TWI486497B - 非織材料及製造該材料之方法 - Google Patents

非織材料及製造該材料之方法 Download PDF

Info

Publication number
TWI486497B
TWI486497B TW098110984A TW98110984A TWI486497B TW I486497 B TWI486497 B TW I486497B TW 098110984 A TW098110984 A TW 098110984A TW 98110984 A TW98110984 A TW 98110984A TW I486497 B TWI486497 B TW I486497B
Authority
TW
Taiwan
Prior art keywords
fiber
fibers
component
organic binder
strength
Prior art date
Application number
TW098110984A
Other languages
English (en)
Other versions
TW201006979A (en
Inventor
Donald S Mueller
Weixin D Song
Bangji Cao
Original Assignee
Usg Interiors Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Usg Interiors Llc filed Critical Usg Interiors Llc
Publication of TW201006979A publication Critical patent/TW201006979A/zh
Application granted granted Critical
Publication of TWI486497B publication Critical patent/TWI486497B/zh

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/067—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • 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
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • 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
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • 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
    • B32B5/08—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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/108—Rockwool fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/101—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/58—Cuttability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B2001/7687—Crumble resistant fibrous blankets or panels using adhesives or meltable fibres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • Y10T428/2931—Fibers or filaments nonconcentric [e.g., side-by-side or eccentric, etc.]
    • 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.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2738—Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith
    • Y10T442/2746—Heat-activatable adhesive
    • 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]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • 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]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/638—Side-by-side multicomponent strand or fiber material
    • 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]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641—Sheath-core multicomponent strand or fiber material
    • 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]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/642—Strand or fiber material is a blend of polymeric material and a filler material
    • 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]
    • Y10T442/699—Including particulate material other than strand or fiber material

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Building Environments (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Artificial Filaments (AREA)
  • Multicomponent Fibers (AREA)
  • Paper (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Laminated Bodies (AREA)

Description

非織材料及製造該材料之方法
該領域係關於一種非織材料以及其製造方法，及更特定言之，一種有效提供吸音作用之適合用作隔音天花板瓦片的非織材料。
典型隔音天花板瓦片為非織結構，其包括由基質纖維、填充劑及黏合劑製造之核心。該等基質纖維通常為礦棉或玻璃纖維。該等填充劑通常為珍珠岩、黏土、碳酸鈣或纖維素纖維。該黏合劑典型地為纖維素纖維、澱粉、乳膠或類似材料。乾燥之後，黏合劑與其他材料形成黏結以形成向該核心提供結構剛性之纖維網。為用作典型天花板瓦片，核心應實質上平坦且為自撐式結構以便懸吊於典型天花板瓦片柵格或類似結構中。
對於適合於隔音天花板瓦片應用之非織結構而言，其通常滿足與防火等級及雜訊降低有關之各種工業標準及建築規範。舉例而言，工業標準典型地規定天花板瓦片具有根據ASTM E84之A類防火等級，其通常需要火焰散佈指數(flame spread index)小於25且煙氣發展指數(smoke development index)小於50。關於雜訊降低，工業標準典型地規定隔音天花板瓦片具有根據ASTM C423至少約0.55的雜訊降低係數。
隔音天花板瓦片通常經由濕式沉降方法來形成，該方法使用水性介質來輸送瓦片組份且使瓦片組份成形為用於 形成隔音天花板瓦片之核心的非織墊。基本方法包括首先將各種瓦片成份摻合至水性漿料中。接著將該水性漿料輸送至流漿箱(headbox)且分布於移動、多孔線網上以形成具有所需尺寸及厚度之均勻墊。接著移除水且乾燥該墊。接著可藉由對天花板瓦片切割、衝壓、塗佈及/或層壓表面修整面層來將經乾燥之墊修整為天花板瓦片結構。在濕式沉降方法中，水充當各種瓦片成份之輸送介質。因為可達成高生產速度且因為可使用低成本原料(例如，再循環新聞紙纖維、再循環波紋紙、碎聚酯纖維、棉絨、廢布碎料及其類似物)，所以此濕式沉降方法為可接受的。然而，使用水製造隔音天花板瓦片呈現許多缺陷，其使得該方法及所形成之產品不達要求。
濕式沉降方法使用大量水來輸送組份且使該等組份成形為天花板瓦片結構。最終必須自產品移除大量水。因此，大多數濕式方法接納藉由一或多個自流排水、真空、壓縮及/或蒸發步驟來移除水。此等方法步驟導致需要大量能量來輸送及移除水。因此，處理大量水以形成瓦片以及隨後移除及蒸發水使得典型濕式沉降方法由於高裝置及操作成本而相對昂貴。
使用濕式沉降方法亦難以形成具有高吸音特性之隔音天花板瓦片。在濕式沉降方法中，所形成之天花板瓦片由於濕式沉降調配物中之成份的性質而傾向於具有密封表面。具有密封表面之天花板瓦片通常具有有效性較小之聲屏障，因為瓦片少孔，其使得瓦片吸音能力較小。密封瓦 片表面實際上可反射聲音，其為隔音天花板瓦之不合需要之特徵。
咸信此等不合需要聲學特徵因濕式沉降方法中典型地所用之瓦片成份的親水性而出現。常用作天花板瓦片中之低成本黏合劑及填充劑的纖維素纖維(例如，再循環新聞紙)具高度親水性且吸引大量水。部分由於該等親水性組份，濕式沉降瓦片典型地具有約65%至約75%之高翻籠水分含量(亦即，即將進入乾燥箱或乾燥室之前板材之水分含量)，其增加在乾燥期間蒸發之需求。因此，在乾燥期間，當自此等親水性組份移除水時，於瓦片成份上產生高表面張力。為極性分子之水賦予其他組份表面張力。此表面張力通常引起瓦片表面由少孔結構密封。咸信表面張力將瓦片中之成份拉得更近，從而在過程中使結構緻密且封閉瓦片孔隙。因此，濕式沉降製造之天花板瓦片需要進一步加工以對瓦片打孔以便達成可接受之雜訊降低。因此，雖然濕式沉降方法由於生產速度增加及能夠使用低成本材料而為可接受的，但當產物需要聲學特徵時，使用水作為輸送介質使得方法及所得產品具有較低成本效率。
在一些情況下，乳膠黏合劑亦可用於隔音天花板瓦片中且在使用礦棉作為基質纖維之濕式沉降方法中常較佳。然而，乳膠通常為天花板瓦片調配物中所用之最昂貴成份；因此，希望限制此相對高成本成份之使用。天花板瓦片中通常所用之其他黏合劑為澱粉及如上文所述之纖維素纖維。然而，澱粉及纖維素具親水性且在加工期間傾向於 吸引水並產生上述高表面張力問題。
諸如紙尿布、衛生濕巾、過濾介質及汽車隔熱材料之其他非織結構可經由空氣沉降方法形成，該方法使用空氣作為形成非織材料之各種成份的輸送介質。空氣沉降方法消除輸送及移除水之需要；然而，調配物中之所有組份必須可於空氣流中輸送。因此，重、緻密或長的纖維以及液體組份通常不適合於空氣沉降方法。亦即，天花板瓦片製造中常用之液體樹脂黏合劑及/或乳膠黏合劑通常不能用於空氣沉降方法中。因此，典型空氣沉降方法較佳使用短玻璃纖維以及一些類型之熱熔性或熱黏合纖維(諸如單組分或雙組份黏合纖維)作為基質纖維(亦即，長度為約10mm)。一旦成形為非織材料，則加熱熱黏合纖維以使纖維之一部分熔融以便使基質纖維結構黏合於所需核心結構中。
WO 2006/107847 A2揭示一種使用雙組份熱黏合纖維及合成或纖維素基質纖維形成汽車隔熱材料及天花板瓦片結構之空氣沉降方法。在一實例中，'847公開案描述一種30%雙組份纖維與70%纖維素纖維(絨毛)之天花板瓦片組成物，其提供相對於市售礦物纖維及玻璃纖維天花板瓦片改良之聲學特性。雖然提供改良之聲學特性，但'847公開案所揭示之天花板瓦片結構具有缺陷，其通常將不符合目前由工業標準規定之用作天花板瓦片的消防法規等級。在天花板瓦片中使用70%纖維素纖維(以及100%有機纖維)之情況下，預期'847公開案之所形成之基質墊將由於該等高纖維素及有機纖維含量而不符合用於天花板瓦片之 ASTM E84要求的消防法規等級。
上述'847公開案及US 2006/0137799 A1進一步表明可使用空氣沉降方法由玻璃纖維以及雙組份纖維製造非織結構。雖然玻璃纖維將提供根據工業標準之增強之防火等級，但相對於其他原料，具有適合於空氣沉降方法之短尺寸的玻璃纖維為更昂貴之原料且具有健康及環境缺點。舉例而言，玻璃纖維可引起對人類皮膚、眼睛及呼吸系統之刺激。許多組織將玻璃纖維視為對皮膚、眼睛及上呼吸道之急性身體刺激。通常，纖維尺寸愈小，刺激愈令人難受。在一些情況下，若充分暴露於玻璃纖維，則纖維可產生刺激性皮膚炎及呼吸困難。在其他情況下，一些研究已展示當將纖維玻璃與粉塵、污垢及水分組合時可為黴菌、真菌及一些細菌之微生物生長的良好培養基。
如上所述，礦棉亦常用於隔音天花板瓦片中以提供增強之防火等級，因為礦棉可具有高達2200℉之熔點，其甚至高於常見玻璃纖維。礦棉常連同澱粉或乳膠黏合劑一起用於濕式沉降方法中以形成隔音天花板瓦片。然而，由於典型礦棉之磨損性質及高渣球含量(shot content)(亦即，在一些情況下至多約60%)，故通常不推薦在空氣沉降方法中使用此原料，因為礦棉纖維之磨損性質傾向於對空氣沉降成形裝置有害且高渣球含量可堵塞空氣過濾系統以降低真空抽氣箱之功效。在真空強度降低之情況下，空氣沉降成形頭難以形成具有足以提供天花板瓦片所需之剛性之基本重量的均勻墊。如本文中所使用，礦棉渣球(mineral wool shot)通常指礦棉製造方法之副產物，其包含直徑範圍為約45微米至約500微米之非纖維、礦物微粒物質。
'847公開案列出作為適合用於空氣沉降方法中之合成基質纖維的玻璃纖維及陶瓷纖維，但未特定列出作為可接受之替代物的礦棉。如通常所瞭解，認為礦棉纖維不同於玻璃纖維及陶瓷纖維。即使所有該等纖維類型通常為人造或合成纖維，但由於原料來源及製造方法，其各具有不同特徵及特性。玻璃纖維經由擠壓方法製造，形成典型地切為所需尺寸之連續長絲；因此，玻璃纖維典型地並不包括明顯渣球含量。另一方面，陶瓷纖維典型地由旋轉法或吹製法用較昂貴原料製成。陶瓷纖維典型地具有實質上比礦棉纖維小之渣球含量。
然而，儘管如上所述，由於空氣沉降成形方法中所用之常見雙組份纖維中之高熔點組份的強度，現有多組份纖維亦具有相對高強度(亦即，斷裂負荷及伸長率)，其為常使用此類纖維之產品(亦即，紙尿布、衛生濕巾、過濾介質及汽車隔熱材料)中所需之特性。然而，隔音天花板瓦片之消費者希望瓦片可手動切割(諸如用常見美工刀)，以使安裝者可易於在天花板瓦片中打眼以供灑水器、燈、HVAC管道及其類似物使用。另外，對於典型懸吊式天花板而言不常需要部分尺寸瓦片用於邊緣或拐角。因為隔音天花板瓦片通常以標準、固定尺寸獲得，所以安裝者常常需要切割個別瓦片以適合天花板柵格之特定要求。通常由於市售雙組份纖維之高強度(亦即，斷裂負荷及伸長率)，故 使用現有雙組份纖維形成隔音天花板瓦片產生需要過大力量來切割且展現纖維拉出之瓦片，其為消費者及安裝者所不需要之特性。
簡言之，現有使用可得常用成份之濕式沉降及空氣沉降方法無法成本有效地製造滿足所有工業及建築規範標準(亦即，隔音要求)以及消費者對隔音天花板瓦片之期望(亦即，可切性、平坦性、自撐式及其類似情況)的可接受之隔音天花板瓦片。現有濕式沉降方法為能量及資本集約型方法且形成聲學特性較不合需要之天花板瓦片。可適合於紙尿布、過濾介質及汽車隔熱材料之空氣沉降非織材料可更經濟地製造，但現有調配物及方法並不適合於製造滿足消費者與工業規格兩者之隔音天花板瓦片。形成具有高纖維素及/或有機纖維量之空氣沉降非織材料通常不會滿足天花板瓦片之工業防火等級標準，且使用可得雙組份纖維使得所形成之材料由於此等纖維之高強度及伸長率而難以切割。雖然短玻璃纖維可用於天花板瓦片及空氣沉降方法，但玻璃纖維可能貴得用不起且具有健康及環境問題。
因此，需要根據工業標準適合作為隔音天花板瓦片(亦即，聲學特性)之包含雙組份纖維之平坦、自撐式非織材料及其製造方法，該隔音天花板瓦片可無需濕式沉降方法之能量及資本成本而製造且亦滿足消費者對可切性之期望。
詳細敘述
一般而言，提供包括無機基質纖維與有機黏合纖維之摻合物的非織材料。藉由一種方法，該非織材料能夠成形為具有足以提供實質上平坦、剛性及自撐式核心之預定基本重量及密度的核心或基質墊，該核心進一步提供對於欲用作隔音天花板瓦片之非織材料有效的吸音作用。舉例而言，亦即，非織材料較佳能夠形成展現根據ASTM C423至少約0.55之雜訊降低係數及根據ASTM E84火焰散佈指數小於約25且煙氣發展指數小於約50之A類防火等級的自撐式核心。然而，非織材料之特徵可視特定應用而變化。該核心亦較佳展現高抗撓強度，但仍可類似於傳統濕式沉降天花板使用輕微或極小壓力手動切割(諸如用常見美工刀)。
在一態樣中，該無機基質纖維較佳為具有至多約60%且較佳介於約10%至約45%之間的渣球含量之礦棉、渣棉、石棉或其組合。合適無機基質纖維為Thermafiber FRF(Wabash,Indiana)；然而，亦可使用其他無機基質纖維。藉由一種方法，非織材料較佳包括約30%至約95%石棉或渣棉。較佳地，無機纖維具有平均約0.1mm至約4mm之長度及約1微米至約15微米之直徑。
在另一態樣中，有機黏合纖維較佳為於同一長絲(亦即整體長絲)中具有兩種組份之雙組份熱黏結纖維。較佳地，非織材料包括約0.1%至約70%且最佳5%至約50%之雙組份纖維。然而，因為市售雙組份纖維通常因其相對高強度(亦即斷裂負荷及伸長率)而已知，所以本文所用之雙 組份纖維較佳經改質以便所形成之非織材料亦展現類似於傳統隔音天花板瓦片之可切性。換言之，非織材料能夠形成展現高抗撓強度、但仍可以輕微壓力或僅極小力氣手動切割(諸如用常見美工刀)之隔音瓦片核心，即使該核心中使用雙組份纖維。為此目的，較佳經改質雙組份纖維具有實質上類似於無機基質纖維及核心之其他組份的預定強度(亦即，斷裂負荷及伸長率)，其通常為與市售雙組份纖維相比降低之強度。
雙組份纖維通常具有至少兩種具有不同化學及/或物理特性之聚合物或樹脂，其中使兩種聚合物成形為整體長絲或纖維。舉例而言，一種聚合物充當黏合組份且另一種聚合物充當結構組份。常見雙組份纖維具有外鞘-核心、並排、偏心外鞘-核心或島-海構型之黏合組份及結構組份。纖維中之一種聚合物(通常為結構組份)具有比纖維之另一種聚合物高的熔點。在此情況下，一旦將所形成之墊加熱至較低熔點聚合物之熔融溫度，則其熔化以將其他瓦片成份黏合在一起。較高熔點聚合物在纖維形式中保持完整以進一步向非織材料提供強度及結構。冷卻後，通常沿基質墊中之單一纖維長度形成複數個黏結。典型雙組份纖維通常包括聚乙烯/聚對苯二甲酸乙二酯(「PE/PET」)、聚乙烯/聚丙烯(「PE/PP」)、聚對苯二甲酸乙二酯共聚物/聚對苯二甲酸乙二酯(「CoPET/PET」)及其類似聚合物組合。較佳地，本文中之非織材料包括具有呈外鞘/核心構型之PE/PET或CoPET/PET聚合物的雙組份纖維。外鞘/核心為有利的，因 為其提供增加之接觸面積及強度，同時維持基質墊之結構完整性。在一具體實例中，外鞘與核心之間的面積比在約80/20至約20/80之範圍內。
如上文所述，雙組份纖維之一種組份(亦即，黏合組份)具有低於另一組份(亦即，結構組份)之熔點。藉由一種方法，黏合組份或第一聚合物組份之熔點比結構或第二聚合物組份之熔點低約25℃至約50℃。以此方式，雙組份纖維在兩種聚合物之間具有足夠熔點差以允許用於非織材料中以使僅聚合物組份中之一者在加熱後熔融。舉例而言，用於非織材料中之較佳雙組份纖維具有約100℃至約220℃之外鞘熔點及約150℃至約270℃之核心熔點。
較佳地，雙組份纖維具有約1公克/9,000公尺至約72公克/9,000公尺之此項技術中稱為丹尼(Denier)的線性密度；然而，視所用調配物、特定應用及其他因素而定，其他丹尼亦可為合適的。雙組份纖維亦較佳具有介於約1mm與約25mm之間且最佳介於1mm與約10mm之間的纖維長度。雖然上文討論無機及有機纖維之通常較佳形成適合於隔音天花板瓦片之核心的特定特徵，但亦可視特定應用與及方法而選擇其他纖維特性。
如【先前技術】中所討論，典型地用於非織織物、紙尿布、濕巾、過濾介質及汽車隔熱材料中之市售雙組份纖維通常過強而無法用於隔音天花板瓦片中，因為所形成之瓦片將需要過大力量來切割。此等纖維之強度可經由斷裂負荷與伸長率之組合來測定(Din EN SSO 5079或ASTM D3217)。如下表中所示，市售雙組份及單絲纖維(如通常由纖維供應商所報導)典型地展現不可接受的範圍為約2公克至約100公克之斷裂負荷及範圍為約30%至約400%之伸長率。此等市售纖維並不具有類似於天花板瓦片中常用之無機基質纖維的組合特性。雖然不欲受理論限制，但咸信此等現有纖維之該纖維強度主要歸因於雙組份纖維中之結構組份的組成。
然而，現有合成黏結纖維之此等高強度水準通常為用於天花板瓦片結構所不可接受的，因為其產生需要大力量來切割之產品，且在切割期間釋放過量纖維廢料。比較而 言，傳統上用於製造天花板瓦片之礦棉或玻璃纖維具有小於3.5公克之斷裂負荷及小於約6%之伸長率。對於良好可切性而言，需要基質墊中之成份在物理上彼此相容或通常實質上在其物理特性(諸如纖維強度)方面並無不同；另外，若個別纖維之物理特性實質上不同，則當使該墊經受切割力時，一種組份將傾向於與另一組份分離。
因此，較佳本文中之經改質雙組份纖維展現類似於礦棉或玻璃纖維之物理特性或可切性。藉由一種方法，經改質雙組份黏合纖維具有有效提供其類似於核心中所用之無機基質纖維的預定強度(亦即，斷裂負荷及伸長率)之組成。在一態樣中，經改質雙組份纖維之預定強度為小於約10公克(較佳約1公克至約10公克且最佳約1公克至約4公克)之斷裂負荷及小於20%(較佳小於約10%且最佳小於約6%)之伸長率。纖維斷裂負荷通常與纖維之丹尼成正比。典型地，纖維愈細，可切性愈好。較佳地，本文中所用之經改質有機纖維的丹尼為約0.7至約1.7且較佳為約1.1至約1.7。
藉由一種方法，經改質雙組份纖維之預定及降低之強度(斷裂負荷及伸長率)係藉由提供有效改良雙組份纖維之結構組份之物理特性的此組份之組成來獲得。舉例而言，纖維(諸如其中之結構組份)之強度可藉由提供熱塑性樹脂與有效量之填充劑的摻合物來改變。在另一方法中，結構組份之強度可藉由提供具有預定分子量範圍之材料(諸如樹脂)來改變。在另一方法中，可改變用於形成 結構組份之樹脂之結晶與非晶形區域的相對量以便獲得所需強度。亦可按需要使用此等方法之組合以達成所需剪切強度水準。
更特定言之，可將填充劑添加至用於形成雙組份纖維之結構組份的聚合物樹脂中以達成降低之強度水準。藉由一種方法，可將以重量計每約100份聚合物樹脂約1至約300份填充劑添加至樹脂中(亦即，聚合物樹脂中約0.25重量%至約75重量%填充劑且較佳約5重量%至約50重量%)以達成所需強度。除強度降低外，經填充之聚合物亦可展現纖維硬化(模數增加)及由於有機質量降低而改良之表面燃燒特徵。
合適填充劑包括(但不限於)經研磨碳酸鈣、沉澱碳酸鈣、高嶺土、滑石粉、二氧化矽、長石、霞石、雲母、矽灰石、珍珠岩、玻璃、矽酸鹽、二氧化鈦、硫酸鈣及其類似物以及其混合物。另外，亦可將氧化銻、氫氧化鋁、磷酸鹽及其類似物以及其組合添加至纖維或樹脂中以提供阻燃性。填充劑之尺寸通常應低於約3微米且較佳為約0.1微米至約2微米；然而，該尺寸可視應用及纖維之尺寸而變化。即使術語「填充劑(filler)」以上述材料之統稱術語用於本揭示案中，然而熟習技術者應瞭解，該等材料各具有可增強隔音天花板瓦片之效能的獨特性質。
雖然不欲受理論限制，但聚合物樹脂與填充劑組合(亦即，混配物)之強度(斷裂負荷及伸長率)與添加至樹脂中之填充劑的量有關。一般而言，添加之填充劑愈多，斷 裂負荷及伸長率愈低。參見例如Katz等人，Handbook of Fillers and Reinforcement for Plastics,1978，第81至118頁，該文獻以引用的方式併入本文中。
所添加之填充劑的量通常視特定填充劑之參數而定，其可至少藉由其填充特徵、尺寸及界面黏結來表徵。藉由一種方法，基質材料中之填充劑的最大容積填充率(Pf )為基於填充劑粒子之尺寸分布及形狀之參數。當填充劑之量接近Pf 時，咸信特定混配物之填充劑粒子僅由相對薄之樹脂膜部分分隔。在此情形下，聚合物樹脂基質體積為最小值且充當支撐拉伸負荷之個別區段或袋。當將拉伸負荷施加於樹脂時，此等基質區段拉伸且遠離粒子，導致高度填充之混配物的較低強度及較低伸長率。因此，為達成降低之斷裂負荷及降低之伸長率，混配於樹脂中之填充劑的量通常應接近特定填充劑之Pf 。藉由一種方法，用於經改質雙組份黏合纖維中之填充劑的Pf 通常將在約0.32至約0.83之範圍內；此意謂聚合物樹脂中所添加之填充劑在約32體積%至約83體積%之範圍內。最佳地，填充劑用量將為約30重量%至約70重量%。然而，應瞭解填充劑之量及尺寸可視所需纖維強度、纖維特徵、特定應用及其他因素而變化。
較佳非織材料包含具有約30重量%至約95重量%石棉或渣棉及約0.1重量%至約70重量%經改質雙組份熱黏結纖維之核心或基質墊。在一種形式下，所形成之基質墊為自撐式、相對剛性且實質上平坦面板，諸如厚度較佳為約0.25 吋至約1.5吋之2'×4'或2'×2'面板。在該形式下，基質墊適合安裝於典型懸吊式天花板柵格或類似結構中。
由於核心中之具有範圍為約0.1mm至約4mm之短長度的較佳無機基質纖維(亦即，礦棉、石棉及/或渣棉)，故所形成之非織核心較佳具有相對高基本重量以便達成製造適合用作天花板瓦片之自撐式核心所需的剛性。舉例而言，較佳該非織材料具有至少3,000公克/平方公尺(gsm)且最佳約3,000gsm至約5,000gsm之基本重量。非織墊亦較佳具有約0.1g/cm3 至約0.5g/cm3 之密度。如上文所討論，即使具有高基本重量及密度，但所形成之天花板瓦片仍能夠僅以極小壓力使用美工刀手動切割，此通常歸因於併有經改質雙組份熱黏結纖維。此等非織墊亦較佳展現約0.3至1.0且最佳0.55至1.0之雜訊降低係數。較佳非織材料亦展現最小10磅/平方吋(psi)之斷裂模數(MOR)或彎曲模數且具有最小約0.5磅之斷裂負荷(ASTM C 367-99)。然而，應瞭解上述特徵可視特定應用所需之調配物及方法而變化。
視情況，非織材料亦可於核心中包括特定應用所需之其他組份。應瞭解可添加此項技術中已知之可用於天花板瓦片以達成特定目的之許多其他組份中的任一者。舉例而言，該材料可包括至多約70重量%顆粒，諸如膨脹珍珠岩、發泡玻璃及其類似物。諸如沸石、活性碳及其類似物之功能性化學物質亦可添加至基質墊中以通常提供空氣淨化能力。除無機基質纖維及雙組份熱黏合纖維外，核心亦可按 需要包括其他可選纖維，諸如天然纖維(亞麻、竹、纖維素、劍麻及其類似物)、玻璃纖維、其他無機纖維、其他有機纖維及其混合物。需要時，非織材料亦可包括塗覆於所形成基質墊之一或多個表面上或滲透於所形成基質墊中以提供其他剛性之液體或乳膠黏合劑。舉例而言，可將至多約30重量%之乳膠黏合劑塗覆於基質墊之一或兩個表面上。
另外，所形成之核心可包含一或多個非織材料層。若存在多層，則各層可具有特定應用所需之與其他層類似或不同的特性，諸如類似或不同的基本重量、密度及組成。多個層可由將多個基質墊層壓在一起來形成或可使用多頭成形機在線形成。
非織材料亦可在核心之一面或兩面上用紗布或表面材料覆蓋。如下文進一步所討論，該表面可向核心提供裝飾面或具有有效允許使用欲使用空氣沉降方法製造之較佳無機基質纖維(亦即，相對短、磨損性及高渣球含量纖維)及有機黏合纖維之非織材料的特性。
說到形成非織材料之細節，將參考圖1及圖2來描述一種方法，該等圖說明適合於使上述非織材料成形為具有足以提供所需剛性之基本重量及密度之核心以使非織材料可用作隔音天花板瓦片的例示性空氣沉降製造方法10。出於本文之目的，「空氣沉降(air-laid)」係指使個別成份懸 浮於空氣或其他氣態流中且較佳於多孔線網或其他多孔載體表面上形成網、基質墊或氈之任何方法或製造方法。一般而言且參看圖1，適合於形成隔音天花板瓦片結構之空氣沉降方法10包括以下方法步驟：(a)原料分散及摻合12；(b)將該等原料計量且饋送至流漿箱14；(c)空氣沉降網成形16；(d)可選壓實18；(e)加熱及冷卻20；(f)可選壓延22；(g)可選層壓24；及(h)修整26。
如上文所討論，形成非織基質墊之原料可包括各種無機或有機纖維、合成或天然纖維、粉末、樹脂、顆粒及其他組份。合適原料的實例包括(但不限於)礦棉、石棉、渣棉、玻璃纖維、雙組份纖維、纖維素纖維、發泡玻璃珠等。較佳原料包括石棉或渣棉及雙組份纖維。如上文所討論，尤其較佳原料包括約30%至約90%石棉或渣棉及約0.1%至約70%有機黏合纖維，諸如如上文所討論之經改質雙組份。
在一些情況下，許多纖維原料通常需要製成適合於空氣沉降成形方法之形式。因此，該方法10首先包括分散及摻合步驟12。舉例而言，呈薄片、板及乾蓋板(dry lap)形式之纖維常常相互黏結且需要在傳遞至空氣沉降成形器之前離解。典型地，此等原料可用錘磨機型裝置離解，該裝置包括具有擺動錘之轉子以使饋送薄片離解。同樣，呈捆包形式之原料(諸如礦棉或合成纖維)可經由開包機預先鬆開且接著經由通風機輸送至計量塔30。不同纖維流之摻合32可藉由以預定重量比率將一股流注入另一股中以形 成預分散之纖維原料流34來完成。
接著經由空氣流將該預分散之纖維原料流34輸送至一或多個纖維塔36中，該纖維塔包括形成初始非織纖維墊之網格帶(未圖示)。纖維之計量較佳經由速度受控之稱量帶來完成。計量確保向空氣沉降機穩定且連貫的供應原料。以該方式計量亦可適用於控制所形成之基質墊的基本重量。計量後，經由輸送風扇將纖維原料饋送至一或多個各別空氣沉降成形頭38。可使用分流器來平衡流入該成形頭38之每一側的流量。雖然圖1說明3個獨立成形頭38，但方法10可按需要包括任何數目之成形頭以形成非織結構之所需厚度、密度及基本重量。較佳地，非織網或氈之成形係於空氣沉降成形頭中進行。合適之空氣沉降成形頭可由Dan-Web(Denmark)、M&J Fiber(Denmark)或FormFiber(Denmark)獲得；然而，其他空氣沉降供應商亦為合適的。
在空氣沉降機10之一態樣中，較佳與原料直接接觸的內表面由展現足夠強度/硬度之材料製成或其上具有增加該等材料之強度或提供可更換/硬化表面之塗覆。舉例而言，空氣沉降機10之管道、吹風機、成形頭等之內表面的至少部分可由具有至少250單位之布氏硬度(Brinell hardness)(ASTM E10)的材料製造。在另一實例中，可能需要將一層碳化鉻或類似材料塗覆於機器10之內表面上以保護下層材料。此塗層可有助於出現明顯渦流之機器區域。在另一實例中，在包括45°或更大轉角之機器位置中，可安裝大半徑彎頭且/或該彎頭可配備有可更換磨損組件，諸如由碳化 鉻或類似材料製成之插入物。該等機器細節僅為少數提供適合於加工本發明方法之纖維之空氣沉降機的方法之實例；當然，存在對於熟習此項技術者閱讀本揭示案後將顯而易見之其他可能方法。
在空氣沉降機10中，使纖維成份在空氣或其他氣態流中流態化以沉積於載體表面40(諸如多孔線網、紗布或其他多孔材料)上以形成非織材料之網或氈。使用各種裝置來使纖維或其他成份懸浮於空氣中。在一實例中，如圖1中所說明，成形頭38可包括在橫向加工方向上及在該載體表面40上方水平安置之兩個轉鼓42。在該實例中，鼓42可具有狹槽或孔穴以使分散之纖維穿過各鼓42。在一些情況下，當纖維圍繞兩個鼓移動時，可形成回轉流型。為流態化纖維，鼓亦可包括位於各鼓內之針輥。當纖維經由狹槽進入鼓時，該針輥攪動且篩分纖維。空氣渦流及拋擲作用進一步分散纖維。在另一實例中，可將纖維吹入無鼓成形器中，在該成形器中一排針輥輸送纖維下降至正形成之織物上。其他類型之成形頭亦可為合適的。在一實例中，合適空氣沉降鼓描述於美國專利第4,640,810號中，該案以引用的方式併入本文中。
纖維原料較佳在兩端饋送至成形頭38之一或多者。若使用，則可在不同位置處饋送粉末或顆粒組份。對於纖維與粉末之均勻摻合物而言，可將粉末分配單元44安裝於成形頭38之每一者上方(此特定型式未展示於圖中)，在該單元中粉末及纖維可混合以形成均勻混合物。對於在形成 網後塗覆於非織結構上之粉末狀層而言，如圖1中所說明，可將粉末分配單元44安裝於成形頭38之一或多者之間或之後以於非織材料之表面上形成一或多個獨立粉末層。
相鄰於成形頭38，較佳將一或多個真空抽氣箱46安裝於載體表面40下方。由真空形成之吸力引導成形頭38中之空氣及纖維向載體表面40沉積。較佳地，該等真空箱46經設計以維持穿過成形頭38且穿過真空箱之整個開口之恆定空氣速度以便可形成均勻墊。
由於上述非織材料中較佳存在相對細且短的無機基質纖維(亦即，高渣球含量及低至約0.1mm之纖維長度)，傳統多孔載體表面40之孔隙率通常不足以允許使用礦棉、石棉及/或渣棉及傳統空氣沉降成形頭來形成具有3,000gsm或更大之基本重量的非織材料。舉例而言，雖然多孔載體表面40允許空氣流過，而保留纖維及其他成份，但市售空氣沉降機所用之典型載體表面40無法防止本文所用之成份的部分穿過。舉例而言，礦棉、石棉及渣棉常常使低至約0.1mm之纖維長度進入且包括至多約60%渣球含量。在一些情況下，此等材料可穿過多孔載體表面40且堵塞空氣過濾系統。
因此，藉由一種方法，方法10亦包括使用安置於多孔載體表面40上之多孔襯墊或表面材料50來保留成份且防止空氣過濾系統堵塞。為此目的，多孔襯墊50之孔隙率較佳小於多孔載體表面40之孔隙率，但仍足以允許形成所需密度及基本重量之非織墊。較佳地，多孔襯墊50為薄紙片、 玻璃墊、紗布或其類似物。需要時，非織材料可經由黏著劑或當加熱時藉由使有機黏結纖維與多孔襯墊50黏結來與多孔襯墊50黏結。在此情況下，多孔襯墊50亦可包含所形成天花板瓦片的裝飾性外層。如圖1中所示，多孔襯墊50在空氣沉降成形頭38之前自饋料輥52展開；然而，襯墊50可以任何已知方式向成形頭供應。
較佳地，襯墊50為透音表面材料且具有允許使用空氣沉降頭38及真空箱46使無機基質纖維及經改質雙組份熱黏結纖維成形為基本重量為至少約3,000gsm之基質墊的特性。如上文所討論，襯墊50可緊固於所形成之核心上以於其外表面上達成所需美學訴求。另外，襯墊50亦可向所形成之面板添加額外結構完整性。
合適之襯墊50具有足以有效允許在空氣沉降頭中均勻地形成所需基本重量且亦限制相對小尺寸的纖維及渣球穿過之孔隙率。藉由一種方法，適合用於製造襯墊50之材料為玻璃纖維或由合成纖維或無機纖維與有機纖維之混合物製成的其他非織織物。在一態樣中，襯墊50之基本重量較佳介於約50gsm至約200gsm之間(若襯墊由玻璃纖維及黏合劑製成)且較佳為約50gsm至約125gsm。在另一態樣中，襯墊50較佳具有約10psi之最小拉伸強度(TAPPI T220)及約500格利剛性(Gurley stiffness)單位(TAPPI T543)。在其他態樣中，最大特定空氣流阻力通常為約2000Pa-s/m(ASTM C522)；然而，較佳襯墊具有約50Pa-s/m或更小之空氣流阻力。下表2鑑別適合於使用本文方法製造 隔音天花板瓦片之玻璃纖維襯墊的實例。
形成非織核心後，未黏結之網或氈可經由軋輥60壓實以改良其結構或強度。該等軋輥之壓力及溫度通常為可調節的以能夠進行不同程度之壓實。另外，軋輥60通常亦配備有可調節間隙以控制網或氈之厚度。軋輥60有助於在黏結之前維持墊之物理完整性且可降低墊表面之粗糙度。藉由一種方法，軋輥60將使用低壓力。
如上文所討論，非織核心中之成份的黏結較佳經由使用經改質雙組份熱黏結纖維來達成。然而，亦可替代地使用其他黏結方法或與經改質雙組份纖維組合使用以用於特定應用。舉例而言，另一融合非織材料之方法係在將纖維與礦棉摻合32之前將諸如苯酚-甲醛或脲-甲醛樹脂之熱固性樹脂塗覆於纖維。在加熱至預定樹脂凝固溫度後，由於樹脂單體之聚合而形成黏結。在另一方法中，亦可使用噴霧器62將乳膠黏合劑傳遞於網表面上或使網浸漬於乳膠混合物中。另外，可使網再濕潤，隨後經由壓延機或軋輥壓 實。乳膠之使用亦可有助於使襯墊50與核心黏合。
一旦使非織材料形成於核心中且將可選黏合劑材料塗覆於網上，則準備加熱及固化20。藉由一種方法，使用熱烘箱或乾燥器64將網加熱至至少有機黏合纖維中之黏合組份的熔點以便使纖維融合為纖維基質。保留於網中之任何水分(若存在)亦可在此加熱步驟期間蒸發。雖然可使用任何已知烘箱或乾燥器，但較佳烘箱中之熱傳遞為傳導性或對流性熱傳遞，且通氣流式烘箱(through-air flow oven)為最佳，因為其通常將加速加熱且因此需要較小烘箱。
一旦離開烘箱64，則較佳藉由使經加熱網暴露於由風扇66吹送之冷空氣流使其冷卻。或者，藉由穿過冷空氣抽氣箱使所形成之非織物品冷卻，該箱可壓實非織墊且增加其密度。需要時，該冷空氣抽氣箱可用於控制該物品之密度。
在通過砑光輥68之後，視情況，亦可使用標準層壓機70將網層壓24以便向網自多孔襯墊50之另一側提供另一表面材料。接著可藉由切割為所需尺寸、剪修為最終產品及/或塗佈來進一步修整26經層壓之網以產生具有適當尺寸、邊緣細節、表面紋理、顏色及其類似情況之隔音天花板瓦片。
因此，上述非織材料可較佳經由空氣沉降方法來製造且仍包含無機纖維(亦即，礦棉)及經改質雙組份黏合纖維。該方法及調配物使得此等組份能夠成形為適合用作滿足隔音及物理需求且提供優於習知濕式沉降隔音天花板瓦 片之優勢的隔音天花板瓦片之核心結構。因為空氣沉降成形方法實質上不含水，所以存在極小且較佳無施加於纖維之表面張力，從而產生具有較好聲學性質之更有彈性或蓬鬆結構。較佳及經改質雙組份纖維(合成纖維)之使用使所形成之墊具有結構完整性、抗撓強度及可切性，同時維持該墊之蓬鬆性。較佳及經改質黏合纖維之獨特性在於其提供增強之強度及降低之樹脂含量(亦即，增加之填充劑含量)，且提供所需強度，同時維持墊之可切性，其為對於安裝者重要之特徵。較佳及經改質雙組份纖維亦由於相對高填充劑(較佳為無機填充劑)含量而具有較好表面燃燒效能(亦即，較低生煙量及較慢火焰散佈)之優點。另外，黏合組份之低熔點可按需要定製以於各種黏結溫度下黏結各種材料。
本文所述之非織材料的優勢及具體實例進一步藉由以下實施例來說明；然而，此等實施例中所述之特定材料及其量以及其他條件及細節不應理解為過度地限制申請專利範圍。除非另有指示，否則所有百分比均以重量計。
實施例 實施例1：
用市售雙組份纖維及礦棉製備非織材料。將具有2.2丹尼(Denier)及6mm長度之PE/PET雙組份熱黏結纖維(T-255,Invista,Wichita,KS)預先鬆開且與預先鬆開之礦棉摻合。Invista PE/PET纖維具有250℃之核心熔點及135℃之外鞘熔點。纖維原料含有約90%礦棉及約10%雙組份 纖維。
將纖維混合物摻合物計量於Laroche計量塔(Laroche,SA)中且饋送至空氣沉降成形機(Dan-Web,Denmark)之成形鼓中。在成形鼓中，藉由旋轉針及由兩個轉鼓產生之剪切作用使雙組份纖維及礦棉分散及懸浮於空氣中。配備有真空箱之成形線位於成形鼓下方。當真空引導纖維沉積於移動之線上時，於成形線上形成網或氈。發現成形線具有過多孔而難以保持礦棉中之渣球含量。因此，使用薄紙襯墊使纖維材料保留於成形線上。
形成後，將該氈加熱至135℃以使外鞘組份熔融。冷卻後，基質墊變硬。所形成之基質墊具有邊緣可切性(需要過大力量且在切割期間展現纖維拉出)。基質墊在置於90℉及90% RH室中一週後展現極小尺寸變化。以下表3及表4列出所形成之基質墊的物理及聲學特性。所形成之墊上並不具有襯墊或紗布。
實施例2：
使用各種丹尼及長度之雙組份纖維作為熱黏結纖維以在空氣沉降機(Spike System,FormFiber,Denmark)中形成隔音天花板瓦片之基質墊。成形室由兩個垂直安置之具有尖峰的輥組成。基質墊含有如表5中所提供之各種百分比的礦棉、碎新聞紙、劍麻纖維及PE/PP雙組份纖維(Chisso Corporation,Japan)。核心(PP)具有162℃之熔點且外鞘(PE)具有110℃之熔點。測試樣品之聲學特性且結果列於以下表5及表6中。所形成之墊上並不具有襯墊或紗布。
實施例3：
在空氣沉降機中使用礦棉及具有1.1丹尼及6mm長度之約10%市售PE/PET雙組份纖維作為黏合劑纖維(Hoechst-Trevira Type-255(Charlotte,NC))形成天花板。將礦棉及黏合纖維摻合在一起，且接著饋送至一或兩個Laroche計量塔中。藉由首先將其傳送至纖維單元，接著下降至移動帶上來計量原料。藉由改變帶速度來控制饋送速度。使用輸送風扇將原料饋送至空氣沉降成形頭。
於纖維素薄紙層上或於自對接輥展開之玻璃纖維紗布(A125EX-CH02,Owens Corning)上形成基質墊。該玻璃纖維紗布用於保留及承載纖維而不影響真空抽吸。其亦充當面板之表面層。
在形成基質墊後，在進入加熱烘箱之前，視情況使另一薄紙層、纖維玻璃紗布(Dura-Glass 5017,Johns Manville)或塗佈噴霧沉降於基質墊之頂部。烘箱溫度為約329℉。線速度為每分鐘28吋。離開加熱烘箱，使所形成之面板於室溫下冷卻。
所形成之面板展現如下表7中所列之特性。所有樣品均展現邊緣可切性及自邊緣表面拉出纖維且需要相對強的力量來完成切割。樣品H展現明顯下垂，表明其不適合於 天花板瓦片。在具有表面襯墊之情況下，儘管樣品I基本重量低，但展現大大改良之下垂。樣品J為自撐式且剛性的。樣品K之兩面皆層壓有襯墊且基本上無下垂。
實施例4
如實施例3形成含有約17.5%雙組份纖維(T 255，1.1 Denier，6mm)之基質墊。於玻璃纖維紗布(A125EX-CH02,Owens Corning)上形成基質墊。接著用液體黏著劑(HB Fuller glue)以約3.4g/ft2 對所形成之基質墊進行噴霧。加熱後，將其用另一玻璃纖維紗布(A125EX-CH02)層壓。切割經層壓面板之邊緣且以約10g/ft2 至約12g/ft2 塗佈表面以及邊緣以將該面板修整為天花板瓦片。塗層組成物包括乙烯氯乙烯(EVCL)聚合物(Air Products,Allentown,PA)、二氧化鈦(Huntsman,Billingham,England)、碳酸鈣(J.M.Huber,Atlanta,GA)及黏土(J.M.Huber)。該面板之平均厚度為約0.76吋且密度為約9.44lbs/ft3 ，其提供約2929gsm之基本重量。如根據ASTM C-423-07所測試，此天花板瓦片之吸聲係數為約0.8。該樣品由於包含具有高斷裂負荷及伸長率之雙組份纖維而展現邊緣可切性，但該樣 品為自撐式的，剛性的，且基本上無下垂，表明其將適合於隔音天花板瓦片。
應瞭解熟習此項技術者可在如隨附申請專利範圍中所表述之原則及範疇內對本文已描述及說明以便闡明非織材料之性質及其製造方法的部分及組份之細節、材料及排列作出各種變化。
10‧‧‧空氣沉降方法
12‧‧‧原料分散及摻合
14‧‧‧將原料計量且饋送至流漿箱
16‧‧‧空氣沉降網成形
18‧‧‧可選壓實
20‧‧‧加熱及冷卻
22‧‧‧可選壓延
24‧‧‧可選層壓
26‧‧‧修整
30‧‧‧計量塔
32‧‧‧摻合
34‧‧‧預分散之纖維原料流
36‧‧‧塔
38‧‧‧成形頭
40‧‧‧載體表面
42‧‧‧轉鼓
44‧‧‧粉末分配單元
46‧‧‧真空箱
50‧‧‧多孔襯墊
52‧‧‧饋料輥
60‧‧‧軋輥
62‧‧‧噴霧器
64‧‧‧熱烘箱或乾燥器
66‧‧‧風扇
68‧‧‧砑光輥
70‧‧‧標準層壓機
圖1為用於形成本文所述之非織材料之例示性空氣沉降方法的示意圖。
圖2為例示性非織形成方法之流程圖。
10‧‧‧空氣沉降方法
12‧‧‧原料分散及摻合
14‧‧‧將原料計量且饋送至流漿箱
16‧‧‧空氣沉降網成形
18‧‧‧可選壓實
20‧‧‧加熱及冷卻
22‧‧‧可選壓延
24‧‧‧可選層壓
26‧‧‧修整
30‧‧‧計量塔
32‧‧‧摻合
34‧‧‧預分散之纖維原料流
36‧‧‧塔
38‧‧‧成形頭
40‧‧‧載體表面
42‧‧‧轉鼓
44‧‧‧粉末分配單元
46‧‧‧真空箱
50‧‧‧多孔襯墊
52‧‧‧饋料輥
60‧‧‧軋輥
62‧‧‧噴霧器
64‧‧‧熱烘箱或乾燥器
66‧‧‧風扇
68‧‧‧砑光輥
70‧‧‧標準層壓機

Claims (14)

  1. 一種包括非織材料之天花板瓦片，其包含：一實質上平坦及自撐式核心，包括一無機基質纖維及一有機黏合纖維，其中：該有機黏合纖維為一雙組份熱黏結纖維，其藉由於整體長絲中組合一有機黏合組份及一有機結構組份而形成；該黏合組份具有一熔點足夠低於該結構組份之熔點，以致於將該有機黏合纖維加熱至約該黏合組份之熔點時，該無機基質纖維及該有機黏合纖維至少部分相互黏合，藉此該核心對作為一天花板瓦片使用而言係充分為自撐式；且該結構組份為一塑性樹脂與填充劑之摻合物，其係減少該有機黏合纖維之強度以致於該無機基質纖維與有機黏合纖維之纖維強度實質上並無不同，藉此該核心展現高抗撓強度並能夠例如用常見美工刀以輕微壓力或僅極小努力而手動切割；該有機黏合纖維具有斷裂負荷為約10公克或更小且伸長率為約20%或更小之纖維強度。
  2. 如申請專利範圍第1項之包括非織材料之天花板瓦片，其中該結構組份包含約5重量%至約50重量%之該填充劑。
  3. 如申請專利範圍第1項之包括非織材料之天花板瓦片，其中該填充劑係選自由碳酸鈣、黏土、滑石粉、二氧化矽、長石、霞石、雲母、矽灰石、珍珠岩、玻璃、矽酸 鹽、二氧化鈦、硫酸鈣及其混合物組成之群。
  4. 一種天花板瓦片組成物，其包含：一實質上平坦及自撐式核心，包括一無機基質纖維及一有機多組份熱黏合纖維，其中：該多組份熱黏合纖維於整體纖維長絲中包含一低熔點有機纖維組份及一高熔點有機纖維組份；該低熔點纖維組份之熔點係足夠低於該高熔點纖維組份之熔點，以致於當加熱時至少一部分之該多組份熱黏合纖維係藉由熱黏結而黏合到至少一部分之該無機基質纖維以形成該核心；該高熔點纖維組份為一塑性樹脂與填充劑之摻合物，其係減少該熱黏合纖維之強度以致於該無機基質纖維與該有機黏合纖維之纖維強度實質上並無不同，藉此該核心展現高抗撓強度並能夠例如用常見美工刀以輕微壓力或僅極小努力而手動切割。
  5. 如申請專利範圍第4項之組成物，其中該高熔點纖維組份包含約5重量%至約50重量%之該填充劑。
  6. 如申請專利範圍第5項之組成物，其中該填充劑係選自由碳酸鈣、黏土、滑石粉、二氧化矽、長石、霞石、雲母、矽灰石、珍珠岩、玻璃、矽酸鹽、二氧化鈦、硫酸鈣及其混合物組成之群。
  7. 如申請專利範圍第1項之包括非織材料之天花板瓦片，其中該有機黏合纖維具有在斷裂時小於10%之伸長率、在斷裂時約1公克至約4公克之強度、以及在約0.7至約 1.7之範圍內的丹尼。
  8. 如申請專利範圍第1項之包括非織材料之天花板瓦片，其中該有機黏合纖維具有約1毫米至約25毫米之長度、在約0.7至約1.7之範圍內的丹尼、以及在斷裂時小於約6%之伸長率。
  9. 一種形成如申請專利範圍第4項之天花板瓦片組成物的方法，該方法包含：提供無機基質纖維及有機黏合纖維；使該無機基質纖維及該有機黏合纖維成形為非織網；及加熱該非織網以使該無機基質纖維之至少一部分與該有機黏合纖維之至少一部分黏合以形成實質上平坦及自撐式結構。
  10. 如申請專利範圍第9項之方法，其中：該無機基質纖維係選自由礦棉、渣棉、石棉及其混合物組成之群且具有至多約60重量%之渣球含量(shot content)；該非織材料包含約5重量%至約50重量%之摻合於樹脂中的填充劑；且該填充劑係選自由碳酸鈣、黏土、滑石粉、二氧化矽、長石、霞石、雲母、矽灰石、珍珠岩、玻璃、矽酸鹽、二氧化鈦、硫酸鈣及其混合物組成之群。
  11. 如申請專利範圍第10項之方法，其進一步包含：提供使該無機基質纖維及該有機黏合纖維在黏合期間 實質上保留於其上之多孔表面材料。
  12. 如申請專利範圍第11項之方法，其中：該多孔表面材料具有約2000Pa-s/m或更小之空氣流阻力、至少約10psi之拉伸強度、至少約500單位之格利剛性(Gurley stiffness)及約50gsm至約200gsm之基本重量。
  13. 如申請專利範圍第12項之方法，其進一步包含：使該多孔表面材料附著於該實質上平坦及自撐式結構。
  14. 如申請專利範圍第13項之方法，其中使用至少一個空氣沉降成形頭使該無機基質纖維及該有機黏合纖維成形為該非織網。
TW098110984A 2008-04-03 2009-04-02 非織材料及製造該材料之方法 TWI486497B (zh)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US12/061,825 US8563449B2 (en) 2008-04-03 2008-04-03 Non-woven material and method of making such material

Publications (2)

Publication Number Publication Date
TW201006979A TW201006979A (en) 2010-02-16
TWI486497B true TWI486497B (zh) 2015-06-01

Family

ID=41133684

Family Applications (1)

Application Number Title Priority Date Filing Date
TW098110984A TWI486497B (zh) 2008-04-03 2009-04-02 非織材料及製造該材料之方法

Country Status (14)

Country Link
US (1) US8563449B2 (zh)
EP (1) EP2265754B1 (zh)
JP (1) JP5510755B2 (zh)
KR (1) KR101609567B1 (zh)
CN (1) CN101990586B (zh)
BR (1) BRPI0910442B1 (zh)
CA (1) CA2720696C (zh)
CO (1) CO6311118A2 (zh)
MX (1) MX2010010717A (zh)
MY (1) MY157162A (zh)
RU (1) RU2485229C2 (zh)
TW (1) TWI486497B (zh)
WO (1) WO2009124104A1 (zh)
ZA (1) ZA201007848B (zh)

Families Citing this family (44)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USRE44070E1 (en) 2005-06-09 2013-03-12 United States Gypsum Company Composite light weight gypsum wallboard
US20090252941A1 (en) * 2008-04-03 2009-10-08 Usg Interiors, Inc. Non-woven material and method of making such material
JP2012511108A (ja) * 2008-12-04 2012-05-17 イーマン８ ピーティワイ リミテッド 短繊維から製造される不織テキスタイル
DE102009007891A1 (de) 2009-02-07 2010-08-12 Willsingh Wilson Resonanz-Schallabsorber in mehrschichtiger Ausführung
US8950587B2 (en) 2009-04-03 2015-02-10 Hollingsworth & Vose Company Filter media suitable for hydraulic applications
US8062565B2 (en) * 2009-06-18 2011-11-22 Usg Interiors, Inc. Low density non-woven material useful with acoustic ceiling tile products
US9362020B2 (en) 2011-02-09 2016-06-07 Waukesha Electric Systems, Inc. Method of manufacturing a dry type electrical insulation
US9281098B2 (en) * 2011-02-09 2016-03-08 Waukesha Electric Systems, Inc. Dry type electrical insulation
US8323785B2 (en) 2011-02-25 2012-12-04 United States Gypsum Company Lightweight, reduced density fire rated gypsum panels
CN103781956B (zh) * 2011-06-30 2016-09-28 3M创新有限公司 非织造驻极体纤维网及其制备方法
WO2013003391A2 (en) * 2011-06-30 2013-01-03 3M Innovative Properties Company Non-woven electret fibrous webs and methods of making same
US10377108B2 (en) 2012-02-17 2019-08-13 United States Gypsum Company Gypsum products with high efficiency heat sink additives
US9540810B2 (en) 2012-10-23 2017-01-10 United States Gypsum Company Pregelatinized starch with mid-range viscosity, and product, slurry and methods related thereto
US9828441B2 (en) 2012-10-23 2017-11-28 United States Gypsum Company Method of preparing pregelatinized, partially hydrolyzed starch and related methods and products
US10399899B2 (en) 2012-10-23 2019-09-03 United States Gypsum Company Pregelatinized starch with mid-range viscosity, and product, slurry and methods related thereto
WO2014092718A1 (en) * 2012-12-14 2014-06-19 3M Innovative Properties Company Non-woven electret fibrous webs and methods of making same
FR3000971B1 (fr) * 2013-01-11 2016-05-27 Saint Gobain Isover Produit d'isolation thermique a base de laine minerale et procede de fabrication du produit
US9193131B2 (en) 2013-03-14 2015-11-24 Cta Acoustics, Inc. Thermal and acoustical insulation
US9993990B2 (en) 2013-03-14 2018-06-12 Cta Acoustics, Inc. Thermal insulation
US9765451B2 (en) * 2013-05-16 2017-09-19 Esra KARACA Functional polyester thread comprising pearlite and the production method thereof
US8734613B1 (en) * 2013-07-05 2014-05-27 Usg Interiors, Llc Glass fiber enhanced mineral wool based acoustical tile
JP6609898B2 (ja) * 2013-10-01 2019-11-27 セイコーエプソン株式会社 シート製造装置、シート製造方法、及びこれらにより製造されるシート、並びに、これらに用いる複合体、その収容容器、及び複合体の製造方法
US8974925B1 (en) 2013-10-15 2015-03-10 United States Gypsum Company Gypsum board
RU2539462C1 (ru) * 2013-12-17 2015-01-20 Общество с ограниченной ответственностью "ТЕРРАБИЛДИНГ" Способ изготовления акустических панелей и технологическая линия для их производства
US9376810B2 (en) 2014-04-25 2016-06-28 Usg Interiors, Llc Multi-layer ceiling tile
US9243401B2 (en) 2014-05-16 2016-01-26 Awi Licensing Company Acoustic ceiling board with improved aesthetics
DE102014012159A1 (de) * 2014-08-14 2016-02-18 Johns Manville Europe Gmbh Verfahren zur Herstellung von hochgefüllten Vliesstoffen
US10072366B2 (en) 2014-10-29 2018-09-11 Nonwoven Network LLC Moldable automotive fibrous products with enhanced heat deformation
US11566349B2 (en) 2015-03-27 2023-01-31 The United States Of America As Represented By The Secretary Of The Army High strength 3D-printed polymer structures and methods of formation
US9938659B2 (en) * 2015-06-27 2018-04-10 Nonwoven Network LLC Apparatus and method of making a nonwoven ceiling tile and wall panel
EP3133196B1 (de) 2015-08-18 2020-10-14 Carl Freudenberg KG Volumenvliesstoff
US20200232133A1 (en) * 2017-07-18 2020-07-23 Zephyros, Inc. Nonwoven composite for high temperature applications requiring low flammability, smoke, and toxicity
US10696594B2 (en) 2017-08-11 2020-06-30 Usg Interiors, Llc High noise reduction coefficient, low density acoustical tiles
EP3508459A1 (en) 2018-01-09 2019-07-10 OCV Intellectual Capital, LLC Fiber reinforced materials with improved fatigue performance
EP3794171B1 (en) * 2018-05-17 2023-11-29 University of Tennessee Research Foundation Methods of saturating nonwoven fabrics with liquid and the making of electret thereof
CN108866808A (zh) * 2018-07-13 2018-11-23 合肥洁诺医疗用品有限公司 一种抗菌抗紫外线无纺布
US11155734B1 (en) 2018-07-23 2021-10-26 10X Engineered Materials, LLC Sediment mixture configured to be used as an abrasive agent
WO2020107422A1 (en) 2018-11-30 2020-06-04 The Procter & Gamble Company Methods of creating soft and lofty nonwoven webs
EP4074874B1 (en) 2018-11-30 2024-01-03 The Procter & Gamble Company Methods for producing through-fluid bonded nonwoven webs
ES2953189T3 (es) * 2020-06-24 2023-11-08 Sefar Ag Membrana compuesta y procedimiento para producir una membrana compuesta
EP3933135A1 (en) * 2020-07-02 2022-01-05 Saint-Gobain Ecophon AB A method for manufacturing acoustical elements
CN112831916A (zh) * 2020-12-30 2021-05-25 盐城工学院 一种用于沙漠改造的非织造材料制造装置
FR3118633A1 (fr) * 2021-01-07 2022-07-08 Saint-Gobain Isover Procédé de fabrication de produits d’isolation à base de fibres naturelles
US11482201B1 (en) 2021-05-13 2022-10-25 Marimba One, Inc. Materials and fabrication method for percussive musical instruments

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030060113A1 (en) * 2001-09-20 2003-03-27 Christie Peter A. Thermo formable acoustical panel
US20040161993A1 (en) * 2001-09-06 2004-08-19 Gary Tripp Inorganic fiber insulation made from glass fibers and polymer bonding fibers
CN101189380B (zh) * 2005-04-01 2012-12-19 博凯技术公司 用于隔音的非织造材料和制造工艺

Family Cites Families (45)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4006037A (en) 1974-11-04 1977-02-01 The Richardson Company Mineral filled, high impact, polyolefin molding compositions
US4026478A (en) * 1975-04-03 1977-05-31 Jim Walter Corporation Process for making uniform short non-cellulosic fibers
US4795668A (en) 1983-10-11 1989-01-03 Minnesota Mining And Manufacturing Company Bicomponent fibers and webs made therefrom
US4889764A (en) 1987-05-22 1989-12-26 Guardian Industries Corp. Non-woven fibrous product
AU620380B2 (en) 1988-03-18 1992-02-20 Denso Corporation Fiber-reinforced polymer composition and method of producing same
JPH0726252B2 (ja) * 1988-11-16 1995-03-22 帝人株式会社 熱接着性複合繊維
US5108827A (en) 1989-04-28 1992-04-28 Fiberweb North America, Inc. Strong nonwoven fabrics from engineered multiconstituent fibers
JP3144511B2 (ja) 1993-03-04 2001-03-12 東洋紡績株式会社 断熱繊維構造体
IT1276840B1 (it) 1994-04-14 1997-11-03 Eurocompositi Srl Pannello incombustibile e metodo per il suo ottenimento
DE4441765A1 (de) 1994-11-24 1996-05-30 Teodur Nv Bindemittelzusammensetzung zur Herstellung von Faservliesen und Verfahren zur Herstellung von Faservlies-Formteilen
DE19520990A1 (de) * 1995-06-08 1996-12-12 Wacker Chemie Gmbh Schmelzbare, chlorfreie Vinylacetatcopolymerfaser
WO1997000989A1 (en) 1995-06-23 1997-01-09 Minnesota Mining And Manufacturing Company Method of attenuating sound, and acoustical insulation therefor
JPH0911374A (ja) 1995-06-27 1997-01-14 Asahi Fiber Glass Co Ltd 繊維集合体及び断熱吸音材
FR2750978B3 (fr) 1996-07-11 1998-08-07 Saint Gobain Isover Materiau a base de fibres minerales
US5948528A (en) 1996-10-30 1999-09-07 Basf Corporation Process for modifying synthetic bicomponent fiber cross-sections and bicomponent fibers thereby produced
CA2214189C (en) 1997-01-10 2001-05-29 Basf Corporation Novel bicomponent fibers having core domain formed of regenerated polymeric materials and methods of making the same
US5911818A (en) 1997-08-20 1999-06-15 Usg Interiors, Inc. Acoustical tile composition
US5983586A (en) * 1997-11-24 1999-11-16 Owens Corning Fiberglas Technology, Inc. Fibrous insulation having integrated mineral fibers and organic fibers, and building structures insulated with such fibrous insulation
US6797377B1 (en) * 1998-06-30 2004-09-28 Kimberly-Clark Worldwide, Inc. Cloth-like nonwoven webs made from thermoplastic polymers
US7351673B1 (en) 1999-07-30 2008-04-01 Johns Manville Laminates including two or more layers of organic synthetic filament non-wovens and glass fiber webs and scrims
CA2323340A1 (en) 1999-10-18 2001-04-18 Armstrong World Industries, Inc. Foamed composite panel with improved acoustics and durability
US20020160682A1 (en) * 1999-12-29 2002-10-31 Qingyu Zeng Acoustical fibrous insulation product for use in a vehicle
US6855422B2 (en) 2000-09-21 2005-02-15 Monte C. Magill Multi-component fibers having enhanced reversible thermal properties and methods of manufacturing thereof
US6539955B1 (en) 2000-09-29 2003-04-01 Owens Corning Fiberglas Technology, Inc. Acoustical insulation blanket for dishwasher
US7015261B1 (en) 2000-11-17 2006-03-21 Arkema Inc. Impact modifier combination for polymers
JP4830166B2 (ja) * 2001-03-27 2011-12-07 日本ロックウール株式会社 無機繊維シートとその製造方法
US20020168518A1 (en) 2001-05-10 2002-11-14 The Procter & Gamble Company Fibers comprising starch and polymers
JP3816828B2 (ja) 2002-04-03 2006-08-30 株式会社クラレ 高温熱成型可能な立体成型用不織布とそれを用いた吸音材
US7000729B2 (en) 2002-07-08 2006-02-21 Acoustek Nonwovens Five-layer sound absorbing pad: improved acoustical absorber
US6915052B2 (en) 2003-03-06 2005-07-05 E. I. Du Pont De Nemours And Company Covered optical fiber
US20040185225A1 (en) 2003-03-20 2004-09-23 Fay Ralph Michael Spunbond facing and faced insulation assembly
DK200300661A (da) 2003-05-01 2004-11-02 Dan Web Holding As Fremgangsmåde og apparat til törformning af et væv
US20040242107A1 (en) 2003-05-30 2004-12-02 Collins Loren M. Non-woven flame blocking fabric and method
WO2005005198A2 (en) 2003-07-01 2005-01-20 Collins & Aikman Products Co. Sound absorptive multilayer articles and methods of producing same
US7138023B2 (en) 2003-10-17 2006-11-21 Owens-Corning Fiberglas Technology, Inc. Development of thermoplastic composites using wet use chopped strand (WUCS)
US7294218B2 (en) 2003-10-17 2007-11-13 Owens Corning Intellectual Capital, Llc Composite material with improved structural, acoustic and thermal properties
US20050266757A1 (en) 2003-10-17 2005-12-01 Roekens Bertrand J Static free wet use chopped strands (WUCS) for use in a dry laid process
US20080251187A1 (en) 2003-10-17 2008-10-16 Enamul Haque Composite material with improved structural, acoustic and thermal properties
US7226879B2 (en) 2003-12-30 2007-06-05 Owens-Corning Fiberglas Technology Inc. Multidensity liner/insulator formed from multidimensional pieces of polymer fiber blanket insulation
DE102004057874A1 (de) 2004-11-30 2006-06-01 Basf Ag Verfahren zur Nachvernetzung wasserabsorbierender Polymerpartikel
US20060137799A1 (en) 2004-12-29 2006-06-29 Enamul Haque Thermoplastic composites with improved sound absorbing capabilities
US20060292952A1 (en) 2005-06-23 2006-12-28 Building Materials Investment Corporation Fiber mat and process for making same
US20070009722A1 (en) 2005-07-11 2007-01-11 Strait Michael A Polymer/WUCS mat and method of forming same
US20080014815A1 (en) 2006-07-13 2008-01-17 Geel Paul A Highly filled fibrous veil
US20090252941A1 (en) 2008-04-03 2009-10-08 Usg Interiors, Inc. Non-woven material and method of making such material

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040161993A1 (en) * 2001-09-06 2004-08-19 Gary Tripp Inorganic fiber insulation made from glass fibers and polymer bonding fibers
US20030060113A1 (en) * 2001-09-20 2003-03-27 Christie Peter A. Thermo formable acoustical panel
CN101189380B (zh) * 2005-04-01 2012-12-19 博凯技术公司 用于隔音的非织造材料和制造工艺

Also Published As

Publication number Publication date
KR101609567B1 (ko) 2016-04-06
BRPI0910442B1 (pt) 2019-10-22
US8563449B2 (en) 2013-10-22
MY157162A (en) 2016-05-13
CN101990586B (zh) 2013-03-13
TW201006979A (en) 2010-02-16
JP2011518262A (ja) 2011-06-23
RU2485229C2 (ru) 2013-06-20
BRPI0910442A2 (pt) 2018-02-14
MX2010010717A (es) 2010-11-05
ZA201007848B (en) 2011-07-27
WO2009124104A1 (en) 2009-10-08
JP5510755B2 (ja) 2014-06-04
US20090253323A1 (en) 2009-10-08
CN101990586A (zh) 2011-03-23
RU2010142258A (ru) 2012-05-10
KR20100129773A (ko) 2010-12-09
EP2265754A1 (en) 2010-12-29
CA2720696A1 (en) 2009-10-08
CO6311118A2 (es) 2011-08-22
EP2265754B1 (en) 2016-06-08
EP2265754A4 (en) 2011-07-27
CA2720696C (en) 2016-10-25

Similar Documents

Publication Publication Date Title
TWI486497B (zh) 非織材料及製造該材料之方法
TWI475138B (zh) 非織材料及製造該材料之方法
EP2464796B1 (en) Low density non-woven material useful with acoustic ceiling tile products
EP1300511A2 (en) Thermo formable acoustical panel
CN116145882A (zh) 矿物纤维类吊顶板
EP1180182A1 (en) Mineral fibre insulating board comprising a rigid surface layer, a process for the preparation thereof and a use of the insulating product for roofing and facade covering
TWI532899B (zh) 適於隔音天花板瓷磚產品的低密度不織布材料及形成隔音天花板瓷磚之方法
JP2002103533A (ja) 蒸散部材用シート

Legal Events

Date Code Title Description
MM4A Annulment or lapse of patent due to non-payment of fees