CN1479699A - 具有改良的声音吸收值的双层吸音天花板 - Google Patents

具有改良的声音吸收值的双层吸音天花板 Download PDF

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CN1479699A
CN1479699A CNA018056067A CN01805606A CN1479699A CN 1479699 A CN1479699 A CN 1479699A CN A018056067 A CNA018056067 A CN A018056067A CN 01805606 A CN01805606 A CN 01805606A CN 1479699 A CN1479699 A CN 1479699A
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M·A·拜戈
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Abstract

一种具有改良的声音吸收值和双层吸音材料的吸音天花板。基础板坯层中既没有矿棉也没有低矿棉含量。表面层具有在天花板有或者没有孔或龟裂的情况下提供改良的声音吸收值的高矿物棉含量。双层吸音天花板具有至少大约为0.5的噪声降低系数(NRC)值。

Description

具有改良的声音吸收值的双层吸音天花板
本发明的技术领域
本发明涉及具有改良的声音吸收值的吸音天花板。更具体地说，这项发明涉及无论面板有无孔或龟裂都提供改良的声音吸收值的具有低或无矿棉的基础板坯层(mat layer)和高矿棉表面覆盖层的双层吸音天花板。本发明还涉及采用高速水粘结方法制造的双层吸音板。图案可以在面板干燥之前被加上去(湿端面压花)，或者图案可以在干燥之后的面板上形成。
本发明的现有技术
稀释的矿棉水分散体和轻絮团的水粘结是用来制造吸音天花板的大批量生产方法。在该方法中，矿棉、轻絮团、粘合剂和其它需要的或必要的组分的分散体流到诸如Fourdrinier或Oliver板坯成形机的那种用于脱水的移动式小孔支撑网上。该分散体首先凭借重力然后凭借真空抽吸脱水。在真空脱水之后，湿板坯在热对流干燥炉中干燥，然后经过干燥的板坯被切割到想要的镶板或面板尺寸。如果需要，镶板或面板可以用涂料涂上一层面漆。
吸音天花板也可以用在美国专利第1,769,519号中描述的那类湿浆料模塑或浇注的方法制造。按照这种方法，包括粒状的矿棉纤维、填料、着色剂和粘合剂(例如，淀粉凝胶)的模塑组合物是为模塑或浇注面板准备的。该组合物被放在已用纸或金属箔覆盖的适当的盘子上，然后用刮板或滚筒将该组合物平整到需要的厚度。装饰性表面(例如，长裂缝)可以用刮板或滚筒提供。然后，装满矿棉组合物的托盘被放在炉子中干燥或固化。
在1993年10月5日授权的美国专利第5,250,153号中，揭示了一种用来通过形成矿棉纤维和/或絮团以及靠阴离子稳定的乳胶粘合剂的水稀释分散体在小孔支撑网上制造矿棉镶板的方法。粘合剂是通过添加少量的阳离子絮凝剂沉积到矿棉纤维上的。实质上所有的粘合剂乳胶都变成与矿棉纤维结合的。湿板坯可以凭借让能够维持其结构的热空气通过板坯被很快地干燥。
在1996年9月24日授权的我的美国专利第5,558.710号中，我揭示了一种能够代替全部或一部分正常地存在于吸音天花板中的矿棉的石膏/纤维素纤维组合物。这种石膏/纤维素纤维组合物与轻絮团物质和粘合剂合并，形成在制造吸音天花板的水粘结方法中使用的组合物。
如同在美国专利第5,558,710号的实施例1中揭示的那样，水粘结方法被用来制造吸音面板。在板坯成形期间使进料浆料保持4％的固含量，而这个4％固含量的稠度也在制造对照面板时使用。采用100％矿物纤维(即没有石膏/木纤维)的对照面板具有下列配方：
    重量％
    矿物纤维     37.58
    膨胀珍珠岩     34.83
    新闻纸     15.91
    CTS-1粘土     3.54
    淀粉     8.01
    絮凝剂     0.06
    表面活性剂     0.08
对照面板的试样是用阻抗管法对NRC(噪声降低系数)进行测试的。试样上没有孔、龟裂或油漆。对照面板具有仅为0.434的平均NRC值。
一般地说，用水粘结方法制成的吸音面板有坚硬的表面，这种表面没有良好的吸收声音的特性。吸收声音实质上是通过在表面上形成龟裂和/或打孔来增加NRC值得到改善的。然而，许多购买者为了它的美学外表更喜欢光滑的无孔的吸音天花板。
如同在美国专利第5,250,153号中揭示的那样，平均的NRC等价于市售的浇注型天花板的吸音天花板可以这样制造，即采用阴离子稳定的乳胶粘合剂和阳离子絮凝剂将乳胶粘合剂结合到矿物纤维材料上。在用这种方法制造的吸音面板中，矿物纤维构成干的固体总含量的大约50％或更多，优选从吸音板的大约60wt％到大约95wt％。然而，用这种方法制造的面板与具有淀粉粘合剂的水粘结面板相比较是相当软的。此外，用乳胶粘合剂制造的面板具有比较低的结构强度和至少大约1/2英寸的厚度，而且时常有编织织物应用于它以增加强度。这些吸音面板确实有光滑的表面和来源于较高的矿棉含量的较高的NRC值。
矿棉吸音面板是多孔的，这对于提供良好吸音作用是必不可少的。现有技术(美国专利第3,498,404、5,013,405和5,047,120号)还揭示了诸如膨胀珍珠岩之类的矿物填料可以被并入组合物，以改善吸音性能。
这项发明的目的是提供一种具有双层吸音材料(两者都包含矿物纤维)的或者具有无矿物纤维的基础板坯的吸音面板。
这项发明的另一个目的是提供具有比较低的矿物纤维含量或没有矿物纤维的水粘结基础板坯和具有高矿物纤维含量的表面层，以便形成具有改良的吸音性能的吸音面板。
这项发明进一步的目的是提供一种具有光滑的无孔表面和良好的吸音性能的双层吸音天花板。
这项发明再进一步的目的是提供一种具有至少大约为0.50的声音吸收值(NRC)的双层吸音天花板。
鉴于下面的描述，这些和其它的目的对于熟悉这项技术的人将是明显的。
本发明的概述
业已发现具有改良的声音吸收值(NRC)的双层吸音天花板可以用水粘结方法来制造，其中基础板坯层有比较低的矿物纤维含量，而具有高矿物纤维含量的表面层覆盖在基础板坯上。基础板坯层是由低矿物纤维含量或无矿物纤维的材料制成的，它具有比较低的NRC值，除非它的表面被打孔和/或龟裂。厚度大约为1/4英寸或其以下的富含矿物纤维的表面层在这样的厚度下也具有比较低的NRC值。业已发现这两种低NRC值材料可以结合起来，提供具有高NRC值的双层天花板。本发明的详细说明
这项发明的吸音天花板是以下述发现为基础的，即两种NRC值比较低的吸音材料可以结合起来，形成具有卓越的声音吸收值(NRC)的双层吸音天花板。这些天花板是用水粘结方法制造的，该方法将形成基础板坯层和富纤维表面层两者。在实施这种方法时，使用两个网前箱把吸音材料输送给生产线。
使用一个网前箱把矿物纤维含量比较低(按矿物纤维的重量少于大约50％)或不包含矿物纤维的基础板坯材料输送到诸如Fourdrinier或0liver板坯成形机的那种用于脱水的移动式小孔支撑网上。在通过支撑网凭借重力除掉水之后，可以通过把真空应用于湿的基础板坯除去额外的水，但是鉴于网前箱中的基础板坯材料的稠度、线速度和其它考虑，在富含纤维的表面覆盖材料沉积到基础板坯上之前为了脱水使用真空可能不是必要的。基础板坯材料基本上由矿棉纤维、膨胀珍珠岩、纤维素纤维、淀粉粘合剂和石膏组成，优选的是它们能按下述的数量存在并且具有至少大约30wt％的膨胀珍珠岩：
    组分     重量％
    矿棉纤维     5-25
    膨胀珍珠岩     30-60
    纤维素纤维     10-21
    淀粉粘合剂     4-9
    石膏     3-30
基础板坯材料在支撑网上初步脱水之后，仍然潮湿的基础板坯在用来压制板坯的压机轧辊之下通过，从而除去较多的水和确定湿的基础板坯的厚度。一般地说，湿的基础板坯的厚度恰好在沉积富含纤维的表面层之前可以在大约1英寸到大约2.5英寸之间变动。优选的是完全干燥的基础板坯具有在大约0.25英寸到大约0.625英寸之间变动的厚度。
如果需要或有必要增加双层天花板的强度，玻璃纤维织物可以在沉积富含纤维的表面层之前被放到湿的基础板坯上。玻璃纤维织物既可以是纺织的又可以是无纺的。如果使用玻璃纤维织物，通常优选的是把它放在基础板坯材料和富含纤维的表面层之间，然而，如果需要，织物可以被放在富含纤维的表面层之上或者与基础板坯材料的背部接触，在这种情况下来自网前箱的基础板坯浆料将沉积在织物上。
为了如同在美国专利第5,250,153号中揭示的那样使乳胶粘合剂沉积到矿棉纤维上，富含纤维的表面层基本上由矿棉纤维、石膏、粘土填料、乳胶粘合剂、淀粉粘合剂和絮凝剂组成。这些组分可能是优选按下述的数量存在的：
    组分     重量％
    矿棉纤维     70-90
    珍珠岩     0-15
    纤维素纤维     3-7.5
    石膏     1-15
    粘土填料     0-12
    乳胶粘合剂     3-9
    淀粉粘合剂     3-9
    絮凝剂     0.05-0.1
富含纤维的表面材料是按照在美国专利第5,250,153号中揭示的方法制备的，其中阴离子稳定的乳胶粘合剂是通过把少量的诸如阳离子聚丙烯酰胺之类的絮凝剂添加到浆料中沉积到或结合到矿物纤维上的。按照这项发明，富含纤维的浆料包含非常大量的矿棉纤维(至少大约75wt％)和极少的或甚至没有膨胀珍珠岩。来自第二个网前箱的富含纤维的材料沉积在基础板坯上，形成凭借把真空应用于湿的双层材料和让湿的双层材料在压机轧辊之下通过来脱水的双层材料。压机轧辊帮助除去一些水。富含纤维的表面是有纹理的，而且双层材料的厚度是在图案/纹理轧辊之下确定的。双层材料随后被送到炉子中，完成干燥过程和使淀粉粘合剂和乳胶粘合剂固化。
当完全干燥后被切割成天花板的时候，双层材料有光滑的或有纹理的表面，该表面富含矿棉纤维并且是无孔的。一般地说，优选的是干燥后双层天花板具有在大约0.5英寸到大约1英寸范围内变动的总厚度，其中富含纤维的表面层的厚度在大约0.125英寸到大约0.5英寸范围内变动。富含矿棉的表面层的厚度可以从大约0.5英寸增加到大约0.625英寸，以便提供比较高的NRC值。
在让双层材料在炉中干燥之前，优选把“湿端面涂层”涂到富含矿物纤维的光滑的无孔表面上。可以喷涂一种或多种涂料。业已发现涂料的应用实际上增大NRC值，因为不涂油漆的表面倾向于反射声音，因此具有比较低的NRC(噪音吸收系数)。
其它的组分也可以存在于基础板坯或富含纤维的表面层或这两层中。这类组分的实例包括染料、颜料、无机填料、抗氧剂、表面活性剂、防水剂、阻燃剂等。
如上所述，石膏(硫酸钙二水合物)是优选存在于两层之中的。石膏在包括基础板坯和富含纤维层两者的进料材料的水相浆料中是溶解的。在处理浆料时石膏的溶解度使石膏能在浆料配方中起絮凝剂的作用。絮凝功能在混合期间提供存在于配方中的细小粒子(例如，粘土、石膏、珍珠岩和淀粉)的均匀分布。这种絮凝功能有助于防止细小的高密度粒子移向板坯的底部。此外，石膏有助于使矿棉纤维分散到水相浆料中。
淀粉粘合剂也存在于基础板坯和富含纤维的表面层两者之中。优选的是以凝胶的形式使用淀粉，该凝胶是这样制备的：将淀粉颗粒分散在水中并且给浆料加热，直到淀粉被完全煮熟并且浆料变成粘稠的凝胶。如果粘合剂是玉米淀粉，烹煮温度可以在大约180°F(82℃)到大约195°F(90℃)的范围内变动。应该注意，淀粉也可以在不事先把淀粉煮成凝胶的情况下作为粘合剂使用。此外，淀粉可以以仅仅通过把它添加到水中不需要煮它就变成凝胶的预先凝胶化的形式被使用。
下面明确提出的实施例进一步说明本发明的各种明确的实施方案。  除非另有规定，所有的数量都是在干的固体的总重量的基础上表示成按重量计算的份数。当然，人们应该理解这些实施例仅仅是为了举例说明，而不是构成对本发明的限制。
                         实施例1
在市面上购买的富含矿物纤维的吸音天花板的试样被用来确定用于薄层(大约1/4英寸厚)材料的声音吸收性能(NRC值)。这样的材料没有可以以这样的薄层用水粘结方法制作的足够的结构强度，因此，天花板被制成具有大约0.7英寸的厚度和大约16磅/立方英尺的密度。这种面板有以大约24克/平方英尺的覆盖率涂布的35-C粘土的背面涂层(干的)，该涂层使面板的密度增加大约0.85磅/立方英尺。薄层试样是从面板的背面切割下来的。试样1-4具有下述配方：
    试样1&2     试样3&4
    重量％     重量％
    矿棉纤维     88.9     91.8
    石膏     1.5     1.5
    粘土涂料     0     0
    乳胶粘合剂     6.6     4.7
    淀粉粘合剂     3.0     2.0
    絮凝剂     0.07     0.07
试样3没有粘土背面涂层。试样被切割成12英寸的正方形用于测试。下面的NRC(阻抗管)值是被记录下来的：
    试样     厚度(英寸)     实际的NRC
    1-a     0.225     0.23
    1-b     0.225     0.23
    2-a     0.25     0.33
    2-b     0.25     0.33
    3-a     0.25     0.21
    3-b     0.25     0.23
    4-a     0.25     0.32
    4-b     0.25     0.30
这些数据表明在大约1/4英寸的厚度中富含纤维的材料具有非常低的NRC值。
                         实施例2
这个试验的目的是确定在富含纤维的覆盖层配方中不同数量的乳胶粘合剂的作用，尤其是它对干的板坯表面硬度的影响。基础板坯具有下述的配方：
    重量％
矿棉纤维     36.6
淀粉凝胶粘合剂(预先煮过的)     6
粘土(CTS-2)     5
纸纤维     14
珍珠岩     38.4
标准的水粘结方法被用来制作基础板坯，其中储料有大约5.8％重量固含量的稠度。线速度是大约30英尺/分钟。干燥的基础板坯具有大约0.5英寸的厚度。
富含纤维的覆盖材料具有下述的配方：
         重量％
    A     B
矿棉纤维     86.4     86.4
淀粉凝胶粘合剂(预先煮过)     6     3
乳胶(Dow XU31518.00)     3     6
粘土(CTS-2)     2.3     2.3
石膏     2.3     2.3
絮凝剂     0.07     0.07
矿棉、淀粉、乳胶粘合剂、粘土和石膏合并后具有173.6磅的总重量并且被添加到500加仑水中，提供按固体的重量计算大约4％的原料稠度。絮凝剂随后被添加进去，与原料充分混合之后，使乳胶粘合剂沉积在矿物纤维上。原料是以大约125加仑/分钟的速度通过4英尺宽的网前箱输送的。
NRC值是用阻抗管法确定的，结果如下：
覆盖层配方 总厚度(英寸) 密度(磅/立方英尺)     NRC
    A     0.731     16.3     0.53
    B     0.725     16.5     0.51
干燥的面板表面(两个配方)都是硬的。
                           实施例3
在这个试验中，对纸纤维在富含纤维的覆盖层配方中的用途进行评估。基础板坯使用与实施例2相同的配方以及相同的标准水粘结方法。
富含纤维的覆盖层材料具有下述配方：
         重量％
    A     B
矿棉纤维     82.6     85
淀粉凝胶粘合剂(预先煮过)     2.9     6
乳胶粘合剂(Dow，XU31518.00)     3.9     0
粘土(CTS-2)     3.9     2
石膏     1.9     2
纸纤维     4.8     5
絮凝剂     0.07     0
在试验A中，干燥前在生产线上涂布湿端面涂层。标准的涂料(18％的固体)被涂上去，其中干面板上的覆盖率等于10克/平方英尺。
NRC值是用阻抗管法确定的，结果如下：
覆盖层配方 总厚度(英寸) 密度(磅/立方英尺)     NRC
    A     0.676     19.6     0.54
    B     0.683     17.8     0.52
在覆盖层配方中纸纤维的用途是在没有对NRC值的不利影响的情况下改善表面平滑度、湿端面的纹理加工性和湿强度。
                       实施例4
这个试验评估较大量的石膏在覆盖层配方中的用途。基础板坯使用与实施例2相同的配方以及相同的标准水粘结方法。
富含纤维的覆盖层材料具有下述的配方：
        重量％
    A     B
矿棉纤维     83.1     83.1
淀粉凝胶粘合剂(预先煮过)     2.9     2.9
乳胶粘合剂(Dow，XU31518.00)     2.9     2.9
石膏     11.1     11.1
絮凝剂     0.07     0.07
在两个试验中，湿端面涂料(18％固体)是在生产线上涂布的。干面板上的涂层覆盖量等于10克/平方英尺。在试验B中，喷涂涂料(55％固体)被涂布到干面板上，覆盖量等于8.5克/平方英尺。
NRC值是用阻抗管法确定的，结果如下：
  试验 总厚度(英寸) 密度(磅/立方英尺)     NRC
    A     0.690     18.0     0.56
    B     0.710     18.2     0.51
增大覆盖层配方中的石膏用量将增加表面的硬度和平滑度。
                        实施例5
这些试验是为了评估各种各样的面板精饰方法而完成的。基础板坯采用与实施例2相同的配方以及相同的标准水粘结方法。
富含纤维覆盖层材料具有下述配方：
    数量(重量％)
矿棉纤维     80.9
淀粉凝胶粘合剂(预先煮过)     2.8
乳胶粘合剂(Dow XU31518.00)     3.9
粘土(CTS-2)     2.7
石膏     9.7
絮凝剂     0.07
在每个试验中评估一对试样。在试验1中，试样被喷涂一次。在试验2中，试样被喷涂两次，而在试验3中，它们被喷涂三次。
NRC值是用阻抗管法确定的，结果如下：
  试验   总厚度(英寸) 密度(磅/立方英尺)     NRC
    1     0.724     15.62     0.55
    1     0.729     15.55     0.58
    2     0.731     16.24     0.63
    2     0.729     16.01     0.60
    3     0.737     16.57     0.63
    3     0.741     16.46     0.65
我们认为在这些试验中改良的NRC值来源于与以前的试验相比面板的密度比较低。通常优选的是双层天花板的密度在大约12磅/立方英尺到大约21磅/立方英尺的范围内变动。
                        实施例6
这些试验是为了比较用全尺寸NRC试验对这项发明的双重层天花板的NRC估计值(阻抗管)。基础板坯和覆盖层的配方如下：
    组分   基础板坯(wt％)   覆盖层(wt％)
    矿棉     36.6     86
    膨胀珍珠岩     39.4     0
    纸纤维     19     0
    淀粉粘合剂     5     3
    乳胶粘合剂     0     4
    石膏     0     7
    絮凝剂     0     0.07
三个试样都是为了得到NRC值而被制备和测试的。
  试验   覆盖层厚度(英寸)   面板总厚度(英寸)    面板总密度(磅/立方英尺)    NRC估计值(阻抗管)
  1     0.274     0.693        17     0.58
  2     0.262     0.622        17.2     0.62
  3     0.250     0.7525        16.1     0.54
试验   覆盖层厚度(英寸)   面板总厚度(英寸)  面板总密度(磅/立方英尺)   全尺寸NRC值
  1     0.274     0.725     15.8     0.61
  2     0.262     0.675     16.3     0.56
  3     0.250     0.725     15.8     0.61
                      实施例7
两种不同的覆盖层配方对它们的全尺寸NRC值进行测试。基础板坯配方与在实施例6中报告的相同。覆盖层的配方如下：
    组分   配方B(wt％)   配方C(wt％)
    矿棉     83.1     86.4
    淀粉粘合剂     2.9     3
    乳胶粘合剂     2.9     6
    石膏     11.1     2.3
    粘土     0     2.3
    絮凝剂     0.07     0.07
全尺寸NRC值如下：
  配方   面板总厚度(英寸)    面板总密度(磅/立方英尺) 全尺寸NRC值
    B     0.725     16.9     0.50
    C     0.725     16.5     0.51
                         实施例8
双层天花板已被制成，包括把玻璃纤维织物加到富含矿棉的表面上。基础板坯配方与在实施例6中使用的相同。富含矿棉的覆盖层大约0.25英寸厚，并且按重量计包含86％的矿棉。
富含矿棉的覆盖层表面是不抛光的而且没有孔。但是，标准的无纺玻璃纤维织物用胶粘剂贴到富含矿棉的覆盖层表面上。胶粘剂是3M公司制作的Super77多用途喷雾胶粘剂。胶粘剂的覆盖率大约为1.5克/平方英尺。
用标准的吸音面板涂料喷涂双层面板的富含矿棉的表面(喷涂一次)。涂料的覆盖率大约为27克/平方英尺。这种面板将对NRC的估计值(阻抗管)进行测试。
    试验   厚度(英寸) 密度(磅/立方英尺)     E-NRC
    1-a     0.627     16.5     0.53
    1-b     0.627     16.5     0.54
    2-a     0.770     15.6     0.68
    2-b     0.770     15.6     0.66
                       实施例9
有碳酸钙表面涂层的双层天花板就NRC的估计值进行评估。这种双层砖是无孔的。基础板坯配方与在实施例6中使用的配方相同。富含矿棉的覆盖层大约0.25英寸厚，而且按重量计包含86％的矿棉。
富含矿棉的表面是用干燥的碳酸钙粒子涂饰的。粗的碳酸钙是以大约38克/平方英尺的覆盖率喷涂的。在涂碳酸钙之前，先用标准的吸音面板涂料涂覆这些面板。涂料是先用辊涂后用浇涂涂布的，然后干燥。在喷涂碳酸钙之后，再用标准的吸音面板涂料喷涂这些面板，然后干燥。
这种有碳酸钙涂层的双层天花板具有0.50的NRC估计值。

Claims (14)

1.一种具有改良的声音吸收值(NRC)的双层吸音天花板，它包括包含按重量低于约50％的矿物纤维并且具有约0.25英寸到约0.625英寸的厚度的低矿物纤维基础板坯，和包含按重量计至少约75％的矿棉纤维并且具有在约0.125英寸到约0.5英寸的厚度的富含矿棉纤维的表面覆盖层，所述的天花板具有至少约为0.50的噪声降低系数(NRC)值。
2.根据权利要求1的天花板，其中低矿物纤维基础板坯包含按重量计至少约30％的膨胀珍珠岩。
3.根据权利要求1的天花板，其中富含纤维的表面层包含淀粉粘合剂和乳胶粘合剂两者。
4.根据权利要求1的天花板，其中所述的富含矿物纤维的表面层具有约1/4英寸或低于1/4英寸的厚度。
5.根据权利要求1的天花板，其中在基础板坯材料和富含纤维的表面层之间有玻璃纤维织物。
6.根据权利要求3的天花板，其中在富含纤维的表面层中的乳胶粘合剂已通过把少量的絮凝剂添加到包含矿物纤维和乳胶粘合剂的含水浆料中沉积在矿物纤维上。
7.根据权利要求1的天花板，其中两者的低矿物纤维基础板坯材料和富含纤维的表面层两者都包含在与基础板坯材料和富含纤维的表层材料合并之前已被预先煮过的淀粉凝胶粘合剂。
8.根据权利要求1的天花板，其中天花板具有在约0.375英寸到约1英寸的总厚度。
9.根据权利要求1的天花板，其中富含纤维的表面层包含约3wt％到约7.5wt％的纤维素纤维。
10.根据权利要求1的天花板，其中面板的两层都包含仅仅通过把它添加到水中就转化成凝胶的呈预先凝胶化的淀粉形式的淀粉凝胶粘合剂。
11.根据权利要求1的天花板，其中天花板具有基础板坯材料和富含纤维的表面层，两者都包含纸纤维。
12.根据权利要求1的天花板，其中面板的密度在约12磅/立方英尺到约21磅/立方英尺。
13.根据权利要求1的天花板，其中有应用于富含纤维的表面层的玻璃纤维织物。
14.根据权利要求1的天花板，其中在富含纤维层的表面上有碳酸钙涂层。
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