JP2019529166A - 改良された吸音パネル性能のためのケイ酸塩コーティングおよびその製造方法 - Google Patents
改良された吸音パネル性能のためのケイ酸塩コーティングおよびその製造方法 Download PDFInfo
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- JP2019529166A JP2019529166A JP2019512225A JP2019512225A JP2019529166A JP 2019529166 A JP2019529166 A JP 2019529166A JP 2019512225 A JP2019512225 A JP 2019512225A JP 2019512225 A JP2019512225 A JP 2019512225A JP 2019529166 A JP2019529166 A JP 2019529166A
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- coating
- silicate
- binder
- inorganic
- layer
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- 238000000576 coating method Methods 0.000 title claims abstract description 129
- 239000011248 coating agent Substances 0.000 title claims abstract description 121
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 title description 31
- 238000004519 manufacturing process Methods 0.000 title description 4
- 239000011230 binding agent Substances 0.000 claims abstract description 154
- 239000011256 inorganic filler Substances 0.000 claims abstract description 99
- 229910003475 inorganic filler Inorganic materials 0.000 claims abstract description 99
- 239000008199 coating composition Substances 0.000 claims abstract description 85
- 238000000034 method Methods 0.000 claims abstract description 53
- 239000007787 solid Substances 0.000 claims abstract description 50
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims abstract description 40
- 229910052915 alkaline earth metal silicate Inorganic materials 0.000 claims abstract description 32
- 229920000620 organic polymer Polymers 0.000 claims abstract description 32
- 239000011247 coating layer Substances 0.000 claims abstract description 29
- 239000000945 filler Substances 0.000 claims abstract description 20
- 239000010410 layer Substances 0.000 claims description 62
- 239000000835 fiber Substances 0.000 claims description 53
- 229910052914 metal silicate Inorganic materials 0.000 claims description 39
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 34
- 229910052751 metal Inorganic materials 0.000 claims description 34
- 239000002184 metal Substances 0.000 claims description 34
- 239000000203 mixture Substances 0.000 claims description 32
- 239000000126 substance Substances 0.000 claims description 32
- 239000002491 polymer binding agent Substances 0.000 claims description 29
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 28
- 239000004115 Sodium Silicate Substances 0.000 claims description 27
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 27
- 239000004927 clay Substances 0.000 claims description 18
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 17
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 17
- 238000000151 deposition Methods 0.000 claims description 15
- 239000002253 acid Substances 0.000 claims description 14
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 12
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 10
- 229910052602 gypsum Inorganic materials 0.000 claims description 9
- 239000010440 gypsum Substances 0.000 claims description 9
- 235000019353 potassium silicate Nutrition 0.000 claims description 9
- 239000004111 Potassium silicate Substances 0.000 claims description 8
- 239000000378 calcium silicate Substances 0.000 claims description 8
- 229910052918 calcium silicate Inorganic materials 0.000 claims description 8
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 claims description 8
- QZVSYHUREAVHQG-UHFFFAOYSA-N diberyllium;silicate Chemical compound [Be+2].[Be+2].[O-][Si]([O-])([O-])[O-] QZVSYHUREAVHQG-UHFFFAOYSA-N 0.000 claims description 8
- 229910052913 potassium silicate Inorganic materials 0.000 claims description 8
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 claims description 8
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical class O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 7
- PAZHGORSDKKUPI-UHFFFAOYSA-N lithium metasilicate Chemical compound [Li+].[Li+].[O-][Si]([O-])=O PAZHGORSDKKUPI-UHFFFAOYSA-N 0.000 claims description 7
- 229910052912 lithium silicate Inorganic materials 0.000 claims description 7
- 239000000391 magnesium silicate Substances 0.000 claims description 7
- 229910052919 magnesium silicate Inorganic materials 0.000 claims description 7
- 235000019792 magnesium silicate Nutrition 0.000 claims description 7
- 239000011787 zinc oxide Substances 0.000 claims description 6
- 239000011324 bead Substances 0.000 claims description 5
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- 229910052618 mica group Inorganic materials 0.000 claims description 5
- 239000004576 sand Substances 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 239000000454 talc Substances 0.000 claims description 5
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- 239000010456 wollastonite Substances 0.000 claims description 5
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- NWONKYPBYAMBJT-UHFFFAOYSA-L zinc sulfate Chemical compound [Zn+2].[O-]S([O-])(=O)=O NWONKYPBYAMBJT-UHFFFAOYSA-L 0.000 claims description 5
- 229910000368 zinc sulfate Inorganic materials 0.000 claims description 5
- 229960001763 zinc sulfate Drugs 0.000 claims description 5
- 238000001035 drying Methods 0.000 claims description 4
- ZADYMNAVLSWLEQ-UHFFFAOYSA-N magnesium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[Mg+2].[Si+4] ZADYMNAVLSWLEQ-UHFFFAOYSA-N 0.000 claims 1
- 238000007789 sealing Methods 0.000 abstract description 36
- 238000002360 preparation method Methods 0.000 abstract 1
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 102
- 239000000243 solution Substances 0.000 description 25
- 239000011162 core material Substances 0.000 description 24
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 21
- 238000001723 curing Methods 0.000 description 20
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- 239000011490 mineral wool Substances 0.000 description 15
- 235000019698 starch Nutrition 0.000 description 15
- 150000003839 salts Chemical class 0.000 description 14
- 239000008107 starch Substances 0.000 description 14
- 239000005995 Aluminium silicate Substances 0.000 description 13
- 235000012211 aluminium silicate Nutrition 0.000 description 13
- 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 13
- 239000006185 dispersion Substances 0.000 description 12
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- 239000011734 sodium Substances 0.000 description 8
- 239000000654 additive Substances 0.000 description 7
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- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 7
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- WEVYAHXRMPXWCK-UHFFFAOYSA-N Acetonitrile Chemical compound CC#N WEVYAHXRMPXWCK-UHFFFAOYSA-N 0.000 description 6
- 229920000877 Melamine resin Polymers 0.000 description 6
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- 150000001768 cations Chemical class 0.000 description 6
- 239000004615 ingredient Substances 0.000 description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 239000011777 magnesium Substances 0.000 description 6
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 6
- 230000008569 process Effects 0.000 description 6
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 5
- 229910052782 aluminium Inorganic materials 0.000 description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 5
- DMSMPAJRVJJAGA-UHFFFAOYSA-N benzo[d]isothiazol-3-one Chemical compound C1=CC=C2C(=O)NSC2=C1 DMSMPAJRVJJAGA-UHFFFAOYSA-N 0.000 description 5
- 239000011575 calcium Substances 0.000 description 5
- 238000004132 cross linking Methods 0.000 description 5
- 230000018044 dehydration Effects 0.000 description 5
- 238000006297 dehydration reaction Methods 0.000 description 5
- 230000033001 locomotion Effects 0.000 description 5
- 229910052749 magnesium Inorganic materials 0.000 description 5
- 239000000463 material Substances 0.000 description 5
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- 239000010451 perlite Substances 0.000 description 5
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- 239000002002 slurry Substances 0.000 description 5
- 239000007921 spray Substances 0.000 description 5
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 4
- 239000008365 aqueous carrier Substances 0.000 description 4
- 229910052791 calcium Inorganic materials 0.000 description 4
- 230000015556 catabolic process Effects 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 238000006731 degradation reaction Methods 0.000 description 4
- 239000011888 foil Substances 0.000 description 4
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 4
- 229910052500 inorganic mineral Inorganic materials 0.000 description 4
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- HORQAOAYAYGIBM-UHFFFAOYSA-N 2,4-dinitrophenylhydrazine Chemical compound NNC1=CC=C([N+]([O-])=O)C=C1[N+]([O-])=O HORQAOAYAYGIBM-UHFFFAOYSA-N 0.000 description 3
- 229940100555 2-methyl-4-isothiazolin-3-one Drugs 0.000 description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 238000010521 absorption reaction Methods 0.000 description 3
- 150000001342 alkaline earth metals Chemical class 0.000 description 3
- 229910052788 barium Inorganic materials 0.000 description 3
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 3
- 239000002585 base Substances 0.000 description 3
- 229910052790 beryllium Inorganic materials 0.000 description 3
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 239000002655 kraft paper Substances 0.000 description 3
- BEGLCMHJXHIJLR-UHFFFAOYSA-N methylisothiazolinone Chemical compound CN1SC=CC1=O BEGLCMHJXHIJLR-UHFFFAOYSA-N 0.000 description 3
- JPMIIZHYYWMHDT-UHFFFAOYSA-N octhilinone Chemical compound CCCCCCCCN1SC=CC1=O JPMIIZHYYWMHDT-UHFFFAOYSA-N 0.000 description 3
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- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 3
- 239000011701 zinc Substances 0.000 description 3
- UEFCKYIRXORTFI-UHFFFAOYSA-N 1,2-thiazolidin-3-one Chemical class O=C1CCSN1 UEFCKYIRXORTFI-UHFFFAOYSA-N 0.000 description 2
- VOHCMATXIKWIKC-UHFFFAOYSA-N 1-hydroxypyridine-2-thione;zinc Chemical compound [Zn].ON1C=CC=CC1=S VOHCMATXIKWIKC-UHFFFAOYSA-N 0.000 description 2
- 229940100484 5-chloro-2-methyl-4-isothiazolin-3-one Drugs 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
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- DHNRXBZYEKSXIM-UHFFFAOYSA-N chloromethylisothiazolinone Chemical compound CN1SC(Cl)=CC1=O DHNRXBZYEKSXIM-UHFFFAOYSA-N 0.000 description 2
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- 235000019982 sodium hexametaphosphate Nutrition 0.000 description 1
- UGTZMIPZNRIWHX-UHFFFAOYSA-K sodium trimetaphosphate Chemical compound [Na+].[Na+].[Na+].[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 UGTZMIPZNRIWHX-UHFFFAOYSA-K 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000008261 styrofoam Substances 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 238000001029 thermal curing Methods 0.000 description 1
- WJCNZQLZVWNLKY-UHFFFAOYSA-N thiabendazole Chemical compound S1C=NC(C=2NC3=CC=CC=C3N=2)=C1 WJCNZQLZVWNLKY-UHFFFAOYSA-N 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
Classifications
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Abstract
Description
一般に、無機結合剤は、互いに結合して、全ての成分を所望の構造マトリックス内に保持するのを容易にする結合系を形成する、硬化性金属ケイ酸塩化合物を含む。無機結合剤は、1種以上のアルカリ金属ケイ酸塩、アルカリ土類金属ケイ酸塩、およびそれらの組み合わせを含む。アルカリ金属ケイ酸塩およびアルカリ土類金属ケイ酸塩は、架橋および/または脱水によりコーナー形状のSiO4四面体で構成されるケイ酸塩のネットワークを有利に形成する。
適切な無機充填剤としては、例えば、粘土(例えば、カオリン粘土およびベントナイト)、雲母、砂、硫酸バリウム、シリカ、タルク、石膏、炭酸カルシウム、珪灰石、酸化亜鉛、硫酸亜鉛、中空ビーズ、ベントナイト塩、およびそれらの混合物が挙げられる。実施形態では、充填剤は、粘土、雲母、砂、硫酸バリウム、シリカ、タルク、石膏、炭酸カルシウム、珪灰石、酸化亜鉛、硫酸亜鉛、中空ビーズ、ベントナイト塩およびそれらの組み合わせからなる群から選択される。実施形態では、充填剤は炭酸カルシウムを含む。実施形態では、充填剤は炭酸カルシウムおよびカオリン粘土の組み合わせを含む。
本開示はさらに、本開示のコーティング組成物でコーティングされたパネル(例えば、吸音パネル、シーリングタイル)に関する。図1に概略的に示されるように、本開示の一態様によるコーティングパネル10は、裏打ち面30と対向面40とを有するパネルコア20を備える。パネルは、任意選択で、裏打ち面30と接触している裏打ち層35、および/または対向面40と接触している対向層45をさらに備える。裏面コーティング層50は、例えば裏打ち面30または任意選択の裏打ち層35と接触するように配置される。任意選択で、さらなる前面コーティング層60が、例えば、対向面40または任意選択の対向層45の上に配置される。
本開示はさらに、シーリングタイルをコーティングする方法を提供し、方法は、裏打ち面と、反対側の対向面とを有するシーリングタイルを提供することと、無機結合剤および無機充填剤を含む層を裏打ち面上に堆積させることであって、無機結合剤は、層中の固体の全体積に基づいて10〜50体積%の量で存在し、無機充填剤は、層中の固体の全体積に基づいて50〜90体積%の量で存在し、無機結合剤は、アルカリ金属ケイ酸塩またはアルカリ土類金属ケイ酸塩を含み、無機結合剤および無機充填剤は同じではなく、無機結合剤および無機充填剤は、有機ポリマー結合剤を実質的に含まない、堆積させることと、層を少なくとも350°F(約176℃)の表面温度に加熱し、それによってシーリングタイルの裏打ち面に金属ケイ酸塩コーティングを形成することとを含む。
シーリングタイルの垂れ下がりは、ASTM C367M−09に従って測定することができる。簡潔に説明すると、シーリンググリッドを模した試験ラックにシーリングタイルを配置する。ラックにセットされたパネルの幾何学的中心の垂直位置を測定して、70°F(21℃)/50%R.H.の1時間の調整後の製品の初期位置を決定する。パネルのタイルの初期位置が測定されると、タイルは単一の試験サイクルを含むさまざまな環境条件に曝される。特に、下記の実施例では、104°F(40℃)/50%R.H.で12時間、続いて70°F(21℃)/50%R.H.で12時間のサイクルが3回完了され、各サイクルの完了後に中心位置が測定される。垂れ下がりは、2つの様式で報告される。「総移動」は、3回のサイクルが完了した後のシーリングタイルの初期位置とタイルの最終位置との間の垂直位置の差を取ることによって決定される。「最終位置」は、タイルの最終的な垂直位置を取ることによって決定される。特に指定のない限り、垂れ下がりは2’×4’のタイルのインチ単位で列挙される。本開示の適切なタイルは、コーティングされていないタイルよりも垂れ下がりが少ないこと、例えば、約1.0インチ未満、または約0.8インチ未満、または約0.6インチ未満、または約0.5インチ未満、または約0.4未満、または約0.3インチ未満、または約0.2インチ未満、または約0.1インチ未満の垂れ下がりを示す。
繊維パネルは、裏打ち面と、パネルの少なくとも片面に配置された硬化コーティング層を有する反対側の対向面とを備える繊維パネルを備えており、硬化コーティング層は、
乾燥コーティングの全体積に基づいて、10〜50体積%の無機結合剤と、
乾燥コーティングの全体積に基づいて、50〜90体積%の無機充填剤とを含み、
無機結合剤は、アルカリ金属ケイ酸塩またはアルカリ土類金属ケイ酸塩を含み、無機結合剤および無機充填剤は同じではなく、コーティングは有機ポリマー結合剤を実質的に含まない、コーティングされた繊維パネル。
乾燥コーティング組成物中の固体の全体積に基づいて、10〜50体積%の無機結合剤と、
乾燥コーティング組成物中の固体の全体積に基づいて、50〜90体積%の無機充填剤とを含み、
無機結合剤は、アルカリ金属ケイ酸塩またはアルカリ土類金属ケイ酸塩を含み、無機結合剤および無機充填剤は同じではなく、コーティングは有機ポリマー結合剤を実質的に含まない、硬化性コーティング組成物。
裏打ち面と、反対側の対向面とを有する繊維パネルを提供することと、
繊維パネルの少なくとも片面に層を堆積させることであって、層は、無機結合剤および無機充填剤を含み、無機結合剤は、乾燥層中の固体の全体積に基づいて10〜50体積%の量で存在し、無機充填剤は、乾燥層中の固体の全体積に基づいて50〜90重量%の量で存在し、無機結合剤は、アルカリ金属ケイ酸塩またはアルカリ土類金属ケイ酸塩を含み、無機結合剤および無機充填剤は同じではなく、無機結合剤および無機充填剤は、有機ポリマー結合剤を実質的に含まない、堆積させることと、
層を少なくとも350°F(約176℃)の表面温度に加熱し、それによって繊維パネルの少なくとも片面に金属ケイ酸塩コーティングを形成することとを含む方法。
一連のコーティング吸音シーリングタイルを製造し、垂れ下がり抵抗について試験した。他に指定のない限り、実施例において使用される全てのシーリングタイルは、Chicago、IllのUSG Interiors,Inc.から入手可能なRadar(商標)ブランドのシーリングタイルである。Radar(商標)ブランドのタイルは、厚さ5/8インチの水フェルトスラグウールまたは鉱物ウール繊維パネルであり、以下の組成を有する:1〜75重量%のスラグウール繊維、5〜75重量%の膨張パーライト、1〜25重量%セルロース、5〜15重量%のデンプン、0〜15重量%のカオリン、0〜80重量%の脱水硫酸カルシウム、2重量%未満の石灰石またはドロマイト、5重量%未満の結晶性シリカ、および2重量%未満の酢酸ビニルポリマーまたはエチレン酢酸ビニルポリマー。鉱物ウール繊維の直径は、実質的な範囲、例えば0.25〜20ミクロンにわたって変動し、また繊維の大部分は直径3〜4ミクロンの範囲内にある。鉱物繊維の長さは、約1mm〜約8mmの範囲である。
一連のコーティング吸音シーリングタイルを製造し、垂れ下がり抵抗について試験した。無機充填剤と組み合わせたケイ酸ナトリウム溶液を含むホルムアルデヒド不含結合剤組成物を含む本開示のコーティング組成物を使用して、試料を調製した。ケイ酸塩コーティング組成物は、45.7重量%のケイ酸ナトリウム溶液(N Sodium Silicate Solution、3.22 SiO2:Na2O、37.5%固体、PQ Corporation、Valley Forge、PA)(固体の全体積に基づいて27.3体積%)、8.6重量%の水、および45.7重量%の炭酸カルシウム(固体の全体積に基づいて72.7体積%)(CC90、Superior Minerals Company、Savage、MN)を含んでいた。以下の表に記載されるように、一連の2’×4’シーリングタイルをロールコーターでタイルの裏面にコーティングした。試料を、約400°Fの裏面温度を達成する600°F(315.5℃)の空気温度で高速空気衝突対流オーブンに通した。いくつかの試料は、ロールコーターを用いて第2の層のケイ酸塩コーティングでコーティングし、同じオーブンを通過させ、約400°Fの裏面温度を達成した。次いで、ロールコーターまたは噴霧コーターを用いて、下記の表に記載のアルカリ土類金属塩の水溶液でタイルをコーティングし、約375°Fの裏面温度を達成する約400°Fの空気温度で、ガス燃焼直火仕上げオーブンに通過させた。記録された全ての重量は、乾燥ベースで示されている。タイルは標準的な穿孔/亀裂およびトップ仕上げコートで仕上げられた。シーリングタイルの内部への穴または亀裂の穿孔または穴開けは、音波の吸収および減衰を提供する。上記のように、湿気により誘導される垂れ下がりに対する耐性について試料を試験した。メラミンホルムアルデヒドベースのコーティングを施した試料タイルおよびコーティングを施していないシーリングタイルを対照として試験した。
Claims (10)
- コーティングされた繊維パネルであって、
繊維パネルは、裏打ち面と、パネルの少なくとも片面に配置された硬化コーティング層を有する反対側の対向面とを備えており、前記硬化コーティング層は、
乾燥コーティングの全体積に基づいて、10〜50体積%の無機結合剤と、
乾燥コーティングの全体積に基づいて、50〜90体積%の無機充填剤とを含み、
前記無機結合剤は、アルカリ金属ケイ酸塩またはアルカリ土類金属ケイ酸塩を含み、前記無機結合剤および前記無機充填剤は同じではなく、前記コーティングは有機ポリマー結合剤を実質的に含まない、コーティングされた繊維パネル。 - 硬化性コーティング組成物であって、
乾燥コーティング組成物中の固体の全体積に基づいて、10〜50体積%の無機結合剤と、
乾燥コーティング組成物中の固体の全体積に基づいて、50〜90体積%の無機充填剤とを含み、
前記無機結合剤は、アルカリ金属ケイ酸塩またはアルカリ土類金属ケイ酸塩を含み、前記無機結合剤および前記無機充填剤は同じではなく、前記コーティングは有機ポリマー結合剤を実質的に含まない、硬化性コーティング組成物。 - 前記金属ケイ酸塩が、ケイ酸ナトリウム、ケイ酸カリウム、ケイ酸リチウム、ケイ酸マグネシウム、ケイ酸カルシウム、ケイ酸ベリリウム、およびそれらの組み合わせからなる群から選択される金属ケイ酸塩を含む、請求項1または請求項2に記載の繊維パネルまたは組成物。
- 前記無機充填剤が、粘土、雲母、砂、硫酸バリウム、シリカ、タルク、石膏、炭酸カルシウム、珪灰石、酸化亜鉛、硫酸亜鉛、中空ビーズ、ベントナイト塩、およびそれらの組み合わせからなる群から選択される充填剤を含む、請求項1〜3のいずれか一項に記載の繊維パネルまたは組成物。
- 繊維パネルをコーティングする方法であって、
裏打ち面と、反対側の対向面とを備える繊維パネルを提供することと、
前記繊維パネルの少なくとも片面に層を堆積させることであって、前記層は、無機結合剤および無機充填剤を含み、前記無機結合剤は、乾燥層中の固体の全体積に基づいて10〜50体積%の量で存在し、前記無機充填剤は、乾燥層中の固体の全体積に基づいて50〜90重量%の量で存在し、前記無機結合剤は、アルカリ金属ケイ酸塩またはアルカリ土類金属ケイ酸塩を含み、前記無機結合剤および前記無機充填剤は同じではなく、前記無機結合剤および前記無機充填剤は、有機ポリマー結合剤を実質的に含まない、堆積させることと、
前記層を少なくとも350°F(約176℃)の表面温度に加熱し、それによって前記繊維パネルの少なくとも片面に金属ケイ酸塩コーティングを形成することと、を含む方法。 - (a)硬化性コーティング組成物を形成するように、前記無機結合剤および前記無機充填剤が予備混合される、または
(b)前記無機充填剤が第1の層として堆積され、前記無機結合剤が第1の層と接触する後続層として堆積される、請求項5に記載の方法。 - 化学的硬化をさらに含む、請求項5または請求項6に記載の方法。
- 化学的硬化が、金属ケイ酸塩コーティング層を多価金属または酸の溶液でコーティングすること、およびコーティングを乾燥することを含む、請求項7に記載の方法。
- 前記金属ケイ酸塩コーティングが、約0.01lb/ft2(乾燥ベース)〜約0.07lb/ft2(乾燥ベース)の範囲内のコーティング重量を有する、請求項5〜8のいずれか一項に記載の方法。
- 前記化学的硬化が、5mmol/ft2〜約30mmol/ft2の範囲内のコーティング重量(乾燥または湿潤)で前記多価金属溶液を塗布することを含む、請求項8に記載の方法。
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2017
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- 2017-09-14 JP JP2019512225A patent/JP7046057B2/ja active Active
- 2017-09-14 WO PCT/US2017/051522 patent/WO2018057390A1/en unknown
- 2017-09-14 EP EP17787978.0A patent/EP3515875B1/en active Active
- 2017-09-14 PL PL17787978.0T patent/PL3515875T3/pl unknown
- 2017-09-14 KR KR1020197009149A patent/KR102479244B1/ko active IP Right Grant
- 2017-09-14 CN CN201780054573.4A patent/CN109661382B/zh active Active
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EP3515875B1 (en) | 2022-11-02 |
CN109661382A (zh) | 2019-04-19 |
KR20190057070A (ko) | 2019-05-27 |
RU2759765C2 (ru) | 2021-11-17 |
PL3515875T3 (pl) | 2023-02-20 |
US20220333380A1 (en) | 2022-10-20 |
EP3515875A1 (en) | 2019-07-31 |
RU2019108369A (ru) | 2020-09-22 |
KR102479244B1 (ko) | 2022-12-19 |
US20180079691A1 (en) | 2018-03-22 |
CN109661382B (zh) | 2022-10-11 |
JP7046057B2 (ja) | 2022-04-01 |
WO2018057390A1 (en) | 2018-03-29 |
RU2019108369A3 (ja) | 2020-12-30 |
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