201202516 六、發明說明： 【發明所屬之技術領域】 該領域係關於一種不織布材料， 立坪§之，係關於 效提供適於用作隔音天花板究碍之隔熱及隔音低 度不織布材料。 在 【先前技術】 習知隔音天花板竞碑為不織布結構，其包括由組 型為天花板瓷磚結構之基質纖維、填充劑及黏合劑構： 核心。基質纖維通常為礦棉或玻璃纖維。填充劑可為势珠 岩、黏土、碳酸妈、纖維素纖維及其類似物。黏合劑典型 地為纖維素纖維、澱粉、乳膠及其類似物。乾燥後，黏合 劑即與基質纖維及填充劑形成黏合以形成纖維網狀物，: 提供免碑結構剛性且形成吸音之多孔結構。為用作典型天 花板究磚，不織布結構或基質墊應為實質上平坦且自撐的 以便懸浮於典型天花板瓷磚栅格或類似結構中。 .對於適於隔音天花板瓷磚應用之不織布結構而言，不 織布結構亦需符合關於噪音降低及防火等級之各種工業標 準及建築規範。舉例而·!·，工業標準需要天花板荒磚具有 根據ASTM E84之A級防火等級，其通常需要小於25之火 焰蔓延指數（f】ame spread index )及小於5〇之煙氣發生指 數（smoke deveI〇pment jndex)。關於噪音降低工業標準 典型地需要隔音天花板瓷磚具有根擄ASTM C423至少為約 0.55之。永音降低係數（n〇ise reducti〇n，NRC)。 隔音天花板究磚通常經由濕式佈層（wet-laid )製程形 3 201202516 成，該製程使用水性介質輸送瓷磚組分且使其成型為所需 結構。基本過程涉及首先將各種瓷磚成分摻合至水性漿料 中，將漿料輸送至高位調漿箱（head box)成型台，且經由 移動的多孔絲網將漿料分配至具有所需尺寸及厚度之均勻 墊中。移除水且接著乾燥該墊。經乾燥之墊可藉由開槽、 衝壓、塗佈及/或層壓表面修整至瓷碑而修整為天花板瓷磚 結構。在濕式佈層製程中，水充當各種瓷磚成分之輸送介 質。然而，雖然便利於高製造速度、及使用低成本原料（例 如，再循環新聞紙纖維、再循環瓦楞紙、廢聚酯纖維、棉 絨、廢織物及其類似物）之能力，但使用水製造隔音天花 板竞磚亦呈現許多缺點，使得該製程及所形成之產品較不 合乎需要。 濕式佈層製程使用大量水輸送組分且使其成型為天花 板瓷碑結構。最終必須自產品移除大量水。因此，大多數 濕式製程提供藉由自由或重力排水、冑真空及低真空、壓 縮及蒸發中之一或多個步驟進行水移除。令人遺憾的是， 此等製程步驟需要較大能量需求來輸送及移除水。因此， 處置大量水以形成£磚以及隨後移除及蒸發水可提供典型 濕式佈層製程，其由於高設備及操作成本而相對昂貴。 亦難以使用濕式佈層製程形成具有高吸音性質之隔音 天花板瓷碑。在濕式佈層製程中，所形成之天花板瓷磚： 於濕式佈層調配物中之成分的性質而趨向於具有密封表 面：具有密封表面之天花板曼磚通常具有有效性較低的聲 屏·^因為竟磚之多孔性較低，此使得究碑吸音之能力較 差。密封之£碑表面可實際上反射聲音，&為隔音天花: 4 201202516 瓷磚之非所需特徵。 咸信此等非所需隔音特徵由 用之咨石皇ct、八It 7佈層製程十血/太 用之无磚成分的親水性引 /、i地使 本黏合劑及填充劑的纖維素纖維(例==中之低成 !高度親水性且吸收大量水。部分地由具 力，濕式佈層究碑典型地具有 、:親水性組 分含量（亦即，在即將進入乾燥箱或：75:^ 含量)，此會增加乾燥期間對蒸 t之-板之水分 間’由於自此等親水性組分移除水 此’在乾燥期 表面張力。水A錄托而在竞磚成分上產生高 此表面張力通常引起竟磚：予其他組分表面張力。 表面由多孔性較低之結構密封。 咸6在製程中表面張力將咨s m力將^中之組成部分拉得更靠攏， 從而使結構緻密並閉合瓷磚 亢蜉孔隙。因此，濕式佈層製造之 天化板竟碑需要進一步處理以在竞碑中打孔，以便達成可 接受之噪音降低。因此，雖然濕式佈層製程可能由於製造 速度增加及使用低成本材料之能力而為可接受的，但當隔 音特徵為產品所需時’使用水作為輸送介質使得該製程及 所得產品之成本效率較低。 在-些情況下，乳膠黏合劑亦可用於隔音天花板竞碑 中且常f為使用礦棉作為基質纖維之濕式佈層製程中的首 選。然而，礼膠通常為天花板瓷磚調配物中所用之最昂貴 成分；因此，希望限制此相對較高成本成分之使用。常用 於天花板瓷•磚中之其他黏合劑為澱粉及如上文所述之纖維 素纖維。然而’澱粉及纖維素具有親水性且在處理期間趨 向於吸水並產生上述高表面張力問題。 201202516 使用濕式佈層製程製造之隔音天花板究碑的常見缺點 為，該等所形成之竟磚通常經由上述機制而導致較高密 度。高密度常常會導致高氣流阻力’此會損害吸音二 典型地，以習知配方製造之瓷磚的密度為約i2 ibs/ft3至約 20驗3’視其組成而定。其亦具有約〇55至約〇 8〇之噪 音降低係數（NRC)，視特定組成而定。對於具有類似組^ 之基質墊而5 ’較低密度通常導致較低氣流阻力或較高孔 隙率，由此改良吸音作用。然而，若組成不同，則密度與 孔隙率之相關性未必如上文所述。 已開發替代黏合纖維，但該等替代纖維仍使用親水括 組分製造而成因此將展現與現有天花板㈣成分中所見 相同之缺點。舉例而言，美國專利第Mi8,295號及第 6’ ’5〇6號及美國公開案第2005/0026529號描述一種上方 具有複數個微原纖維之微細纖維。此等參考文獻之發明者 表明微原纖維在機械方面增強不織布材料以提供改良之抗 張強度。然而’此等參考文獻中之纖維仍使用澱粉基質構 成’該基質提供天然聚合物將各組分結合在一起。在此等 情況下’因為殿粉使得任何所形成之材料均為生物可降解 的’故其為重要的。然而，若使用此等參考文獻令所述之 激粉形成天扣狀咨碰 曰丨^^ 是碑則所形成之瓷磚將因澱粉之親水性 而展現與濕式佈層瓷碑中所見相同之缺點。㈣，如上文 所述：預期澱粉基質將在水移除期間形成高表面張力且趨 向於形成密封丧面你 了表面從而降低瓷碑吸音之能力。此等參考 獻.^表明，可自纖維結構移除澱粉基質且僅使用微 原.、$ @ ’在此情況下，若天花板竞磚中僅使用個別 6 201202516 微原纖維而不利用基質纖維結構的優點，則該等微原纖維 不會提供足以充當天花板瓷磚結構中之有效黏合劑的黏合 基質及強度。 因此’需要一種具有最少親水性組分之低密度不織布 結構，其為平坦的，自樓的，且在工業標準下適用於符合 使用者對於手動可切性之期望的隔音天花板瓷磚（亦即， 熱性質與聲學性質）。 【發明内容】 一般而言’提供一種包括無機基質纖維及合成熱黏合 纖維之低密度不織布材料。藉由一種方法，該低密度不織 布材料能夠成型為具有足以提供實質上平坦、剛性且自推 的材料之預定基本重量及低密度的核心或基質墊，該實質 上平坦、剛性且自撐的材料能夠提供足以用作隔音天花板 瓷磚之熱特徵與聲音特徵。本文中所用之術語平坦（Hu ) 或平坦度（flatness )意謂當將2 ft長的面板置於柵格上時 中間之撓曲度。舉例而言，t質上平坦的面板可具有約〇 25 '^或更小之撓曲度。如本發明中所使用，「低密度（_ density)」通常指約〗〇lbW(PCf)或更小，且通常在約7 匕至、勺1 3 PCf之範圍内。又，如本發明中所論述’「孔隙 率（porosuy)」由氣流阻力定量且可根據astm c似及⑶6 2測m卜’本發明預期㈣本文所述之製程製造之 碑的較佳厚度通常在約0.W至約i•"之範圍内。 【實施方式】 7 201202516 舉例而§，不織布材料能夠形成實質上平坦、自撐、 抗下垂的核心，該核心展現根據ASTM C423至少為約〇 55 之噪音降低係數及A級防火等級，根據ASTM E84，其火焰 蔓延彳a數為約25或更小且煙氣發生指數為約5〇或更小。 即使具有低密度，核心亦較佳展現高撓曲強度，但仍可手 動切割，諸如使用普通美工刀以輕微或最小壓力切割。 在各種具體實例中，無機基質纖維較佳為礦棉 '渣棉、 石棉或其混合物，其渣球含量較佳為最多約6〇重量％且最 佳為約U)重量％至約45重量％。如本文中所使用，礦棉渣 球通常指礦棉製造製程之副產物’其包含直徑在約5〇微米 至約500微米範圍内之非纖維礦物質微粒。適合之無機基 質纖維為 Thermafiber FRF 牌纖維（USG Interi〇rs 公司， Chicago, Illinois);然而，亦可使用其他無機基質纖維，諸 如玻璃纖維及其類似物。較佳地，無機纖維之平均長度為 約0.1 mm至約4 mm且平均直徑為約i微米至約15微米。 藉由一種方法，不織布材料之核心包括以重量計約3〇%至 約95%之石棉或渣棉。 在各種具體實例中，合成熱黏合纖維較佳為單組分或 雙組分合成纖維，當加熱至適當溫度時，其溶化或與周圍 材料黏合。較佳地，不織布合成材料包括以重量計約〇 至約50%’且最佳為約1%至約25%之合成單組分或雙组分 纖維。如本文中所使用，「合成（synthetie)」指❹非天然 來源之組分製造的纖維。舉例而言’合成熱黏合纖維較佳 由聚丙烯酸系⑯、乙烯乙酸乙烯酯、聚酯、聚烯烴 '聚醯 胺、紛-甲酸、聚乙稀醇、聚氣乙烯或其混合物構成。此等 201202516 材料之炫點通f為約1⑼。c至約250T：。某些可使用之合成 熱黏合纖維由聚烯烴樹脂構成且至少一種組分展現約 12 5 C 至約 1 3 之熔點。亦可使用由除聚烯烴樹脂外之材 料構成的纖維且該等纖維可提供諸如強度之良好性質，但 可能較為昂貴。 藉由一種方法，較佳之合成熱黏合纖維通常為非生物 可降解的且基本上不含澱粉、蛋白質及其他天然存在之聚 合物’此等物質大部分具有親水性且將導致先前技術纖維 中所見的非所需表面張力性質。如下文進一步論述，本文 中之合成熱黏合纖維通常保留疏水性，即使處理成具有親 水性表面以改良分散穩定性。 一較佳之合成熱黏合纖維具有與纖維長度及直徑有關之 网表面積以便提供高黏合表面積。舉例而f，較佳之合成 黏合纖維之平均長度小於3匪（較佳為約G丨_至:3 _)’平均直徑小於50微米（較佳為約5微米至約3〇微 米但具有大於約〇5平方公尺/公克且較佳介於約丄平方 公尺/公克㈣12平方公尺/公克之間的大表面積。該表面 積比市售早組分或雙組分熱黏合纖維大約—個至兩 級，該等市售單組分或雙組分熱黏合纖維在…丹尼爾 二一之纖維下通常具有約CM平方公尺/公克至約Μ 平方公尺/公克之表面積。 下表！展示標準市售未原纖化纖維以丹尼爾及密度計 的-糸列表面積。舉例而言’如圖表中所示，若纖唯且有3 丹尼爾m密度為0.95g/em3’則標準未原纖成 之表面積將為0.199 m2/g。 隹 201202516 表 面積 每一長絲之 丹尼爾數 密度為0.90 g/cm3 1 0.354 2 0.251 3 0.205 4 0Λ77 5 0.158 ~ 0Ί45 ' 密度為0.95^ g/cm3 0.345 0.244 0.199 "0.172 標準、未原纖化之合成織維以m2/g計的表 密度為1.00 g/cm3 ~0336[ "0338" 為達成該與纖維長度及直徑有關之高表面積 之纖維較佳規定細長纖維基質或主體及許多自該細長纖 基質的外表面向外延伸之将八* $ ''' 雜與" 延伸之撻刀支或微原纖維，或微原纖維 例而言’單纖維可規定許多微原纖維，其直徑各A 約〇. 1微米至約1 〇微米。適人古 二’’、、 白Mitsui Chemicals ―:问又面積原纖化纖維可獲201202516 VI. Description of the invention: [Technical field to which the invention pertains] This field relates to a non-woven material, which is a heat-insulating and sound-insulating low-non-woven material suitable for use as a soundproof ceiling. [Prior Art] Conventional soundproof ceilings are a non-woven structure comprising a matrix fiber, a filler and a binder composed of a ceiling tile structure: a core. The matrix fibers are typically mineral wool or fiberglass. The filler may be metabolith, clay, carbonated mother, cellulose fiber and the like. The binder is typically cellulosic fibers, starch, latex and the like. After drying, the binder forms a bond with the matrix fibers and the filler to form a fibrous web: a porous structure that provides rigidity to the monumental structure and forms a sound absorbing structure. For use as a typical ceiling tile, the nonwoven structure or matrix mat should be substantially flat and self-supporting to be suspended in a typical ceiling tile grid or similar structure. For non-woven structures suitable for soundproof ceiling tile applications, the non-woven structure also meets various industrial standards and building codes for noise reduction and fire rating. For example, the industry standard requires ceiling bricks to have a Class A fire rating according to ASTM E84, which typically requires a flame spread index of less than 25 (f]ame spread index) and a smoke generation index of less than 5 inches (smoke deveI) 〇pment jndex). Regarding Noise Reduction Industry Standards It is typically desirable to have a soundproof ceiling tile having a root 掳 ASTM C423 of at least about 0.55. Yongyin reduction coefficient (n〇ise reducti〇n, NRC). Sound-insulating ceiling tiles are typically formed by wet-laid process 3 201202516, which uses an aqueous medium to transport the tile components and shape them into the desired structure. The basic process involves first blending various tile components into an aqueous slurry, delivering the slurry to a high head box forming station, and dispensing the slurry to a desired size and thickness via a moving porous screen. Uniform pad. The water is removed and the pad is then dried. The dried mat can be trimmed to a ceiling tile structure by grooving, stamping, coating and/or laminating the surface to a porcelain monument. In a wet lay-up process, water acts as a transport medium for various tile components. However, while facilitating high manufacturing speeds and the ability to use low cost materials (eg, recycled newsprint fibers, recycled corrugated paper, waste polyester fibers, cotton linters, waste fabrics, and the like), the use of water to make soundproof ceilings There are also many shortcomings in competing bricks, making the process and the products formed less desirable. The wet layup process uses a large amount of water to transport the components and shape them into a ceiling tile structure. Ultimately, a large amount of water must be removed from the product. Therefore, most wet processes provide water removal by one or more of free or gravity drainage, helium vacuum and low vacuum, compression and evaporation. Unfortunately, these process steps require greater energy requirements to transport and remove water. Thus, disposal of large amounts of water to form a brick and subsequent removal and evaporation of water can provide a typical wet-laid process that is relatively expensive due to high equipment and operating costs. It is also difficult to form a soundproof ceiling porcelain monument having a high sound absorbing property using a wet cloth layer process. In a wet-laid process, the resulting ceiling tile: tends to have a sealing surface in the nature of the composition in the wet-laid formulation: a ceiling with a sealing surface typically has a less effective sound screen. ^Because the bricks are less porous, this makes the monument's ability to absorb sound worse. The sealed surface of the monument can actually reflect the sound, & for the soundproof ceiling: 4 201202516 Undesired features of the tile. Xianxin believes that the non-required sound-insulating characteristics are made of the stone that is used by the Shishihuang ct, the eight It 7 layer, the ten-blood/used brick-free hydrophilicity, and the cellulose of the binder and filler. Fiber (example == low to medium! Highly hydrophilic and absorbs a lot of water. Partially by force, wet cloth layer monument typically has: hydrophilic component content (ie, just entering the drying oven or :75:^ content), this will increase the surface tension during the drying period of the steaming-to-plate moisture 'because the hydrophilic component removes water from this, during the drying period. The water A is recorded in the brick component Producing a high surface tension usually causes the brick to: surface tension of other components. The surface is sealed by a structure with a low porosity. The surface tension in the process of the salt 6 will pull the components of the ^ closer together. Thereby making the structure dense and closing the pores of the tile. Therefore, the wet-laid layer of the finished layer needs further processing to punch holes in the monument in order to achieve an acceptable noise reduction. Therefore, although the wet cloth layer Process may increase due to manufacturing speed and use of low cost materials The ability is acceptable, but when the sound-damping feature is required for the product, 'using water as the transport medium makes the process and the resulting product less cost effective. In some cases, the latex adhesive can also be used for soundproof ceilings. The monument and often f are the first choice in the wet-laid process using mineral wool as the matrix fiber. However, the gum is usually the most expensive component used in ceiling tile formulations; therefore, it is desirable to limit this relatively high cost component. Other adhesives commonly used in ceiling porcelain tiles are starch and cellulosic fibers as described above. However, 'starch and cellulose are hydrophilic and tend to absorb water during processing and produce the above high surface tension problems. 201202516 A common disadvantage of sound-insulating ceilings made using a wet-laid process is that the bricks formed by these fibers generally result in higher density via the above mechanism. High density often leads to high airflow resistance 'this would damage sound absorption 2 typically The density of the tile made by the conventional formula is about i2 ibs/ft3 to about 20, depending on its composition. It also has about The noise reduction factor (NRC) from 55 to about 8 , depends on the specific composition. For matrix mats with similar groups, the 5 'lower density usually results in lower airflow resistance or higher porosity, thereby improving sound absorption. However, if the composition is different, the correlation between density and porosity is not necessarily as described above. Alternative adhesive fibers have been developed, but these alternative fibers are still made using hydrophilic components and will therefore exhibit the composition of existing ceilings (4). The same disadvantages are seen in the examples. For example, U.S. Patent Nos. Mi. No. 295 and No. 6' '5, and U.S. Patent Publication No. 2005/0026, 529, each of which is incorporated herein by reference. The inventors of the references indicate that microfibrils mechanically reinforce nonwoven materials to provide improved tensile strength. However, the fibers in such references still use a starch matrix to form a matrix that provides a natural polymer to bind the components. together. In these cases, it is important that the material formed is biodegradable because it is made of powder. However, if these references are used, the powder formed by the above-mentioned reference is formed into a buckle. The tile formed by the monument will be the same as that seen in the wet porcelain layer due to the hydrophilicity of the starch. Disadvantages. (d), as described above: It is expected that the starch matrix will form a high surface tension during water removal and tend to form a seal surface that reduces the ability of the porcelain to absorb sound. These references indicate that the starch matrix can be removed from the fiber structure and only the micro-origins are used. In this case, if only the individual 6 201202516 microfibrils are used in the ceiling tiles, the matrix fiber structure is not utilized. The advantage is that the microfibrils do not provide an adhesive matrix and strength sufficient to act as an effective binder in the ceiling tile structure. Therefore, there is a need for a low density nonwoven structure having the least hydrophilic component, which is flat, self-contained, and suitable for use in soundproof ceiling tiles that meet the user's desire for manual cutability under industry standards (ie, Thermal properties and acoustic properties). SUMMARY OF THE INVENTION Generally, a low density nonwoven fabric material comprising an inorganic matrix fiber and a synthetic heat bonding fiber is provided. By a method, the low density nonwoven material can be formed into a core or matrix mat having a predetermined basis weight and a low density sufficient to provide a substantially flat, rigid and self-propelling material, the substantially flat, rigid and self-supporting material It is capable of providing thermal and acoustic features sufficient for use as a soundproof ceiling tile. The term flat (Hu) or flatness as used herein means the degree of deflection in the middle when a 2 ft long panel is placed on a grid. For example, a panel that is flat on t can have a deflection of about 25 '^ or less. As used in the present invention, "low density" generally refers to about 〇 lbW (PCf) or less, and is typically in the range of about 7 匕 to, and 1 3 PCf. Further, as discussed in the present invention, "porosuy" is quantified by airflow resistance and can be measured according to astm c and (3) 6 2 m. The present invention is expected to have a preferred thickness of the process of manufacturing the process described herein. Within the range of about 0.W to about i•". [Embodiment] 7 201202516 By way of example, the non-woven material can form a substantially flat, self-supporting, sagging-resistant core exhibiting a noise reduction factor of at least about 55 and a Class A fire rating according to ASTM C423, according to ASTM E84. The flame spread 彳a number is about 25 or less and the smoke generation index is about 5 〇 or less. Even with a low density, the core preferably exhibits high flexural strength, but can still be manually cut, such as using a conventional utility knife to cut with a slight or minimal pressure. In various embodiments, the inorganic matrix fibers are preferably mineral wool 'slag wool, asbestos or mixtures thereof, preferably having a slag content of up to about 6% by weight and most preferably from about U) to about 45% by weight. . As used herein, mineral wool slag balls generally refer to by-products of the mineral wool manufacturing process, which comprise non-fibrous mineral particles having a diameter ranging from about 5 Å to about 500 microns. Suitable inorganic binder fibers are Thermafiber FRF brand fibers (USG Interi®, Chicago, Illinois); however, other inorganic matrix fibers such as glass fibers and the like can also be used. Preferably, the inorganic fibers have an average length of from about 0.1 mm to about 4 mm and an average diameter of from about i microns to about 15 microns. By one method, the core of the nonwoven material comprises from about 3% to about 95% by weight of asbestos or slag wool. In various embodiments, the synthetic heat-bonded fibers are preferably one-component or two-component synthetic fibers that melt or adhere to the surrounding material when heated to a suitable temperature. Preferably, the nonwoven composite material comprises from about 5% to about 50% by weight and most preferably from about 1% to about 25% by weight of the synthetic one-component or bicomponent fibers. As used herein, "synthetie" refers to a fiber made from a component that is not of natural origin. For example, the synthetic heat-bonded fiber is preferably composed of polyacrylic acid 16, ethylene vinyl acetate, polyester, polyolefin 'polyamine, sulfonic acid, polyethylene glycol, polyethylene gas or a mixture thereof. These 201202516 materials are about 1 (9). c to about 250T:. Some of the synthetic heat-bondable fibers that can be used are composed of a polyolefin resin and at least one component exhibits a melting point of from about 12 5 C to about 1 3 . Fibers composed of materials other than polyolefin resins may also be used and such fibers may provide good properties such as strength, but may be relatively expensive. By one method, the preferred synthetic heat-bonded fibers are generally non-biodegradable and substantially free of starch, protein, and other naturally occurring polymers. These materials are mostly hydrophilic and will result in what is seen in prior art fibers. Undesired surface tension properties. As discussed further below, the synthetic heat-bonded fibers herein generally retain hydrophobicity even when processed to have a hydrophilic surface to improve dispersion stability. A preferred synthetic heat bonded fiber has a web surface area associated with fiber length and diameter to provide a high bond surface area. For example, f, preferably, the synthetic binder fibers have an average length of less than 3 Å (preferably about G 丨 to: 3 _) and an average diameter of less than 50 μm (preferably from about 5 μm to about 3 μm but having greater than about 〇 5 m ^ 2 / g and preferably a large surface area between about 丄 m ^ 2 / g (four) 12 m ^ 2 / g. This surface area is about one to two than the commercial early component or two-component thermal bonding fiber Grades, such commercially available one-component or two-component heat-bonded fibers typically have a surface area of from about CM square meters per gram to about 平方 square meters per gram under the fibers of Daniel Dimensions. For the unfibrillated fiber, the tantalum and densitometer - 糸 list area. For example, as shown in the chart, if the fiber has a density of 3 denier m of 0.95g/em3', the standard unfibrillated surface area It will be 0.199 m2/g. 隹201202516 Surface area Daniel number density per filament is 0.90 g/cm3 1 0.354 2 0.251 3 0.205 4 0Λ77 5 0.158 ~ 0Ί45 ' Density is 0.95^ g/cm3 0.345 0.244 0.199 "0.172 Standard Unfibrillated synthetic weave in m2/g The density is from 1.00 g/cm3 to 0336 [ "0338" To achieve the high surface area of the fibers associated with fiber length and diameter, it is preferred to provide an elongated fibrous matrix or body and a plurality of outer surfaces extending from the outer surface of the elongated fibrous substrate. * $ ''' Miscellaneous " Extended knives or microfibrils, or microfibrils, 'single fibers can specify a number of microfibrils, each having a diameter of about 〇. 1 micron to about 1 〇 micron.适人古二'',, White, Mitsui Chemicals ―: ask the area of fibrillated fiber
Amenca (Rye Br〇〇k，γAmenca (Rye Br〇〇k, γ
MimflberS( Johns〇n City，Tennessee)。 飞 在較佳具體實例中，人& # 性，且因此通常不丄=熱:二纖維較佳具有疏水 a導致先則技術濕式佈層形成之天花板 乾燥期間之表面張力增加。較佳具體實例 纖維形成通常多孔且膨鬆的結構，該結構能 ==度下提供所需之聲音降低特徵。咸信所得結構多 之一個原因在於與有較多纖維素之結構相 原纖化合成纖維= ; = 少氫鍵。另-方面， 強度而不損害可::積使仔黏合位點增加’從而改良 在-些情況下，合成纖維之疏水性使其難以分散於水 10 201202516 性漿料中。為改良分散穩定性，合成熱黏合纖維亦可經表 面處理以使得外表面或外表面之一部分具有親水性。為使 得外表面具有親水性，纖維製造商在用於形成纖維之聚合 物中引入某些親水性官能基，諸如羧基（_c〇〇H)或羥基 (-OH )。在親水性外表面之情況下，合成熱黏合纖維在水 性漿料中通常較為穩定。 本文中之不織布材料通常產生至少〇 55及更大之所要 噪音降低係數。咸信至少兩種機制可負責約7至13 pcf之 核心密度下的噪音降低特徵。首先’如上文所述，較佳之 合成熱黏合纖維具有疏水性，此降低乾燥期間核心之表面 張力。因此，疏水性纖維通常避免所形成核心的表面及主 體中發生孔隙閉合，而此問題在先前技術之親水性纖維中 會發生。另外，亦已觀察到，即使將纖維處理成具有親水 性表面，合成原纖化熱黏合纖維總體上仍展現疏水性性質 以降低乾燥後之表面張力。 咸信經親水性處理之纖維仍在乾燥期間展現疏水性傾 向，因為經處理之纖維具有恰好足夠的連接於疏水性聚合 物鏈之親水性官能基，使得其可懸浮於水中且與其他成分 一起分散。然而，此等纖維整體仍具有疏水性，且其具有 極低吸水性。當聚合物熔化時，其不會失去此等基團，因 此保留疏水性傾向。 其次’合成熱黏合纖維之至少一部分係設定成在預定 溫度下炫化’其中基質纖維與其他核心組分結合在一起。 在原纖化合成熱黏合纖維之情況下，在此預定熔化溫度之 刖任何核心組分之間較佳無黏合。因此，咸信即使利用 201202516 濕：佈層製程，無機基質纖維及其他成分通常仍將呈現如 二虱佈層製程中所見之更天然/膨鬆的組態或形式。詳言 =::使用礦棉之無機基質纖維的情況下，所形成之墊通 常^得極其龐大或膨鬆，因為此等纖維相對較硬且形成膨 鬆結構。因此’—旦乾燥後核心最後達到合成黏合纖維之 熔點’則黏合材料會使硬礦棉之基質熔合至此膨鬆結構 中。冷卻後，原纖化合成黏合纖維即固定究碑組分且使究 :具有岡"生，同時具有膨鬆結構。因為合成纖維不展現先 刖技術黏合劑之辦力的本 當伴a加的表面張力，故所形成之膨鬆結構通 樣而不會因水蒸發所引起之表面張力而變緻密。 、讀況’不織布核心可包括其他組分。舉例而言，核 〜可按需要包括其他填充劑，諸如纖唯辛_維卩t 铋）、π μ ^ 纖，准素纖維（亦即新聞 :氏）、m弓、珍珠岩、玻璃珠、黏土、粒狀物、軟木及其 員似物。#想要時’亦可將諸如 之劢处外现σ 孟性奴及其類似物 -化子。。添加至基質墊中以通常提供 除無機基質纖維及合成Μ合纖維外 ^力。 :他：兄選用之纖維，諸如天然纖維（亞 維素'劍麻及其類似物）、玻璃 竹·義 缱維月4人t 其他無機纖維、有機 纖隹及其混合物。若想要時，不 液體或乳膠樹脂，盆塗覆於所带成:：亦可包括粉末狀、 八土復7、尸/]·小成之基質墊 面上或滲透於所形成基質塾 三夕 皮盈m r以k供額外剛十生、社合、 水屏障或其他功能性fe舉例而言，多❸ … 脂可塗覆於基質墊之一或兩個表面上。 ^直%之樹 另外’所形成之基質墊可包含— 若形成多，，則每一層可按特定廣用：：：不織布材料。 應用之需要具有與其他層 12 201202516 類似或不同之性質’諸如類似或不同的基本重量、密度及 且成。夕層可藉由將多個基質墊層壓在一起而形成或可使 用多頭成型機聯機形成。 匕3…、拽基質纖維及合成熱黏合纖維之不織布材料可 成型為適於隔音天花板竟磚之核心，其中使用諸如濕式佈 層、乾式佈層或空氣佈層成型製程之任何標準製程形成不 織布材料。舉例而言，若使用濕式佈層製程，則較佳地首 先用液壓製漿機、高頻疏解機、精製機或其他適合之設備 使合成熱黏合纖維脫纖維。接著將脫纖維之合成纖維推合 至水性衆料中。藉由一種方法，使得激料之固體含量較佳 士約1%至約15%。接著可使用該漿料，使用標準濕式佈層 南位調聚箱形成具有約重量％至約5〇重量％之合成熱黏 。’截、准及、約50重量％至約95重量％之無機基質纖維（諸如 礦棉、渣棉及/或石棉）之不織布核心。 形成核心後’接著按需要經由重力排水、真空及/或加 熱來移除水。當施加約7忖汞至約1〇忖汞之真空時，本發 明之不織布材料的典型初始水分含量（亦即，在即將進入 乾燥箱或乾燥室之前的板之水分含量）為約6〇%。相比之 下’由標準材料製成之板的典型水分含量A 7G%。因為合 成纖維含量增加’故初始水分減少。若想要時，可使用壓 2向墊提供光滑表面且幫助控制最終密度。較佳地，乾燥 箱在約3GG°F下或在比合成黏合纖維之溶點高至少約5卞至 約獅下操作以確保竟碑成分之充分炫化及黏合。若想要 時，在加熱後，亦可冷卻核心或塾及/或將其封閉於空氣循 13 201202516 為達成不織布墊之均$..N ^ 7勺分佈，充分分散之合成熱黏a 纖維為較佳的。已發規，人α、σ δ成纖維及無機基質纖維之最佳 分散液可使用約MU聚料溫度達成，但已顯示約3η^ 約7 0 °C之範圍起很好的作田 乍用。咸尨此溫度範圍很重要，因 為-些市售原纖化合成纖維以濕聚板（㈣形式出售， 其要使用時需再製漿。較高溫度有助於縮短減水時間及分 :接者’昆D 4料約10分鐘至約30分鐘’直至漿料為 均質的。較佳地，亦在添加其他聚料組分之前使人 成熱黏合纖維分散於水中以確保良好分散品卜為檢驗； 散’應用玻璃杯或藍色破璃檢查毁料以確保合成纖維完全 分散》 凡王 確保花費足夠時間進行完全分散為何重要之一個原因 在於，如剛才所提及之-些市售原纖化合成纖維呈墊之形 ：在使用之前需要分散。完全分散或再製漿確保纖維 提i、取大數目之黏合位點，因此改良機械強度及孔隙率。 :分散不足’則纖維可能會自身黏合在一起，且其可能喪 失作為黏合劑之有效性。另一方 μ 为方面，一些市售合成纖維為 乾紐纖且不需要大量時間來達成充分分散。 另外，如上文所述’為改良分散品質，合成纖維亦可 經表面處理以使其至少在其外表面上具有親水性。在雙组 分纖維之情況下，機赫箱考？田α , 械預處理可使得纖維更適於製造天花 板瓷磚。預處理包含齡，设總秘 rTT _ , #厍義維、研磨纖維及形成原纖維。 乾式研磨製程自身亦產生足夠力及剪切作用以進一 維原纖化。 本文所述之不織布材料的優點及具體實例進一步藉由 201202516 以下實施例來說明； 及其量以及其他條件 除非另有指示，否則 重量計。 然而，此等實施例 及細節不應解釋為 上文及下文所提及 中所述之特定材料 限制不織布材料。 之所有百分比均以 實施例 實施例1 將、.勺75公克E 38〇F乾短纖聚乙稀漿（Minifibers )分 散於水中且接著以約5%稠度與約425公克礦棉混合約4分 鐘（以乾固體計約15%聚乙稀毅）。將聚料傾倒於Μ 口寸 成型盒中。首先藉由重力排出過量水，接著進一步使用約 7" Hg真空進行移除。在不進行壓製之情況下，在約鳩卞 下將所形成之板直接置於乾燥箱中歷日"小時。冷卻後， 該板即變得相對具㈣性。㈣成U磚展現以下特徵. 厚度： 1.2 叫· 噪音降低（NRC): — 0.88 密度 ___8.2 pcf. 實施例2 與實施例1類似，將約75.6公克E38〇F纖維分散於水 中且以5%稠度與約428.4公克礦棉混合4分鐘（約15% E380F纖維）。如實施例1中，將原料傾倒於成型盒中。首 先排出過量水’接著進一步使用約8，，Hg真空進行移除歷時 約30秒。接著將板壓至約0.45，，厚，且在3〇〇卞烘箱中乾燥 3小時。冷卻後，該板即變得相對具有剛性。所形成之板展 現以下特徵： 15 201202516 厚度 0.97 吋 密度 9.2 pcf 噪音降低（NRC) 0.82 斷裂模數（MOR) 15 psi 實施例3 首先將呈濕聚板形式之Fybrel E790 ( Mitsui Chemicals America)以約4.8%稠度分散於液壓製漿機中。約47.1公 克Fybrel790與約267公克礦棉混合4分鐘後，將漿料傾倒 於14"χ 14·'成型盒中（約15% Fybrel )»首先藉由重力排出 過量水，接著進一步使用約8’’ Hg真空進行移除歷時約30 秒。接著將板壓至約0.295"厚，且在300T烘箱中乾燥3小 時。冷卻後，該板即變得相對具有剛性。板展現以下特徵： 厚度 0.7吋 密度 7.81 pcf 噪音降低（ENRC) 0.61 斷裂模數（MOR) 6 psi 比較貫施例4 字、•勺 47.1 么克 Fybrel E790( Mitsui Chemicals America) 與約219.8公克礦棉、，約47」公克新聞紙及約25公克碳酸 鈣/tJ °勺4分鐘（約13·8% Fybrel)。接著如實施例1中， 將7灸料傾倒於1 4丨丨X 1 4 ·丨A、讲丨】人rb w 14 14成型盒中。首先藉由重力排出過量 水:接著進—步使用約U|，Hg真空進行移除^接著將板壓 至、力0.265|’厚，且在3〇(Γρ烘箱中乾燥約3小時。冷卻後， §亥板即變得相對具有剛性。板展現以下特徵： 16 201202516 厚度 0.38 吋 密度 16.5 pcf 噪音降低（ENRC) 0.4 斷裂模數（M0R) 34 psi 應/主意在比較貫施例4中，調配物中使用丨3 5 0/〇纖維素 纖’准（新聞紙）。親水性纖維素纖維會產生高表面張力，從 而在乾燥期間使板緻密。因此，密度高，孔隙率低，且nrc 低0 比較實施例5 將約61」公克SS 935 10,—種親水性原纖化pE纖維 (Minifibers)a 4 5%稠度與約346公克礦棉混合約*分鐘 (、.·勺1 5 Λ P E纖維）。接著將衆料傾倒於1 2 ’ | x 1 2，，成型盒中。 首先藉由重力排出過量水，接著進一步使用真空進行移 除接著使用真空牽引熱空氣穿過墊。當墊溫度達到3〇〇卞 時，加熱該墊約8分鐘。冷卻後，板即變得相對具有剛性。 該板展現以下特徵： 厚度 0.75 吋 密度 13.14 pcf 噪音降低（ENRC) 0.69 斷裂模數（M0R) 13 psi ^應注意在此比較實施例5中，所達成之高密度為通風 乾垛（through-air drying)之結果。將墊置於真空下以使埶 空氣穿過該墊，由此使墊緻密。此實施例亦展示通風乾燥 有助於在乾燥期間保持孔隙率，由此在類似密度下保持較 佳 NRC。 17 201202516 實施例6 首先將約H)8公克ESS50F，—種親水性原纖化^纖 維（Minifies )以約2%稠度分散於水中。接著將所分散之 纖維與約403公克礦棉混合約4分鐘（約21% pE纖維）。 接著將漿料傾倒於14，，χ14，，成型盒中。首先藉由重力排出過 量水，接著進一步使用約6 8"Hg真空進行移除。接著將板 壓至約0.49吋厚且在300Τ烘箱中乾燥約3小時。冷卻後， s亥板即變得相對具有剛性。板展現以下特徵： __Μ_ 0.83 吋 密度 10.6 pcf 噪音降低（ENRC) 0.8 斷裂模數（MOR) 23 dsi 比較實施例7MimflberS (Johns〇n City, Tennessee). In a preferred embodiment, the human &#, and therefore generally not = heat: the two fibers are preferably hydrophobic a. This results in an increase in surface tension during drying of the ceiling formed by the wet-laid fabric. Preferred Embodiments The fibers form a generally porous and bulky structure that provides the desired sound reduction characteristics at == degrees. One of the reasons for the large number of structures obtained by Xianxin is that it is fibrillated synthetic fiber with a structure with more cellulose = ; = less hydrogen bonds. On the other hand, strength does not impair:: product increases the bond site of the child's improvement. In some cases, the hydrophobicity of the synthetic fiber makes it difficult to disperse in the water 10 201202516. To improve dispersion stability, the synthetic heat-bonded fibers can also be surface treated to render one of the outer or outer surfaces hydrophilic. In order for the outer surface to be hydrophilic, fiber manufacturers introduce certain hydrophilic functional groups, such as carboxyl (_c〇〇H) or hydroxyl (-OH), into the polymer used to form the fibers. In the case of a hydrophilic outer surface, the synthetic heat-bonded fibers are generally relatively stable in aqueous slurries. The non-woven materials herein generally produce a desired noise reduction factor of at least 〇 55 and greater. At least two mechanisms are responsible for the noise reduction characteristics at a core density of approximately 7 to 13 pcf. First, as described above, the preferred synthetic heat-bonded fibers are hydrophobic, which reduces the surface tension of the core during drying. Therefore, hydrophobic fibers generally avoid the occurrence of void closure in the surface of the core formed and in the body, and this problem occurs in the hydrophilic fibers of the prior art. In addition, it has also been observed that even if the fibers are treated to have a hydrophilic surface, the synthetic fibrillated heat-bonded fibers generally exhibit hydrophobic properties to reduce the surface tension after drying. The hydrophilically treated fiber still exhibits a hydrophobic tendency during drying because the treated fiber has just enough hydrophilic functional groups attached to the hydrophobic polymer chain so that it can be suspended in water and together with other ingredients. dispersion. However, these fibers as a whole are still hydrophobic and have extremely low water absorption. When the polymer melts, it does not lose these groups and therefore retains a hydrophobic tendency. Next, at least a portion of the synthetic heat-bonded fibers are set to smear at a predetermined temperature wherein the matrix fibers are combined with other core components. In the case of fibrillating synthetic heat-bonded fibers, it is preferred that there is no adhesion between any of the core components at this predetermined melting temperature. Therefore, even with the 201202516 wet: cloth process, inorganic matrix fibers and other components will generally exhibit a more natural/bulk configuration or form as seen in the second layer process. In detail =:: In the case of inorganic matrix fibers using mineral wool, the mats formed are generally extremely bulky or bulky because they are relatively hard and form a bulky structure. Therefore, the adhesive material will fuse the matrix of the hard mineral wool into the bulky structure after the core has finally reached the melting point of the synthetic bonded fiber. After cooling, the fibrillated synthetic binder fiber is fixed to the monument component and is made to have a bulky structure. Since the synthetic fiber does not exhibit the surface tension of the prior art binder, the formed bulk structure is not densified by the surface tension caused by water evaporation. The read condition 'non-woven core may include other components. For example, the core ~ may include other fillers as needed, such as fiber weixin _ wei 卩 t 铋), π μ ^ fiber, quasi-fibres (ie, news: Shi), m bow, perlite, glass beads, Clay, granules, cork and their likes. When you want it, you can also make σ 性 奴 slaves and their analogues like 劢 劢. . It is added to the matrix mat to generally provide an external force in addition to the inorganic matrix fibers and the synthetic conjugate fibers. : He: The fiber chosen by the brother, such as natural fiber (Avicel's sisal and its analogues), glass, bamboo, 缱, 缱, 4 months, other inorganic fibers, organic fiber, and mixtures thereof. If desired, no liquid or latex resin, the pot is coated with:: can also include powdery, Batro complex 7, corpse /] · Xiaocheng on the mat surface or infiltrated into the formed matrix For example, in the case of an additional just ten, a social, water barrier or other functional fe, the grease may be applied to one or both surfaces of the substrate mat. ^ Straight % tree The other 'formed mats can be included - if formed, each layer can be used in a specific way::: Non-woven material. The application needs to have similar or different properties as the other layers 12 201202516, such as similar or different basis weights, densities, and combinations. The layer can be formed by laminating a plurality of matrix mats together or can be formed in-line using a multi-head molding machine. The non-woven material of 匕3..., 拽 matrix fiber and synthetic heat-bonded fiber can be formed into the core of the sound-proof ceiling brick, wherein the non-woven fabric is formed by any standard process such as wet cloth layer, dry cloth layer or air cloth layer forming process. material. For example, if a wet lay-up process is used, it is preferred to first de-fiber the synthetic heat-bonded fibers with a hydraulic pulper, a high-frequency disintegrator, a refiner, or other suitable equipment. The defibrated synthetic fibers are then pushed into the waterborne mass. By one method, the solids content of the pulverizer is preferably from about 1% to about 15%. The slurry can then be used to form a synthetic thermal bond having from about 5% by weight to about 5% by weight using a standard wet-laid southern conditioning box. ' Non-woven core of inorganic matrix fibers (e.g., mineral wool, slag wool, and/or asbestos) of about 50% to about 95% by weight. After forming the core, the water is then removed by gravity drainage, vacuum and/or heating as needed. The typical initial moisture content of the nonwoven material of the present invention (i.e., the moisture content of the sheet immediately before entering the drying or drying chamber) is about 6% when a vacuum of from about 7 Torr to about 1 Torr is applied. . The typical moisture content of the board made of standard materials is 7 G%. Since the synthetic fiber content is increased, the initial moisture is reduced. If desired, a pressure gauge can be used to provide a smooth surface and help control the final density. Preferably, the drying cabinet is operated at about 3 GG °F or at least about 5 Torr higher than the melting point of the synthetic bonded fibers to ensure sufficient glazing and adhesion of the ingredients. If desired, after heating, the core or crucible can be cooled and/or sealed in air. 13 201202516 To achieve a non-woven mat of $..N ^ 7 scoop distribution, fully dispersed synthetic hot-adhesive a fiber Preferably. It has been proposed that the optimum dispersion of human α, σ δ fiber and inorganic matrix fibers can be achieved using a temperature of about MU, but it has been shown to be good for field application in the range of about 3 η ^ about 70 ° C. This temperature range is important because some commercially available fibrillated synthetic fibers are sold as wet slabs ((4), which require re-pulping when used. Higher temperatures help to reduce water reduction time and points: 'Kun D 4 material for about 10 minutes to about 30 minutes' until the slurry is homogeneous. Preferably, the heat-bonded fibers are also dispersed in water before adding other polymer components to ensure good dispersion. ; Disperse the use of glass or blue broken glass to check the material to ensure that the synthetic fiber is completely dispersed. One of the reasons why Van Wang ensures that it takes enough time to completely disperse is that, as mentioned earlier, some of the commercially available fibrillation Synthetic fibers are in the form of mats: they need to be dispersed before use. Completely dispersing or repulping ensures that the fibers are extracted, and a large number of bonding sites are taken, thus improving mechanical strength and porosity. If the dispersion is insufficient, the fibers may adhere to themselves. Together, and it may lose its effectiveness as a binder. On the other side, some commercially available synthetic fibers are dry-core fibers and do not require a significant amount of time to achieve adequate dispersion. As described in the article 'To improve the dispersion quality, the synthetic fiber can also be surface treated to have hydrophilicity at least on its outer surface. In the case of bicomponent fibers, the machine can be used in the field. Make the fiber more suitable for the manufacture of ceiling tiles. Pretreatment contains the age, set the total secret rTT _, #厍义维, grinding fibers and forming fibrils. The dry grinding process itself also produces sufficient force and shear to enter the one-dimensional fibrillation. The advantages and specific examples of the non-woven materials described herein are further illustrated by the following examples of 201202516; and the amounts and other conditions are by weight unless otherwise indicated. However, such embodiments and details should not be construed as The specific materials described in the text and the following are limited to the non-woven material. All percentages are as in Example Example 1. The 75 grams of E 38〇F dry staple fiber polystyrene (Minifibers) is dispersed in water and It is then mixed with about 425 grams of mineral wool at about 5% consistency for about 4 minutes (about 15% polyethylene by dry solids). The material is poured into a 成型-shaped box. First by gravity Excess water is removed, and then further removed using a vacuum of about 7" Hg. The plate formed is placed in a dry box for about a few hours without pressing. After cooling, the The board becomes relatively (four). (4) U-bricks exhibit the following characteristics. Thickness: 1.2 Calling · Noise Reduction (NRC): - 0.88 Density ___8.2 pcf. Example 2 Similar to Example 1, approximately 75.6 grams The E38〇F fiber was dispersed in water and mixed with about 428.4 g of mineral wool for 4 minutes (about 15% E380F fiber) at a consistency of 5%. As in Example 1, the material was poured into a molded box. The excess water was first discharged. With about 8, the Hg vacuum was removed for about 30 seconds. The plate was then pressed to about 0.45, thick, and dried in a 3 inch oven for 3 hours. After cooling, the plate becomes relatively rigid. The resulting panel exhibits the following characteristics: 15 201202516 Thickness 0.97 吋 Density 9.2 pcf Noise Reduction (NRC) 0.82 Breaking Modulus (MOR) 15 psi Example 3 First Fybrel E790 ( Mitsui Chemicals America) in the form of a wet slab 4.8% consistency is dispersed in the hydraulic pulper. After mixing about 47.1 grams of Fybrel 790 with about 267 grams of mineral wool for 4 minutes, pour the slurry into a 14"χ 14·' forming box (about 15% Fybrel) » first drain excess water by gravity, then further use about 8' 'Hg vacuum removal takes about 30 seconds. The panel was then pressed to about 0.295 < thick and dried in a 300 T oven for 3 hours. After cooling, the plate becomes relatively rigid. The board exhibits the following characteristics: thickness 0.7 吋 density 7.81 pcf noise reduction (ENRC) 0.61 modulus of rupture (MOR) 6 psi comparison of example 4 words, • spoon 47.1 gram Fybrel E790 ( Mitsui Chemicals America) with approximately 219.8 gram mineral wool , about 47" grams of newsprint and about 25 grams of calcium carbonate / tJ ° spoon for 4 minutes (about 13.8% Fybrel). Next, as in Example 1, the moxibustion material was poured into a 14 丨丨X 1 4 ·丨A, 丨 丨 人 human rb w 14 14 molded case. First, the excess water is discharged by gravity: then, using about U|, Hg vacuum is removed, then the plate is pressed to a force of 0.265|', and dried in a 3 〇 oven for about 3 hours. The board is relatively rigid. The board exhibits the following characteristics: 16 201202516 thickness 0.38 吋 density 16.5 pcf noise reduction (ENRC) 0.4 modulus of rupture (M0R) 34 psi should be / in the comparison of example 4, blending丨3 5 0/〇cellulose fiber 'Quasi (Newspaper) is used. Hydrophilic cellulose fibers produce high surface tension, which makes the plate dense during drying. Therefore, the density is high, the porosity is low, and the nrc is low. Comparative Example 5 Approximately 61 minutes of about 61 gram of SS 935 10, a hydrophilic fibrillated pE fiber (Minifibers) a 4 5% consistency with about 346 grams of mineral wool (, . . . Then pour the bulk into 1 2 ' | x 1 2, in the molded box. First drain excess water by gravity, then further use vacuum to remove and then use vacuum to draw hot air through the mat. When the mat temperature reaches At 3 ,, heat the pad for about 8 minutes. Cold After that, the plate becomes relatively rigid. The plate exhibits the following characteristics: thickness 0.75 吋 density 13.14 pcf noise reduction (ENRC) 0.69 modulus of rupture (M0R) 13 psi ^ should be noted in this comparative example 5, achieved The high density is the result of through-air drying. The pad is placed under vacuum to allow helium air to pass through the pad, thereby densifying the pad. This example also demonstrates that venting drying helps to maintain it during drying. Porosity, thereby maintaining a preferred NRC at a similar density. 17 201202516 Example 6 Approximately H) 8 grams of ESS50F, a hydrophilic fibrillating fiber (Minifies), was first dispersed in water at a consistency of about 2%. The dispersed fibers were then mixed with about 403 grams of mineral wool for about 4 minutes (about 21% pE fiber). The slurry was then poured into 14, a crucible 14, in a molded box. The excess water is first drained by gravity and then further removed using a vacuum of about 68 "Hg. The plate was then pressed to about 0.49 inch thickness and dried in a 300 inch oven for about 3 hours. After cooling, the s-board becomes relatively rigid. The board exhibits the following characteristics: __Μ_ 0.83 吋 density 10.6 pcf noise reduction (ENRC) 0.8 modulus of rupture (MOR) 23 dsi Comparative Example 7
首先將約75.6公克具有相對較長纖維長度（21 mm) 之E990 ’ 一種原纖化PE纖維（Minifibers )分散於水中。 與約428.4公克礦棉混合約4分鐘後，在混合結束時添加約 151 公克脹性珍珠岩（USG，Red wing，MN)(約 n 5% pE 纖維）。接著將漿料傾倒於14，，xl 4，，成型盒中。首先藉由重 力排出過量水，接著進一步使用約6 8，，Hg真空進行移除歷 時約30秒。壓至約〇 71吋厚後，將板在3〇〇卞烘箱中乾燥 約3小時。冷卻後，該板即變得相對具有剛性。所形成之 板展現以下特徵： 厚度 0.88 吋 密度 12.88 pcf 噪音降低（ENRC) 0.77 斷裂模數（MOR) 14 psi 18 201202516 應注意在此實施例 -- 賴不添加輕暂拮·*·»·, 珠岩不會；. 、充制脹性珍 ^。吸曰作用。通㊉在典型濕式佈層製程 夕 >珠岩添加至基質墊中，NRC愈低。 〜 声么 G馆/兄下，高密 又加填充劑之結果。因為可將珍珠岩添加至天花板瓷 碑、、且刀中以改良表面燃燒及強度特徵，故此為重要的。_ 應瞭解’熟習此項技術者可使本文中已描述及說明以 便解釋不織布材料之性質的細節、材料及製程條件中之各 種變化處於如隨附申請專利範圍中所表述之原則及範嘴 内。另外，本文中所引用之任何參考文獻均亦以全文引用 的方式併入本文中。 【圖式簡單說明】 益 4 »>> 【主要元件符號說明】 益 i 19First, about 75.6 grams of E990' a fibrillated PE fiber (Minifibers) having a relatively long fiber length (21 mm) was dispersed in water. After mixing with about 428.4 grams of mineral wool for about 4 minutes, about 151 grams of swellable perlite (USG, Red wing, MN) (about n 5% pE fiber) was added at the end of the mixing. The slurry was then poured into 14, xl 4, in a molded box. The excess water was first drained by gravity, and then further removed using a Hg vacuum for about 30 seconds. After pressing to a thickness of about 71 Torr, the plate was dried in a 3-inch oven for about 3 hours. After cooling, the plate becomes relatively rigid. The resulting plate exhibits the following characteristics: thickness 0.88 吋 density 12.88 pcf noise reduction (ENRC) 0.77 modulus of rupture (MOR) 14 psi 18 201202516 It should be noted that in this embodiment - it is not necessary to add light temporary stagnation **», The pearls will not; Sucking effect. In the typical wet-laid process, the addition of pearls to the matrix mat, the lower the NRC. ~ Sounds G Hall / brother, high density and the result of adding fillers. This is important because perlite can be added to the ceiling porcelain and the knives are used to improve surface burning and strength characteristics. _ It should be understood that those skilled in the art may describe and describe the details, materials, and process conditions described and illustrated herein to explain the nature of the nonwoven material in the principles and vanes as expressed in the accompanying claims. . In addition, any references cited herein are also incorporated herein by reference in their entirety. [Simple description of the schema] Benefit 4 »>> [Key component symbol description] Benefit i 19