TW576885B - Thermo formable acoustical panel - Google Patents

Thermo formable acoustical panel Download PDF

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Publication number
TW576885B
TW576885B TW91119827A TW91119827A TW576885B TW 576885 B TW576885 B TW 576885B TW 91119827 A TW91119827 A TW 91119827A TW 91119827 A TW91119827 A TW 91119827A TW 576885 B TW576885 B TW 576885B
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Taiwan
Prior art keywords
polymer
fiber
fibers
scope
patent application
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TW91119827A
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English (en)
Inventor
Peter A Christie
Anthony L Wiker
Brian L Springer
John R Garrick
Kenneth E Heisey
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Armstrong World Ind Inc
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    • E04—BUILDING
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    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials

Description

J/Οδδ：) 五、發明說明q) [技術領域] 本發明 可熱成形之 [發明背景 纖維防 維、黏結劑 物棉、珠岩 纖維板 水、界面活 纖維板之組 纖維素材料 材料，該材 素材料通常 岩、亮度劑 雄、度而黏土 澱粉、乳膠 生使所有組 有機黏 之基本成分 黏結劑。例 係有關一種防音板， 防音板。 I 音板係用於多種不同 及填料之配合所組成 、纖維素纖維、填料 製法乃利用使纖維、 性劑及其他添加劑混 合。有用之纖維實例 礦物棉為一種輕質 料經纺絲而成類似玻 為新聞用紙之形式。 ’例如氧化鈦、及黏 可加強耐火性。用於 及再生紙製品，其將 分固定成結構基體之 結劑（例如澱粉）常為 。因為澱粉相當價廉 如，諸多含有新聞用 更詳細而言，係有關一種 用途且 。基本 及黏結 填料、 合成漿 包含礦 、玻璃 璃纖維 添加之 土。膨 纖維板 所有組 結合系 可提供 ，所以 紙、礦 係由 上， 劑所 膨脹 體， 物棉 性及 之纖 填料 服珠 之黏 分結 統。 纖維 其常 物棉 不同種 纖維板 製成。 劑、黏 再將其 、玻璃 以矽石 維結構 可包含 岩可降 結劑實 合在一 類之纖 係由礦 結劑、 加工成 纖維及 為主之 。纖維 膨脹珠 低物質 例包含 起並產 板結構黏附性 為較佳之有機 及珠岩之纖維 板可藉由澱粉而黏結在一起。澱粉可賦與纖維板結構強度 與耐久性二者，但其易受濕氣及下垂現象的影響。 已使用例如苯乙稀-丙烯酸酯晶格及聚對苯二甲酸乙 二醇酯單絲纖維之合成聚合物材料，將以礦物纖維為主之
576885 五、發明說明 物件黏結 現行方 結合纖維 格之表面 用如此對 抗下垂性 顆粒附著 物纖維流 處理之纖 由礦 彎曲或不 對該等板 該等板常 该荨成形 是密度低 噪音降低 具有較低 設。該等 〇 · 4 5至 〇 · 其他 螭纖維所 為相當長 維製品具 後成形， (2) 在一起 法係作 與粒狀 電荷轉 濕氣不 之板。 至玻璃 導入新 維，然 物纖維 規則形 進行壓 以澱粉 板容易 至足以 係數， 之孔隙 薄板具 5 5的範 防音纖 製成的 且連續 有明顯 戶斤以坡 么=盡力克服有機黏結劑的缺點。例如， 物之= = ;作二”膠及 :至礦物纖丄 =^ =黏Μ㈤可提供在尺寸i更穩定且具 〃貝例包含將聚合物纖維及熔化之纖维 =上，此乃藉由將高分子量之單絲；合 ^ ^玻璃纖維熱流中，並收集經聚合物 後進行熱成形以形成物件。 所形成之纖維防音板為剛硬且無法模製成 狀 ^外’使用具破壞性之製程將極難以 紋，壓紋會降低孔隙度並破壞防音功能。 黏結而具有約1 2至1 6磅/英尺之高密度。 折斷且不會吸收衝擊能。該等成形板特別 具有高吸音特性者則容易產生凹陷。最大 NRC值約為〇. 75。該等組成物之薄板必須 度以使其堅固而能予以運送、搬運及裝 ^甚至更不佳之吸音特性，其NRC值在 圍内。 ί板2 ΐ要類型包含由與紛樹脂黏結之玻 不斷與岩石或礦渣礦物棉相較，玻璃纖維 更夕的纖維。玻璃纖維板比現行的礦物纖 螭I I!吸音特性。因為熱固性黏結劑無法 、 、、、板頗為剛硬。該等板為黃顏色且具 576885 五、發明說明（3) 有不規則的表面且密度不均勻。需要昂貴的稀鬆布及塗料 以隱藏黃顏色，同時聲音亦會穿透該板。此外，傳統上用 以黏結玻璃纖維絮的酚樹脂會有環境上的問題。樹脂會沉 積在製程設備上，需要經常停工以清洗該設備。同時，當 樹脂硬化時，甲醛氣體會釋放出來。 因此，需要可模製及可壓紋且為高度吸音體並具有光 滑易塗表面的彈性防音板。此外，若可將板作薄，而該板 仍相當耐用且具有高的NRC值，則為較佳。此外，對濕氣 不靈敏且無需使用塗布或背面塗布系統來防止該板在潮濕 環境中下垂之板亦較佳。 [發明之摘述] 本發明提供一種可熱成形之防音板的組成物及其成形 方法。該防音板可將多成分聚合物纖維或單絲聚合物纖維 分散於礦物纖維絮中形成。藉由施加熱而使該聚合物纖維 與礦物纖維黏結在一起。 更詳細而言，該防音板包含具有實質上圍繞著内部核 心4之鞘層的多成分聚合物纖維。鞘層包括第一聚合物， 該第一聚合物熔點低於包括内部核心之第二聚合物熔點。 此外，防音板係由礦物纖維或礦物棉所組成。該防音板亦 可包含纖維素及珠岩且可以有機塗層或稀鬆布予以塗敷。 該防音板通常具有約5磅/英尺3至約2 0磅/英尺乏密度，且 其NRC值至少為0. 65。 防音板之成形方法包括下列步驟：提供具有圍繞著内 部核心之鞘層的多成分聚合物纖維。該鞘層係由第一聚合
92179.ptd 第7頁 576885 五、發明說明（4) 物組成，且該第一聚合物的熔點低於包括内部核心之第二 聚合物的熔點。然後將所提供之聚合物與礦物纖維混合以 形成纖維絮。接者將該纖維絮加熱以熔化聚合物鞘層用以 將纖維絮之聚合物纖維黏結至礦物纖維而形成防音板。可 將該等纖維混合並分散於高速空氣流中、或與水結合而形 成濕的混合物，而後再脫水以形成纖維絮。可將該纖維絮 壓密以增進防音板強度。該板可經由連續的加熱及冷卻步 驟而壓密並壓製為該成形防音板。 其他具體實施例包含防音板之成形方法，該方法包括 下列步驟：提供單絲聚合物纖維，該等單絲聚合物纖維與 礦物纖維分散並混合於混合水溶液中以形成濕纖維絮。然 後將濕的纖維絮脫水並加熱且經由熔化聚合物纖維而將聚 合物纖維與礦物纖維黏結在一起。 其他防音板之成形方法包括下列步驟：提供可分散的 聚合物顆粒黏結劑，使該黏結劑與礦物纖維分散並混合於 高速空氣流中，以形成纖維絮。然後將該纖維絮加熱而後 顆狀黏結劑會熔化以黏結纖維絮而形成防音板。 其他具體實施例包含防音板之成形方法，該方法包括 下列步驟··提供具有約-5 0°C至約7 5°C玻璃轉移溫度之可 分散聚合顆狀黏結劑，及將顆狀黏結劑與礦物棉分散並混 合於混合水溶液中以形成濕纖維絮。然後將濕纖維絮脫水 以形成脫水絮，並將其加熱以熔化脫水絮中之顆粒黏結劑 以形成防音板。 其他具體實施例包含多層防音板，該多層防音板包括
92179.ptd 第8頁 576885 五、發明說明（5) 至少第一層及第二層。第一層包含具有實質上圍繞著内部 核心之鞘層的多成分聚合物纖維。該鞘層係由第一聚合物 所組成，且第一聚合物的熔點低於包括内部核心及礦物纖 維之第二聚合物的熔點。第二層與第一層接觸而第二層包 含黏結劑及填料二者。 其他具體實施例包含包括第一單絲聚合物纖維及第二 單絲聚合物纖維的防音板成形方法。該第一聚合物纖維的 熔點低於該第二聚合物纖維的熔點。然後將結合之第一纖 維及第二纖維與礦物棉分散並混合於混合水溶液中以形成 濕纖維絮。然後將濕纖維絮脫水並加熱。加熱時，第一聚 合物纖維實質上熔化而將該等纖維黏結在一起以助於形成 防音板。 於其他具體實施例中，防音板之成形方法包括下列步 驟：提供可分散的聚合物顆粒黏結劑及聚合物纖維二者， 及將該二者與礦物棉分散並混合以形成纖維混合物。然後 合併該纖維混合物以形成纖維絮，並加熱而實質上熔化纖 維絮中之顆狀黏結劑以形成防音板。 [本發明之詳細說明] 本發明提供一種可熱成形之防音板的組成物及其成形 方法。該防音板可將多成分聚合物纖維或單絲聚合物纖維 分散於礦物纖維絮中形成。藉由施加熱而使該聚合物纖維 與礦物纖維黏結在一起。 多成分聚合物 更詳細而言，多成分聚合物纖維通常包括至少兩種聚
92179.ptd 第9頁 576885 五、發明說明（6) 合物。二成分聚合物纖維6通常係由實質上鞠層2圍繞著内 部核心4而組成。鞘層2實質上包封著内部核心4。該鞘層2 不需完全圍繞著或包封著内部核心4。該鞘層2係由比内部 核心4溶點更低之聚合物所組成。嫁點的差異使得在加熱 時該鞘層2會軟化或熔化而與通常為礦物纖維之外圍纖維 進行黏結。内部核心4較佳實質上保持完整無缺或未熔化 使得内部核心4纖維成為板的纖維支撐體。 多成分板可為乾式成形或濕式成形。該板之成形方法 包含將聚合物纖維與礦物棉分散並混合以形成纖維絮8， 並加熱纖維絮8以熔化聚合物鞘層2而形成防音板。於乾式 成形製程中，將礦物纖維混合並分散於高速空氣流中。於 濕式成形製程中，將聚合物纖維及礦物纖維與水混合以形 成濕混合物，然後脫水以形成纖維絮8。 於加熱纖維絮8之步驟中，將該纖維絮加熱至高於第 一聚合物的熔化溫度但低於第二聚合物的熔化温度之溫 度。該方法可又包括經由連續的加熱及冷卻步驟而將成形 之防音板壓密。可藉由將成形之防音板壓製成平坦或彎曲 的形狀而進一步加工該板。 防音板通常包括礦物纖維或礦物棉。礦物棉可能包括 石棉或玄武岩礦棉之纖維。通常纖維之直徑為約3^1米至6 微米。此外，可使用”上膠π態或’’裸’’態之纖維。可使用例 如礦油或丙烯酸系聚合物分散液之上膠劑。該等纖維有助 於結構完整性及板強度。 為了增加額外的強度及抗下垂性，該板又可包括衍生
92179.ptd 第10頁
3 /OOOJ 五、發明說明（7) 自木纖維、一級紙纖維、二級紙纖維 纖維。該一級紙纖維及二級紙纖維分別勺2纖維之纖維素 者紙製品，例如新聞用紙。纖維長度古έ别及後-消費 更長。在一具體實施例中，纖維素纟=達約1/4英吋或 其通常具有約1 /4毫米至約5毫米之長度:新聞用紙纖維， 1毫米。特別是，新聞用紙包括纖維素八且平均長度約為 纖維於濕式成形製程中當其自漿體轉総、'、^，该等纖維素 布態（sol id wet f el t en route)以虑A J只貝上固體濕毛 濕強度。 X马板時，有助於板的 於濕式成形製程中可使用保留劑，、 中將基本黏結劑、非纖維狀填料及复以幫助於脫水操作 發明可使用市場上能購得之許多=中之纖維保留住。本 一為由H e r c u 1 e s化學公司製在市^ 剎。該等保留劑中之 陽離子聚丙烯醯胺。 每上稱為PURACHEM 24 0之 可使用0至約20乾重量％之# 維狀填料可選自高嶺黏土、碳萨P、准狀填料於板中。非纖 土或膨潤土、滑石、雲母、石=、巧、矽石、蛭石、球狀黏 可使用0至約3 0乾重量％之膨^ f二合物。 山 山玻璃礦石，類似於黑曜石呈^ :珠岩於板中。珠岩為火 火山玻璃礦石通常包括石夕石力:熱時大巾_的能力， 金屬石夕酸鹽。#岩有助於板之、⑦酸μ其他驗土 Q1 1 0 10^^,, 之整體性及硬度。美國專利第 5，9 11，8 1 8唬中述及膨脹珠岩及 此併入本文作為參考。$常珠？造膨脹珠岩之方法，在 ^ 通$珠岩包含65至75多Si 02、10至 2〇%AL2〇及2至5%^及較少量之蘇打' 碳酸鉀及石灰。膨
92179.ptd ιιι^η 頁 第11 576885 五、發明說明（8) 脹珠岩為任何玻璃s，更特別為在快速 迅速"膨脹之火山玻璃。當將壓碎 大…或 ,.. 杆之珠石顆粒加孰至垂炫 r 1 n c 1 p 1 e n t f u s i ο η)溫度時，” m、击除 …、 τ 迅速膨脹現象丨丨通當合蛴 •。含於顆粒中之水分轉換成茱氣 a ^ ^ ^ ^ ^ ^ Μ ^ . “、、孔柃壓碎之顆粒會膨脹 以开/成輕貝、逄鬆、多孔的顆粒。一 少十倍。冑脹珠岩之特徵通常為同、、：f體積會增加至 統，此稱為珠岩結構同岩=的裂縫系 〜八、％脹度、翁询女小；5 其壁厚度及製品之孔隙度）不同。 ” Λ石朋^ 了提仏财火& &可包含硬爛辦石或石朋酸。亦可添 口 ===助於防止板在沿條毛布乾燥（weit feit打 =中變t。可使用其他防燃劑。此外，可使用顏料及拒 水劑。 :添加額外的水及"乾燥廢紙"。"乾燥廢紙"大部分為 2丢棄或自商業上可接受之板切除之回收板料及其他廢棄 物。 μ板形成時可添加其他添加劑，例如分散劑、消泡劑、 t Ϊ Ϊ及其組合。1亥等添加劑為習知者且可輕易為熟習此 項技藝者所用。 _ ^更ί細而言，第1圖說明二成分聚合物纖維6。聚合物 j j之實例包含購自K〇Sa(以前為H〇echstm FIT&司者。 ^⑽纖維之内部核心4最常為聚酯，特別是具有約28 0°C熔 # 度之PET(聚對苯二甲酸乙二醇酯）。外部鞘層最常為 乂氐熔點之聚酯，可為衍生自例如ρΕτ一g或聚烯烴（如聚丙
576885 五、發明說明（9) 烯或聚乙烯）之共聚合PET。 苐2圖$兒明其中散佈有二成分聚合物纖維6之礦物棉絮 8之截面圖。礦物棉係以短的細線來代表’而二成分纖維 係以粗的多層管來代表。當結合成礦物纖維絮時，巨觀上 甚至低百分比之一成分纖維可於密度相當低之高度開放絮 結構中提供彈性且連繽的結構。可利用各種方法來形成:亥 絮。 7 Μ 可利用空氣成形法，其於空氣流中將纖維輸送並予以 共混合’接著於透氣之轆網運送機上沉積。然而較佳為於 纖維分散及共混合程序中不會破壞礦物纖維。空氣成形法 之實例包含經DOA GmbH設計者，其中纖維係於^速空氣流 中分散並混合。 ^ 於 散並共 第 核心聚 序。對 該聚合 結在*— 板結構 性且連 第 黏結的 板之兩 濕式成形方法（例如造紙方法）中，纖維係於水中八 混合，接者可於轆網運送機上進行沉積及脫水。刀 3圖說明加熱至高於聚合物鞘層的熔點但低於 合物的熔點之纖維絮8。加熱程序接者為成形。 絮施加熱以提供超過二成分鞘層熔化溫度的溫度。 物鞘層溶化並流入纖維基體巾 ％ 又 起並將礦物棉與核心聚合I:維：：： =彼Π 成分之核心聚合物纖維則保持完整。如此可伴^ 續的絮，並將纖維黏結在—起。 此了保持淨 4圖說明經壓密步驟後之所得板°。於 絮可進行連續的力:熱及冷卻之壓平程d 側上弄平及歴細夕孔表層10時，可進_步壓密該
576885 五、發明說明（ίο) 絮。壓製之加熱階段使黏結劑再度熔化可同時壓縮並弄平 表面。冷卻階段將黏結劑凝固，使該板結構處於適當的狀 態。 田 此外，可以圖案或花紋對成形之防音板進行壓紋及/ 或模=成所需之形狀或形式。"熱成形"一詞係用於說明所 有》亥等私序，其中成形之防音板係藉由施加熱及/或壓力 而進一步加工以對該板進行壓紋或使其形成各種形狀 同尺寸。 濕式成無壓密步驟 當板為濕式成形時，可形成充分堅固且自給支撐 (self-Supp〇rting)的板而無需壓密步驟。藉由添加數個 百分比之製漿新聞用紙纖維可支撐濕式成形板。將製漿新 聞用紙纖維與相當低含量之二成分黏結劑纖維結合起來使 用可賦與剛性及製程之濕紙匹強度（wet — web strength)。 此外’添加天然纖維亦可有助於剛性及自給支撐性。實例 包含製漿劍麻、大麻、蕉麻或其他纖維素纖維或1 / 4英忖 長或更長之非製漿纖維的切斷絲束。亦可使用堅硬的無機 纖維例如玻璃、礦物及碳。表一說明濕式成形結構的配方 實例：
92179.ptd 第14頁 576885 五、發明說明（11)表1 κ> 類型 77.43 68.93 ο Ki o % 新聞用 紙纖維 o 〇 私 o % 二成分 黏結劑 纖維 10.00 20.00 % 珠岩 o o p o % 凝劑 o ON o On 絮厚度 (in) 00 00 o 1 絮密度 (Ib/fB) 1 2973 v〇 K) 絮 M0E (PSI) o >—* K) o i 下垂長 度⑽ o bo U) o bo 預期 NRC 值 26.51 1 熱值 (MJ/kg) M-l (Q=0) M-l (Q=〇) 法蘭西 卡賓 結果 sc*^
92179.ptd 第15頁 576885 五、發明說明（12) 下垂長度為樣品材料自支撐台邊緣所測量的水平伸展 長度，該材料自支撐台邊緣向下偏差或”下垂，，二英吋，其 為材料剛性之相對測量度。具有2〇英吋下垂長度之板可自 給支撐，於標準2，χ 2,及2，x 4,平頂支撐網中具有最小向 下偏差。”法蘭西卡賓”（”French Cabin”）火焰伸展試驗 (f lamespread test)(NFP92至 50伊披拉迪圖 ” (Epiradiateur)試驗）及計算出之熱值指出該材 法國嚴格M-0耐火性的材料。 為遵寸 具有一成分黏結劑纖維之濕式成形的防音板可六
度低且高開度之吸音結構。在製程的乾燥步驟中，^ ^ 明顯的彈回膨脹現象，黏結劑並未移動以端+ ； ’』衣面孔陏 度’例如使用殿粉。將新聞用紙與二成分纖維社人 ” 比標準濕式成形礦物纖維產品甚至更大之濕紙^ "可具1 音降低係數（N R C )。可成功地加工出輕如〇 . 2 5碎度及木 及1 / 4英对材料厚之該板。本發明成形之防音板可尺重 濕氣所導致之下垂現象，並可利用標準長網造紙1抗拒因 (F 〇 u r d r i n i e r )濕式成形技術來製造。可加熱該 彎曲、具有形狀或壓紋的板。 …、μ反而形成 金物纖維 可將單絲聚合物纖維添加至纖維絮8以制、生
衣k防去 黏結有單絲聚合物纖維（例如聚丙烯或聚乙稀）的曰板。 地予以濕式成形。於濕式成形之礦物纖維板中可板可成功 聚合物纖維（例如聚丙烯、聚對笨二甲酸乙-鮮恭加單絲 烯）作為黏結劑以製造出可自給支撐、具耐火性、j聚乙 、高度吸
576885 五、發明說明（13) ' — 音的可熱成形之防音板。 μλμμ # ^ m :於空氣成形之平頂防音板中添加粒狀聚丙烯、聚酉旨 及了父聯之熱塑性塑膠顆粒（例如W a c k e Γ V i η n e X τ核-殼|占 結，）。可將顆粒分散入氣流舖置網（air laid webs)中。 该等成形絮可予以加熱黏結而製造出高度吸音之軟纖維 板’其可經後壓縮或將表面弄粗以使該板具有最適之剛性 及自給支撐性。此外，可將顆粒於水中分散，經絮凝作用 並保留於濕式成形板中，並於纖維網乾燥程序中予以加熱 黏結。 此外’可使用乳膠作為黏結劑。可使用具有低玻璃轉 移溫度（T g )之乳膠（例如苯乙烯—丁二烯）作為黏結劑。可 使用T g為約-5 0°C至約7 5°c之的乳膠。 虚_層板 成層板可為乾式成形或濕式成形。於乾式成形程序 中，可利用數種方式來積層。可將成形單元以串聯方式沿 著運送機成形篩網放置；該等商業上可購得之乾式成形製 程如Danweb、A/S及M&J A/S系統，其可形成拋棄式物品及 保健市場用之各種產品的層狀結構。防音板通常比該等產 品之厚度更厚及重量更重。礦物纖維的密度明顯地比有機 纖維、填料及包括具拋棄式之吸收體者更高。可使用其他 根據黏漿輥/真空技術之乾式成型系統，例如Laroche S. A及DOA GmbH系統將分開之纖維流沿著運送成形筛網而輸 送至數個黏漿輥。或者，可將預成形之非織造稀鬆布或絮
92179.ptd 第17頁 576885 五、發明說明（14) 展開並在核心纖維絮流之下方或上方予以輸送，且於熱黏 結爐中經由加熱或化學作用而使彼此黏附在一起。 此外，濕式成形技術可運用於沿運送成形轆網設置之 複數個成形高位箱其中之一的單獨原料流，並利用真空脫 水技術。可使用’’奥利弗”型真空鼓或長網造紙機方法。 多層礦物纖維板包括一層及共成形之或層積在另一層 之第二層。額外的第二層係由約0 · 2 %至約1 5 %之黏結劑所 組成。黏結劑可由二成分低熔點之單絲黏結劑纖維、熱塑 性之粒狀物、乳膠或樹脂黏結劑、熱塑性之粒狀物、乳膠 或樹脂黏結劑、熱塑性/熱固性之粒狀物、乳膠、樹脂黏 結劑之組合或其組合所組成。填料可包括約8 5至約 9 9.8%。填料可為玻璃、合成聚合纖維素纖維或天然纖維 素纖維或其組合。 可使用第二層作為表面層，以賦予製品平滑性、均勻 性及表面加工性。第二層可亦有助於板之剛性、強度及結 構一致性。亦可使用第二層作為支撐、強度及抗下垂性用 之墊層及作為障壁層以阻止聲音穿透製品俾增加板之CAC (最高衰減等級（ceiling attenuation class))。通常表 面層可為密度低、可穿透、比第一層或主要層更薄的層， 且均勻成形及具外觀品質。空氣及聲音通常無法穿透該墊 層。 亦可有額外的層。例如，表面層及墊層可予以共成形 或層積至核心層。亦可有具更多層之結構。 多種單絲聚合物纖維
92179.ptd 第18頁 576885 五、發明說明（15) 防音板之又一成形方法，包括製造含有至少二種單絲 聚合物纖維之防音板。於一具體實施例中，將第一單絲聚 合物纖維與第二單絲聚合物纖維結合成纖維混合物。該第 一聚合物纖維的熔點低於第二聚合物纖維的熔點。較低熔 點之聚合物於加熱時實質上會熔化而與外圍之纖維黏結。 較高熔點之聚合物黏結時在板之纖維基體内為實質上未熔 化之纖維。當然可使用二種以上形式之聚合物纖維。一般 認為可使用多種具有不同熔點之聚合物纖維。 於一具體實施例中，將第一纖維與第二纖維結合，然 後與礦物棉分散並混合於混合水溶液中以形成濕纖維絮 8。然後將纖維絮8脫水加熱。加熱時，第一聚合物纖維實 質上會熔化而將該等纖維黏結在一起以幫助形成防音板。 顆粒黏結劑及聚合物纖維 於此具體實施例中，提供一種包括可分散之聚合物顆 粒黏結劑及聚合物纖維之防音板成形方法。當然此方法可 結合多種黏結劑及纖維。於此方法中黏結劑及纖維可與礦 物棉進行分散並混合以形成纖維混合物。然後可結合纖維 混合物以形成纖維絮8，然後加熱以於纖維絮8中將該等顆 粒黏結劑實質上熔化而形成防音板。 [實施例] 本發明將參考下列實施例及對照例進一步具體說明如 下，惟該等實施例僅用於說明本發明，而非限制本發明之 範缚。
進行本發明之濕度下垂試驗四個週期。一週期在8 2°F
92179.ptd 第19頁 576885 五、發明說明（16) -90%1^下為17小時，接者在82卞-35%1^下為6小時。通常 於第4週期間9 0 %RH條件下可觀察到最大的下垂偏差現象。 噪音降低係數（NRC)係由反響室試驗ASTM C423測定。 4個臨界頻率之平均吸音量值在〇 · 〇 〇至1 · 〇 〇之間。 FSR通常為火焰伸展性能之指標而FSR試驗值係於 ASTME84風道試驗（tunnel test)下測定。 本發明實施例所用之空氣成形系統係由奥地利威爾斯 之DOA GmbH所設計製造。於濕式成形實施例中，可使用阿 姆斯壯濕法成網長網造紙辅助機（w e ^ _ 1 a y F 0 u r d r i n i e r p l 1 o t m a c h l n e ) °雖然濕法成網製程之二成分纖維的長度 與所需長度會有差異，且初始絮之成形品質及表面平滑度 會有些不同’但二者製程皆可製造出適當成形之絮，該等 絮可經壓縮而成平滑、堅硬、自給支撐、耐用的防音板。 實施例1 於實施例1中’材料係利用D0A製程而進行空氣成形。 板之加工壓、縮及平滑程序係在Sch〇t1： & Meissner Thermo fix之壓平加熱/冷卻階段持續壓縮單元上完成。成 形防音板之配方列舉如下： 材料 質量％ 來源 規格 破物棉 70 Armstrong Pontarlier 廠 0.7至1.2毫米長 4至6微米直徑 二成分纖維 30 Leigh纖維斯巴達堡， 南卡羅來納 曰本 PET/PET 110°c鞘層熔化， 4丹尼，2英忖長
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IIH 92179.ptd 576885 五、發明說明（17) 加工板之尺寸、密度及物理性質列舉如下·· 雛型組 密度(碎 /英尺3) 尺寸長、 寬、厚 (英叶） 懸浮偏差 (英吋） 於第4週 期 90%RH 下之偏差* (英对） 投影 NRC** (阻抗） 未背墊 投影NRC (阻抗） 背墊 FSR*** 30-30 隧道 1 12.2 24,24， 0.78 (-)0.029 00.061 0.94 0.74 26 2 17.6 飞24厂 0.69 (-)0.019 — (-)0.051 0.71 0.69 — 此外，將塗料之標準塗敷法施用於實施例1所成形之 防曰板上。塗料係施用於非常堅韋刃且财用的玻璃纖維稀鬆 布上，而該玻璃纖維稀鬆布係黏附在製品上。金屬泰恩牽 弓I 試驗（tyne drag test)，π赫斯傾度（Hess rake)n 試 驗’係用來測量防音板之表面耐刮性。經塗覆之雛型材料 的赫斯傾度失效值（break through value )為2 5。 —實」 於此實施例中，黏結劑的量予以減少以形成較薄的 板。此實施例利用DO A氣流成網（a i r - 1 ay )製程及 Thermof i χ壓縮早元。將一至一英叶之亞麻纖維併入配方 中以賦予密度降低類型所呈現的彈性。下表將說明試驗結 果。 、口
576885 五、發明說明（18) 類塑 配方 礦物相 二成4 亞麻 \、 、、 密度(碎/ 英尺3) 尺寸長、 寬、厚 (英对） 懸浮偏差 (英口寸） 於第4週 期90% RH下之 偏差 试驗之 NRC (未背墊） 武驗之 NRC (背墊） 1 90 10 0 21.48 24,24， 0.215 (-)0.109 00.140 — — 2 85 15 0 28.04 24,24， 0.305 (-)0.116 00.145 — — 3 70 20 10 11.34 24,24， 0.518 (-)0.068 00.082 0.90 0.65 4 80 20 0 30.19 24,24， 0.382 (-)0.052 00.080 0.71 0.45 此外，將實施例2所成形之防音板置於轆網圓筒之頂 部上，並於對流爐中加熱至3〇〇τ。該板可經軟化而與圓 筒形狀一致。冷卻時，該板形成牢固彎曲的板。板厚度並 無改變。 實施例3 實施例3說明在長網造紙機輔助管路上利用 ，程來形成^方音4反’然後乾燥並於連續s流爐中進行熱固 Ζ。製程所用之二成分纖維係來自KoSa公司，查羅提， ϊ且成I來納州。此稱為cellb〇nd 105之纖維為聚^烯鞘層 長 ：不是低熔點之PET靭層，且該纖維僅為1/2英吋 言ί明Γ =是2英吋長。核心為PET。實施例3所用之配方將
92179.ptd 第22頁 576885 五、發明說明（19) 材料 質量％ .來源 規格 礦物棉 90 MFS，伯利恆，賓州 0·7至1.2毫米長 4至6微米直徑 二成分纖維 10 KoSa纖維 查羅提，北卡羅來納州 二成分 ΡΕ/ΡΕΤ 128°C鞘層熔化，4 丹尼，1/2英吋長 散 於此實施例中，C e 1 1 b ο n d 1 0 5與礦物棉非常均勻地分 驭於水中。分散液於長網造紙機上迅速脫水，而產生相當 良好成形之濕磨木漿（wet —mat)，該濕磨木漿係利用軋輥 ，八足夠平滑。不需絮凝劑來幫助脫水並測得水分含量 聚（42%)。當然可使用絮凝劑。排水清潔且 。ί Ϊ過^機將Λ磨^轉移至多孔金屬板筛上用以 將材料置於帶式直‘ $ f ^ 〇ven)中乾燥，並机八且逋對流爐（through-con vecti 〇η 得絮的密度^顯低^在35 0°F下進行約30分鐘。觀察到所 絮者，所得絮宓产 空氣成形製程所製得之類似配方 傍/英尺3。此“夕卢傍/英尺3,而不是15碎/英尺3至20 象所致。使用頂部蛊^度可能係由於水蒸發引起的膨脹現 絮壓製成板。將壓皆加熱之靜電壓平壓力機使該等 的鋼板放置於壓製，絮儘快自壓力機移除，並將冷而重 ^續/英尺3至19傍岑H避免彈回現象發生。如此可達到 撐且相當平滑。 、尺t密度，而所得板可相當自认支
576885 五、發明說明（20) 雖然本發明已參照實施例說明如上，然其可作各種之 更動。因此，任何熟習此技藝者，在不脫離本發明之精神 和範圍内，當可作各種之增加、刪減及修飾，本發明之保 護範圍當視後附之申請專利範圍所界定者為準。
92179.ptd 第24頁 576885 圖式簡單說明 [圖式之簡單說明] 第1圖係說明外部鞘層圍繞著内部核心之多成分聚合 物纖維之示意圖。 第2圖係具有散佈於礦物棉中的多成分聚合物纖維之 礦物絮示意截面圖。 第3圖係具有已流入礦物棉基體中之熔化聚合物鞘層 的加熱纖維絮示意截面圖。 第4圖顯示經壓縮、壓密之加工防音板。 [圖式符號說明] 2 鞘層 4 内部核心 6 二成分聚合物纖維 8 纖維絮 10 多孔表層
92179.ptd 第25頁

Claims (1)

  1. 576885
    l 91119827 年A月％ 曰 修正 1 . 一種防音板，包括下列組分： 多成分聚合物纖維，各聚合 繞著内部核心之鞘層，該鞘層包 一聚合物的熔點低於包括該内部 熔點；以及 具有範圍自0. 7至1. 2毫米之 2. 如申請專利範圍第1項之防音板， 之該第一聚合物係選自聚酯、聚 合所成組群。 3. 如申請專利範圍第1項之防音板， 核心之該第二聚合物係選自聚酯 成組群。 4. 如申請專利範圍第3項之防音板， 笨二曱酸乙二醇酯。 5. 如申請專利範圍第1項之防音板， NRC值至少為0. 65。 6. 如申請專利範圍第1項之防音板， 7. 如申請專利範圍第6項之防音板， 包括該防音板之高達4 0重量％。 8. 如申請專利範圍第1項之防音板， 至2英吋長度的補強纖維。 9. 如申請專利範圍第1項之防音板， 維包括該防音板之2重量％至4 0重 1 0 .如申請專利範圍第1項之防音板， 物纖維具有實質上圍 括第一聚合物，該第 核心之第二聚合物的 長度的礦物棉纖維。 其中，包括於該鞘層 乙烯、聚烯烴及其組 其中，包括於該内部 、聚丙烯及其組合所 其中，談聚酯為聚對 其中，該防音板之 復包括纖維素材料。 其中，該纖維素材料 復包含具有0 . 2英吋 其中，該些多成分纖 量％。 其中，該防音板具有
    2003.09. 05.026 576885 _案號91119827 ^年A月％曰 修正_ 六、申請專利範圍 5磅/英尺3至4 0磅/英尺蚋密度。 1 1.如申請專利範圍第1 0項之防音板，其中，該防音板的 密度為5磅/英尺3至1 0磅/英尺3。 1 2.如申請專利範圍第1項之防音板，其中，該防音板具有 壓紋表面。 1 3 .如申請專利範圍第1項之防音板，其中，該防音板於 9 0 %RΗ下展現低於0 . 1 2 5英吋之濕度下垂試驗偏差。 1 4. 一種防音板之成形方法，包括下列步驟： 提供多成分聚合物纖維，該聚合物纖維具有實質 上圍繞著内部核心之鞘層，該鞘層包括第一聚合物， 該第一聚合物的熔點低於包括該内部核心之第二 聚合物的熔點； 分配及混合該些聚合物纖維與礦物棉纖維以形成 纖維絮，該礦物棉纖維具有範圍自0. 7至1 . 2毫米之長 度；以及 熔化該些聚合物鞘層以形成該防音板。 1 5 .如申請專利範圍第1 4項之方法，其中，該些聚合物纖 維與該些礦物纖維係混合且分散於高速空氣流中。 1 6 .如申請專利範圍第1 4項之方法，復包括混合且分散該 些聚合物纖維及該些礦物纖維於水中以形成濕混合 物。 1 7 .如申請專利範圍第1 4項之方法，其中，該成形之防音 板係經硬化成形。 1 8. —種防音板之成形方法，包括下列步驟：
    92179.i：ic. 第2頁 2003.09. 05.027 576885 _案號91119827 〇1>年0月 3日 修正_ 六、申請專利範圍 提供單絲聚合物纖維； 使該些聚合物纖維與礦物棉纖維分散且混合於水 性混合物中，以形成濕纖維絮，該礦物棉纖維具有範 圍自0 . 7至1 . 2毫米之長度； 使該濕纖維絮脫水以形成脫水絮；以及 熔化該些聚合物纖維於該脫水絮中，以形成該防 音板。 1 9 .如申請專利範圍第1 8項之方法，其中，該些單絲聚合 物纖維係選自聚丙烯、聚對苯二曱酸乙二醇酯、聚乙 烯及其組合所成組群之纖維。 2 0. —種防音板之成形方法，包括下列步驟： 提供可分散的聚合物顆粒黏結劑； 使該些顆粒黏結劑與礦物棉纖維分散且混合於高 速空氣流中，以形成纖維絮，該礦物棉纖維具有範圍 自0 . 7至1 . 2毫米之長度；以及 熔化該些顆粒黏結劑於該纖維絮中，以形成該防 音板。 2 1 .如申請專利範圍第2 0項之方法，其中，該些顆粒黏結 劑係選自聚丙烯、聚酯、可交聯之熱塑性塑膠及其組 合所成組群。 2 2 .如申請專利範圍第2 0項之方法，復包括壓密該成形之 纖維絮。 2 3 .如申請專利範圍第2 2項之方法，其中，該纖維絮經連 續的加熱及冷卻步驟而壓密。
    92179.ptc 第3頁 2003. 09. 05. 028 576885 _案號91119827 穴λ年A月l S 修正 六、申請專利範圍 2 4 .如申請專利範圍第2 2項之方法，復包括壓製該成形之 纖維絮。 2 5 .如申請專利範圍第2 0項之方法，復包括將稀鬆布黏附 至該成形之纖維絮。 2 6 . —種防音板，包括下列組分： 第一層，該第一層包含多成分聚合物纖維，該些 聚合物纖維具有實質上圍繞著内部核心之鞘層，該鞘 層包括第一聚合物，該第一聚合物的炼點低於包括該 内部核心及礦物棉之第二聚合物的熔點；以及 第二層，該第二層與該第一層接觸，該第二層包 含黏結劑與填料。 2 7 .如申請專利範圍第2 6項之防音板，其中，該黏結劑係 選自多成分聚合物纖維、單成分聚合物纖維、熱塑性 粒狀物、乳膠、樹脂、熱固性粒狀物及其組合所成組 群。 2 8 .如申請專利範圍第2 6項之防音板，其中，該填料係選 自玻璃、聚合物材料或纖維素或其組合所成組群。 2 9 . —種防音板，包括下列組分： 第一單絲聚合物； 第二單絲聚合物，其中該第一聚合物的熔點高於 該第二聚合物的熔點；以及 具有範圍自0 · 7至1. 2毫米之長度的礦物棉。
    92] /9.ptc 第4頁 2003.09,05.029
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