CN105492690B - 具有改进的耐火性的增强的石膏板 - Google Patents

具有改进的耐火性的增强的石膏板 Download PDF

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CN105492690B
CN105492690B CN201480047811.5A CN201480047811A CN105492690B CN 105492690 B CN105492690 B CN 105492690B CN 201480047811 A CN201480047811 A CN 201480047811A CN 105492690 B CN105492690 B CN 105492690B
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S.莱洛吉
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Abstract

石膏板具有两个相反的面和埋置在该板的面之一中的纤维垫。所述纤维垫包括由聚合物粘合剂粘合的纤维。所述纤维的长度大于20mm并且直径大于14微米。所述聚合物粘合剂基本不含甲醛。所述纤维垫在无需将阻燃剂掺入粘合剂的情况下实现石膏板中的耐火性并且提供挠曲强度。

Description

具有改进的耐火性的增强的石膏板
技术领域
本发明涉及包括纤维垫面体(facer)的石膏板以及用作这样的面体的纤维垫。
背景技术
已知通过在两个相反的纸衬垫之间沉积石膏浆料层来产生用于例如建筑中的石膏板。然而，为了即使在潮湿的环境中也能保持板的性能，已提出用部分由玻璃纤维垫形成的相反的层来代替纸面板(paper facing sheets)。这种垫的纤维通常使用脲(甲)醛树脂粘合剂来粘合。
由于有关于从脲醛树脂发出的挥发性有机化合物的气味以及需要符合限制这些化合物水平的法规的问题，因而期望提供基本不含甲醛的用于垫的粘合剂。
为了提高耐火性，通常使用的不含甲醛的粘合剂包括阻燃剂。
发明内容
在其最一般的情况下，本发明提供用作石膏增强件的垫，所述垫包括由不含甲醛的粘合剂粘合的纤维，其中在无需将阻燃剂掺入所述粘合剂的情况下实现可接受的耐火性，并且还实现可接受的挠曲强度。
本文所使用的术语“不含甲醛”意指根据ISO 16000标准测试，在28天后以低于10μg/m3、优选低于5μg/m3的水平释放或发出甲醛的粘合剂。
在第一方面，本发明可提供具有两个相反的面的石膏板，其中纤维垫埋置(嵌入)在所述板的面之一中，所述纤维垫包括由聚合物粘合剂粘合的纤维，其中所述聚合物粘合剂基本不含甲醛，所述纤维的长度大于20mm，并且所述纤维的直径大于14微米。
有效地，所述纤维垫提供用于所述板的面体。
优选地，所述聚合物粘合剂是亲水性的。所述粘合剂可为本质上亲水性的，或者可通过亲水性添加剂的存在而具备亲水性质。
在某些实施方式中，可将所述垫完全埋置在所述板的面中。也就是说，石膏层存在于所述垫的内表面和外表面两者上。典型地，当使已沉积在所述垫的内表面上的石膏浆料渗透穿过该垫，由此提供掩蔽所述垫的外表面的石膏外层时，形成这些实施方式。如本领域公知的，可通过辊的作用(如例如US 6,524,679中所描述的)或施加振动(如例如US 4,378,405中所描述的)来帮助石膏浆料渗透穿过所述垫。
在其它实施方式中，所述垫可仅部分地埋置在所述板的面中，也就是说，没有掩蔽所述垫的完整的石膏外层。
优选地，所述垫中纤维的长度大于22mm，更优选大于23mm。据认为，通过增加纤维长度，在火的情况下即使在粘合剂已大部分被烧掉之后所述垫也能够继续向石膏板提供增强。因此，甚至在没有阻燃剂的情况下，板的完整性也得以保持并且火的蔓延被抑制。
一般说来，所述纤维的长度小于30mm，优选小于28mm，更优选小于27mm。
所述聚合物粘合剂的亲水性质确保生产过程中石膏浆料良好地渗透纤维垫，使得实现可接受的挠曲强度水平。
优选地，所述纤维的直径大于15微米。一般说来，该纤维的直径小于30微米，优选小于20微米。
用于所述垫的聚合物粘合剂可包括丙烯酸酯聚合物例如聚羧酸酯、聚(甲基)丙烯酸酯、丙烯酸酯-甲基丙烯酸酯共聚物、苯乙烯丙烯酸类共聚物、苯乙烯甲基丙烯酸类共聚物、苯乙烯丁二烯共聚物、或它们的混合物。任选地，所述聚合物粘合剂包括亲水性添加剂。合适的亲水性添加剂包括聚山梨醇酯表面活性剂(例如聚氧乙烯失水山梨醇单月桂酸酯)以及聚氧乙烯和聚氧丙烯的非离子表面活性剂共聚物。合适的丙烯酸酯聚合物是AcronalDS 2416(来自BASF)、Acrodur DS 3530(来自BASF)、Aquaset TF 150(来自Dow)、HF05(来自Dow)、和Acronal DS 5350(来自BASF)。
可优选Acronal DS 2416作为所述聚合物粘合剂，因为它不需要添加单独的亲水性物质。
典型地，所述聚合物粘合剂是热塑性的聚合物或弹性体。
一般来说，所述纤维垫包括玻璃纤维，例如E-玻璃。替代地，所述纤维垫可包括其它无机纤维，如岩棉(例如由玄武岩制造)。
所述垫典型地包括10-1100g/m2、优选地20-300g/m2的量的矿物纤维。所述粘合剂通常相对于矿物纤维垫的重量以5-350％、优选10-100％、和有利地15-30％的量存在。
在第二方面中，本发明可提供包括由亲水性聚合物粘合剂粘合的纤维的纤维垫，其中所述聚合物粘合剂基本不含甲醛，纤维的长度大于20mm，并且纤维的直径大于14微米，所述垫用于埋置在石膏中以提供根据本发明的第一方面的石膏板。
根据本发明的第二方面的纤维垫可包括埋置在根据本发明的第一方面的石膏板的面之一中的垫的一个或多个任选的特征。
在本领域中已知用于将粘合剂施加至垫的若干方法。例如，可通过喷涂方法或通过使用辊将粘合剂施加至所述垫。在其它方法中，可借助涂布器将粘合剂施加至垫，当所述垫被传送通过涂布器开口时所述涂布器将受控供应的粘合剂材料供给至该垫上。在替代的方法中，可将粘合剂材料沉积在所述垫上并且借助于刮刀元件分配在整个垫上。
具体实施方式
现将仅以实例的方式描述本发明。
实施例1
制备包含250g羟乙基纤维素(增稠剂：由Hercules以标记NatrosolTM出售)和0.3g乙氧基化的十八烷基胺/十八烷基胍(octadecyclamine/octadecylguanidine)复合物(表面剂：由Cytec以标记Aerosol C-61出售；固体含量：70％)的两升的水溶液。
将2.54g E-玻璃的切割纱线(cut yarns)(长度：24mm；直径：16微米)添加至所述溶液。
将所获得的玻璃纱线的悬浮液转移至使得可制造垫的设备。该设备包括具有穿孔基底的容器，该穿孔基底容许所述容器的内部容积和位于该容器下方的抽吸装置之间流体连通。
所述悬浮液被放置在该容器中并且通过剧烈搅拌而均质化，之后启动抽吸装置以移除流体。在筛上收取到具有30cm x 30cm的尺寸并且具有28.2g/cm2的重量/表面积的玻璃纤维垫。
将所述垫在丙烯酸类树脂(由BASF出售的Acronal DS 2416)的水溶液中浸渍1分钟。通过抽吸除去所述垫中过量的粘合剂，并且之后在210℃加热所述垫1分钟以将其加固。在该处理之后，所述垫包含5g/m2的丙烯酸类树脂。
实施例2和比较例3-6
实施例2和比较例3-6涉及在两面上具有埋置的玻璃纤维垫的石膏板。玻璃纤维垫的特性总结于表1中。
耐火性：测试1
使根据实施例2和比较例3-6的石膏板经受按照BS∶EN 1364 1∶1999的耐火性测试。简而言之，构建隔板，其中框架在各面上包覆有12.5mm厚的板的单层。所述隔板的一侧暴露于炉火。
如果所述隔板的未经暴露的面上的平均温度保持低于140℃至少60分钟，则所述板的性能被表征为满意的。结果总结于表1中。
耐火性：测试2
使用BS EN 1363-1∶1999的方法进行根据实施例2和比较例3-6的石膏板的另外的火测试。简而言之，将钢梁用20mm厚的板的单层包覆并暴露于炉火。
如果所述钢梁的平均温度保持低于550℃至少82分钟并且所述板保留其机械完整性超过90分钟，则所述板的性能被表征为满意的。
挠曲强度测试
使根据实施例2和比较例3-6的石膏板经受根据BS∶EN 520中所列的方法的挠曲强度测试。如果挠曲强度超出预定的水平，则所述板的性能被表征为满意的。结果示于表1中。
浆料渗透的表征
浆料渗透通过所述纤维垫的程度通过视觉检查来表征，并且如果渗透是完全的且所得的板的表面是平的，则被归类为“满意”的。结果示于表1中。

Claims (18)

1.石膏板，其具有两个相反的面，其中纤维垫埋置在所述板的面之一中，所述纤维垫包括由聚合物粘合剂粘合的纤维，其中所述聚合物粘合剂不含甲醛，所述纤维的长度大于20mm，并且所述纤维的直径大于14微米，其中“不含甲醛”意指根据ISO16000标准测试，在28天后以低于10μg/m3的水平释放或发出甲醛的粘合剂。
2.根据权利要求1所述的石膏板，其中所述聚合物粘合剂是亲水性的。
3.根据权利要求1或2所述的石膏板，其中所述纤维垫完全埋置在所述板的面中。
4.根据权利要求1或2所述的石膏板，其中所述纤维垫部分地埋置在所述板的面中。
5.纤维垫用于埋置在石膏中以提供根据权利要求1至4任一项所述的石膏板的用途，所述纤维垫包括由聚合物粘合剂粘合的纤维，其中所述聚合物粘合剂不含甲醛，所述纤维的长度大于20mm，并且所述纤维的直径大于14微米，其中“不含甲醛”意指根据ISO16000标准测试，在28天后以低于10μg/m3的水平释放或发出甲醛的粘合剂。
6.根据权利要求5所述的用途，其中所述聚合物粘合剂是亲水性的。
7.根据权利要求5或6所述的用途，其中所述聚合物粘合剂选自：丙烯酸酯聚合物、甲基丙烯酸酯聚合物、丙烯酸酯-甲基丙烯酸酯共聚物、苯乙烯丙烯酸类共聚物、苯乙烯-甲基丙烯酸酯共聚物、苯乙烯丁二烯共聚物、和它们的混合物。
8.根据权利要求7所述的用途，其中所述聚合物粘合剂还包括亲水性添加剂。
9.根据权利要求8所述的用途，其中所述亲水性添加剂选自：聚山梨醇酯表面活性剂以及聚氧乙烯和聚氧丙烯的非离子表面活性剂共聚物。
10.根据权利要求9所述的用途，其中所述聚山梨醇酯表面活性剂为聚氧乙烯失水山梨醇单月桂酸酯。
11.根据权利要求8或9或10所述的用途，其中所述丙烯酸酯聚合物选自：来自BASF的Acrodur DS 3530、来自Dow的Aquaset TF 150和来自Dow的HF05。
12.根据权利要求7所述的用途，其中所述丙烯酸酯聚合物是来自BASF的Acronal DS2416。
13.根据权利要求5至12任一项所述的用途，其中所述纤维垫包括玻璃纤维。
14.根据权利要求5至13任一项所述的用途，其中所述纤维的直径大于15微米。
15.根据权利要求14所述的用途，其中所述纤维的直径大于16微米。
16.根据权利要求5至15任一项所述的用途，其中所述纤维的长度大于22mm。
17.根据权利要求16所述的用途，其中所述纤维的长度大于23mm。
18.根据权利要求5至17任一项所述的用途，其中所述垫是非织造垫。
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