JP2013523597A - 軽量キャスト音響製品の成形 - Google Patents
軽量キャスト音響製品の成形 Download PDFInfo
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- JP2013523597A JP2013523597A JP2013504953A JP2013504953A JP2013523597A JP 2013523597 A JP2013523597 A JP 2013523597A JP 2013504953 A JP2013504953 A JP 2013504953A JP 2013504953 A JP2013504953 A JP 2013504953A JP 2013523597 A JP2013523597 A JP 2013523597A
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- 238000000465 moulding Methods 0.000 title description 2
- 238000002156 mixing Methods 0.000 claims abstract description 56
- 229920002472 Starch Polymers 0.000 claims abstract description 54
- 235000019698 starch Nutrition 0.000 claims abstract description 52
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 52
- 239000008107 starch Substances 0.000 claims abstract description 49
- 239000011490 mineral wool Substances 0.000 claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 30
- 239000000203 mixture Substances 0.000 claims abstract description 27
- 210000002268 wool Anatomy 0.000 claims abstract description 22
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- 230000005587 bubbling Effects 0.000 claims abstract description 13
- 239000004094 surface-active agent Substances 0.000 claims abstract description 11
- MRUAUOIMASANKQ-UHFFFAOYSA-N cocamidopropyl betaine Chemical compound CCCCCCCCCCCC(=O)NCCC[N+](C)(C)CC([O-])=O MRUAUOIMASANKQ-UHFFFAOYSA-N 0.000 claims abstract description 9
- 229940073507 cocamidopropyl betaine Drugs 0.000 claims abstract description 9
- 238000010438 heat treatment Methods 0.000 claims abstract description 9
- 150000003839 salts Chemical class 0.000 claims abstract description 7
- 238000004519 manufacturing process Methods 0.000 claims description 18
- 239000000835 fiber Substances 0.000 claims description 12
- 239000010440 gypsum Substances 0.000 claims description 11
- 229910052602 gypsum Inorganic materials 0.000 claims description 11
- 241000196324 Embryophyta Species 0.000 claims description 7
- 239000004327 boric acid Substances 0.000 claims description 7
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 6
- 150000004996 alkyl benzenes Chemical class 0.000 claims description 5
- 229940077388 benzenesulfonate Drugs 0.000 claims description 4
- 238000005266 casting Methods 0.000 claims description 4
- 239000011800 void material Substances 0.000 claims description 4
- 229920002261 Corn starch Polymers 0.000 claims description 3
- 239000008120 corn starch Substances 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 238000003756 stirring Methods 0.000 claims description 3
- 240000003183 Manihot esculenta Species 0.000 claims description 2
- 235000016735 Manihot esculenta subsp esculenta Nutrition 0.000 claims description 2
- 239000012528 membrane Substances 0.000 claims description 2
- 229910001562 pearlite Inorganic materials 0.000 claims description 2
- 229920001592 potato starch Polymers 0.000 claims description 2
- 229940100445 wheat starch Drugs 0.000 claims description 2
- 241000220317 Rosa Species 0.000 claims 1
- -1 alkylbenzene sulfonate Chemical class 0.000 claims 1
- 239000004088 foaming agent Substances 0.000 abstract description 65
- GVGUFUZHNYFZLC-UHFFFAOYSA-N dodecyl benzenesulfonate;sodium Chemical compound [Na].CCCCCCCCCCCCOS(=O)(=O)C1=CC=CC=C1 GVGUFUZHNYFZLC-UHFFFAOYSA-N 0.000 abstract description 4
- 229940080264 sodium dodecylbenzenesulfonate Drugs 0.000 abstract description 4
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- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 3
- 239000010451 perlite Substances 0.000 description 3
- 235000019362 perlite Nutrition 0.000 description 3
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 description 3
- HFQQZARZPUDIFP-UHFFFAOYSA-M sodium;2-dodecylbenzenesulfonate Chemical compound [Na+].CCCCCCCCCCCCC1=CC=CC=C1S([O-])(=O)=O HFQQZARZPUDIFP-UHFFFAOYSA-M 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 239000004575 stone Substances 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- PASHVRUKOFIRIK-UHFFFAOYSA-L calcium sulfate dihydrate Chemical compound O.O.[Ca+2].[O-]S([O-])(=O)=O PASHVRUKOFIRIK-UHFFFAOYSA-L 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
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- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
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- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 235000019982 sodium hexametaphosphate Nutrition 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 description 2
- 239000013585 weight reducing agent Substances 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- QXNVGIXVLWOKEQ-UHFFFAOYSA-N Disodium Chemical compound [Na][Na] QXNVGIXVLWOKEQ-UHFFFAOYSA-N 0.000 description 1
- 229920000881 Modified starch Polymers 0.000 description 1
- 108010073771 Soybean Proteins Proteins 0.000 description 1
- 239000012814 acoustic material Substances 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000005054 agglomeration Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 239000010427 ball clay Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 125000005619 boric acid group Chemical group 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- ZOMBKNNSYQHRCA-UHFFFAOYSA-J calcium sulfate hemihydrate Chemical compound O.[Ca+2].[Ca+2].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O ZOMBKNNSYQHRCA-UHFFFAOYSA-J 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
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- 238000010276 construction Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
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- 238000010411 cooking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000009950 felting Methods 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 235000019426 modified starch Nutrition 0.000 description 1
- 239000010893 paper waste Substances 0.000 description 1
- 238000000059 patterning Methods 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 229940001941 soy protein Drugs 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 238000007655 standard test method Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 230000002087 whitening effect Effects 0.000 description 1
Images
Classifications
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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
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
-
- 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
-
- 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
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/52—Sound-insulating materials
Abstract
Description
試験ボードの作製
音響パネル用のパルプの基本処方は、表Iに示される。デンプン、ホウ酸、およびスタッコを個別のカップ内に秤取した。350グラムの冷水を計量し、小さい金属ビーカーに入れた。最初にデンプン、次いでホウ酸、そして最後にスタッコを添加することにより、撹拌しながら乾燥成分を冷水に添加した。2571グラムの沸騰水を混合物に添加した。混合物を撹拌して均一なゲルを得た。871グラムになるようにミネラルウールを計量し、HOBART(登録商標)ミキサーに入れた。ゲルをミキサーに添加し、速度1で45秒間混合することによりパルプを形成した。混合ボウルの側面上のブレンドされない成分をパルプ中に押し下げて、パルプを速度2でさらに3分間混合した。
試験ボードの性質
実施例1で作製された各試験ボードの物理特性を測定した。結果は表IIIに示される。
試験サンプルの作製
実施例1および2のスクリーニング試験で特定された最も有望な起泡剤を選択してさらなる試験に供した。起泡剤が存在する場合には表IVに従って添加して、パルプの基本処方のサンプルを実施例1に従って作製した。
ボードの物理特性
実施例2と同一の試験方法を用いて、実施例3で作製したボードの物理特性を試験した。試験の結果は表Vに示される。
混合速度、混合持続時間、および気泡水の影響
混合速度、混合持続時間、および気泡水(界面活性剤希釈液)の量がボードの密度および物理特性に及ぼす影響を調べるために、実験室試験を行った。パルプの基本処方を用いて実施例1の方法に従ってサンプルを作製した。コカミドプロピルヒドロキシスルタイン起泡剤を約0.25%(6.01g)の量ですべてのサンプルに添加した。以上で参照した変数の変化は、表VIに示される。混合速度および持続時間は、泡発生の最終的混合工程を意味する。
ウールノットの発生
音響材料を製造するためにプラント追試験を行った。実施例1の基本パルプの成分および割合をより大きいバッチサイズで使用した。Bio−Soft D−40を0.40重量%(6.1lbs)の量で計量し、約300lbsの気泡水に添加した。気泡水の温度を46°Fの曇点超に維持した。起泡剤を水に添加し、スパチュラで撹拌することにより一体化させた。
実施例1の方法に従って表IXの量でデンプンゲルを調製した。
音響試験
発泡音響製品のサンプルを作製して、音響試験に付した。実施例7の方法に従ってさまざまな密度を有するように表VIIIの量を用いてA〜Eで表示された5つのサンプルを作製した。サンプルの組成は下記の表XIIに示される。
Claims (10)
- デンプンを冷水とブレンドすることと、
このデンプン/水ブレンドを加熱してデンプンゲルを形成することと、
前記デンプンゲルにミネラルウールを添加してパルプを形成することと、
ウールノジュールが形成されるまで前記パルプを湿式混合することと、
界面活性剤を一定量の気泡水と組み合わせることであって、ただし、前記界面活性剤は、線状アルキルベンゼンスルホネート、コカミドプロピルベタイン、コカミドプロピルヒドロキシスルタイン、それらの塩、およびそれらの混合物からなる群から選択されるものとすることと、
前記界面活性剤、前記気泡水、および前記パルプを混合して発泡パルプを形成することと、
前記発泡パルプを成形型内にキャストすることと、
前記発泡パルプを乾燥させて発泡製品を形成することと、
前記成形型から前記発泡製品を取り出すことと、
を含む、発泡音響製品の製造方法。 - 前記方法の製品にパーライトが添加されない、請求項1に記載の方法。
- 前記ブレンド工程のデンプンが植物デンプンを含む、請求項1に記載の方法。
- 前記ブレンド工程の植物デンプンがさらに、トウモロコシデンプン、ジャガイモデンプン、コムギデンプン、およびタピオカデンプンから選択される群に属する1つを含む、請求項3に記載の方法。
- 前記植物デンプンが架橋トウモロコシデンプンである、請求項4に記載の方法。
- 前記混合工程が、あらかじめ形成された泡を作製することと、前記あらかじめ形成された泡を前記湿潤パルプに混合導入することと、を含む、請求項1に記載の方法。
- 前記導入工程がさらに、界面活性剤溶液を前記湿潤パルプに添加することと、前記湿潤パルプを撹拌して前記発泡パルプを形成することと、を含む、請求項1に記載の方法。
- 前記添加工程のミネラルウールが繊維状ミネラルウールとして添加される、請求項1に記載の方法。
- ミネラルウールの乾燥構造体を含み、前記ミネラルウールの繊維間の空間が、ボイドを内有する乾燥デンプンゲルで充填され、前記ボイドの内部表面が、線状アルキルベンゼンスルホネート、コカミドプロピルベタイン、コカミドプロピルヒドロキシスルタイン、それらの塩、およびそれらの混合物からなる群から選択される膜で覆われ、前記ミネラルウールが、バラ繊維の形態でまたは3mm以下のウールノジュールとして存在する、発泡音響製品であって、
少なくとも16ポンド毎ft3の密度および少なくとも80重量ポンドの硬度を有する、製品。 - 石膏、ホウ酸、およびそれらの混合物からなる群に属する少なくとも1つをさらに含む、請求項9に記載の製品。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/759,308 US8028803B1 (en) | 2010-04-13 | 2010-04-13 | Molding a lightweight cast acoustical product |
US12/759,308 | 2010-04-13 | ||
PCT/US2011/031560 WO2011130091A1 (en) | 2010-04-13 | 2011-04-07 | Molding a lightweight cast acoustical product |
Publications (1)
Publication Number | Publication Date |
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JP2013523597A true JP2013523597A (ja) | 2013-06-17 |
Family
ID=44259773
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP2013504953A Pending JP2013523597A (ja) | 2010-04-13 | 2011-04-07 | 軽量キャスト音響製品の成形 |
Country Status (14)
Country | Link |
---|---|
US (1) | US8028803B1 (ja) |
EP (1) | EP2558429A1 (ja) |
JP (1) | JP2013523597A (ja) |
CN (1) | CN102822111B (ja) |
AR (1) | AR080959A1 (ja) |
AU (1) | AU2011240937B2 (ja) |
BR (1) | BR112012024605A2 (ja) |
CA (1) | CA2795267C (ja) |
MX (1) | MX2012011497A (ja) |
MY (1) | MY157674A (ja) |
RU (1) | RU2012141688A (ja) |
TW (1) | TW201139526A (ja) |
UA (1) | UA107700C2 (ja) |
WO (1) | WO2011130091A1 (ja) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8961675B2 (en) | 2010-12-28 | 2015-02-24 | Usg Interiors, Llc | Acoustic building material employing chitosan |
US10395633B2 (en) * | 2013-05-09 | 2019-08-27 | Acoustic Space Pty Ltd | Sound insulating sheet material with a cellular structure including gelatine and/or a process for producing the same |
US10400105B2 (en) | 2015-06-19 | 2019-09-03 | The Research Foundation For The State University Of New York | Extruded starch-lignin foams |
US9896807B2 (en) * | 2015-09-25 | 2018-02-20 | Usg Interiors, Llc | Acoustical ceiling tile |
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- 2011-04-07 BR BR112012024605A patent/BR112012024605A2/pt not_active IP Right Cessation
- 2011-04-07 WO PCT/US2011/031560 patent/WO2011130091A1/en active Application Filing
- 2011-04-07 MX MX2012011497A patent/MX2012011497A/es active IP Right Grant
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- 2011-04-07 EP EP11715809A patent/EP2558429A1/en not_active Withdrawn
- 2011-04-07 MY MYPI2012004368A patent/MY157674A/en unknown
- 2011-04-07 CN CN201180016721.6A patent/CN102822111B/zh not_active Expired - Fee Related
- 2011-04-07 RU RU2012141688/03A patent/RU2012141688A/ru not_active Application Discontinuation
- 2011-04-07 CA CA2795267A patent/CA2795267C/en active Active
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Also Published As
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TW201139526A (en) | 2011-11-16 |
US8028803B1 (en) | 2011-10-04 |
WO2011130091A1 (en) | 2011-10-20 |
CA2795267A1 (en) | 2011-10-20 |
CN102822111A (zh) | 2012-12-12 |
CA2795267C (en) | 2017-07-11 |
CN102822111B (zh) | 2015-07-22 |
MY157674A (en) | 2016-07-15 |
UA107700C2 (uk) | 2015-02-10 |
AU2011240937A1 (en) | 2012-10-18 |
EP2558429A1 (en) | 2013-02-20 |
US20110247894A1 (en) | 2011-10-13 |
RU2012141688A (ru) | 2014-05-20 |
AU2011240937B2 (en) | 2013-06-20 |
BR112012024605A2 (pt) | 2018-05-15 |
AR080959A1 (es) | 2012-05-23 |
MX2012011497A (es) | 2013-01-18 |
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