CN202310303232A CN116145882A CN 116145882 A CN116145882 A CN 116145882A CN 202310303232 A CN202310303232 A CN 202310303232A CN 116145882 A CN116145882 A CN 116145882A
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CN
China
Prior art keywords
mat
basalt
mineral
thickness
slag
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Pending
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CN202310303232.3A
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English (en)
Inventor
W·A·弗兰克
M·T·兰登
W·栾
M·W·布朗
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USG Interiors LLC
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USG Interiors LLC
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Publication of CN116145882A publication Critical patent/CN116145882A/zh
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Abstract

一种隔音板，具有湿法成网矿物纤维底垫、粘附到所述底垫且由光反射透气涂层覆盖的无纺多孔纤维玻璃膜，所述底垫的重量的至少90％包括矿棉和粘合剂，所述粘合剂的重量小于矿物纤维的重量的1/11，所述底垫的密度介于约11.4磅/立方英尺与约14.2磅/立方英尺之间，所述矿物纤维的平均直径介于4.5微米与8.3微米之间，所述底垫、膜以及涂层的复合结构呈现良好NRC和CAC性能值。

Description

矿物纤维类吊顶板
本案是本申请人于2016年4月28日提交的申请号为201680076488.3、题为“矿物纤维类吊顶板”的专利申请的分案申请，该母案的全部内容通过引用并入本分案。
本申请是2016年1月14日提交的第14/995,213号申请的部分接续。
背景技术
本发明涉及矿物纤维类隔音吊顶板。
术语矿物纤维及矿棉在本文中可互换使用。广泛用于悬挂式吊顶中的隔音板根据其声波吸收和声波传递特性定级。在行业中，利用降噪系数(noise reductioncoefficient；NRC)测量声波吸收率，所述降噪系数应在0.55以上从而认定为具有可接受的隔音特性。高性能板通常具有大约0.85或更大的NRC评分。声波穿透率测量为吊顶衰减等级(ceiling attenuation class；CAC)，且可接受的值是至少23。
通用类型的吊顶板具有在熟知的水毡制或湿法成网过程中主要由矿棉制造的底垫或芯材。矿棉、粘合剂以及较小量的其它固体在稀释水浆料中混合且沉积于移动、有孔的筛网上。在混合过程期间，矿棉纤维往往会滚成球且形成节结，当沉积于形成垫的筛网上时所述节结很大程度上保持其特征。在筛网上水与固体以重力和真空方式分离，且随后加热并风干固体以形成硬质底垫。
惯例是用砂纸磨光干燥的水毡制底垫的一侧，以便于无纺纤维玻璃纱布或膜的粘附性附接。通常对膜进行喷涂或涂布以改进其光反射。
常规矿棉类湿法成网底垫的密度范围介于约14磅/立方英尺到约16.5磅/立方英尺之间。这一密度范围的下限已至少部分地受限于在制造具有足够的低密度和湿强度的垫中难以在整个制造过程中移动时维持垫的完整性，特别当底垫用于适当低厚度的制品时。通常用于本申请中的矿物纤维的平均纤维直径是3.5微米到4.1微米。
发明内容
本发明涉及在噪音吸收率和噪音穿透率两者中实现相对高隔音特性的矿物纤维吊顶板。发明性构造表征为由与传统上用于本申请中的矿物纤维直径相比相对大的平均直径矿棉纤维制造的低密度湿法成网底垫。相对大的纤维直径已发现能在沉积并形成于水毡制或湿法成网过程的金属丝筛网上时使底垫的蓬松度或自由体积增大。增大的蓬松度容许研发具有相对低密度和空气流动阻力的底垫。结果是即使在低厚度(即相对薄)的成品板情况下，也有高降噪系数(NRC)潜力。
利用所公开的底垫制造的且无背涂层的吊顶板呈现有用的吊顶衰减等级(CAC)测量值。此外，所公开的吊顶板构造可在仅有限地损失NRC的情况下通过涂覆粘土类背涂层来容易地且低成本地调整以提高CAC性能。
本发明还包括下列项目：
1.一种用于主要由矿物纤维以及淀粉和/或乳胶粘合剂制造的隔音板的湿法成网底垫，所述矿物纤维由炉渣形成且自然岩石含量超出6重量％，所述矿物纤维的直径介于4.5微米与8.3微米之间，所述底垫的密度介于11.4磅/立方英尺与14.2磅/立方英尺之间。
2.根据项目1所述的湿法成网底垫，其中所述自然岩石是花岗石。
3.根据项目2所述的湿法成网底垫，其中在所述矿物纤维中所述花岗石含量是约17重量％。
4.根据项目1所述的湿法成网底垫，其中所述自然岩石是玄武岩。
5.根据项目4所述的湿法成网底垫，其中在所述矿物纤维中所述玄武岩含量介于约20重量％与约40重量％之间。
6.根据项目1所述的湿法成网底垫，其中所述矿物纤维是常规纺丝工艺的制品，在所述常规纺丝工艺中使用除尘液且所述矿物纤维携带残余的除尘液。
7.一种具有形成大体上全部的板厚度的湿法成网矿物纤维底垫的低厚度隔音板，无纺多孔纤维玻璃膜粘附到所述底垫的一侧且在远离所述底垫的一侧上由光反射透气涂层覆盖，所述底垫的重量的至少90％包括矿棉和粘合剂，所述粘合剂的重量小于所述矿物纤维的重量的1/11，所述底垫的密度介于约11.4磅/立方英尺与约14.2磅/立方英尺之间，所述矿物纤维的平均直径介于4.5微米与8.3微米之间，所述底垫的厚度小于11/16英寸，当复合结构的厚度标称地是1/2英寸时，所述底垫、膜以及涂层的所述复合结构呈现约0.60的NRC和约23的CAC，且当所述复合结构的所述厚度标称地是5/8英寸时，NRC是约0.75且CAC是约24。
8.根据项目7所述的低厚度隔音板，其中所述矿物纤维由铁高炉炉渣和花岗石的混合物制造，花岗石的重量百分比超出6％。
9.根据项目7所述的低厚度隔音板，其中所述矿物纤维由铁高炉炉渣和玄武岩的混合物制造。
10.根据项目9所述的低厚度隔音板，其中所述玄武岩的范围介于所述矿物纤维重量的约20％与约40％之间。
11.根据项目7所述的低厚度隔音板，其中所述矿物纤维喷雾式涂布有防尘液，在湿法成网工艺中所述防尘液用以促进低密度底垫的制造。
12.一种具有形成大体上全部的板厚度的湿法成网矿物纤维底垫的高性能隔音板，无纺多孔纤维玻璃膜粘附到所述底垫的一侧且在远离所述底垫的一侧上由光反射透气涂层覆盖，所述底垫的重量的至少90％包括矿棉和粘合剂，所述粘合剂的重量小于所述矿物纤维的重量的1/11，所述底垫的密度介于约11.4磅/立方英尺与约14.2磅/立方英尺之间，所述矿物纤维的平均直径介于4.5微米与8.3微米之间，所述底垫的厚度大于5/8英寸，所述底垫的背面由声学反射材料覆盖，所述板呈现至少0.85的NRC。
13.根据项目12所述的高性能隔音板，其中所述声学反射材料是粘土涂层。
14.根据项目12所述的高性能隔音板，其中所述矿物纤维是炉渣和花岗石的混合物，所述花岗石超出所述纤维的6重量％。
15.根据项目12所述的高性能隔音板，其中所述矿物纤维是炉渣和玄武岩的混合物，所述玄武岩介于所述矿物纤维的约20重量％与约40重量％之间。
附图说明
图1是体现本发明的隔音吊顶板的透视图；以及
图2是吊顶板的断片式截面视图。
具体实施方式
图1说明根据本发明建构的高性能隔音吊顶板10。所图示的板是在其主要表面上标称地测量为2英尺×2英尺的方形。涵盖其它常规表面大小，如2英尺×4英尺。所属领域的技术人员将理解，本文中所引用的尺寸可改变为依照行业公制标准的那些等效尺寸。
板10包括当安装板时在底垫朝向室内的一侧上由无纺膜或纱布12覆盖的底垫或芯材11。膜12可喷涂在室内侧上且底垫的背侧可具有任选的背涂层。
底垫11由主要由矿物纤维和粘合剂组成的基于水的稀释浆料形成。借助于实例，底垫固体组分(按重量百分比计)可大约是：
85％到95％、优选地约91.8％，矿棉，包含普通丸粒含量；
0％到3％、优选地约1.5％，石膏；
5％到10％、优选地6.7％，一或多种粘合剂，例如3.8％乳胶、2.9％淀粉。
可包含少量的其它材料，如杀生物剂或阻燃剂。总共，固体可在其余重量包括水的情况下相当于浆料的重量的4.2％到4.5％。
从前述内容将理解，底垫主要是矿物纤维且矿物纤维和粘合剂组合起来优选地超过固体的90％，且粘合剂优选地介于矿棉的重量的约1/11与1/15之间。
垫形成于行业中熟知的常规湿法成网或水毡制过程中。底垫组分在稀释水浆料中彻底混合，所述稀释水浆料随后沉积于移动、有孔的筛网上成高度受控制的一层。通过筛网利用重力和真空从固体排干水。利用另一上覆筛网和/或滚轮在筛网上略微按压静态湿底垫成所需厚度，且随后在烘炉中干燥。粘合剂用以将矿物纤维固定在一起呈硬质多孔块状物。
按常规，底垫的一侧是碾磨平坦的，以便于无纺纤维玻璃膜粘附性接合到底垫。适合的膜的实例是欧文斯康宁膜荷兰私人有限公司(Owens Corning Veil NetherlandsB.V.)制造的制品CH52且描述如下：
面积重量-125g/m2
空气孔隙度-在100Pa下1900l/m2/s
在不明显改变膜或底垫的空气流动特性的情况下，适合的粘附剂用于将膜粘附到底垫。粘附剂可以是可商购的基于水的制品，如以3.6g/ft2到3.9g/ft2的比率应用的由HenkleTM出售的AquenceTM PL114A。膜的外表面通常使用例如11.2g/ft2的固体涂层(主要TiO2)由多孔或非阻挡光反射涂层或涂料覆盖以达成例如0.87的所需光反射率(LR)，或约15g/ft2的固体涂层，90的LR。膜的主要功能是美观性，从而提供相对均匀的平坦表面以用于光反射涂层。LR涂层和膜不明显影响底垫的隔音特性。此外，当板安装于吊顶格栅中且支撑于其周界处时，膜用以阻挡板的下垂。
根据本发明的一个方面，如标称1/2英寸和5/8英寸厚度板的低厚度隔音吊顶板构造由具有优选地约10.0磅/立方英尺到约14.5磅/立方英尺且更优选地约11.4磅/立方英尺到约14.2磅/立方英尺的密度的湿法毡制矿物纤维类底垫制造。
为在低厚度制品中获得这些相对低的密度，已发现需要修改常规矿棉调配物且表面上反直觉地，根据常规使用的纤维直径来增大纤维直径。如上所陈述，典型的常规矿棉平均直径通常介于3.5微米与4.1微米之间。本发明涵盖4.5微米到8.3微米的平均矿棉纤维直径，其中目标是6微米且所述直径为所制造的随机长度。
典型的现有技术矿棉调配物的重量百分比是94％炉渣和6％花岗石岩石。按重量百分比计用于本发明中的新的炉渣/自然岩石矿棉调配物包含83％炉渣、17％花岗石岩石下的“高花岗石”矿棉以及80％炉渣、20％玄武岩岩石下的玄武岩矿棉。潜在的其它调配物包含60％炉渣、40％玄武岩岩石的玄武岩矿棉。前述的重量百分比比率可通过例如使花岗石或玄武岩增加或减小10％且使炉渣减小或增加相同百分比而变化。A包含玄武岩的矿物纤维组成物具有比花岗石/炉渣组成物更高的弹性或回弹性且是当前优选的。
如本文中所使用的术语“炉渣”是具有通常如国家炉渣协会(National SlagAssociation)(U.S.A.)所报告的主要化学组分的铁高炉炉渣，亦即：
铁高炉炉渣中的主要化学组分
Figure BDA0004145880040000051
近年来，铁高炉炉渣表征为矿物质的组合：
黄长石(镁黄长石和钙铝黄长石)[Ca2MgSi2O7-Ca2Al2SiO7]
镁硅钙石，钙-镁-硅酸盐[Ca3MgSi2O8]
钙-硅酸盐[CaSiO3]
钙镁橄榄石[CaMgSiO4]
粗略近似的比例是：
黄长石约70％，其余方面(镁硅钙石、钙-硅酸盐以及钙镁橄榄石)构成另外30％。
当组合起来时，这些组分通常作为具有以下通式的同构混合物存在：
Ca2(MgFeAl)(SiAl)2O7。
已发现的是，当沉积于底垫制造过程的移动金属丝筛网上时，使用以上阐述的底垫调配物的4.5微米到8.3微米的平均直径的矿物纤维产生较高蓬松度的浆料固体。这种高蓬松度使得底垫的最终密度较低。
在11/16英寸或小于标称厚度的低厚度隔音吊顶板中，约11.4磅/立方英尺到14.2磅/立方英尺的湿法形成的矿物纤维类底垫密度提供极佳NRC值和有用的CAC值两者。可通过涂覆背涂层(通常粘土固体和水)修改板的性能，以在NRC性能仅小有损失的情况下改进CAC值。在具有所描述的膜和LR涂料的板中，这些关系阐述于以下制品描述表中的E列、F列以及G列处，其中矿物纤维是80％炉渣和20％玄武岩。
制品描述表
Figure BDA0004145880040000061
平均直径大约6微米(即介于4.5微米与8.3微米之间)的矿物纤维用以出于两个原因来提供寻求具有矿物纤维底垫的低厚度高性能隔音板的解决方案。首先，如上所陈述，已发现大于普通纤维直径在纤维垫形成于湿法毡制过程的移动金属丝筛网上时会增大纤维垫的蓬松度。其次，较大直径提供在沿生产线进行加工时用以使底垫保持结构上在一起的提高的个别矿物纤维拉伸强度，在所述生产线中底垫在传送机滚轮和/或传送带之间转移且用砂纸磨光底垫并修整边缘。
已发现通过使用适当化学喷雾涂层(有时称为除尘液)有助于底垫中的高蓬松度，以在常规纺丝过程中制造矿物纤维时使矿物纤维从空气流中沉淀出来。以例如矿物纤维的重量的0.5％到1.0％的比率喷涂在矿物纤维上作为喷雾的聚乙二醇(PEG)水溶液(13.5％PEG，86.5水)用以提升在湿法毡制过程中矿物纤维的蓬松性能。代替水和PEG除尘喷雾，适合的矿物油可用于除尘功能。油状物应具有低的VOC排放且具有高的闪点和燃点，其中高温干燥器用于干燥底垫。这类油状物的实例具有以下特征：ISO等级100，AGMA号3，SAE齿轮油号80，SAE号30，在40℃/100℃下粘度cSc-95/11，粘度指数101，闪点500℉/260℃燃点555℉/291℃。可使用对矿物纤维的重量来说0.5重量％到1.0重量％的矿物油的比率。咸信，残余的除尘液存在于本文中所描述的最终底垫制品中。
在低厚度板构造中，所公开的底垫意外地呈现NRC和CAC两者的独特的和所需的隔音特性。通常相比于发明性底垫在例如具有相同厚度的纤维玻璃类底垫中不可获得这种性能。
根据本发明的另一方面，以上所公开的炉渣/玄武岩矿物纤维和底垫调配物可用于制造具有高降噪系数(NRC)和吊顶衰减等级(CAC)值两者的高性能隔音面板。这可通过增加底垫的厚度(thickness/caliper)以及通过用声学反射材料对底垫进行背面涂布来实现。如所描述，可维持粘附地附接、喷涂的膜。
制品描述表中的A列和B列指示呈较大厚度大小的所描述的炉渣/玄武岩底垫组成物(80％炉渣，20％玄武岩)的特征。常规现有技术炉渣/花岗石制品表征于C列和D列中。A列和B列中的NRC值与C列和D列中的值的比较展示在本发明的炉渣/玄武岩调配物中NRC相对于现有技术调配物显著增大。B列中的制品有意地制造有比其它炉渣/玄武岩制品(A列、E列、F列以及G列)相对更高的底垫密度，从而调整用于所需较高的CAC。
在制品描述表中记录的声学反射背涂层含量水平可应用于两个连续涂层中。在干燥之前的一或多个背涂层包括高岭粘土和水，在第二涂层中具有约5重量％的少量乳胶。F列的制品由出于外观而涂布的单一背涂层覆盖。表面涂层是主要为二氧化钛的隔音的非阻挡涂料，且可应用于两个涂层中。
本文中所描述的炉渣/玄武岩矿物纤维底垫调配物在湿法铺设或毡制过程中呈现改进的蓬松度，以使得有可能铺设具有较少纤维和其它浆料材料的初始目标预压缩厚度，且因此密度较小。将符合具有较少材料的最小目标厚度的炉渣/玄武岩纤维底垫按压成最终、研磨前的设计厚度，其中材料含量相同地减小。由于改进的排水和下降的密度，炉渣/玄武岩矿棉的使用可获得改进的生产线速度(主要由于干燥器能力)。在炉渣/玄武岩矿棉的情况下，对于给定体积的底垫，存在待干燥的较少块状物和通过底垫的较佳空气流动，且由此干燥器负荷较小。
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，除非以下权利要求书必要地如此限定。

Claims (5)

1.一种用于主要由矿物纤维以及淀粉和/或乳胶粘合剂制造的隔音板的湿法成网底垫，所述矿物纤维是铁高炉、常规纺丝的炉渣/自然岩石矿棉调配物，其按重量百分比计包括从80％炉渣、20％玄武岩岩石下的玄武岩矿棉到60％炉渣、40％玄武岩岩石的玄武岩矿棉，前述的重量百分比比率通过例如使玄武岩增加或减小10％且使铁高炉炉渣减小或增加相同百分比而变化，所述矿物纤维具有介于4.5微米与8.3微米之间的相对大的直径，所述底垫的密度介于11.4磅/立方英尺与14.2磅/立方英尺之间，所述底垫的厚度小于11/16英寸，所述底垫能够构造具有面网和涂层的低厚度隔音板，当复合结构的厚度标称地为1/2英寸时，其表现出约0.60的NRC和约23的CAC，并且当复合结构的厚度标称地为5/8英寸时，其表现出约0.75的NRC和约24的CAC。
2.一种具有形成大体上全部的板厚度的湿法成网矿物纤维底垫的低厚度隔音板，不织布多孔纤维玻璃面网粘附到所述底垫的一侧且在远离所述底垫的一侧上由光反射透气涂层覆盖，所述底垫的重量的至少90％包括矿棉和粘合剂，所述粘合剂的重量小于所述矿物纤维的重量的1/11，所述底垫的密度介于约11.4磅/立方英尺与约14.2磅/立方英尺之间，所述矿物纤维是铁高炉炉渣/自然岩石矿棉的常规纺丝的调配物，其按重量百分比计包括从80％炉渣、20％玄武岩岩石下的玄武岩矿棉到60％炉渣、40％玄武岩岩石的玄武岩矿棉，前述的重量百分比比率通过例如使玄武岩增加或减小10％且使炉渣减小或增加相同百分比而变化，且平均直径介于4.5微米与8.3微米之间，所述底垫的厚度小于11/16英寸，当复合结构的厚度标称地是1/2英寸时，所述底垫、面网以及涂层的所述复合结构呈现约0.60的NRC和约23的CAC，且当所述复合结构的所述厚度标称地是5/8英寸时，NRC是约0.75且CAC是约24。
3.根据权利要求2所述的低厚度隔音板，其中所述矿物纤维喷雾式涂布有防尘液，在湿法成网工艺中所述防尘液用以促进低密度底垫的制造。
4.一种具有形成大体上全部的板厚度的湿法成网矿物纤维底垫的高性能隔音板，不织布多孔纤维玻璃面网粘附到所述底垫的一侧且在远离所述底垫的一侧上由光反射透气涂层覆盖，所述底垫的重量的至少90％包括矿棉和粘合剂，所述粘合剂的重量小于所述矿物纤维的重量的1/11，所述底垫的密度介于约11.4磅/立方英尺与约14.2磅/立方英尺之间，所述矿物纤维的平均直径介于4.5微米与8.3微米之间，所述底垫的厚度大于5/8英寸，所述底垫的背面由声学反射材料覆盖，所述板呈现至少0.85的NRC，所述矿物纤维是炉渣/自然岩石矿棉调配物，其按重量百分比计包括从80％炉渣、20％玄武岩岩石下的玄武岩矿棉到60％炉渣、40％玄武岩岩石的玄武岩矿棉，前述的重量百分比比率通过例如使玄武岩增加或减小10％且使炉渣减小或增加相同百分比而变化。
5.根据权利要求4所述的高性能隔音板，其中所述声学反射材料是粘土涂层。
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