1234599 經 濟 部 智 慧 財 產 局 員 工 消 費 合 社 印 製 Α7 Β7 五、發明說明（1 ) 本申請案主張各申請於1999年10月1日之美國暫時 申請案第60/157,269，60/157,301號；及各申請於2000年 1月3]曰之美國暫時申請案第60/179,367，60/1 79,385， 及60/179,420號的利益。 發明領| 本發明係有關建築材料之領域，尤指為隔音所設計之 膠接材料的生產方法及裝置。發泡膠接組成物之膠接物可 為液壓膠接物’包含但不限於波特蘭（P〇rtlan(J)、石膏、索 瑞爾（sorrel)、礦渣、飛灰或氧化鋁鈣水泥。另外，石膏可 包含硫酸鈣α半水合物或硫酸鈣沒半水合物、天然、合咸 或化學改質之硫酸鈣沒半水合物以及上述水泥成分之混合 物。 登明背景 牆壁及天花板的隔音板提供隔音、美觀、及隔離天花 板中之設施空間。生產者努力於藉由改善製造程序以降低 能源使用、材料成本及廢物而以最低可能的成本發展裝飾 性隔音牆及天花板。成本降低雖然重要，但程序能夠簡化 多少且依然能製造符合隔音性能、防潮性、及防火性之需 求的面板有天生的限制。 一般的牆板製造係以經採礦及粉碎之石膏岩石或自煙 道氣脫硫工廠合成獲得之石膏開始。在煅燒過程中，將粉 末狀石膏加熱以使石膏脫水成半水合物。經煅燒的石膏或 半水合物稱為塗壁材料。將填料如珍珠岩及玻璃纖維添加 至塗壁材料中以達成完成之牆板所要的性質。其他添加劑 本紙張尺度適用中國國家標準（CNS)A4規格⑵Q χ 297公爱） 312529 ------------裝--------訂--------- ί請先閱讀背面之注音？事項再填寫本頁} 1234599 經濟部智慧財產局員工消費合作社印製 A7 -—---------B7___ 五、發明綱（2 ) ~' -- 包含澱粉有助於將芯黏附至紙面。可添加阻滯劑及促進劑 以調整反應速率。這些成分與水及肥皂泡沫在高速或針式 混合機中組合。雖然添加肥皂泡沫以降低芯密度，但所得 之結構可能不具有被视為隔音之㈣孔隙&。將所得之混 合物放置在兩片紙板間再以滾筒隔出厚度。在芯建立後， 將板子切成所要長度，然後轉移至烘箱中予以乾燥。 製造隔音天花板的現行方法係利用纖維、填料、黏合 劑、水及/或界面活性劑的各種組合混合成加工成面板之 漿液。此方法非常類似於使用於造紙之方法。使用之纖維 的實例可包含礦物纖維、玻璃纖維、及纖維素材料。質輕、 玻化、氧化矽為主之材料之礦棉紡成類似於玻璃纖維之纖 維結構亦可使用。礦棉強化隔音板的隔音性能、防火性、 及抗下垂性。 填料可包含膨脹珍珠岩及黏土。膨脹珍珠岩降低材料 密度而黏土提升隔音板的防火性。使用於隔音板之黏合劑 的實例可包含澱粉、乳膠及/或再生紙產品，其連接在一 起並產生將所有成分鎖入結構基質中之結合系統。 當適當地組合及加工上述成分時，製得適合使用作為 隔音天花板及其化種類之建構板之多孔隔音板。現今，讀 種面板係使用類似於紙生產之非常高體積的方法予以製 造。 組合纖維、填料與黏合劑之製程的結果形成夾帶空氣 之水性多孔狀發泡體。最後乾燥此水性多孔狀發泡體以提 供其内可安居纖維、黏合劑及填料並結合以產生基質之安 t--------tT---------· (請先閱讀背面之注意事項再填寫本頁) 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） 2 312529 1234599 經濟部智慧財產局員工消費合作社印製 3 A7 五、發明說明（3 ) 定結構。此水性多孔狀發泡體混合物可包含界面活性劑以 促進將空氣夾帶至混合物中。典型習知技藝天花板材料的 結構示於第1圖之30X顯微照片。珍珠岩顆粒可識別為包 埋於礦棉與再生新聞用紙纖維之互連基質中之圓形團塊。 數造天化板之現行方法複雜’包含許多步驟，且使用 大量的水及能源。在製程中，經由組合排水 '加壓、及高 溫烘箱加熱自產物逐漸地移除水。可回收一些排放水，伸 主要係在處理後排放至環境中。1234599 Printed by the Consumers ’Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs A7 B7 V. Description of the Invention (1) This application claims that each application was filed in the US Provisional Application Nos. 60 / 157,269, 60 / 157,301 on October 1, 1999; and Each application has the benefit of US Provisional Applications Nos. 60 / 179,367, 60/1 79,385, and 60 / 179,420 dated January 3, 2000. The invention | The invention relates to the field of building materials, in particular to a method and a device for producing glued materials designed for sound insulation. The cementitious composition of the foam cementitious composition may be a hydraulic cementitious composition including, but not limited to, Portland (Portlan (J), gypsum, sorrel, slag, fly ash, or alumina calcium cement In addition, the gypsum may contain calcium sulfate alpha hemihydrate or calcium sulfate hemihydrate, natural, salty or chemically modified calcium sulfate hemihydrate, and a mixture of the above cement components. Panels provide sound insulation, aesthetics, and isolation of facility space in ceilings. Producers strive to develop decorative acoustic walls and ceilings at the lowest possible cost by improving manufacturing processes to reduce energy use, material costs, and waste. Cost reductions are important, though important However, the procedure can simplify how much and still can produce panels that meet the requirements of sound insulation, moisture resistance, and fire resistance. Natural wallboard manufacturing is based on mining and crushing gypsum rock or desulfurization from flue gas. The gypsum obtained in the factory synthesis begins. During the calcination process, the powdered gypsum is heated to dehydrate the gypsum to hemihydrate. The calcined gypsum or hemihydrate The compound is called wall-coating material. Fillers such as perlite and glass fiber are added to the wall-coating material to achieve the desired properties of the finished wallboard. Other additives The paper dimensions are applicable to Chinese National Standard (CNS) A4 specifications ⑵Q χ 297 male Love) 312529 ------------ install -------- order --------- ίPlease read the phonetic on the back first? Please fill in this page again for the matter} 1234599 Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs A7 ------------- B7___ V. Outline of Invention (2) ~ '-Containing starch helps to adhere the core to Paper surface. Blockers and accelerators can be added to adjust the reaction rate. These ingredients are combined with water and soap foam in a high speed or pin mixer. Although soap foam is added to reduce the core density, the resulting structure may not have the pores & considered as sound insulation. The resulting mixture was placed between two sheets of cardboard and separated by a roller to thickness. After the core is established, the board is cut to the desired length and then transferred to an oven to dry. The current method of manufacturing acoustic ceilings uses various combinations of fibers, fillers, adhesives, water and / or surfactants to form a slurry that is processed into a panel. This method is very similar to the method used for papermaking. Examples of the fibers used may include mineral fibers, glass fibers, and cellulosic materials. Lightweight, vitrified, silica-based materials can be used if they are spun into a fiber structure similar to glass fibers. Mineral wool reinforces the sound insulation performance, fire resistance and sag resistance of sound insulation boards. Fillers can include expanded perlite and clay. Expanded perlite reduces the density of the material and clay increases the fire resistance of the acoustic panel. Examples of adhesives used in sound insulation panels may include starch, latex, and / or recycled paper products that are joined together to create a bonding system that locks all the ingredients into the structural matrix. When the above-mentioned components are appropriately combined and processed, a porous sound-insulating panel suitable for use as a sound-proof ceiling and a construction board of its kind is produced. Today, reading panels are manufactured using very high volume methods similar to paper production. As a result of the process of combining fibers, fillers and binders, an air-containing, porous foam is formed. Finally, the water-based porous foam is dried to provide an anchoring fiber, a binder, and a filler therein, which are combined to produce a matrix t -------- tT --------- · (Please Please read the notes on the back before filling this page) This paper size is applicable to the Chinese National Standard (CNS) A4 specification (210 X 297 mm) 2 312529 1234599 Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 3 A7 V. Description of the invention ( 3) Fixed structure. This aqueous porous foam mixture may contain a surfactant to facilitate entrainment of air into the mixture. The structure of a typical conventional ceiling material is shown in Figure 30, a 30X photomicrograph. Perlite particles can be identified as circular masses embedded in an interconnected matrix of mineral wool and recycled newsprint fiber. The current method of making weathering panels is complex 'involves many steps and uses a large amount of water and energy. During the process, water is gradually removed from the product via combined drainage 'pressurization, and high temperature oven heating. Some of the discharged water can be recovered, which is mainly discharged into the environment after treatment.
不同的製造方法及漿液配方產生具有不同隔音及結構 特性的面板。在隔音性能與耐用性間有一替代。高度多孔 性，低密度材料可呈現最佳隔音性能。不幸地，低密度材 料易脆且難以處理而呈現低耐用性 '低洗滌性、及低抗拉 強度。基於本發明的目的，耐用性一詞係指量測面板材料 在壓縮下如何容易變形之面板的壓縮降伏強度。抗手指壓 痕性為良好壓縮降伏強度實例。洗務性為濕洗務^之 重複來回動作的抗磨蝕性。抗拉強度係指面板無破裂下沿 著一邊緣提起或支撐面板的能力Q 使用各種方法及配方以平衡隔音天花板之製造中所固 有之替代。例如’天花板之一普通結構為如第2圖所示之 使用不同材料層之層合物。—層201包括軟質、隔音材料， 而另層202面對房間，較為耐用，有時為對聲音相對上 較透明之結構材料。面板的隔音性能為層201之大功能， 而層202則提升耐用性、洗務性、及美觀。第2圖中之外 層202可為供給材料之第二者 _ ^ ^ ~ ^ 般而言，接著劑使外層 過用中國國家鮮規格⑽χ挪公^· 312529 ^-----I--^--------- (請先閱讀背面之注意事項再填寫本頁} 經濟部智慧財產局員工消費合作社印製 1234599 A7 "I ---____ 五、發明說明（4 ) 一 撕貼附於層跡該種層合面板之製造_所涵蓋的其他步 驟包含粉刷、切成所要之尺寸、及包裝。 層合面板提供性能與耐用性間之良好平衡。該種面板 具有在某些步驟中易於連續製造加工的優點q旦需要額外 2加工步驟及額外的材料，例如’外層材料及接著劑（當製 每均勻面板時則热需此者）。再者，外層材料通常為高成本 構成且層合程序需要額外的機械、材料、及人力資源。雖 然隔音材料201成分的製造通常可以連續方式進行，但層 合步驟不是連續製程。結果’對製造者而言，層合面板相 對上較昂貴。 亦使用澆鑄或成形方法產生如第丨圖之面板結構。澆 鑄製造非常耐用且具有良好隔音性質之均勻材料。澆鑄材 料通常具有高甚多之密度，而在層合結構中無需存在額外 層。洗~基本上為將材料倒入模具中之批式製程。模具的 底部通常以載體或脫模劑襯底以防止沾黏。在模具中乾燥 材料，移除模具，且面板進行整理程序。成形的面板通常 具有良好的機械強度性質且呈現良好的耐用性而隔音性能 則通常無法如層合面板一般妤。成形方法的缺點包含··整 個製程中持續地需要移動模具，侷限於模具尺寸而導致較 小面板；需要自模具移除面板之額外步驟；及由於增加面 板密度而使每個面板的材料成本較高。 製造具有第1圖所示之結構之面板的另一一般方法為 將漿液擠壓至鋼絲帶上，再使水排出及/或自槳液逐出 水。其他製程步驟包含成形、乾燦、及表面處理或砂磨所 ·1tr---------· (請先閱讀背面之注咅^事項再填寫本頁) 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） 4 312529 1234599 B7 五、發明說明（5 ) 得之面板以接近連锖夕制 岸。 、之I轾產生所要的結構以製造隔音 ^的，、程步驟如壓花或對材料穿小孔可進-步提升面 的隔音性。缺點包含乾燥及處理排放水的高能源成本。 处，留：别迷問題’有需要製造使用於具有良好隔音性 保持材料之結構耐用性的天花板及其他 的低密度材料。 古w此外，有需要製造具有高抗下垂性'?文良之耐用性、 兩噪音降低係數⑽C)及高聲音傳送係數（STC)的面板。 再者，有f要產±無需額夕卜添加刺來提升防火性之面 板及產生在主）一面上具有硬，高密度表面之非均勻面 板。 概述 本發明提供一種生產隔音多孔板之方法，包括下述步 驟·分配乾膠接材料，分配纖維以產生乾混合物及使水、 界面活{±劑和空氣水性混合以產生發泡體。然後此方法提 供組合及混合發泡體與乾混合物以形成包括以濕基準計， 約53wt%至約68wt%水泥，約I7wt%至約48wt%水，約 〇.〇5wt%至約5wt〇/0纖維，及約0.01wt%至約1〇wt%界面活 性劑之發泡膠接材料。然後乾燥或熟化此發泡膠接材料。 此外’知：供生產隔音天花板之方法，包括下述步驟·· 利用乾混合機乾式混合水泥、矽酸鈣及纖維以產生乾混合 物’再以水藏合機水性混合水及界面活性劑以產生稀釋之 界面活性劑溶液。然後以組合混合機組合及混合稀釋之界 面活性溶液、空氣及乾混合物以產生發泡膠接材料。然後 312529 本紙張尺度適用中國國家標準（CNS)A4規格（210 x 297公釐 1234599 經 濟 部 智 慧 財 產 局 員 工 消 費 合 作 社 印 製 A7 Β7 五、發明說明（6 ) 在乾燥室中乾燥此發泡膠接材料以形成具有約10至40 lb/ft3之密度，至少12之赫斯傾度手指刮痕試驗結果，至 少0.5之噪音降低係數，及於90% rh之小於0，15吋之下 垂試驗結果的隔音多孔板。 再者，提供生產隔音天花板的方法，包括下述步驟： 乾式混合水泥及合成有機纖維以產生乾混合物，再水性混 合水及界面活性劑以產生稀釋之界面活性劑溶液^然後組 合及混合發泡體及乾混合物以形成包括以濕基準計，約 56wt%至約61wt%水泥，約32wt%至約42wt%水，約 0.28wt%至約1.3wt%纖維，及約〇.7wt0/D至約2wt%界面活 性劑之發泡膠接材料。然後乾燥此發泡膠接材料。 上述方法亦包含自發泡膠接板之一面移除高密度表層 以曝露隔音目的之低密度基質。此外，此方法可生產具有 強化防火性的隔音板。 再者，提供生產隔音板之裝置’包括輸送膠接材料之 分配器，水性混合水與界面活性劑以產生稀釋之界面活性 劑溶液之水混合機，組合及混合發泡體與乾混合物以形成 發泡膠接材料之組合混合機及輸送纖維材料之分配器。在 退出組合混合機後，纖維材料可與發泡體及膠接材料組 合。於一具體實例中，發泡膠接材料包括以濕基準計，約 56wt%至約61wt%膠接材料，約32wt%至約42wt%水，約 0.28wt%至約i.3wty〇纖维，及約〇 7wt%至約2以％界面活 性劑°然後在乾燥室中乾燥此發泡膠接材料。 上述裝置亦包含自發泡膠接板之一面移除高密度表層 本紙張尺度_中_家標準（CNS)A4規格⑵G χ撕公餐 312529 -----------裝--------訂--------- (請先閱讀背面之注意事項再填寫本頁) 1234599 經 濟 部 智 慧、 財 產 局 消 費 合 社 印 製 7 A7 五、發明說明（7Different manufacturing methods and slurry formulations produce panels with different sound insulation and structural characteristics. There is an alternative between sound insulation and durability. Highly porous, low-density material provides optimal sound insulation. Unfortunately, low-density materials are brittle and difficult to handle, exhibiting low durability, low washability, and low tensile strength. For the purposes of the present invention, the term durability refers to the compressive yield strength of a panel that measures how easily the panel material deforms under compression. Finger indentation resistance is an example of good compressive yielding strength. Detergency is the abrasion resistance of repeated wet and dry operations. Tensile strength refers to the ability of a panel to lift or support the panel along an edge without cracking. Q Various methods and formulations are used to balance all the alternatives inherent in the manufacture of acoustic ceilings. For example, a common structure of the 'ceiling is a laminate using different material layers as shown in FIG. The layer 201 includes soft, sound-proof materials, while the other layer 202 is more durable facing the room, and is sometimes a structural material that is relatively transparent to sound. The sound insulation performance of the panel is a major function of the layer 201, and the layer 202 improves durability, washability, and aesthetics. The outer layer 202 in FIG. 2 may be the second one of the supply material. ^ ^ ~ ^ In general, the adhesive agent makes the outer layer use the Chinese national standard ⑽χ Norwegian ^ 312529 ^ ----- I-^ --------- (Please read the notes on the back before filling this page} Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 1234599 A7 " I ---____ V. Description of the invention (4) Laminated Panels Laminated Panels The other steps covered by the manufacturing process include painting, cutting to the desired size, and packaging. Laminated panels provide a good balance between performance and durability. The panels have some benefits The advantages of easy and continuous manufacturing process in the step are that it requires 2 additional processing steps and additional materials, such as' outer layer materials and adhesives (this is required when making each uniform panel). Moreover, the outer layer materials are usually high cost The construction and lamination process requires additional machinery, materials, and human resources. Although the manufacturing of the 201 component of the sound insulation material can usually be performed in a continuous manner, the lamination step is not a continuous process. As a result, for the manufacturer, the laminated panel is relatively high More expensive. Also used The casting or forming method produces the panel structure as shown in the figure. Casting is a very durable and homogeneous material with good sound insulation properties. The casting material usually has a very high density, and there is no need for additional layers in the laminated structure. Wash ~ Basic The above is a batch process of pouring materials into a mold. The bottom of the mold is usually supported by a carrier or release agent to prevent sticking. The material is dried in the mold, the mold is removed, and the panel is subjected to a finishing process. The formed panel is usually It has good mechanical strength properties and good durability, while sound insulation performance is usually not as good as laminated panels. Disadvantages of the forming method include: · Continuously moving the mold during the entire process, limited to the size of the mold, resulting in smaller panels Additional steps to remove the panels from the mold; and higher material cost per panel due to increased panel density. Another general method of manufacturing panels with the structure shown in Figure 1 is to squeeze the slurry to steel The ribbon, and then drain the water and / or expel the water from the paddle fluid. Other process steps include forming, drying, and surface treatment or Sand Mill · 1tr --------- · (Please read the notes on the back ^ ^ Matters before filling out this page) This paper size is applicable to China National Standard (CNS) A4 (210 X 297 mm) 4 312529 1234599 B7 V. Description of the invention (5) The panel obtained can approach the shore of Lianyungxi. I can produce the required structure to make sound insulation ^, process steps such as embossing or puncture the material can be entered- Improve the sound insulation of the surface. Disadvantages include the high energy cost of drying and treating the discharged water. Attention: Don't get lost. There is a need to manufacture ceilings and other low-density materials that are used in structures with good sound insulation and structural durability. In addition, there is a need to manufacture a panel with high sag resistance, 'Wen Liang's durability, two noise reduction coefficients (C), and a high sound transmission coefficient (STC). In addition, there are f to produce ± non-uniform panels with hard, high-density surfaces on the main surface, without the need to add thorns to improve fire resistance. Summary The present invention provides a method for producing a sound-proof perforated sheet, which includes the following steps: distributing dry-glued materials, distributing fibers to produce a dry mixture, and mixing water, interfacial agents, and air-water to produce a foam. This method then provides the combination and mixing of the foam and the dry mixture to form a composition comprising, on a wet basis, about 53 wt% to about 68 wt% cement, about 17 wt% to about 48 wt% water, and about 0.05 wt% to about 5 wt%. 0 fiber, and about 0.01wt% to about 10wt% surfactant foaming cement material. This foam cement material is then dried or cured. In addition, 'Knowledge: A method for producing soundproof ceilings, including the following steps ... Dry mixing of cement, calcium silicate, and fibers using a dry mixer to produce a dry mixture', and then mixing the water and surfactant with the water storage machine to produce a dry mixture Diluted surfactant solution. Then use a combination mixer to combine and mix the diluted interface active solution, air and dry mixture to produce a foamed cementitious material. Then 312529 this paper size applies the Chinese National Standard (CNS) A4 specification (210 x 297 mm 1234599 printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs A7 B7 V. Description of the invention (6) Dry the foam adhesive in a drying room Material to form a sound insulation with a density of approximately 10 to 40 lb / ft3, a finger scratch test result of at least 12 Hess inclination, a noise reduction factor of at least 0.5, and a droop test result of less than 0,15 inches at 90% rh Furthermore, a method for producing a soundproof ceiling is provided, which comprises the following steps: dry-mixing cement and synthetic organic fibers to produce a dry mixture, and water-mixing water and a surfactant to produce a dilute surfactant solution ^ and then combining and Mixing the foam and the dry mixture to form a composition comprising from about 56 wt% to about 61 wt% cement, from about 32 wt% to about 42 wt% water, from about 0.28 wt% to about 1.3 wt% fiber, and about 0.7 wt% on a wet basis D to about 2% by weight of a foamed cementitious material with a surfactant. The foamed cementitious material is then dried. The above method also includes removing a high-density surface layer from one side of the foamed cementboard to expose the insulation. The purpose is a low-density substrate. In addition, this method can produce sound-proof boards with enhanced fire resistance. Furthermore, a device for producing sound-proof boards is provided, which includes a dispenser for conveying adhesive materials, an aqueous mixture of water and a surfactant to produce a diluted Water mixer for surfactant solution, combined mixer for combining and mixing foam and dry mixture to form foam cement material and dispenser for conveying fiber material. After exiting the combination mixer, fiber material can be mixed with foam Body and cement material combination. In a specific example, the foam cement material includes about 56wt% to about 61wt% cement material on a wet basis, about 32wt% to about 42wt% water, and about 0.28wt% to about i.3wty fiber, and about 7% by weight to about 2% surfactant, and then the foamed cementitious material is dried in a drying chamber. The above device also includes removing a high-density surface layer from one side of the foamed cementitious board. Size of this paper_Medium_Home Standard (CNS) A4 Specification ⑵G χ Tearing Meal 312529 ----------- Installation -------- Order --------- ( (Please read the notes on the back before filling out this page) 1234599 Ministry of Economic Affairs Printed by Fei Heshe 7 A7 V. Description of Invention (7
X曝路隔音目的之低密度基質的打磨器。此外，此裝置可 生產具有強化防火性之隔音板Q 當參酌附圖閱讀下述說明書時，將可清楚瞭解本發明 之這些及其他特點與各方面。 第1圖為依據習知技術所製造之以礦棉為主之材料的 3〇x顯微照片。 第2圖為依據習知技術所製造之層合物型隔音板的示 意透視圖。 第〇圖為製造使用作為耐用隔音板之無機膠接發泡結 構之方法的示意圖。 本發明包括生產具有隔音性、良好壓縮強度、優異表 面耐用性（如抗割痕性）、及在潮濕條件下之尺寸安定性（如 抗下垂性）之發泡膠接材料的方法及裝置，如第3圖所述。 此方法概括地包括下述步驟：分配乾成分、水性混合液體 及氣態成分、組合乾與水混合物、分配、形成結構、切割、 乾燥、砂磨、整理切割及密封^此裝置概括地包括乾混合 機、水混合物、組合混合機、分配器、壓花機、切割機、 乾燥室、打磨器、整理切割機及喷霧室。 基本上，此方法係以分配乾纖維及水泥開始。乾纖維 與水泥可選擇性組合以產生乾混合物。混合水、界面活性 齊〕及空氣以產生發泡體°此發泡體與乾成分或乾混合物組 合及混合以形成發泡膠接材料。此混合發泡膠接材料在濕 312529 (請先閱讀背面之注咅？事項再填寫本頁} 1234599 經濟部智慧財產局員工消費合作社印製 8 Α7 Β7 五、發明說明（8 ) 基準上可包括約53wt%至約68wt%水泥，約1 至約 48wt%水，約〇.〇5wt%至約5wt%纖維，及约〇,〇lwt%至約 l〇wt%界面活性劑。 連續地生產多孔無機材料之裝置包括分配及乾式混合 膠接材料，如纖維及若有需要之其他集料之配件；分配包 含水、空氣及界面活性劑之濕成分之配件；將濕及乾混合 物組合成水性發泡材料之配件；計量分配材料厚度之配 件；使材料形成結構之配件；切割材料寬度之配件；砂磨 材料之配件；將材料整理切割成個別面板之配件；密封及 粉刷面板之配件；及包裝面板之配件。 基本上’此裝置係以利用乾混合機乾式混合纖維及水 泥以產生乾混合物開始，再水性混合水、界面活性劑及空 氣以產生發泡體◊此發泡體與乾混合物組合及混合以形成 發泡膠接材料。此混合發泡膠接材料在濕基準上可包括約 53wt%至約68wt%膠接材料，約i7wt%至約48wt%水，約 0.05wt%至約5wt%纖维，及约（K〇lwt%至约i〇wt〇/〇界面活 性劑。 經混合之發泡膠接材料之其他配方以濕重量百分率計 可包含約54%至約61 %水泥；約32%至約44%水；約0,1% 至約3%纖維；及約〇 5%至約5%界面活性劑。此外，未熟 化之發泡膠接材料以濕重量百分率計可包含約56%至約 61%水泥；約32%至約42%水；約〇 28%至約i 3%纖維； 及約0.7¾至約2%界面活性劑。 一開始生產發泡膠接材料後，其後可分配至輸送機 木紙張尺度適用中國國家標$NS)A4規格⑽χ 297公爱 312529 -----------^--------1--------- (請先閱讀背面之注意事項再填寫本頁) 1234599 Λ7 B7 五 發明說明（ 9 上，使得製程可為連續者。然後 m IL μ ㈢由社輸送機上以侧薄 度。亦可寬Γ使發泡膠接材料計量至所要的厚 :=面增加裝飾性或隔音功能的圖案。然後可將發泡 产。；切割成由所得之隔音板的應用而決定之所要長 後將切割之發泡膠接材料乾燥至約5%或更低之濕 轧3里或約至切割之發泡膠接材料的表面或面板可被砂磨 之點二一經乾燥後’面板通常具有約101bs/ft3至約40 ibs/ft之密度^於另一具體實例中，面板可具有約1心識3 至約35如/妒或約2〇如出3至約3〇 ibsm3之密度。 此外，在所形成之面板的外表面上形成包括所形成之 面板之總厚度之小於約1%至約2%的硬稠密表層。自面板 之一側移除此稠密層以增加面板的隔音性且通常係藉由砂 磨予以移除。 9磨後，對面板進行整理切割及塗敷有機塗料或密封 劑^^塗敷的塗料增加面板的美觀並增加其表面完整性。 吸音係聲音能量的功能，其部份反射而部份吸收。藉 由移除稠密層’面板内所形成之孔隙的内部基質曝露出 來’由而隔音能量可穿透面板傳送或被面板材料轉化成 熱。由材料吸收之聲音能量的量係藉由稱為，，反響房間方法 之聲音吸收及聲音吸收係數的標準試驗方法，，之標準試驗 程序ASTM C4 23-90a予以測定。吸收率係以被吸收之聲音 月b里對入射囬板衣面之聲音能量的比率表示之。聲音吸收 本紙張尺度適用中關緖準（CNS_IA4規格⑵Q χ 297公爱） (請先閱讀背面之注意事項再填寫本頁) tl---------^w.. 經 濟 部 智 慧 財 產 局 員 工 消 費 合 作 社 印 製 312529 1234599 A7 經濟部智慧財產局員工消費合作社印製 五、發明說明（10 率數據經常併入稱為噪音降低係數（其係由圍繞於〇〇5之 最近多重恶於250，5 0〇，1〇〇〇及2〇〇〇112之八的平均值獲 得之）之單一數值中。NRC值愈高，則於此頻率範圍中之 平均聲音吸收率愈大。目前隔音多孔板通常具有大於〇5 之嗶音降低係數。於另一具體實例中，面板具有大於〇 6 之NRC且於又一具體實例中，面板具有大於❹7之NRc。 具有STC結果之試驗係由八灯]^[£9〇所示之嵌入損失測定 表面完整性it常係測量料硬度㈣能且經常係利用 使用10 S 25安】度之抗刮痕性測量之，#中數帛愈大表示 抗刮痕性愈佳。本發明中，面板具有約12或更大之抗刮痕 性試驗值。當面板的表面以有機塗料（如油漆）塗覆時，此 值通常為至少16且當面板塗覆兩種油漆塗料時可大如至 少22。一般而言，未塗覆之面板平均為約12至14而單一 塗覆油漆之面板則為約16至1 8。 [抗刮痕性試驗] 此試驗係由跨過天花板瓦或面板的面或邊緣“搜遍” “試探者”計量(彈簧鋼)成品之各種厚度所組成。量測標 準係不損傷試驗材料之最高，，試探者，，計量厚度（數千吋）。 金屬板舌或手指堅固平均地排成橫列且各具有大約1875 叶之突起長度。板舌的厚度由橫列之一端增加至另一端。 板舌厚度為10、12、14、16、18、20、22、及25哩相對 應地增加硬挺度。將試樣放置在位於一系列板舌下方之支 樓物中，而試樣凸緣低於切口形成凸緣。使板舌重憂跨過 ‘纸張尺度i用中國，標準（CNS)A4規格⑵G χ 297公i 10 312529 (請先閱讀背面之注意事項再填寫本頁) ·裝 IT. 1234599 A7 ___B7___ 五、發明說明（U ) 試樣的頂邊緣而板舌的底部距離切α形成凸緣中之試樣表 面下方大約7/32吋。然後以每分鐘20吋的速度跨過試樣 拉伸板舌。較厚的板舌比較薄的板舌更容易造成刮痕且更 容易損傷邊緣。 此外，硬度可測定作為ASTMC 367所示之抗壓縮性 的功能。此試驗係使用1-吋球，30 lbs力及1/2忖/min之 十字頭速度予以變更。本發明中，面板通常具有小於〇12 吋之抗壓縮性。於另一具體實例中，抗壓縮性可為小於〇」 吋且於第二具體實例中，抗壓縮性可為小於〇 08忖。 所形成之隔音膠接多孔板相對上亦具有防潮性。此可 定量為由下垂試驗所測定之值。以下為各種具體實例之大 約四回下垂試驗範圍。各回係由於82T及90% RH對 2ftX2ft試樣施加1 7小時接著於82°F及35% RH施加6小 時所組成。於一具體實例中，於90% RH，通常導致小於 0.15吋之下垂。於第二具體實例中，於90% RH，通常導 致小於0,1吋之下垂。於第三具體實例中，於90% rh，通 常導致小於0.05吋之下垂。 發泡膠接組成物的水泥可為液壓水泥包含，但不限 於，波特闌、索爾、礦 >查、飛灰或氧化銘的水泥。此外， 水泥可包含硫酸鈣α半水合物或硫酸鈣点半水合物、天 然、合成或化學改質之硫酸妈沒半水合物，以及上述水泥 成分之混合物。例如，本發明可包括氧化鋁鈣與波特蘭水 泥之混合物以得到較快的硬化時間。 發泡膠接組成物亦可包含對發泡水泥之整體硬度有貢 (請先閱讀背面之注意事項再填寫本頁) ------—丨訂·--------· 經濟部智慧財產局員工消費合作社印製 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公爱） 11 312529 1234599 經 濟 部 智 彗 14、 財 產 局 員 工 消 費 合 作 杜 印 製 A7 B7 五、發明說明（12 ) 添刀α背]該種水泥硬度係用於改善耐用性及抗壓痕性 和衝擊損傷。添加劑可有助於通常含有妈及/或氧化石夕化 ^物之波特蘭水泥的整體硬度。以鈣為主之硬化劑實例包 含氧化妈、氫氧化約及碳酸鹽。氧化梦添加劑可包含石夕酸 云母精細研磨砂、及某種氧化矽含量高之灰如稻殼 灰及飛灰。純佳具體實例中，&良強度及保持發泡體密 度的添加劑為矽酸鈣。在較佳具體實例中使用稱為矽灰石 或Orleans One之纖維級的矽酸鈣^ 發泡膠接組成物亦可包含無機纖維材料，如玻璃纖維 及礦棉。於一具體實例中，發泡膠接組成物包含約〇 25至 0 75吋長，較佳長度為約〇 5吋，且具有約〇 〇⑽5至〇 〇〇7 十之直拴的聚酯纖維。較長的纖維在混合步驟中較容易成 團’而較短的纖維易於降低抗拉強度。 為了在混合過程中產生發泡體之目的，本發明亦可包 含界面活性劑。水泥内的發泡效果很重要，此乃由於其可 在混合物内產生開放晶胞結構以改良水泥的隔音性能之 故。界面活性劑可包含兩性、陰離子性、及非離子性部份 而疏水性分子部份含有8至20個碳。一具體實例的界面活 性劑為月桂基磺基琥珀酸二鈉（dis〇dium laureth sulfosuccinate)，此乃由於在水合過程中其可最有效地懸浮 水泥顆粒之故。為了使硫酸鈣α:半水合物發泡之目的，具 有含有8至1 3個碳之疏水性分子部份之乙氧基化烷基酚界 面活性劑，產生石膏之最適顆粒懸浮性質。 --------^--------- (請先閱讀背面之注意事項再填寫本頁) Μ在約6 8 F至約10 0 F製備界面活性劑溶液時發生膠Low-density substrate sander for X-exposure sound insulation purposes. In addition, this device can produce soundproof panels with enhanced fire resistance. When reading the following description with reference to the drawings, these and other features and aspects of the present invention will be clearly understood. Figure 1 is a 30x photomicrograph of mineral wool-based materials manufactured according to conventional techniques. Fig. 2 is a schematic perspective view of a laminated type sound insulation panel manufactured according to a conventional technique. Figure 0 is a schematic diagram of a method for manufacturing an inorganic cemented foam structure using a durable sound-proof panel. The invention includes a method and a device for producing foamed cementitious materials with sound insulation, good compressive strength, excellent surface durability (such as cut resistance), and dimensional stability (such as sag resistance) under wet conditions, As shown in Figure 3. This method generally includes the steps of dispensing dry ingredients, aqueous mixed liquid and gaseous ingredients, combining dry and water mixtures, dispensing, forming a structure, cutting, drying, sanding, finishing cutting, and sealing ^ This device generally includes dry mixing Machine, water mixture, combination mixer, dispenser, embossing machine, cutting machine, drying room, sander, finishing cutting machine and spraying room. Basically, this method starts with the distribution of dry fibers and cement. Dry fibers and cement can optionally be combined to produce a dry blend. Mix water, interfacial activity, and air to produce a foam. This foam is combined and mixed with dry ingredients or dry mixtures to form a foamed cementitious material. This hybrid foam adhesive material is printed on wet 312529 (please read the note on the back? Matters before filling out this page) 1234599 Printed by the Intellectual Property Bureau Employee Consumer Cooperatives of the Ministry of Economic Affairs 8 Α7 Β7 V. Description of Invention (8) Standards can include About 53 wt% to about 68 wt% cement, about 1 to about 48 wt% water, about 0.05 wt% to about 5 wt% fiber, and about 0.01 wt% to about 10 wt% surfactant. Continuous production of porous Devices for inorganic materials include dispensing and dry-mixing cementitious materials such as fibers and other aggregates if needed; accessories that dispense wet ingredients including water, air and surfactants; combining wet and dry mixtures into aqueous hair Accessories for foam materials; accessories for measuring and distributing the thickness of materials; accessories for forming the structure of materials; accessories for cutting the width of materials; accessories for sanding materials; accessories for finishing and cutting materials into individual panels; accessories for sealing and painting panels; and packaging Panel accessories. Basically, this device starts by using a dry mixer to dry mix fibers and cement to produce a dry mixture, and then mixes water, surfactant, and air to produce a dry mixture. Foam: This foam is combined with a dry mixture and mixed to form a foamed cementitious material. This mixed foamed cementitious material may include from about 53 wt% to about 68 wt% cemented material on a wet basis, from about 7 wt% to about 48wt% water, about 0.05wt% to about 5wt% fiber, and about (K0lwt% to about 100wt // surfactant. Other formulations of the mixed foamed cement material are based on wet weight percentage May include from about 54% to about 61% cement; from about 32% to about 44% water; from about 0.1% to about 3% fiber; and from about 5% to about 5% surfactant. In addition, uncured hair The styrofoam material may comprise from about 56% to about 61% cement in terms of wet weight percentage; from about 32% to about 42% water; from about 028% to about 3% fiber; and from about 0.7¾ to about 2% interfacial activity After the initial production of styrofoam bonding material, it can then be assigned to the conveyor wood paper size applicable to the Chinese national standard $ NS) A4 specifications ⑽χ 297 公 爱 312529 ----------- ^- ------ 1 --------- (Please read the precautions on the back before filling out this page) 1234599 Λ7 B7 Five invention descriptions (9 above, so that the process can be continuous. Then m IL μ薄 Side thickness on the conveyor It can also be wide Γ to measure the foamed adhesive material to the desired thickness: = pattern with decorative or sound insulation function on the surface. Then foam can be produced .; cut to the desired length determined by the application of the obtained sound insulation board The cut foamed adhesive material is dried to about 5% or less of the wet rolled 3 mile or to the point where the surface of the cut foamed adhesive material or the panel can be sanded. After drying, the panel usually has about A density of 101 bs / ft3 to about 40 ibs / ft ^ In another specific example, the panel may have a density of about 1 mind 3 to about 35 such as / jealous or about 20 such as 3 to about 30 ibsm 3. In addition, a hard dense skin layer including less than about 1% to about 2% of the total thickness of the formed panel is formed on the outer surface of the formed panel. This dense layer is removed from one side of the panel to increase the sound insulation of the panel and is usually removed by sanding. After grinding, the panel is trimmed and cut and coated with organic paint or sealant ^^ The applied coating increases the appearance of the panel and increases its surface integrity. Sound absorption is the function of sound energy, which is partially reflected and partially absorbed. By exposing the internal matrix of the pores formed in the dense layer 'panel, the sound insulation energy can be transmitted through the panel or converted into heat by the panel material. The amount of sound energy absorbed by a material is determined by a standard test method called, "Resonant Room Method, Sound Absorption and Sound Absorption Coefficient," and a standard test procedure ASTM C4 23-90a. The absorptance is expressed as the ratio of the sound energy absorbed in the sound b to the sound energy incident back to the board surface. Sound absorption This paper is applicable to Zhongguan Xuzhun (CNS_IA4 specification ⑵Q χ 297 public love) (Please read the precautions on the back before filling this page) tl --------- ^ w .. Intellectual Property of the Ministry of Economic Affairs Printed by the Bureau ’s Consumer Cooperatives 312529 1234599 A7 Printed by the Consumer Property Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 5. Description of the invention (10-rate data is often incorporated into the noise reduction coefficient (which is caused by the recent multiple multiples around 0.05 which are worse than 250) , The average value of 50,000, 100,000, and 2000112 of 8) was obtained.) The higher the NRC value, the greater the average sound absorption in this frequency range. The current sound insulation is porous Panels usually have a beep reduction factor greater than 0. In another specific example, the panel has an NRC greater than 0. 6 and in yet another specific example, the panel has an NRc greater than ❹ 7. The test with the STC result was performed by eight lamps. ] ^ [£ 90 The insertion loss shown on the surface integrity is often measured by measuring the hardness of the material and is often measured using scratch resistance using 10 S 25 ampere degrees. The better the scratchability. The present invention The panel has a scratch resistance test value of about 12 or more. When the surface of the panel is coated with an organic coating (such as paint), this value is usually at least 16 and can be as large as when the panel is coated with two paint coatings. At least 22. Generally speaking, uncoated panels average about 12 to 14 and single coated panels are about 16 to 18. [Scratch Resistance Test] This test is performed across a ceiling tile or panel The surface or edge is "searched through" and the "tester" measures the thickness of the finished product (spring steel). The measurement standard is the highest thickness that does not damage the test material. The tester measures the thickness (thousands of inches). Metal plate The tongues or fingers are lined up firmly and evenly and each has a protrusion length of about 1875 leaves. The thickness of the tongue increases from one end of the row to the other. The thickness of the tongue is 10, 12, 14, 16, 18, 20, 22, and 25 miles correspondingly increase stiffness. Place the sample in a branch below a series of tongues, and the flange of the sample is lower than the cut to form a flange. Make the tongue worry over the paper Zhang scale i uses China, standard (CNS) A4 size ⑵G χ 297 male i 10 312529 ( Please read the precautions on the back before filling this page.) · Install IT. 1234599 A7 ___B7___ 5. Description of the invention (U) The top edge of the sample and the bottom of the tongue are cut by α to form a flange about 7 below the surface of the sample. / 32 inches. Then stretch the tongue across the specimen at a rate of 20 inches per minute. Thicker tongues are more likely to cause scratches and damage edges than thinner tongues. In addition, hardness can be measured as ASTMC 367 The compression resistance function shown. This test uses a 1-inch ball, a force of 30 lbs, and a crosshead speed of 1/2 忖 / min. In the present invention, the panel generally has a compression resistance of less than 012 inches. In another specific example, the compression resistance may be less than 0 ″, and in the second specific example, the compression resistance may be less than 0 08 ″. The formed sound-proof glued perforated plate is also relatively moisture-proof. This can be quantified as a value determined by a sagging test. The following is about four rounds of droop test range for various specific examples. Each round consisted of 82T and 90% RH applied to a 2ftX2ft specimen for 17 hours and then applied at 82 ° F and 35% RH for 6 hours. In a specific example, at 90% RH, it usually results in sagging of less than 0.15 inches. In the second specific example, at 90% RH, it usually results in sagging of less than 0.1 inches. In a third specific example, at 90% rh, it usually results in sagging of less than 0.05 inches. The cement of the foamed cement composition may be hydraulic cement, but is not limited to cements such as Porter, Sol, Mine > Check, fly ash, or oxide. In addition, the cement may contain calcium sulfate alpha hemihydrate or calcium sulfate point hemihydrate, natural, synthetic or chemically modified maleic sulfate hemihydrate, and a mixture of the above cement components. For example, the present invention may include a mixture of calcium alumina calcium and Portland cement to achieve faster hardening times. The foam cement composition can also contribute to the overall hardness of the foamed cement (please read the precautions on the back before filling this page) ---------- 丨 Order · -------- · Printed on the paper by the Consumers' Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs, the paper standard is applicable to the Chinese National Standard (CNS) A4 specification (210 X 297 public love) 11 312529 1234599 Description of the invention (12) Adding knife α back] This kind of cement hardness is used to improve durability and resistance to indentation and impact damage. Additives can contribute to the overall hardness of Portland cement, which typically contains ma and / or oxide oxides. Examples of calcium-based hardeners include oxide oxides, hydroxides, and carbonates. The oxidative dream additive may include sarcoic acid mica fine grinding sand, and some ash with high silica content such as rice hull ash and fly ash. In the specific example of pure goodness, the additive with good strength and foam density is calcium silicate. In a preferred embodiment, a fiber-grade calcium silicate, called wollastonite or Orleans One, is used. The foamed cementitious composition may also include inorganic fiber materials such as glass fiber and mineral wool. In a specific example, the styrofoam composition comprises a polyester fiber having a length of about 025 to 075 inches, preferably a length of about 0.5 inches, and having about 0.005 to 0.75 in length. . Longer fibers are easier to agglomerate 'in the mixing step and shorter fibers tend to reduce tensile strength. For the purpose of generating foam during the mixing process, the present invention may also contain a surfactant. The foaming effect in cement is important because it can create an open cell structure in the mixture to improve the sound insulation performance of the cement. Surfactants may contain amphoteric, anionic, and non-ionic moieties while hydrophobic molecular moieties contain 8 to 20 carbons. A specific example of the surfactant is disodium laureth sulfosuccinate, which can effectively suspend cement particles during hydration. For the purpose of foaming calcium sulfate α: hemihydrate, an ethoxylated alkyl phenol surfactant having a hydrophobic molecular moiety of 8 to 13 carbons, resulting in optimum particle suspension properties of gypsum. -------- ^ --------- (Please read the precautions on the back before filling out this page) Μ Gel occurs when preparing the surfactant solution at about 6 8 F to about 10 0 F
12 312529 1234599 Α7 Β7 經 濟 部 智 慧 財 產 局 消 費 合 作 社 印 製 五、發明說明（13) 接組成物之最大發泡。於一具體實例中，係於大約90°F製 備界面活性劑溶液。此達成膠接組成物之最大發泡。申請 人亦測定自最適溫度範圍之水溫度偏差每1 〇卞偏差會以 每立方吸5磅之因子增加發泡體的密度。因此，有利地將 界面活性劑水溶液溫度保持在大約9〇下。 可能創造不同方法或使用不同裝置以近似使用成形或 塗佈方法所製造之揭露物件，由而將混合物倒在提供結構 支撐物之基材上或圍繞著基材直至混合物熟化。然後可藉 由加熱或溶劑作用移除基材材料，留下後面的孔隙網狀結 構。 在水性混合及發泡步驟中，為了更大效率，可能將高 速及低速混合之分別步驟合併成單一步驟。 生產類似材料之另一方式包含以相同製程步驟，使用 不同族群之纖維，如木材纖維。然而，此產生不同的材料 特性。 -在所揭露之方法中產生發泡作用之另一乎段為使用不 同的界面活性劑。聚乙稀醇為使用於類似用途之已知界面 活性μ然而，月桂基磺基琥珀酸二鈉為較佳之界面活性 劑。 夾π氣體至水性處合物令之另_方式為使用化 取代所揭露之機械手段。 卞仅 另一具體實例可使用^石膏作為波特蘭水泥或^ f 之種選擇。為了提升点石膏的水耐受 的製程步驟，如添加；而額外 W張尺‘用中國規格⑽χ^ΓΤ (請先閱讀背面之注意事項再填寫本頁) _·裝 tr· 13 312529 經濟部智慧財產局員工消費合作社印製 1234599 五、發明說明（l4 與其藉由砂磨 孔而可曝露材料®以移除表層，不如對稠密表層穿 W内部，多孔結構以撞擊聲波。 所逑方法盔带协 _ 集料，面板可多 方法所共通使用之集料。沒有 本方法為連續:且Γ貝域中習知的工具予以切割。此外， 顏色更淡，因此^理材料可以比由其他方法所生產者的 匕所需油漆較少。 形成結構的步驟姐 乂驟棱升田板的隔音性能。隆起、孔洞或 _。’ 面之其他要素將會影響其隔音性能以及板美 2之形成結構裝置比習知技術方法產生較少之廢 ^料及％^之表面整理。此外，可發生表12 312529 1234599 Α7 Β7 Printed by the Consumer Affairs Agency, Intellectual Property Agency of the Ministry of Economic Affairs 5. Description of the invention (13) Maximum foaming of the bonded composition. In one embodiment, a surfactant solution is prepared at about 90 ° F. This achieves maximum foaming of the cementitious composition. The applicant also determined that the water temperature deviation from the optimum temperature range will increase the density of the foam by a factor of 5 pounds per cubic ounce for every 10 ° deviation. Therefore, it is advantageous to maintain the temperature of the aqueous surfactant solution at about 90 °. It is possible to create different methods or use different devices to approximate the use of a shape or coating method to expose the object, thereby pouring the mixture on or surrounding the substrate providing a structural support until the mixture is mature. The substrate material can then be removed by heat or solvent, leaving behind a porous network structure. In the aqueous mixing and foaming steps, for greater efficiency, it is possible to combine the high speed and low speed mixing steps into a single step. Another way to produce similar materials involves using the same process steps, using fibers from different groups, such as wood fibers. However, this results in different material characteristics. -Another aspect of the foaming effect in the disclosed method is the use of different surfactants. Polyvinyl alcohol is a known interfacial activity for similar applications. However, disodium laurylsulfosuccinate is a preferred interfacial active agent. The other way to sandwich the π gas to the water-based compound is to use chemical instead of the mechanical means disclosed.卞 Only another specific example can use ^ plaster as the choice of Portland cement or ^ f. In order to improve the water resistance of gypsum, the process steps, such as adding; and the extra W ruler 'use Chinese specifications ⑽χ ^ ΓΤ (please read the precautions on the back before filling this page) _ · 装 tr · 13 312529 Ministry of Economic Affairs wisdom Printed by the Consumer Cooperative of the Property Bureau, 1234599 V. Description of the Invention (14) Instead of exposing the material by sanding holes to remove the surface layer, it is better to penetrate the dense surface layer through the inside, and the porous structure to impinge on the sound waves. _ Aggregate, the panel can be used in common by multiple methods. Without this method, it is continuous: and it is cut by the conventional tools in the field. In addition, the color is lighter, so the material can be produced more than other methods. The painter's dagger requires less paint. Steps to form the structure The sound insulation performance of the riser plate is raised suddenly. The bulges, holes, or other factors on the surface will affect its sound insulation performance and the structure of the board. Known technical methods produce less waste and surface finishing. In addition,
時材料依然是濞的士 A J 晨的。本發明之形成結構方法比傳統之研磨 成刻模方法產生輪小Μ产 較义的廢棄材料及較佳的表面整理。 生產隔音膠接客了丨4 /楼夕孔板的方法及裝置更進一步詳細說明 如下： [乾式混合] 、於具體實例中，方法的初始步驟涵蓋分配下述成分： ⑴水泥（通b為波特蘭水泥），⑺聚酿纖維（通常為聚對苯 二甲酸乙二醇_(PET)，具有約θ·5作G.25，，)之公稱長度 具有d 0·0005叫至約〇 〇〇7吋直徑之公稱直徑的纖維）； 及（小夕酸妈（通常為矽灰石，或〇γ1_§⑽）。參考第3圖， k些乾成分可籍由下述者分開加料或分別組合於混合裝置 306 · (1)水泥加料器3〇3，其中稱量水泥的用量再加料混 合；（2)纖維加料器304,其中稱量聚酯纖維的用量再加料 混合；及（3)矽酸鈣加料器3]8，其中稱量矽灰石的用量再 312529 裝--------訂--------- (請先閱讀背面之注意事項再填寫本頁) 1234599 A7The material is still a taxi A J morning. The method of forming a structure of the present invention produces smaller waste material and better surface finishing than the conventional grinding and engraving method. The method and device for the production of sound-proof adhesives are described in more detail as follows: [Dry mixing] In specific examples, the initial steps of the method include the following components: ⑴Cement (Tong b is Porter) Blue cement), ⑺polyvinyl alcohol fiber (usually polyethylene terephthalate (PET), with about θ · 5 as G.25 ,,) has a nominal length of d 0.005 to about 0.0000. 7-inch diameter nominal diameter fibers); and (Xiao Xi acid mother (usually wollastonite, or 0γ1_§⑽). With reference to Figure 3, some dry ingredients can be added separately or combined by the following In a mixing device 306 · (1) a cement feeder 300, in which the amount of cement is weighed and then mixed; (2) a fiber feeder 304, in which the amount of polyester fibers is weighed and mixed; and (3) silicon Calcium Acid Feeder 3] 8, in which the amount of wollastonite is weighed and then 312529 packs -------- Order --------- (Please read the precautions on the back before filling this page) 1234599 A7
五、發明說明（15 ) 加料混合。 經濟部智慧財產局員工消費合作社印製 使水泥加料器303，纖維加料器304，及梦灰石加料卷 318連接於轉鼓式混合機306,其中使乾成分平均地分配在 乾處合物中。轉鼓式混合機306連接於乾加料器3〇7，此 處稱量材料的用量再進一步加工。 乾式混合步驟可藉由能夠以相當均勻的方式在整個乾 混合物中分佈纖維之其他手段進行之。該種方法可包含各 種機械方法如欖拌器、鼓風機、混合機或藉由振動。所添 加之纖維的均勻分佈藉由聯鎖基質而增加所形成之面板的 強度。 [水性混合] 進一步步驟涵蓋混合下述液態及氣態成分··（〗）水；（2) 界面活性劑；及（3)空氣。參考第3圖，較隹各分別藉由下 述者予以計量·（1)在水供應上之控制閥301，其中計量混 合所要用量之水；（2 )在界面活性劑供給上之控制閥3 〇 2， 其中計量混合所要用量之界面活性劑；及（3)在空氣供給上 之控制閥300，其中計量混合所要用量之空氣^將特定用 量之水、空氣、及界面活性劑加料至混合裝置305中，其 中混合裝置：>05徹底地混合水與界面活性劑，再夹帶空氣 至混合物中以產生水性發泡體。將發泡機305的輸出物加 料至混合裝置中。此外’水性成分通常係於約41 °F至約168 °F之溫度混合及充氣或發泡。於另一具體實例中，稀釋之 界面活性劑溶液可於約58°F至約142°F或约68°F至約92 F之溫度混合。達成該種溫度之一該種方法係在混合前決 i氏張尺度適用中國國家標準（CNS)A4規格（210 X 297公餐)~ ---- 15 312529 -----—-----裝--------訂--------- (請先閱讀背面之注咅？事項再填寫本頁) 1234599 經濟部智慧財產局員工消費合作社印製 16 A7 ________Β7___ 五、發明說明（16 ) 定溫度於該範圍或者可將混合物設定在該範圍。 [乾式及水性混合] 使乾混合物與水性發泡體流在包括連續混合機308之 混合系統中組合，其中乾成分進一步分配並與水性發泡體 混合’導致具有下述比例（以重量計）之成分的濕混合物·· 1.膠接材料一約5 3至約6 8 % 2·水一約17至約48% 3，選擇性之無機纖維如矽灰石一約1至約丨〇%，於較 佳具體實例中為約1 〇/〇 4’聚酯纖維一約0.05至約5%，於較佳具體實例中為 約1 % 5·界面活性劑—約〇 01至約1〇%，於較佳具體實例中 為約1 %。 於此混合階段，已注意到界面活性劑有助於使纖維在 正個奶合物中懸浮及三維定向Q此外，已發現大約〇 5对 纖維長度亦有助於使纖維分佈在整個混合物中。採用於組 合水泥材料與液體及/或發泡體之混合容器，如那些於水 泥生產及分佈產業中所發現者，可適用於此裝置之此步 驟。 [分配] 然後發泡膠接混合物於配件309(其將濕材料移動至包 括319之移動輸送機上）進行分配操作：（1)移動輸送機帶， 其中混合機的輸出物係位在非常接近於由下方支撐之撓曲 移動帶，使得材料分配在移動帶上；及（2)侧擋板或定紙 本紙張尺度適用中國國家標準（CNS)A4規格⑵0x 297公髮) --------- 312529 裝--------訂--------- (請先閱讀背面之注咅？事項再填寫本頁) 1234599 經濟部智慧財產局員工消費合作社印製 17 A7 五、發明說明（17 ) 框，其中固定垂直表面在材料於帶上移動時與材料的邊緣 接觸，使其侷限在恆定的整體寬度。此側擂板可貼附於輸 送機或可對於輸送機為固定者。或者，噴射高速度水流之 疋紙框亦可作為擠壓發泡體之切割或寬度固定構件。 [試量] 材料分配至移動輸送機上並藉由下述者侷限厚度qj) 计量滾筒3 1 0，使材料在限制材料厚度之圓筒形滾筒下通 過。此製程步釋可產生約〇,25吋至約1，〇吋之較佳產品厚 度。此計量裝置應鄰接於形成結構配件並與其分開一預定 距離，如以下所說明。 [形咸結構] 於此步驟中，藉由壓花製程，如藉由壓花滾筒311對 材料施加表面處理。更明確地說，輸送機帶在旋轉圓筒形 壓钯滾筒下攜帶材料，其在材料表面上印記裝飾性及/或 隔音功能的圖案。 计量滾筒3 1 〇，壓花滾筒311及切割機3 1 2通常基於 石燙或使用於產品之其他水泥的熟化速率而分開一預定距 離例如，在某些情形下，為了清楚印記壓花圖案或為了 有效地移除或剌扎材料的外表層以提升材料之一侧的隔音 性，可希望在配件3 11壓花前使發泡體表面部份熟化。若 已知熟化時間，則可由輸送機迷度乘上熟化時間決定距 離。 【切割] 於此步驟中，藉由切割機裝置3 12以恆定間隔在垂直 312529 Αν ^--------^--------- (請先閱讀背面之注意事項再填寫本頁) 1234599 經 濟 部 智 慧 財 產 局 員 工 消 費 合 作 社 印 製 A7 五、發明說明（W ) 於=送機帶移動的方向分割材料。更明確地說，輸送機帶 攜帶在切割裝置（其以固定間隔切割垂直於輸送機帶移動 之材料）下形成裝飾物之材料。切割機制可包括任何數量之 1體實例，包含但不限於在•以間隔之垂直往復式刀、翼 或賣射回速度水流之水刀。喷霧與輪送機速度間之時 間長度將會決定切割間之材料長度。 在材料部伤熟化期間形成結構與切割步驟間有一固定 時段。此時段係由當自分配步驟開始輪送機連續地移動材 料時之輸送機319的速度所設定。因此’壓花滾筒3ιι與 切割機312間的距離係由熟化時間乘上輸送機速度所決 定。 [乾燥] 於此步#中，輪送機將材料攜帶至乾燥t 313中，再 使材料曝露於約2〇〇°f之公穩、严；。a & π J "之A如皿度。此乾燥步驟驅走未結 合於材料之結晶結構中之過多的水。 [砂磨] 於此步驟中，輸送機319移動在砂磨圓鼓314下方之 乾燥材料，其中輸送機帶在以砂磨介質覆蓋之快速轉動之 ==鼓下攜帶乾燥材料通過。此步驟移除在熟化及乾 所產生之硬表皮。又，若為了裝飾性目的而特別 屢化，則可省略砂磨步驟。選擇性地，若進行形成結構， 則可使用喷砂機提供雇花的深度或賦與產品表面特別的影 像。砂磨的深度將會小於壓花的深度。將具有寬真嘴 •之真空口放置在接近於砂磨圓鼓及產品表面以移除廢棄材 本紙張尺度適用中國國豕標準（CNS)A4規格（210 X 297公釐） 312529 -----------裝--------訂--------- (請先閱讀背面之注意事項再填寫本頁) 18 1234599 A7 五、發明說明（ 料。 [整理切割] 輸送機3 1 9將砂磨板移動 (請先閱讀背面之注意事項再填寫本頁) 匕3下逑者之整理切割裝 置315(1)側邊切割裝置，其中乾燥板沿著兩邊緣自砂磨移 動至將乾燦板修整成成品尺寸及外形之裝置；及⑺端邊切 割裝置’ λ中乾燥板沿著其餘之兩邊緣自第—整理切割操 作移動至進-步修整成成品尺寸及外形之另_裝置。此切 割裝置亦可適合於提供特定所要之邊緣細部。 [密封及粉刷] 藉由輸送機將處理板移動至油漆噴霧裝置中，其中整 理切割板沿著輸送機帶移動至喷霧室，在噴霧室中對材料 的頂端表面塗敷氣溶膠油漆以獲得所要的顏色。 [包裝] 於包裝機317將整理板標識，收縮包裝並裝成箱以送 給倉儲及經銷。 經濟部智慧財產局員工消費合作社印製 雖然具體實例已說明如上，但可認知對於本發明之特 點及構件可做變動。因此，雖然本發明僅揭露較佳形式， 但熟知此項技藝者將可顯而易知其中可做許多添加、刪除 及修飾而不偏離本發明的精神及範圍，而且其上不應設置 不當的限制除非如以下申請專利範圍所示。例如，配方中 所使用之水泥的種類可視材料所要的性質而變。此外，纖 維的種類、長度及丹尼爾數可視由面板裝配之最終產品所 需的強度而變。 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） 19 3125295. Description of the invention (15) Feeding and mixing. Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs, the cement feeder 303, fiber feeder 304, and dream limestone feeder 318 are connected to the drum mixer 306, in which the dry ingredients are evenly distributed in the dry compound. . The drum mixer 306 is connected to the dry feeder 307, where the amount of material is weighed for further processing. The dry mixing step can be performed by other means capable of distributing the fibers throughout the dry mixture in a fairly uniform manner. The method may include various mechanical methods such as a blender, a blower, a mixer, or by vibration. The uniform distribution of the added fibers increases the strength of the formed panel by interlocking the matrix. [Aqueous Mixing] The further steps include mixing the following liquid and gaseous ingredients: (()) water; (2) a surfactant; and (3) air. Referring to Figure 3, each is measured by: (1) the control valve 301 on the water supply, which measures the amount of water to be mixed; (2) the control valve 3 on the surfactant supply 〇2, in which the required amount of surfactant is metered and mixed; and (3) the control valve 300 on the air supply, in which the required amount of air is metered and mixed ^ a specific amount of water, air, and surfactant is added to the mixing device In 305, the mixing device: > 05 thoroughly mixes water and the surfactant, and then entrains air into the mixture to generate an aqueous foam. The output of the foaming machine 305 is fed into a mixing device. In addition, the 'aqueous ingredients are usually mixed and aerated or foamed at a temperature of about 41 ° F to about 168 ° F. In another embodiment, the diluted surfactant solution can be mixed at a temperature of about 58 ° F to about 142 ° F or about 68 ° F to about 92 ° F. One of these temperatures is reached. This method is based on the Chinese standard (CNS) A4 specification (210 X 297 meals) before mixing. ~ ---- 15 312529 ------------- --Equipment -------- Order --------- (Please read the note on the back? Matters before filling out this page) 1234599 Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 16 A7 ________ Β7 ___ 5. Description of the invention (16) The temperature is set in this range or the mixture can be set in this range. [Dry and Aqueous Mixing] Combining the dry mixture with the aqueous foam stream in a mixing system including a continuous mixer 308, wherein the dry ingredients are further distributed and mixed with the aqueous foam 'results in the following ratio (by weight) Wet mixture of ingredients ... 1. Gluing material-about 5 3 to about 6 8% 2 · Water-about 17 to about 48% 3, selective inorganic fibers such as wollastonite-about 1 to about 0% In a preferred embodiment, it is about 10/04 'polyester fiber-about 0.05 to about 5%, and in a preferred embodiment, it is about 1%. 5 · surfactant-about 0.001 to about 10% In the preferred embodiment, it is about 1%. At this mixing stage, it has been noticed that the surfactant helps to suspend and three-dimensionally align the fibers in the positive milk compound. In addition, it has been found that about 0.5 pairs of fiber lengths also help distribute the fibers throughout the mixture. Mixing containers used in combination with cement materials and liquids and / or foams, such as those found in the cement production and distribution industry, can be adapted to this step of the plant. [Distribution] The styrofoam glue mixture is then distributed on the accessory 309 (which moves the wet material onto a moving conveyor including 319): (1) the moving conveyor belt, where the output of the mixer is in close proximity The deflected moving belt supported by the lower side, so that the material is distributed on the moving belt; and (2) the side baffle or the fixed paper size is applicable to the Chinese National Standard (CNS) A4 specification (0x 297 public hair) ----- ---- 312529 Pack -------- Order --------- (Please read the note on the back? Matters before filling out this page) 1234599 Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs 17 A7 V. Description of the invention (17) The frame, in which the fixed vertical surface contacts the edge of the material when the material moves on the belt, so that it is confined to a constant overall width. This siding can be attached to the conveyor or it can be fixed to the conveyor. Alternatively, a squeegee frame that sprays high-speed water can also be used as a cutting or width fixing member for extruded foam. [Trial volume] The material is distributed on a mobile conveyor and the thickness is restricted by the following qj) measuring roller 3 10, allowing the material to pass under a cylindrical roller that limits the thickness of the material. This process step yields a preferred product thickness from about 0.25 inches to about 1.0 inches. This metering device shall be adjacent to and form a predetermined distance from the structural fitting, as described below. [Shaped structure] In this step, surface treatment is applied to the material by an embossing process, such as by an embossing roller 311. More specifically, the conveyor belt carries the material under a rotating cylindrical palladium-pressed roller, which imprints decorative and / or soundproofing patterns on the surface of the material. The measuring cylinder 3 1 0, the embossing cylinder 311 and the cutting machine 3 1 2 are usually separated by a predetermined distance based on the curing rate of stone iron or other cement used in the product. For example, in some cases, in order to clearly imprint the embossed pattern or In order to effectively remove or pierce the outer surface of the material to enhance the sound insulation of one side of the material, it may be desirable to ripen the surface of the foam before embossing the accessory 3 11. If the maturation time is known, the distance can be determined by multiplying the conveyor's degree by the maturation time. [Cut] In this step, 312529 Αν ^ ^ ---- ^ --------- at a constant interval by the cutting machine device 3 12 (Please read the precautions on the back before (Fill in this page) 1234599 Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs A7 V. Description of Invention (W) Dividing materials in the direction of movement of the conveyor belt. More specifically, the conveyor belt carries the material under the cutting device that cuts the material moving perpendicular to the conveyor belt at fixed intervals to form a decoration. The cutting mechanism can include any number of one-body instances, including but not limited to vertical reciprocating knives, wings, or waterjets that shoot back at speed at intervals. The length of time between the spray and the speed of the conveyor will determine the length of material between the cuts. There is a fixed period of time between the formation of the structure during the aging of the material and the cutting step. This period is set by the speed of the conveyor 319 when the carousel continuously moves the material from the beginning of the dispensing step. Therefore, the distance between the embossing roller 3m and the cutter 312 is determined by the aging time multiplied by the conveyor speed. [Drying] In this step #, the carousel carries the material to the drying t 313, and then exposes the material to about 200 ° f, which is stable and strict; A & π J " This drying step drives away excess water that is not bound to the crystalline structure of the material. [Sand Grinding] In this step, the conveyor 319 moves the dry material under the sanding drum 314, wherein the conveyor belt rotates quickly under the drum covered with the sanding medium == to carry the dry material under the drum. This step removes the hard cuticles that are produced during curing and drying. Moreover, if it is especially repeated for decorative purposes, the sanding step may be omitted. Alternatively, if the structure is formed, a sand blasting machine can be used to provide the depth of the flowers or to give a special image to the product surface. The depth of sanding will be less than the depth of embossing. Place the vacuum mouth with wide true mouth • Close to the sanding drum and the surface of the product to remove waste material. The paper size is applicable to China National Standard (CNS) A4 (210 X 297 mm) 312529 ---- ------- Installation -------- Order --------- (Please read the notes on the back before filling this page) 18 1234599 A7 V. Description of the invention (Materials. [ Finishing and cutting] Conveyor 3 1 9 Move the sanding plate (please read the precautions on the back before filling this page) Dagger 3 finishing cutting device 315 (1) side cutting device, where the drying plate is The edge is moved from sanding to the device for trimming the dry-can board to the finished product size and shape; and the end-edge cutting device 'λ drying board moves along the remaining two edges from the first-finishing cutting operation to the further-trimming to the finished product Another dimension and shape of the device. This cutting device can also be adapted to provide specific required edge details. [Seal and paint] Move the treatment board to the paint spraying device by the conveyor, where the cutting board is arranged along the conveyor belt Move to the spray chamber and apply aerosol paint to the top surface of the material in the spray chamber Get the desired color. [Packing] Mark the finishing board on the packaging machine 317, shrink-wrap and pack it into a box for storage and distribution. Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs, although the specific examples have been described above, but can be recognized Changes can be made to the features and components of the present invention. Therefore, although the present invention only discloses the preferred form, those skilled in the art will clearly and easily know that many additions, deletions and modifications can be made without departing from the spirit of the present invention. And the scope, and should not set improper restrictions on it, except as shown in the scope of the following patent applications. For example, the type of cement used in the formulation can vary depending on the desired properties of the material. In addition, the type, length, and Daniel number of the fiber can be viewed The strength required by the final product assembled by the panel varies. This paper size applies to China National Standard (CNS) A4 (210 X 297 mm) 19 312529