TW200829764A - Reduced dust acoustic panel - Google Patents
Reduced dust acoustic panel Download PDFInfo
- Publication number
- TW200829764A TW200829764A TW96133293A TW96133293A TW200829764A TW 200829764 A TW200829764 A TW 200829764A TW 96133293 A TW96133293 A TW 96133293A TW 96133293 A TW96133293 A TW 96133293A TW 200829764 A TW200829764 A TW 200829764A
- Authority
- TW
- Taiwan
- Prior art keywords
- layer
- panel
- slurry
- sound
- board
- Prior art date
Links
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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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
- B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
-
- 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
- C04B11/00—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
- 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
-
- 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
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/001—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by provisions for heat or sound insulation
-
- 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
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/0068—Ingredients with a function or property not provided for elsewhere in C04B2103/00
- C04B2103/0075—Anti-dusting agents
-
- 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
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
- C04B2111/0062—Gypsum-paper board like materials
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Physics & Mathematics (AREA)
- Ceramic Engineering (AREA)
- Architecture (AREA)
- Structural Engineering (AREA)
- Acoustics & Sound (AREA)
- Organic Chemistry (AREA)
- Civil Engineering (AREA)
- Materials Engineering (AREA)
- Electromagnetism (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Building Environments (AREA)
- Laminated Bodies (AREA)
- Soundproofing, Sound Blocking, And Sound Damping (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Description
200829764 九、發明說明: 【發明所屬之技術領域】 本發明係關於一種在石膏板生產線上製造且切割時粉塵 減少的天花板板材。 【先前技術】 眾所周知隔音板或天花板在天花板區域提供精飾外觀以 及在需要之處提供吸聲表面。理想地,板組合有吸音性與 長期耐久性。通常使用礦棉,因為其提供用於吸聲的多孔 纖維構造。天花板製造中所使用的其他常見材料包括玻璃 纖維、膨脹珍珠岩、黏土、石膏、灰泥、碳酸鈣及紙纖 維。 許多天花板係以類似於製造紙或纖維板所使用之方法之 方式製造。在該水範化方法中,將纖維、骨料、黏合劑及 其他添加劑之水性分散液分配於多孔表面或金屬線上,配 料在该多孔表面或金屬線上因重力及真空抽吸而脫水。將 濕墊在對流烘箱中乾燥且隨後切割成想要長度。若想要, 則將表面刷塗產生精飾板。該板之實例為由USG Interi〇rs (Chicago, IL)製造的AURATONE⑧天花板板材。 如美國專利第1,769,519號所述,製造天花板的另一方法 為澆鑄。將礦棉纖維、填料、著色劑、諸如熟澱粉之黏合 劑及水之組合物置放於經紙或紙背箔片覆蓋之塔盤中。隨 後,將組合物用成形板刮平至想要的厚度。藉由使用刮樣 棒或圖案化卷筒給洗鑄材料表面提供圖案可獲得諸如浮雕 圖案之裝飾表面。USG Interiors (Chicago, IL)之ACOUSTONE® 123539.doc 200829764 天花板板材為該洗鑄板之實例。 該兩種製造天花板之方法相對昂貴,因為其使用大量水 及能量。諸如紙或澱粉之吸濕性黏合劑產生易下陷之板。 當板支持絕緣或其他負荷時或當板經受高級別濕度及溫度 時,板之下垂可增強。 石貧板不太傾向於下垂且在高速方法中高效率製造。然 而,石膏很重且其缺乏吸音性。當前,其藉由在板中包括
洞且在穿孔板之背面置放吸聲背襯而適合用作隔音天花 板。雖然洞提供-些重量減少及聲音吸收,但消f者認為 其在美觀上不合意。 另一具有隔音層之石膏板描述於美國專利公開案第 2004/023 1916號中。該杯夕—音你点丨曰士 通板之貫施例具有形成於用於增強 強度之背襯片上之發泡石膏的隔音層。板質輕、抗下垂且 美觀上合意。 該層狀石嘗板具有如下缺點。安裝期間,切割板以適合 天花板及/或固持其於適當位置之諸如天花板格柵之結構 中的開口的形狀。切穿石膏之複合物產生細粒空浮粉塵, 歸因於粉塵之小粒徑,丨需耗費很長時間沈降。粉塵之細 度使其在最終沈降之前移動很長距離。切割作用可f造可 降低能見度以及進入眼睛、耳朵及鼻子的令人討厭的粉 塵。沈降後,存在待清理之極大凌亂場面,因為細粉塵可 :透門及其他障壁’且可在離切割發生處—段距離内沈 降0 砂磨、切割及研磨期間減少粉塵已變為石膏產品的重要 123539.doc 200829764 特徵。3M之美國專利第6,863,723號暗示藉由將數種粉塵 減少劑中之一種添加至含石膏產品中減少粉塵。Unhed States Gypsum Company之美國專利第6,673,144號之特徵 為具有I乙一醇之接合化合物,其中聚乙二醇在室溫下為 固體。在美國專利第6,355,099號中,使用聚乙二醇作為内 部黏合劑之可喷灑硬石膏加工時產生較少細粉塵。該等參 考文獻中沒有一個揭示將聚乙二醇添加至隔音板中。 【發明内容】 fl _ 先前技術之需要由本發明解決,本發明之特徵在於隔音 板,其包括一隔音層及切割時減少粉塵之凝聚添加劑。 更詳言之,隔音層具有二水合硫酸鈣交鎖基質、除塵劑 及由纖維、輕質骨料及其混合物組成之群組中之至少一 者。隔音層在交鎖基質中具有經組態以吸聲之空隙。選擇 聚乙二醇以在切割板時摩擦所產生之溫度下凝聚粉塵細 粒。 Ο —種製造隔音板之方法,其包括製造包含半水合硫酸 鈣、聚乙二醇、水及由輕質骨料、纖維及其組合組成之群 中之至少一者的漿料。將發泡體添加至漿料中,較佳在混 - 合器排放處。由漿料形成隔音層材料之連續條帶。藉由將 • 條帶切割成個體板形成隔音板。最終,使部分水合2半水 合硫酸4弓完全凝固。 板視情況亦包括-或多個稀鬆層、密化層及背概材料。 該等可選層提供對隔音層之保護及支撐。輕質隔音板可能 易碎且容易破裂。包括稀鬆層、密化層及背襯層提供: 123539.doc 200829764 揮’使板在破裂性減小之情況下切割及懸吊。如使用懸浮 天花板格柵時,使用支揮亦減小當板僅由轉角或邊緣支樓 時的下垂。 Τ加聚乙二醇亦減小切割板材時所產生之細粒空浮粉塵 之里。特疋聚乙二醇之 之&擇很關鍵。選擇聚乙二醇以使其 在室溫下為固體形式。+ 在切割時之壓力及摩擦下,其轉化 Γ ϋ 歧聚粉塵之液體或膠黏形式。所得粒子;1夠大以快速降 落至地面以便清掃且交且 一 易地、/月除。該組合物使粉塵細粒之 空浮散布最小化,如此不击 不使石㈢籾塵政布在廣泛區域内。 【實施方式】 本發明提供輕質、減聲 卑I切J時減少粉塵之改進隔音 反二該:包括-具有二水合硫酸約晶體交鎖基質及切割時 =黏=細:之諸如聚乙二醇的合適凝聚添加劑之隔 曰、曰之在度較佳為10 lb/ft3至約25 lb/ft3 地,密度在約12 lb/ft3至約20 lhm3+从 密度為約!6-20 Ib/ft3。… 乾圍内,其中最佳為 或兩者。^。板視情況包括-密化層、-稀鬆層 較佳使用煅燒石膏激#隐立 〜 音層。任何包含半水合硫酸鈣 k人“ 焉或兩者之煅燒石膏均為適用的。半 ““夂鈣產生至少兩種晶形,…形 中通常使用β半水合硫酸舞,:”、、在石貧板 製成之層亦適用於…期由°半水合硫酸舞 兀過用於本發明。使用該等形式中之任 種製造以隔音層之重量計至少5 ^ 石膏之量較佳為至地。纟Μ…佳隔音層。 〇/〇在一些實施財,隔音層為至 123539.doc 200829764 少98重量%石膏。當使用水可 J 4形式硫酸鈣硬石膏時,較 佳以低於2 0 %之較小之量使用。 將一或多種除塵劑添加至太菸 王尽發明隔音層中以減少板切割 』間所產生之細粒私塵。除塵劑為傾向於吸附於細粒粉塵 粒子表面同時對自身具有親和性之惰性非反應性容易分散 之添加劑。較佳除塵劑為在室溫下為固體、在切割條件下 . &㈣物且隨後當切隸開板降落時再固化以凝聚及黏合 粉塵細粒之除塵劑。 ° 除塵劑包括由氧化乙婦及/或院氧基取代氧化乙浠於水 中之加成反應形成之水溶性直鏈聚合物。作為粉塵控制 劑,最佳為聚乙二醇(”PEG")、甲氧基聚乙二醇 (MPEG )、聚氧乙二醇、三官能性聚乙二醇(,,丁卩阶,)或其 組合。因為天花板板材用工作現場可利用之刀切割,所以 PEG應在尤其低之溫度下熔融。已發現適用之低熔點固體 包括 Clariant(Cladant Corporation,Mount H〇Uy,NC)之 (j M75〇。具有室溫(2卜23它)以上之熔點之除塵劑較佳充分 硬化以較佳地供本發明使用。 出於許多原因,本發明較佳使用具有僅在室溫以上之熔 點之聚乙二醇。該等材料具有與其分子量直接相關之相變 • 特徵。在室溫下,較低分子量之聚乙二醇以液體形式存 在,而較高分子量以固體形式存在。固體形式使其適用於 製備乾燥組合物以及液體形式。較低分子量形式可吸附於 粉塵細粒之表面從而使其黏著在一起,而較高分子量形式 可表面吸附且經由自固體相變為液體而機械凝聚粉塵細 123539.doc -11 - 200829764 粒。分子量亦影響溶解度。較高分子量之聚乙二醇具有比 較低分子量之聚乙二醇低的溶解性。作為經由蒸發而水遷 移之運輸之結果,固體形式之較低溶解性使其在乾燥後較 不容易脫離濃度梯度。合適為分子量大於或等於2〇〇公克/ 莫耳之聚乙二醇。PEG之分子量較佳在約75〇公克/莫耳至 約3,000公克/莫耳之範圍内且最佳在約75〇公克/莫耳至約 ι,ιοο公克/莫耳之範圍内。 以任何合適之量添加除塵劑。其較佳以接合化合物之乾 重之約0.1%至8%範圍内的濃度存在。在另一較佳範圍 中,其以約0·5%與約8%之間且最佳約〇·5%與約4 〇%之間 的濃度添加。若除塵劑為乾燥粉末形式,則較佳將其計量 至其他乾燥成分中。 其他潛在合適之除塵劑包括經選擇具有如上所述之相同 溶點範圍之低熔點石蠟。已評估之低熔點石蠟包括
Exx〇nMobil(Exx〇n Mobil,Fairfax,VA)之 Waxrex 2401 以及 來自Borden及Henry之其他類似物。 由水、半水合硫酸鈣及除塵劑製造用於製造隔音層之聚 料。水係以任何適用於製造層之量存在。將足夠水添加至 乾燥組分中以製造可流動漿料。水之合適量超過水合所有 輝又燒石貧以形成二水合硫酸約所需要之量的75%。至少部 分根據將使用該產品之應用及所使用之添加劑的量及類型 判疋水之確切量。部分根據所使用之煅燒石膏之類型判定 水含篁。為達成與β_煅燒灰泥相同的流動性,心煅燒灰泥 需要更少的水。基於水之重量與乾煅燒石膏之重量相比計 123539.doc -12- 200829764 算水與灰泥之比率。較 内K去从 〜佳比率在約〇.5:1至社5:1之範圍 网要為β半水化合物,在此情況 下’水與锻燒石膏之 丰奴么為約〇·7··1至約L5··〗,更佳約 0 771 ^ 更佳、力ο.75:1至約m,且仍更佳約 0.77:1 至約 1·1:1。 用於製造漿料之水應純至實 ^ ^王w用於最佳控制漿料與凝固硬 石用之性質。眾所周知鹽及有機化合物(在自加速劑至凝 口抑制#1之乾圍内廣泛不同)可改變漿料之凝固時間。隨 著二水合物晶體之交鎖基質的形成,某些雜質導致結構之 不規則,從而降低凝固產物之強度。因此,藉由使用無污 染物以實用之水增強產物之強度及稠度。 在二較佳實轭例中,視情況添加纖維以改進精飾板且 增強濕板之生強度(green strength)。較佳為具有小於約3 mm之纖維之諸如紙及再循環新聞紙的纖維素纖維。較佳 纖維具有約2 mm或更小之平均最大直徑。咸信纖維素纖維 與凝固石膏基質結合以使其不易破碎。雖然較佳為纖維素 纖維,但涵蓋使用其他纖維。纖維以高達約丨2重量%之量 存在於精飾層中。一些諸如Kay〇Cel l65〇(AmeHean FiUei>s and Abrasives)之市售紙纖維包括高達5〇重量。/〇之碳酸鈣。 碳酸妈之存在為可接受的且有利的,因為其防止加工期間 紙纖維結塊。 隔音層之另一可選組分為輕質骨料。輕質骨料較佳具有 小於約10 lb/ft之松度且提供填料空間以減小隔音板之密 度及重量。合適輕質骨料之實例包括(但不限於)膨脹聚苯 123539.doc -13 - 200829764 乙烯、膨脹is石、膨脹珍珠岩、陶聽球、樹脂微球及其 類似物或其組合。不太想要親水性骨料,因為其增加裝料 之需水量且增加乾燥隔音層所需之能量之量。諸如切碎的 膨脹聚笨乙浠之疏水性材料為較佳輕質骨料。 以任何產生想要量之填料空間、總密度及/或精飾板重 量之減小的量提供輕質骨料。舉例而言,質骨料係以精 飾層之約0.2重量%至約35重量%之量存在。膨脹珍珠岩、
Cj 膨脹蛭石及膨脹聚苯乙稀為較佳輕f骨料之實例。在較佳 實施例中’精細切碎之膨„苯乙稀具有約〇·2 _3至約 〇.5㈣3之容積密度,輕質骨料以層之固體含量之約02重 量至約3重量。/。的量提供。膨脹聚苯乙稀較佳具有2随 或更小之平均長度。 凝固加速劑亦為該組合物之可選組分。,,csa,,為包含與 5%糖共研磨之95%二水合硫酸鈣且加熱以 使糖焦糖化的石膏凝固加速劑。CSA獲自United States
GyP_ Company,Southard,沉工廠且根據共同擁有之 美國專利第3,573,947號製造,該專利以引用之方式併入本 文中。HRA為:水合硫_,其與糖以每⑽镑二水合硫 酉夂約約5至25時糖之比率新鮮研磨。其進_步 專利第2⑽,199號中,該專利以引用之方式併人本文中0 該兩者均為較佳之加速劑。就使用而言,使用適當量之任 何石膏加速劑或其組合涵蓋在本發明中。 亦視情況將黏合劑添加至锻燒石膏漿料中以改進凝固石 膏基貝之兀整性且改進隔音層與可選背襯片之黏合。可使 123539.doc -14 - 200829764 用任何合適的黏合劑或黏合劑之組合。煅燒石膏水性漿料 中較佳包括黏合劑。黏合劑較佳為殿粉,諸如玉米殿粉或 小麥澱粉;乳膠,諸如聚乙酸乙烯酯、丙烯酸系及丁苯乳 膠;或其組合。較佳黏合劑為形成自身交聯之丙烯系乳劑 之丙烯酸系黏合劑,諸如可獲自Rohm and Haas (Philadelphia,PA)之RH〇PLEX ha]6。較佳以乾燥隔音層 之約〇.5重量%至約5重量%、更佳約〇·8重量%至約i5重量 ^ %之量使用丙烯酸系黏合劑。 在隔音層或密化層或兩者中視情況包括澱粉黏合劑。遷 移或非遷移澱粉均為適用的。非遷移澱粉亦可藉由直接溶 解於紙背襯層中以增強與石膏之黏合來應用。澱粉較佳以 乾燥隔音層之約0.8重量%至約ι·5重量%之量存在。該隔音 層中適用之預膠凝化非遷移澱粉之實例包括GemGel st扣吮 (Manildra Group USA,Shawnee Mission,KS)及 PCF1000 (Lauhoff Grain Co·,St· Louis,MO)。非預膠凝化非遷移澱 ^ j 粉之實例包括Minstar 2000及Clinton 1 06玉米殿粉(兩者均 來自 Archer Daniels Midland Co·,Decatur,IL)。遷移澱粉 之實例包括Hi-Bond澱粉及LC-211澱粉(兩者均來自Archer Daniels Midland Co.,Decatur,IL)。 . 隔音層之另一可選組分為增強漿料之流動性且添加較少 水時使其可流動的水減少劑。聚磺酸鹽、三聚氰胺化合物 及聚竣酸鹽為較佳水減少劑且可以基於成分之乾燥重量高 達1.5%之量包括在漿料中。當以液體形式添加水減少劑 時,量係以乾燥固體重量計計算。較佳水減少劑為Dil〇F1() 123539.doc -15- 200829764 GW (GEO Specialty Chemical, Lafayette, IN)^EthaCryl 6 3070 (Lyondell Chemical C〇., Houston, TX) 〇 在漿料中視情況包括-或多種增強材料以提高強度、空 間穩定性或兩者。增強材料較佳為三偏_鹽化合H 有500-3_個重複單元之聚鱗酸鍵及四偏碟酸鹽化合物, 包括任何該等化合物之鹽或陰離子部分。雖然六偏磷酸越 . &合物有效增強抗下垂性,但不太想要,因為其充當凝固 ⑨緩劑且降低強度。增強材料描述於共同擁有之美國專利 第6,342,284號巾。尤其較佳為三偏錢鹽化合物。增強材 料係以任何合適量、較佳以成分之乾燥重量計約〇._重 量%至約2重量%使用。 當漿料排出漿料混合器時,將發泡體添加至其中以促進 凝固石β基貝中空隙之形成,從而改進吸音性且減少重 篁。任何已知適用於石膏產品中之習知發泡劑均適用於本 申請案。較佳地,發泡劑經選擇,如此其在隔音層中形成 Q 穩定發泡氣室。更佳地,至少一些空隙互連以致形成開放 氣室結構。較佳發泡體積為約35%至約6〇0/。,更佳約4〇% 至約55%且甚至更佳約45%至約5〇%(〇κ)。合適的發泡劑 • 包括烧基_硫酸鹽及月桂醇鱗硫酸鈉,諸如STEOL·® • 230 (Stepan Chemica1,Northfield,IL)。發泡劑係以足以在 隔音層中獲得想要隔音特徵之量添加。較佳地,發泡劑係 以基於乾燥成分之重量約0·003%至約〇 4%、且更佳約 0.005%至約〇.〇3°/。之量存在。視情況,以合適之量將發泡 穩定劑添加至緞燒石膏水性漿料中。 123539.doc -16- 200829764 將煅燒石膏、除塵劑及可選乾燥組分與水在漿料混合器 中混合以形成漿料。較佳地,將諸如锻燒石膏、除塵劑、 Γ ϋ ;斗疑固加速劑、黏合劑及纖維之所有乾燥組分在添加 至水中之前於粉末混合器中摻合。添加乾燥組分之前、期 間或之後,將液體成分直接添加至水中。混合以獲得均質 漿料之後’漿料排出漿料混合器,在此處添加發泡體。 、在將發泡劑添加至轉巾之前,將發㈣m發料混合 以製造發泡體’隨後在漿料混合器排放時,將發泡體添加 至榘料中。一旦將發泡體添加至漿料中,就將其排放至移 動式輸送帶’直接排放於傳送帶表面上或可選背襯片上。 製造期間’背襯片藉由轉移橫穿板長度之壓力,尤其當 板為/閏為時支撐隔音層。類似於石膏牆板製造中所使用之 飾面材料。在較佳實施例中,背襯片為紙,包括馬尼拉硬 紙(manda paper)或牛皮紙、非編織玻璃、金屬荡片或其組 .口 *、擇紙作為背襯片時,諸如習知牆板紙之多層紙為 適用的°層之數目視所選擇之紙而定視情況在1-8層變
化。 I 在f些實施例中,密化層視情況位於背襯片與隔音層之 間。該層增強板之潤濕與乾燥強度,使其在加工及切割期 間或正常磨損及磨破期間不太可能破裂。密化層與隔音層 相比較佳相龍薄且(例如)為约〇.〇5忖至約〇3_、更^ t至,力〇·25吁且且甚至更佳約〇 175忖至約〇 吋。 該層較佳具有至少⑽lbs/ft3、更佳至少Μ 1_3且仍更 佳約40 lbs/ft3至約45 lbs/ft3之密度。 123539.doc -17- 200829764 雖然密化層包括至少石膏’但視情況包括任何或所有併 入隔音層中之添加劑。較佳地’密化層為製造成隔音層之 聚料之滑流,藉由破壞所有或發泡體一部分該流已變二更 桐密。-種達成密化層之方法為藉由使用擊打流體流以使 發泡體泡孔破裂之邊緣混合器。或者,可由添加發泡體之 前所取出之漿料的滑流製造密化層或視情況由 層製造密化層。 稀鬆層為隔音板之另一可選組分。其鄰接隔音層而置。 當使用可選密化層時,稀鬆層較佳位於隔音層與密化戶之 間。若密化層與背襯層均為隔音板之特徵,則板較佳經構 造以具有按順序置放之隔音層、稀鬆層、密化層及背襯 片亦可使用之另-結構為具有稀鬆層作為飾面材料,繼 之以按順序置放之隔音層、密化層及背概片。選擇稀鬆層 以具有類似於背襯片之膨脹性質以防止在不同濕度下翹 曲。較佳地,稀鬆層為多孔的以有助於層連接且促進隔音 層乾燥。若使用稀鬆層作為飾面材料,則選擇聲學上透明 之稀鬆層。任何提供隔音層支撐且具有與背襯片(若 相容之膨脹性質的材料均適用作為稀鬆材料。較佳地,諸 乍背襯片之紙、非編織玻璃纖維稀鬆、編織玻璃纖維 -冑如聚&之合成纖維墊及其組合均為適用稀鬆材 料。與说贿⑽灰泥一起使用之imperial⑧石膏基本 飾面紙(兩者均由USG c,rati〇n,Chicag。,几製造)為較 佳稀#A、材料。杈佳地,當使用紙作為稀鬆層時,較佳不用 防水劑處理外部層。 123539.doc -18- 200829764 在包括稀鬆層之板之實施例中,另一可選組分為稀鬆黏 合劑以改進稀制與隔音層或密化層之㈣性。視情況將 稀鬆黏合㈣覆於稀鬆表面之―面或兩面,或視情況將其 添加至形成隔音層之_中。㈣黏合劑之塗覆可藉由散 布、滾塗、噴m、刮平或任何塗覆該等材料之技術之熟習 者所已知之其他塗覆^法實現。較佳稀鬆黏合冑彳為預膠凝 化澱粉。
Ο 雖然個體隔音板可由此項技術已知之間歇法製造,但以 連續法使其形成可切割成想要長度之板之連續板更為有 利。獲得成形背襯材料且將其置放於接收石膏漿料之位 置。較佳地,背面材料(若存在)具有一定寬度,如此形成 :需兩次切割即製成具有想要成品尺寸之板的連續板條 ▼ °任何已知背襯材料均適用於製造牆板,包括紙、玻璃 墊及塑料片。較佳地,飾面為多層紙背襯。將背襯材料連 續饋入板生產線中。 藉由將乾燥組分與潤濕組分混合在-起形成漿料。在漿 乾燥"且刀(锻燒石嘗及任何乾燥添加劑)進入混合器之 前’將其摻合在_起。將水直接量人混合器中。將液體添 人Μ添加至水中,且將混合器啟動一小段時間以使其摻 合。:在調配物中使用-或多種改質齊!,則較佳在添加灰 匕之月j將改貝劑與分散劑一起添加至混合器中。在混合器 中將乾燥組分添加至液體中,且摻合直至使乾燥組分潤 田水與灰泥之比率下降時,應注意施加於混合器上之負 123539.doc -19- 200829764 荷。聚料水之減少增加混合期間組合物之黏度 加足量分散劑以產生可流動混合物時…备添 散劑有機會分散石膏顆+ /tc^期間在分 合時間並不會對最終產品產生不利影響。 &長的此
Ο 隨後將㈣混合以達成均f漿料。通常將水性發 5於漿料中以控制所得核心材料之密度。該水性發泡體: 常:精=將所得發泡體引入漿料之前將適當發泡劑、水 及空氣㈣切混合而產生。可將發泡體插入混合器中之將 料中’或較佳#漿料在排料管中排出混合器時插入其中Γ 參見例如美國專利第5,683,635號,其以引用之方式併入本 文中。在石膏板工廠中’經常將固體及液體連續添加至混 合器中’㈤時將所得漿料連續排出混合器,且在混合器中 之平均滯留時間小於5秒。 ° 將漿料作為連續條帶經由排出管穿過混合器之一或多個 出口連續分配且沈積於傳送帶上。傳送帶將條帶運載至將 其切割為預選擇之尺寸之板的刀處。 較佳使用兩階段乾燥法。首先使板經受高溫爐以將板快 速加熱且開始驅除過量水。爐之溫度及板之滞留時間隨板 之厚度而變化。舉例而言,i/2吋板(12.7 mm)較佳在超過 300°F(149°C)之溫度下乾燥約20至50分鐘。隨著表面上之 水的蒸發,其受到板内部之毛細作用的拉伸而取代表面 水。水相對快速之移動有助於澱粉及羥基吡啶硫酮鹽向紙 中遷移。第二階段之烘箱具有低於3〇〇卞(149。〇之溫度以 限制板之锻燒。 123539.doc -20- 200829764 實例 在添加或不添加除塵劑之情況下,在實驗室中生產板核 心材料。製備具有不同平均分子量之甲氧基聚乙二醇且測 試其物理性質、可切割性及細粒空浮粉塵之產生。來自 Claimant C〇rporati〇n之除塵劑指定,,M"表示甲基聚乙二醇 以及某一數字表示平均分子量。因此,,,M5〇〇"為具有5〇〇 公克/莫耳之平均分子量之甲基聚乙二醇。 基本組成包括1.2%中級切碎的膨脹聚苯乙烯、〇.5〇/〇 CSA石貧凝固促進加速劑、0 02%界面活性劑、2。/❶紙纖 維、分散劑且固體之剩餘部分為板灰泥(β煅燒半水合硫酸 鈣)。添加至各樣品中之MPEG之類型及量展示於表I中。 將固體材料在雙筒混合器中預混合,隨後與液體成分在 Hob art混合器使用’•鞭形”槳混合。使用in Sfr 〇n Model 1130 測試儀器測試斷裂模數(Modulus of RUpture)(,,MOR,,)。修 正之斷裂模數("CMOR”)調節因樣品密度之差異所致之 MOR。藉由將墊刀固著於測試夾具上以客觀量測切穿板樣 品所必需之力之量來定量量測可切割性。藉由觀察空浮粉 塵之量與切割時降落至基板上之粉塵相比客觀碟定粉塵。 以0-10之量表報導可切割性與粉塵之產生,其中〇最差且 10最佳。
表I
板 PEG類型 PEG % 厚度 密度 MOR CMOR 可切割性 粉塵 1 無 0 0.557 17.27 41.1 33.5 4 3 2 M250 4.0 9.555 17.49 36.0 29.1 9 2 3 M250 4.0 0.534 19.21 44.6 29.5 NA NA 123539.doc -21- 200829764
4 M500 4.0 0.562 17.05 39.3 33.5 NA NA 5 M500 4.0 0.549 17.34 39.8 32.7 9 7 6 M750 4.0 0.535 19.67 57.9 36.8 NA NA 7 M750 4.0 0.528 16.23 38.8 36.1 9 7 8 M1100 4.0 0.557 17.84 54.5 42.7 9 9 9 M1100 4.0 0.519 18.24 55.4 41.2 NA NA 10 無 0 0.562 15.86 303 29.0 NA NA 在切割平滑性及粉塵度方面含mpeg之樣品與對照樣品 之間存在明顯差異。以定性計,用M750及M1100生產之樣 品達成最平滑之切割及最少之空浮粉塵。 雖然已展示及描述少粉塵隔音板之一特定實施例,但熟 習此項技術者應瞭解,在不在本發明之更廣泛態樣及所述 之以下申清專利範圍方面偏離本發明之情況下,可對其進 行改變及修改。 Ο 123539.doc -22-
Claims (1)
- 200829764 十、申請專利範圍: 一種隔音板,其包含一隔音層,該隔音層包含二水合硫 酸約之交鎖基質、除塵劑及由纖維、輕質骨料及其混合 物組成之群中之至少一者,其中該交鎖基質中之空隙經 組態以吸聲且其中該除塵劑係經選擇以在由切割該板時 摩擦所產生之溫度下凝聚粉塵。 2·如請求項1之板,其中該除塵劑具有小於55°C之熔點。 3 ·如請求項1之板,其中該等纖維包含紙。Ο 4·如凊求項1之板,其中該二水合硫酸鈣係以至少85重量0/〇 之濃度存在。 如明求項1之板,其中該等纖維係以小於該隔音板之3重 量%之濃度存在。 6·如睛求項1之板,其中該輕質骨料係以小於該隔音板之3 重量。/〇之濃度存在。 8·如請求们之板,其進-步包含至少_種背概片。 9·如請求項1之板,其中該背襯片包含紙。 ι〇·如請求項1之板,其進一步包令_ _ ^ 3 比该隔音層更緻密之 密化層。 如明求項1之板,其中該輕質骨料為由膨脹蛭石、膨脹 珍珠石及切碎膨脹聚苯乙烯組成之群中之至少一者。 背襯片。 位於該隔音層與該背 η·如請求項10之板,其進一步包含— 12·如請求項u之板,其中該密化層係 襯層之間。 13.如請求項丨之板,其進一步包含—稀鬆片 123539.doc 200829764 14·如請求項13之板,其中該稀鬆片包含一多層紙片。 15·如叫求項14之板,其中該板包含按順序置放之該隔音 層、該稀鬆層、該密化層及該背襯層。 如α求項丨4之板,其中該板包含按噸序置放之該稀鬆 層、該隔音層、該密化層及該背襯層。 17·如明求項1之板,其具有板體積之至少35°/。之空隙體積。 18·如請求項17之板,其具有該板體積之至少之空隙體 積。 19. 如請求項丨之板,其進一步包含包括由聚磷酸銨、三偏 磷酸鹽化合物、四偏磷酸鹽化合物、六偏磷酸鹽化合物 及其組合組成之群中之至少一者的增強材料。 20. 如凊求項丨之板,其進一步包含由凝固加速劑、水減少 劑及其組合組成之群中之至少一者。 21. 一種製造隔音板之漿料,其大體上由半水合硫酸鈣、加 強纖維、輕質骨料及聚乙二醇組成。 22. 種製造隔音板之方法,其包含: 製造包含半水合硫酸鈣、除塵劑、水及由輕質骨料、 纖維及其組合組成之群中之至少一者的漿料; 將發泡體添加至該漿料中; 形成隔音層材料之該漿料之連續條帶; 切割該條帶以形成該隔音板,·及 使該半水合硫酸姜弓凝固。 23. 如請求項22之方法,其進一步包含乾燥該板。 24·如請求項22之方法,其進—步包含置放__㈣層以接收 123539.doc -2 - 200829764 該漿料,且其中該成形步驟之連續 分布在該稀鬆層上而形成。 條帶係藉由將該漿料 25. 如請求項22之方 該漿料分成主流 该成形步驟之連 上而形成。 法’其進一步包含在該成形步驟之前將 及滑流;由該滑流製造密化層;及其中 續條帶係藉由將該漿料分布於該密化層 123539.doc 200829764 七、指定代表圖: (一) 本案指定代表圖為:(無) (二) 本代表圖之元件符號簡單說明: 八、本案若有化學式時,請揭示最能顯示發明特徵的化學式: (無) 123539.doc
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- 2007-09-07 AR ARP070103979 patent/AR062718A1/es unknown
-
2009
- 2009-02-05 IL IL196911A patent/IL196911A0/en unknown
- 2009-02-09 ZA ZA200900914A patent/ZA200900914B/xx unknown
- 2009-03-03 HR HR20090129A patent/HRP20090129A2/xx not_active Application Discontinuation
- 2009-04-02 NO NO20091365A patent/NO20091365L/no not_active Application Discontinuation
- 2009-04-06 CO CO09035338A patent/CO6170379A2/es not_active Application Discontinuation
Also Published As
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IL196911A0 (en) | 2009-11-18 |
US7503430B2 (en) | 2009-03-17 |
RU2009105171A (ru) | 2010-10-20 |
JP2010502866A (ja) | 2010-01-28 |
NO20091365L (no) | 2009-04-02 |
AR062718A1 (es) | 2008-11-26 |
EP2064397A2 (en) | 2009-06-03 |
HRP20090129A2 (en) | 2009-05-31 |
AU2007293442A1 (en) | 2008-03-13 |
CA2662133A1 (en) | 2008-03-13 |
MY167820A (en) | 2018-09-26 |
WO2008030341A3 (en) | 2008-12-04 |
ZA200900914B (en) | 2010-07-28 |
US20080060871A1 (en) | 2008-03-13 |
EP2064397A4 (en) | 2011-01-12 |
UA95301C2 (en) | 2011-07-25 |
WO2008030341A2 (en) | 2008-03-13 |
MX2009001996A (es) | 2009-03-09 |
CN101506442A (zh) | 2009-08-12 |
CO6170379A2 (es) | 2010-06-18 |
KR20090050058A (ko) | 2009-05-19 |
BRPI0714759A2 (pt) | 2013-05-14 |
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