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  • 专利说明
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    • 专利摘要:
    USE OF POROUS NON-WOVEN SCREENS IN ACOUSTIC PANELS An acoustic construction panel and method of manufacturing the same are revealed. The panel modalities include a porous non-woven fabric, a coating deposited on the fabric, a base blanket and an adhesive deposited either on the base blanket or on the fabric in a different way such as in droplets. The modalities of the manufacturing method include the steps of perforating the base blanket, applying the adhesive to the base blanket differently, laminating the canvas to the base blanket and applying the coating to the canvas surface.
    公开号:BR112012014918B1
    申请号:R112012014918-0
    申请日:2010-12-15
    公开日:2021-01-19
    发明作者:Bangji Cao；Weixin D. Song；Gregory Palm
    申请人:Usg Interiors Llc；
    IPC主号:
    专利说明:

    This application claims the priority of provisional patent application No. U.S. 61 / 289,140, filed on December 22, 2009. FIELD OF THE INVENTION
    [0001] This invention relates to acoustic panels used in the construction industry. BACKGROUND OF THE INVENTION
    [0002] Acoustic panels, tiles or walls fall into the category of construction products that transmit architectural values, sound absorption and attenuation and / or utility functions for interior construction. Acoustic panels are generally used in public areas that require noise control such as in office buildings, department stores, hospitals, hotels, auditoriums, airports, restaurants, libraries, classrooms, theaters, cinemas and some residential buildings.
    [0003] Acoustic panels must demonstrate a certain level of sound absorption, which must be effective in controlling noise in buildings. Sound absorption, in a characteristic way, is measured by its noise reduction coefficient (NRC). A detailed method for measuring NRC is outlined in ASTM C423. The NRC is represented by a number between 0 and 1.00, which indicates the percentage of sound that will be absorbed. For example, an acoustic panel that has an NRC value of 0.60 will absorb 60% and deflect 40% of the sound. Another method to test the sound absorption property is the estimated NRC (eNRC), which is measured using a smaller sample size by means of an impedance tube, as detailed in ASTM C 384. The estimated NRC is calculated by obtaining the average normal sound absorption coefficient obtained at the frequencies of 250, 500, 1,000 and 1,600 Hz and multiply it by 1.6.
    [0004] In the construction industry, panel products that are very effective in controlling noise, are said to have high NRC. High NRC panels successfully reduce a good amount of the rebound in open spaces. As such, it is desirable to use elevated NRC panels in buildings that are designed to have large rooms or other open spaces.
    [0005] Several characteristics of acoustic panels and related test methods are managed by industry standards and building codes. A critical requirement for acoustic panels is the ability to remain substantially rigid or free of bending in a humid environment. A standard test to determine the arching of panel product under various conditions of exposure to moisture is described in ASTM C367. Briefly, ceiling panels that are 0.61 m (2 feet) by 1.22 m (4 feet) are placed on a test board, as is known in the art. They are then exposed to a climate of 40 ° C (104 ° F) and 95% relative humidity for 12 hours, followed by a climate of 21.11 ° C (70 ° F) and 50% relative humidity for another 12 hours. . Three of the cycles are repeated. At the end of three cycles, the bending induced by total hydration is recorded as the distance in inches that the center of the panel arches down, compared to the edges that are held stationary by the test frame. The recorded distance indicates the arching performance of the acoustic panel.
    [0006] Currently, most acoustic panels or tiles are made of aqueous slurry containing fibers, fillers and binders. The manufacture of these panels is primarily based on a water filtration process. In the process of filtering with water, the base blanket is formed in a similar way to papermaking. This process is described, for example, in U.S. Patent No. 5,911,818. Briefly, slurry containing diluted aqueous dispersions of mineral wool and light weight aggregate is distributed in porous yarn in motion of the Fourdrinier type blanket forming machine. The water is drained by gravity from the slurry and then optionally dehydrated by means of pressure or vacuum suction. Such dehydrated wet base blankets are dried in a heated convection oven or oven to remove residual hydration. Dry base blankets are also subjected to finishing operations to form panels with size, appearance, and acoustic properties acceptable to end users. These finishing operations typically include surface grinding, sawing, drilling / cracking, spray / roll coating, and edge cutting. Due to its speed and efficiency, the water filtration method is currently the chosen manufacturing process.
    [0007] A typical base layer of acoustic panel comprises inorganic fibers, cellulosic fibers, fillers, and binders. As is well known in the industry, inorganic fibers are either mineral wool (interchangeable with slag wool, rock wool, stone wool) or fiberglass. These inorganic fibers are rigid and are used to provide volume and porosity to the base blanket. Cellulosic fibers like paper fibers, on the other hand, are used as structural elements and help provide resistance to both moisture and dryness to the base blanket. Resistance is believed to occur due to the formation of numerous hydrogen bonds between hydrophilic cellulosic fibers and the various ingredients in the base blanket.
    [0008] A typical base blanket binder used is starch. Typically, starches used in basic blankets are unmodified, uncooked starch granules that are dispersed evenly in water to form slurry. Once heated, the starch granules become "cooked" and bind the other basic blanket ingredients. Starch is typically required for flexural strength, which is measured with the rupture module (MOR). Starch is also typically required to impart hardness and rigidity to the panel.
    [0009] In certain panel formulations, a high concentration of inorganic fibers is desirable. In such formulations, a latex binder is used as the main binding agent. Inorganic-based blanket loads can include both light and heavy weight inorganic materials. Some examples of heavy weight fillers are calcium carbonate, clay, and plaster. An example of light weight cargo is expanded pearlite. The primary function of loads is to provide flexural strength and hardness, however, other functions are possible depending on the load material chosen. As used in this disclosure, it is understood that fillers convey more properties than simply providing mass, strength, hardness or volume to the product.
    [00010] Due to the amount of hydrophilic materials (such as cellulosic fibers or starch, for example) used in typical acoustic panel blankets, the finished panels are susceptible to changes in humidity in the environment. When the humidity level increases in the environment, the hydrophilic components in the panel absorb hydration from the surrounding air. The absorbed water molecules loosen and break the hydrogen bonds that exist between cellulosic fibers, starch, mineral wool, fillers, and other materials in the blanket. The resulting reduced number of hydrogen bonds results in reduced internal resistance. Consequently, the panel starts arching under its own weight. A panel can experience many cycles of high and low humidity in its lifetime of use, and each cycle will introduce additional bending. Increased temperatures speed up the arching process.
    [00011] The accumulation of arching eventually causes reprehensible visual appearance that diminishes the aesthetic appeal of the room. As a result, consumers must regularly replace arched panels. Thus, an acoustic panel that can resist changes in humidity in the environment and that does not show visible bowing even in a highly humid environment should be desirable.
    [00012] Currently, in the construction products market, acoustic panels that have laminated non-woven fabric (also known in the art as coverings, coverings, veils and cloths, among other terms) usually include base blankets made of fiberglass or of mineral wool.
    [00013] An example of laminated fiberglass panels is the Halcyon® brand panel made by USG Interiors, Inc. of Chicago, Illinois, United States of America (USG). An example of laminated mineral wool panels is the Mars® brand panel also made by USG. The basic blankets of these two types of acoustic panels are formed by bonding fiberglass or mineral wool, since the case may be with a thermally binding or latex binder.
    [00014] More than 80% by weight of these basic blankets are either fiberglass or mineral wool, and these inorganic fibers are relatively insensitive to moisture. That is, such fibers are not hydrophilic, so they do not absorb water or appreciable hydration of the air. In addition, binders of thermal configuration such as urea-formaldehyde or phenol-formaldehyde, and latex binders such as acrylic styrene, are typically used as components in these basic blankets, and such components are resistant to moisture. The binders and fibers mentioned above when used together in base blankets convey excellent performance characteristics in terms of bending resistance.
    [00015] In the manufacture of fiberglass or mineral wool panels, the canvas is usually affixed to the panel to accentuate its aesthetic appeal to customers. Many desirable acoustic panels have a smooth surface with a high light reflection value (LRV). As is known in the art, the light reflection value is simply the percentage of light that is reflected by the surface being tested. For example, an acoustic panel, which reflects 85% of the light that shines on it, has an LRV of 85. Typically, a desirable acoustic panel has an LRV of 85 or more.
    [00016] After the screens are laminated to a panel, the screens typically have a decorative coating sprinkled on them to increase brightness or reflection of general light. The coating can be aqueous or non-aqueous. To reduce the amount of coating required to achieve specific LRV, the screens used to produce acoustic panels have relatively high resistance to specific airflow and contain substantial amounts of pigments. The use of coverings increases the reflection of light and aesthetic appeal, however, sometimes results in a significant loss of acoustic absorption by the panels. This is because, among other reasons, the coatings can block the pores on the panel and can act in another way by reflecting the sound, rather than allowing the sound to enter the panel where it can be dispersed. This would be desirable if something could reduce the extent of the loss of sound absorption.
    [00017] Another desirable characteristic of acoustic panels with screens is that the screen must not shift or otherwise become delaminated from the panel's base blanket. To measure how well the screen is attached to the substrate, the peel strength is determined in accordance with ASTM D 903. In this disclosure, peel resistance is tested using the modified ASTM D 903 procedure. The main modifications are that the screen is separated from the substrate at an angle of 45 ° instead of an angle of 180 °, and the sample size is 10.16 cm (4 inches) by 15.24 cm (6 inches) instead 2.54 cm (1 inch) by 30.48 cm (12 inches). The sample in the modified version is shifted in the direction of 15.24 cm (6 inches).
    [00018] Another important property that the desirable canvas must have is sufficient tensile strength. The tensile strength of non-woven fabrics is measured according to ASTM D 828 in samples comprising 5.08 cm (2 inch) strips of the fabric being tested. The most important attribute of the screen, however, is its resistance to airflow. Airflow resistance is a measure of porosity. Screen porosity is essential to achieve sound absorption in the base blanket. This is because the porous screen allows sound to pass through it instead of reflecting the sound back into the room in which the ceiling panel with the screen is installed.
    [00019] In this disclosure, the specific airflow resistance of several screens was determined using the variation of ASTM C 522, "Standard Test Method for Airflow Resistance of Acoustical Materials". The slight modification was made for the test accessory to retain the screen, as shown in Figure 1.
    [00020] As shown in Figure 1, the screen being tested is attached between two solid rubber or closed cell foam linings on the test accessory. The linings provide a mechanism to secure and tighten the screen, as well as to prevent air leakage around the screen and the test accessory. Once the screen is held in place between the linings, air is passed through the screen at a known flow rate, determined using a standard air flow meter. An air flow rate below 50 mm / s is used so that turbulent air flow is avoided as specified in ASTM C 522. The differential air pressure behind the screen (ie, back pressure) and the atmosphere are then recorded at the given flow rate. The differential pressure (P), air flow rate (U) and cross sectional area of the screen exposed to the air flow (S) are used to calculate the resistance to air flow (r) specific to the screen by the equation outlined in ASTM C 522, called r = SP / U. SUMMARY OF THE INVENTION
    [00021] Due to the presence of hydrophilic components such as cellulosic fibers and starch, many acoustic panels exhibit insignificant resistance to bending in humid environments. In embodiments of the present invention, screens with low airflow resistance and high porosity are used to make acoustic laminated panels improve the panel's moisture-bending performance and reduce the loss in sound absorption caused by adhesives and coated canvas.
    [00022] The basic premise of modalities of the present invention is that the panel is under tension on its lower surface when it is suspended on a grid with its edges. By affixing the rigid screen or veil or cover to the bottom surface, the panel must be able to withstand tension and resist arching downwards. However, one factor that determines whether the screen can help with arching performance is the connection between the screen and the base blanket. An insufficiently connected screen cannot restrict the relative movement between the screen and the base mat to which it is attached. Even a slight relative movement in a horizontal direction can allow the panel to have significant movement in the vertical direction, that is, arching. However, the key is to firmly connect the screen to the base mat and restrict the relative movement between the screen and the base mat, making the screen an integral part of the laminated panel.
    [00023] According to the modalities of the present invention, the canvas is first fixed to the base mat by means of a different layer of adhesives. The adhesives must be in a different shape, since the continuous film must cover the perforations in the base blankets and seal the air passage that allows sound absorption. However, the separate layer of adhesives is not sufficient to completely restrict the relative movement between the fabric and the base mat in the horizontal direction. In addition, many glues and adhesives are viscoelastic, making the bond extensible. For these reasons, the choice of glues and adhesives is an important consideration. After the screen is affixed, the panel is then finished with coating or paint sprinkled on its surface.
    [00024] The porosity of the screen represents a critical function for connecting the screen to the base blanket. A porous screen has low specific resistance to airflow, which allows coatings to penetrate or be absorbed through the screen and the base blankets. Once dry, these coatings provide an additional connection between the base blanket and the canvas. Since coatings contain ample amounts of inorganic pigments, the bond provided by coatings is relatively rigid. In this way, the connection can restrict the relative movement between the screen and the base blanket, making the screen an integral part of the laminated roof panel. On the other hand, the dense canvas retains most of the coatings or paint on its surface. The surface coatings cannot contribute to the connection between the base blanket and the canvas. A laminated panel with a dense screen relies exclusively on adhesives to provide bonding. Such a panel will have arching performance similar to that of base blankets without screens.
    [00025] According to the modalities of the present invention, the porous fiberglass screen transmits a 40 to 400% increase in resistance to the detachment of the screen after lamination and coating. The resulting laminated acoustic panel should have a bend induced by total hydration of less than 0.762 cm (0.3 inches) (for panels 0.61 m (2 feet) wide and 1.21 m (4 feet) long) in the humidity chamber after three cycles alternating between 23.88 ° C (75 ° F), for 50% relative humidity (RH), and 40 ° C (104 ° F), for 95% relative humidity (RH).
    [00026] According to the modalities of the present invention, the use of screens with low specific resistance to airflow and high porosity reduces the loss in sound absorption caused by glue / adhesives and coating / paint. Acoustic laminated panels have an eNRC of at least 0.45 and an NRC of at least 0.5. BRIEF DESCRIPTION OF THE DRAWINGS
    [00027] The features and advantages of modalities of the present invention will become apparent by reference to the accompanying drawings when read in conjunction with the detailed description of the invention. The dimensions in the drawing are for the purpose of exemplification, and should not be interpreted as limiting the physical dimensions of the modality. Figure 1 is a schematic drawing of the screen-specific airflow resistance test structure described in this document. Figure 2 illustrates the assembly of laminated acoustic panel, which comprises base blanket or substrate 100, distinct layer of adhesives 110, porous canvas or veil or cover or coating 120, and paint or surface coating 130. Figure 3 illustrates the view in cross-section of the finished piece of acoustic ceiling tile, in which the perforations 140 of the base blanket are shown. DETAILED DESCRIPTION OF THE PREFERENTIAL MODE
    [00028] The method and product described in this document are intended for application in acoustic panels used as construction materials. More specifically, the panels can be used as acoustic wall or ceiling panels or tiles. The detailed description of the invention is the embodiment of the invention, and should not be construed to limit the scope of the invention in any way.
    [00029] According to the modalities of the present invention, basic blankets or substrates are made from liquid slurry containing a mixture of fibers, fillers and binders that employ methods known in the art. The fibers comprise mineral wool and cellulosic fibers; the fillers comprise expanded perlite, calcium carbonate, or clay; the binders comprise starch granules.
    [00030] As known in the art, homogeneous slurry, containing the ingredients mentioned above, transported with the use of a hydraulic pump from a vat to an inbox, is placed in an elevated position so that a stable and constant flow of slurry be supplied to the blanket forming machine. The slurry is then deposited on a moving porous wire to form a wet-based mat. Water is drained from the wire by gravity. Then, the additional water is removed by applying low-strength vacuum (vacuum at a rate of 2.54 cm (1 inch) to 12.7 cm (5 inches) Hg) under the wire that carries the wet base blanket. The base blanket can also be dehydrated by pressing the blanket between two rollers. Additional water can still be optionally removed by applying a relatively high vacuum (vacuum rate of 20.32 cm (8 inches) to 50.8 cm (20 inches) Hg) under the yarn that carries the blanket. The rest of the water in the wet-based mat is evaporated in an oven or oven.
    [00031] Subsequently, the basic blankets formed are cut into various sizes. The surfaces of the base blankets are ground relatively smoothly before the initial coating is optionally applied to the surface. The purpose of the initial coating is to provide a good base on which the glue can adhere more easily and increase the light reflection of the blankets.
    [00032] Subsequently, the base blankets are punctured and cracked to achieve the desired sound absorption. The punching operation provides multiple holes in the mat surface at a controlled depth, size, and density (number of holes per unit area). As known in the art, puncture operations are performed by pressing a plate equipped with a predetermined number of needles on the base mat. The cracks transmit indentations of unique shapes on the surfaces of the base blankets. Cracking operations are performed with a roller device that has a circumference under which the complementary features or standards are installed. Both the punch and the crack open the flat surface and the internal structure of the base blankets, thus allowing air and sound waves to move in and out of the base blanket structure.
    [00033] The next step in the process is to deposit adhesives on the base blankets. The adhesive can be sprayed or coated with an engraving roller on the base blankets. The adhesives on the base blanket must be in a distinct or perforated shape, for example, in the form of drops, so that the blankets do not have continuous unperforated sheet of adhesive film on them. The continuous film of adhesives on the base mat is undesirable, as discussed above. The amount of adhesives should be optimized to reduce their impact on sound absorption while providing sufficient bonding to base blankets. Even with an optimal amount of adhesives deposited differently, a loss of 0.02 to 0.07 in eNRC or NRC is expected. According to the modalities of the present invention, the total amount of adhesives (containing water or solvent) applied to the base blanket is in the range of 0.0005 to 0.008 grams per square centimeter (8 grams / feet2), and is preferably in the range of 0.001 gram / cm2 (1 gram / foot2) to 0.004 gram / cm2 (4 grams / foot2).
    [00034] Alternatively, adhesives can be applied to the non-woven fabric, such as fiberglass fabric, rather than to the base blankets before lamination. The amount of adhesives used and the way it is deposited on the canvas are similar to the methods described for basic blankets. After applying adhesive, the non-woven, porous fiberglass screen is laminated to the base blankets.
    [00035] The objectives of the lamination are to improve the arching performance in a humid environment and to reduce the NRC and eNRC loss caused by dense screens. As mentioned earlier, the specific airflow resistance of the screen has a significant impact on the properties of the laminated acoustic panel. Generally, resistance to airflow is dependent on the base weight, fiber thickness and the amount of binder and load applied to the screen. The screens become dense and have high resistance to specific airflow when the screen is composed of thin glass fibers and contains a relatively high amount of binder; the screens become porous and have low specific airflow resistance when the screen is made up of thick glass fibers and contains a relatively low amount of binder.
    [00036] In accordance with the modalities of the present invention, high porosity screens are required to make the laminated acoustic panel of high resistance to detachment, high resistance to arching and low loss in acoustic absorption. Although it seems unexpected, the screen itself does not significantly affect sound absorption. In fact, affixing any flat panel to the base blanket would increase the eNRC slightly. However, the application of glue and coating would reduce the sound absorption considerably, although the extent of the reduction varies with different screens. With relatively porous screens (specific airflow resistance between 10 and 25 Rayls [Pa.s / m]), the average loss in eNRC or NRC due to glue and coating is 0.03 to 0.06. On the other hand, with relatively dense screens (specific airflow resistance between 25 and 100 Rayls), the average loss in eNRC or NRC due to glue and coating is 0.05 to 0.10. In order to minimize the loss in acoustic absorption, a screen with less than 25 Rayls of specific airflow resistance is desired.
    [00037] The application of the coating or paint on porous canvas can significantly improve the resistance to peeling of the canvas. The increase in resistance to detachment varies from 40 to 400%. However, the increase is dependent on the screen porosity. There is little or no improvement in resistance to peeling when the specific airflow resistance of the screens is greater than 35 Rayls. Examining the pictures of detached screens through the transmitted light, it is revealed that the dense screens have a large amount of coating retained on the screen surfaces. Porous screens made with thick fibers, on the other hand, retain much less amount of coatings on their surfaces. A substantial amount of coating settles on or is absorbed in the base blankets. Once the coating is transmitted to the base layer, the coating acts as a sealant to connect the screen to the base layer, improving the resistance to detachment of the screen. For dense screens made of fine fibers, the coatings cannot penetrate the screen surface as well so they cannot contribute to the improvement in the resistance to detachment. In accordance with the modalities of the present invention, a web with a specific airflow resistance of less than 30 Rayls is laminated over the base blankets to develop a significant improvement in the resistance to detachment by the coatings.
    [00038] The basic principle to improve the resistance to bending by laminating the rigid screen made of material such as fiberglass on the base blanket is that the face of the panel is under tension during the bending and the rigid screen would be able to sustain tension and restrict arching. However, as it is unexpectedly revealed through the experiment with certain modalities of this invention, how well the screen is actually attached to the base mat has a direct impact on the moisture arching performance of a laminated acoustic panel. Surprisingly, there is really an inversely linear relationship between the peel strength and the moisture arching of the laminate panel until the coating no longer contributes to peel resistance as a result of the waterproofness of the screen.
    [00039] If there is no coating or if the coating is mainly on the surface of the fabric due to low porosity, the connection between the fabric and the base mat must depend exclusively on the adhesives. But the amount of adhesives that can be applied is limited in order to prevent clogging of the perforations in the base blanket. In addition, most adhesives are viscoelastic, making the bond extensible. Therefore, the glue alone will not be able to restrict the relative movement between the web and the base web during arching. Even the slight relative movement between the screen and the base blanket would result in significant vertical movement of the flat panel, that is, arching.
    [00040] When the coatings penetrate through the porous mesh, the additional connection between the mesh and the base blanket is formed. Coatings or paint contain a high amount of pigment compared to glues. The connection provided by the coatings / paint is rigid. In this way, the connection can restrict movement between the screen and the base blanket, making the screen an integral part of the laminated roof panel. A tightly bonded screen can improve the moisture arching performance of laminated panels. Since a small amount of moisture bending is highly desirable, the use of porous mesh would add a significant advantage to laminated acoustic panels.
    [00041] In order to have a total arching movement less than 0.762 centimeters (0.3 inches) (for panels 60.96 centimeters wide and 121.92 centimeters long (2 feet wide and 4 feet long)) after three cycles in an alternating humidity chamber between 24 ° C (75 ° F), for 50% RH, and 40 ° C (104 ° F), for 95% RH, the screen must have specific airflow resistance less than 30 Rayls and a tensile strength of at least 44.5 N / 50 mm (10 lbf / 2 in) wide in any direction.
    [00042] The new use of screens with low specific airflow resistance and high porosity claimed in the present invention would reduce the leg in the acoustic absorption caused by adhesives and coatings. The laminated acoustic panel would have an eNRC of at least 0.45 and an NRC of at least 0.5. EXAMPLES EXAMPLE 1
    [00043] A base blanket comprising mineral wool, newsprint fibers, expanded pearlite, starch and clay was ground to have a relatively smooth and initially coated surface. The base blanket was then perforated as described above, the perforations having a depth of 1.016 centimeters (0.4 inches). The perforated base blanket had an eNRC of 0.58. A commercially available XR-3025 glue manufactured by HB Fuller of St. Paul, MN was sprayed onto said base blankets at 0.0045 grams / cm2 (4.5 grams / pe2).
    [00044] A fiberglass screen was then laminated to the base blankets. The screen was purchased from Owens Corning, Toledo, OH. The screen had a specific airflow resistance of 41.4 Rayls, a base weight of 127.7 g / m2, a thickness of 0.5 mm (0.020 inches), a tensile strength of 200 N / 50 mm (45.7 lbf / 2 in) in the machine direction and 184 N / 50 mm (42.1 lbf / 2 in) tensile strength in the machine's transverse direction.
    [00045] After lamination, the surface was sprayed with a coating. The coating contained 80% pigments and 20% latex based on the total solids content. It had a solids content of 50%. The coating was applied at 0.024 grams / cm2 (24 grams / pe2). After the coating was applied, the peel strength was measured to be 325 grams / 10.16 centimeters (grams / 4 inches) wide. The resulting laminated panel had an eNRC of 0.49 and a moisture arc of 1.852 centimeters (0.729 inches). The panel without the screen had a 1.826 cm (0.719 inch) moisture arch. The loss in eNRC was 0.09.
    [00046] The example shows that in relatively dense canvas, there is no improvement in moisture curving and the resistance to the canvas peeling is low. ENRC decreases significantly.
    [00047] EXAMPLE 2
    [00048] A base blanket comprising mineral wool, newsprint fibers, expanded pearlite, starch and clay was ground to have a relatively smooth and initially coated surface. The base blanket was then perforated as described above, the perforations having a depth of 1.016 centimeters (0.4 inches). The perforated base blanket had an eNRC of 0.46. A commercially available XR-3025 glue mentioned above was sprayed onto said base blankets at 0.0048 grams / cm2 (4.8 grams / foot2).
    [00049] A fiberglass screen was then laminated to the base blankets. The screen (sold under the product name Ultra Mate) was obtained from GAF-Elk Corp. from Ennis, TX. The screen had specific airflow resistance of 15.3 Rayls, base weight of 76.7 g / m2, thickness of 0.58 mm (0.023 inch), tensile strength of 130 N / 50 mm (29.8 lbf / 2 in) in the machine direction and 117 N / 50 mm (26.7 lbf / 2 in) tensile strength in the machine's transverse direction.
    [00050] After lamination, the surface was sprayed with a coating. The coating contained 80% pigments and 20% latex based on the total solids content. It had a solids content of 50%. The coating was applied at 0.024 grams / cm2 (24 grams / foot2). Before coating, peel strength was measured at 444 grams / 10.16 centimeters (grams / 4 inches) in width. After coating, the peel strength was 1,598 grams / 10.16 cm (grams / 4 inches) wide. The resulting laminated panel had a 0.183 centimeter (0.076 inch) moisture arc, 0.40 eNRC and 0.48 NRC. The panel without the screen had a 0.945 centimeter (0.372 inch) moisture arch.
    [00051] This example shows that with a relatively porous screen, the peel resistance was increased 3.6 times after the coating was applied, the bending by moisture was drastically reduced and the loss in eNRC was reduced to 0.06. EXAMPLE 3
    [00052] A base blanket comprising mineral wool, newsprint fibers, expanded pearlite, starch and clay was ground to have a relatively smooth and initially coated surface. The base blanket was then perforated as described above, the perforations having a depth of 1.016 centimeters (0.4 inches). The perforated base blanket had an eNRC of 0.46.
    [00053] The XR-3025 glue was sprayed on said base blankets at 0.0048 grams / cm2 (4.8 grams / pe2). A fiberglass screen was then laminated to the base blankets. The screen (sold under the product name Dura-Glass® 7615) was obtained from Johns Manville Corp., Denver, Co. The screen had specific airflow resistance of 12.2 Rayls, base weight of 60.9 g / m2, 0.46 mm (0.018 inch) thickness, 181 N / 50 mm (41.4 lbf / 2 inch) tensile strength in the machine direction and 154 N / 50 mm (35.2) tensile strength lbf / 2 inches) in the transverse direction of the machine.
    [00054] After lamination, the surface was sprayed with a coating containing 80% pigments and 20% latex based on the total solids content. It had a solids content of 50%. The coating was applied at 0.024 grams / cm2 (24 grams / foot2).
    [00055] Before coating, the peel resistance was 412 grams / 10.16 centimeters (grams / 4 inches) wide. After coating, the peel strength was 1597 grams / 10.16 centimeters (grams / 4 inches) wide. The resulting laminated panel had 0.135 centimeter (0.053 inch) moisture bending, 0.39 eNRC and 0.47 NRC. The panel without the screen had a 0.945 centimeter (0.372 inch) moisture arch.
    [00056] This example shows that with a relatively porous screen, the peel resistance was increased 3.9 times after the coating was applied, the bending by moisture was drastically reduced and the loss in eNRC was reduced to 0.07. EXAMPLE 4
    [00057] A base blanket comprising mineral wool, newsprint fibers, expanded pearlite, starch and clay was ground to have a relatively smooth and initially coated surface. The base blanket was then perforated as described above, the perforations having a depth of 1.016 centimeters (0.4 inches). The perforated base blanket had an eNRC of 0.46.
    [00058] The commercially available glue XR-3025 was sprayed on said base blankets at 0.0048 grams / cm2 (4.8 grams / foot2). The fiberglass screen was then laminated to the base blankets. The screen (sold under the product name GFT-25) was obtained from Ahlstrom Corp. from Kotka, Finland. The screen had specific airflow resistance of 23.0 Rayls, base weight of 50.8 g / m2, thickness of 0.33 mm (0.013 inch), tensile strength of 99 N / 50 mm (22.6 lbf / 2 inches) in the machine direction and 67 N / 50 mm (15.3 lbf / 2 inch) tensile strength in the machine's transverse direction. After lamination, the surface was sprayed with a coating containing 80% pigments and 20% latex based on the total solids content. It had a solids content of 50%. The coating was applied at 0.024 grams / cm2 (24 grams / pe2).
    [00059] Before coating, the peel resistance was 329 grams / 10.16 centimeters (grams / 4 inches) wide. After coating, the peel strength was 1596 grams / 10.16 centimeters (grams / 4 inches) wide. The resulting laminated panel had a 0.259 centimeter (0.102 inch) moisture arc, 0.37 eNRC and 0.43 NRC. The panel without the screen had a 0.945 centimeter (0.372 inch) moisture arch.
    [00060] This example shows that with a medium porosity screen, the peel resistance was increased 4.9 times after the coating was applied, the bending by moisture was significantly reduced and the loss in eNRC was 0.09, similar to the results of dense screen.
    [00061] The following Table 1 illustrates the comparative test results that show the relationship between peel strength, specific airflow resistance and moisture bowing for the examples above. TABLE 1.
    Table 1. The test results indicated that when the screen as applied according to the invention had a value below resistance to specific airflow, the resistance to screen peeling became very high after the application of coating. Subsequently, the bending by moisture with such tightly connected screens has been significantly reduced.
    权利要求:
    Claims (13)
    [0001]
    1. Acoustic construction panel comprising: base blanket (100) made from a water-based composition; porous non-woven fabric (120); coating (130) applied to the external surface of the mesh (120), characterized by the fact that an adhesive (110) deposited in a perforated form (140) or distinct between the mesh (120) and the base mat (100); the web having an air flow resistance of less than 30 Rayls such that it is sufficiently porous to allow the coating (130) to penetrate the web from the outer surface of the web (120) to attach to the base web (100 ), and where the coating (130) penetrates the screen (120) and adhered to the base mat (100) increasing the resistance to detachment from the screen (120) to the base mat (100) over a resistance to detachment made by the adhesive ( 110) by at least 40%.
    [0002]
    2. Panel, according to claim 1, characterized by the fact that the base blanket (100) contains perforations (140).
    [0003]
    3. Panel, according to claim 1, characterized by the fact that the screen (120) has a tensile strength of 44.5 N / (10 lbf) per width of 50 mm 5 0.8 mm (2 inches).
    [0004]
    4. Panel, according to claim 1, characterized by the fact that the screen (120) has a base weight between 20 and 125 g / m2.
    [0005]
    5. Panel according to claim 1, characterized in that the surface coating (130) of canvas (120) comprises between 50% and 90% of inorganic pigments based on the total solids content.
    [0006]
    6. Panel according to claim 1, characterized in that the surface coating (130) of canvas (120) is aqueous and is applied at a proportion of 0.01 to 0.05 g / cm2.
    [0007]
    7. Panel, according to claim 1, characterized by the fact that the screen (120) has a thickness between 0.0127 and 0.058 cm.
    [0008]
    8. Panel according to claim 1, characterized in that the deposition of adhesive (110) between the screen (120) and the base mat (100) is in the form of drops.
    [0009]
    9. Panel, according to claim 1, characterized by the fact that the panel has a resistance to the detachment of 400 g by 10.16 cm wide.
    [0010]
    10. Panel, according to claim 1, characterized by the fact that the panel has an arc less than 1.27 cm after three cycles in the humidity chamber, alternating between 23.88 ° C, at 50% relative humidity, and 40 ° C, at 95% relative humidity.
    [0011]
    11. Panel, according to claim 1, characterized by the fact that it has a noise reduction coefficient estimated at 0.45 or more.
    [0012]
    The method of fabricating the panel defined in claim 1, comprising the steps of: forming a liquid slurry containing a mixture of fibers, fillers and binders; the homogeneous slurry is supplied, in a stable and constant flow, to the blanket forming machine; forming a wet blanket (100); drain the water from the blanket (100); cut the blanket (100) and smoothly grind its surfaces before applying the coating (130); punch and crack the blanket (130) to provide multiple perforations (140) on its surface; deposit adhesives (110) on the mat (100) in a distinct or perforated form, for example, in the form of drops, so that they do not have continuous non-perforated sheet of adhesive film, and in an amount optimized to reduce their impact on sound absorption while providing sufficient connection to the base blankets (100); characterized by the fact that the total amount of adhesives (110) applied to the base mat (100) is in the range of 0.0005 to 0.008 g / cm2, preferably in the range of 0.001 to 0.004 g / cm2.
    [0013]
    13. Acoustic construction panel, comprising: base blanket (100); porous non-woven fabric (120); and coating (130) applied to the external surface of the screen (120); characterized by the fact that the screen (120) has specific airflow resistance less than 30 Rayls and the surface coating (130) of screen (120) comprises between 50% and 90% of inorganic pigments based on total solids content ; the surface coating (130) of fabric (120) being effective in absorbing and adhering through the fabric (120) of the base mat (100).
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    同族专利:
    公开号 | 公开日
    CA2784897C|2017-02-14|
    RU2012126805A|2014-01-27|
    UA109886C2|2015-10-26|
    EP2516766A4|2015-11-04|
    JP2013515183A|2013-05-02|
    ECSP10010703A|2011-06-30|
    JP5758403B2|2015-08-05|
    AU2010341649A1|2012-07-19|
    CN102803628A|2012-11-28|
    CA2784897A1|2011-07-21|
    CN102803628B|2015-12-16|
    US8100226B2|2012-01-24|
    AU2010341649B2|2013-11-28|
    BR112012014918A2|2016-08-30|
    AR081055A1|2012-06-06|
    HK1178582A1|2013-09-13|
    WO2011087670A2|2011-07-21|
    RU2560735C2|2015-08-20|
    MY162314A|2017-05-31|
    TW201135022A|2011-10-16|
    EP2516766A2|2012-10-31|
    WO2011087670A3|2011-10-06|
    CO6592050A2|2013-01-02|
    TWI531702B|2016-05-01|
    US20110147119A1|2011-06-23|
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    法律状态:
    2019-01-02| B06T| Formal requirements before examination|
    2019-01-08| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-06-04| B07A| Technical examination (opinion): publication of technical examination (opinion)|
    2019-10-01| B07A| Technical examination (opinion): publication of technical examination (opinion)|
    2020-02-04| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application according art. 36 industrial patent law|
    2020-12-01| B09A| Decision: intention to grant|
    2021-01-19| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 10 (DEZ) ANOS CONTADOS A PARTIR DE 19/01/2021, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US28914009P| true| 2009-12-22|2009-12-22|
    US61/289,140|2009-12-22|
    US12/966,051|2010-12-13|
    US12/966,051|US8100226B2|2009-12-22|2010-12-13|Porous nonwoven scrims in acoustical panels|
    PCT/US2010/060378|WO2011087670A2|2009-12-22|2010-12-15|Use of porous nonwoven scrims in acoustical panels|
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