CN117836252A - 高吸音和低密度基垫 - Google Patents
高吸音和低密度基垫 Download PDFInfo
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- CN117836252A CN117836252A CN202280050398.2A CN202280050398A CN117836252A CN 117836252 A CN117836252 A CN 117836252A CN 202280050398 A CN202280050398 A CN 202280050398A CN 117836252 A CN117836252 A CN 117836252A
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
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- General Chemical & Material Sciences (AREA)
- Structural Engineering (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Civil Engineering (AREA)
- Inorganic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- Dispersion Chemistry (AREA)
- Paper (AREA)
- Laminated Bodies (AREA)
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Abstract
本公开提供了用于纤维面板的基垫,该基垫包括:矿棉,基于该基垫的总重量,该矿棉以至少约60重量%的量存在;矿物填料;纤维素,基于该基垫的总重量,该纤维素以约1重量%至约3重量%的量存在;和粘合剂。该基垫具有背衬侧和饰面侧。还提供了包括本公开的基垫以及多孔面罩的纤维面板。
Description
背景技术
技术领域
本发明总体上涉及用于纤维面板的基垫。更具体地说,本发明涉及一种用于纤维面板的基垫,该基垫包括矿棉、矿物填料、纤维素和粘合剂。
相关技术的简要描述
纤维面板(诸如吊顶板或吸音面板)通常是包括基垫和非织造玻璃或玻璃混合面罩的层压结构。
矿棉和轻质集料的稀释水性分散体的水制毡是用于制造基垫的一种众所周知的商业方法。在该方法中,使水性浆料流到移动的有孔支撑线(诸如富迪尼耶(Fourdinier)或奥立弗(Oliver)垫成形机的支撑线)上以脱水。浆料可首先通过重力脱水,然后通过真空抽吸装置脱水以形成湿基垫。然后可通过在辊与支撑线之间按压(施加或不施加额外的真空)至所需的厚度以去除额外的水来将湿基垫脱水。然后可以将湿基垫在加热的对流式干燥烘箱中干燥,并且将干燥的材料切割成所需的尺寸以产生该基垫,使其开裂和/或穿孔以赋予吸音性,用面罩进行层压,并且任选地进行面涂覆(诸如用油漆)以产生吸音板和面板。在加热的对流干燥烘箱中的干燥通常是生产限制步骤以及最昂贵的生产步骤。
纤维面板的保水值与将浆料脱水后保留的水量有关。保水值越高,在干燥形成纤维面板期间必须去除的水就越多。从生产成本的观点来看,具有相对较低密度的湿基垫通常使用更少的矿棉并且干燥更容易且成本更低。然而,已经发现将基垫的密度降低至小于12磅/立方英尺(pcf)的尝试所提供的基垫由于其降低的湿强度而通常不能经受得住干燥过程。通常,在传送和干燥过程中观察到基垫破裂,潜在地导致窑破坏并产生废物。另外,观察到用于制备基垫的浆料从制造期间使用的辊下落,引起延迟并导致基垫不可用。由于这些失败,通常避免生产密度小于12磅/立方英尺的基垫。
发明内容
在一个方面,本公开提供了一种用于纤维面板的基垫,该基垫包括:矿棉,基于该基垫的总重量,该矿棉以至少约60重量%的量存在;矿物填料;纤维素,基于该基垫的总重量,该纤维素以约1重量%至约3重量%的量存在;和粘合剂,其中该基垫具有背衬侧和饰面侧。
在另一个方面,本公开提供了一种纤维面板,该纤维面板包括:本公开的基垫:和多孔面罩,该多孔面罩具有第一表面和第二表面,其中该第一表面与该基垫的饰面侧接触。
根据以下详细描述的查阅,另外的方面和优点对于本领域的普通技术人员而言将是显而易见的。虽然这些方法和组合物可以有呈各种形式的实施方案,但是下文的描述包括具体的实施方案,应当理解本公开是说明性的,并不旨在将本公开限制于本文所述的具体实施方案。
具体实施方式
有利地,本公开的基垫可用于提供纤维面板,该纤维面板具有高降噪量(NRC)和高吊顶衰减级别(CAC)等级同时还具有降低的密度(相对于常规高NRC和高CAC基垫的密度值),令人惊讶地,甚至在不对基垫穿孔的情况下也实现此类有利的吸音性能。本公开提供了用于具有降低的密度的纤维面板的基垫,该基垫还表现出可接受的强度。例如,本公开提供了表现出足够的湿强度的基垫,使得该基垫尽管具有显著更低的密度(至少相对于常规的高NRC和高CAC基垫),但在生产过程中始终经受得住传送和干燥过程。此外,如所示,本公开的基垫例如通过干燥的基垫的可切割性易于加工。降低的密度将导致降低的材料使用和降低的生产成本。由于在加热的对流烘箱中降低的温度和/或干燥时间,也可以实现显著的能量节约。
特别地,本发明人有利地发现,将少量纤维素纤维(例如,约1重量%至约3重量%纸纤维)掺入到基垫组合物中令人惊讶地允许以显著降低的成本生产具有足以经受得住水制毡加工的湿强度的低密度基垫,并且令人惊讶地甚至在不对基垫穿孔的情况下也不会负面影响可加工性和性能特性(诸如湿强度、可切割性、NRC和CAC)。当然,如果需要,基垫也可任选地被穿孔,但这种穿孔不是实现消费者所需的高吸音特性所必需的。
如本文所用,术语“约”意指任何列举值的+/-10%,或在替代实施方案中,任何列举值的+/-5%。如本文所用,该术语修饰任何列举的值、值的范围或一个或多个范围的端点。
基垫
本公开的基垫包括矿棉、矿物填料、纤维素和粘合剂。基垫具有背衬侧和饰面侧。
如本文所提供的,基垫包括矿棉。如本文所用,术语“矿棉”和“毛”应被认为是可互换的。矿棉由无机原料的纤维构成。矿棉是广泛应用于各种相关玻璃质产品的术语。通常,矿棉是一种由非常细的交织的矿物纤维构成的玻璃纤维样材料,在外观上有点类似于散毛。其主要由钙和铝、铬、钛和锆的硅酸盐构成。通常,矿棉是由天然岩石或矿渣生产的。矿渣是广泛应用于指初生金属和铸造工业的废产物的术语,包括来自炉衬装料杂质的沉积物、来自燃料的灰分以及用于清洁炉和去除杂质的助熔剂。一般而言,尽管矿物纤维具有类似于玻璃纤维的外观,但由于高含量的铁、钙和镁以及相对低比例的二氧化硅和铝,它们的化学组成显著不同于玻璃纤维的化学组成。
矿棉可以是由玄武岩、矿渣、花岗岩或其它玻璃质矿物成分制备的任何常规矿物纤维。以最终基垫产品的总干固体含量的重量百分比表示,矿棉成分可以以至少60重量%的量存在。因此,在本文中,除非另外具体地报告,否则基垫中组分的量以最终基垫的干重基提供(例如,在去湿和/或干燥之后)。例如,基于基垫的总重量,矿棉可以以至少约60重量%、至少约65重量%、至少约70重量%、至少约75重量%或至少约80重量%和/或至多约70重量%、至多约75重量%、至多约80重量%、至多约85重量%、至多约90重量%或至多约95重量%的量提供,基于基垫的总重量,矿棉可以以约60重量%至约95重量%、约60重量%至约90重量%、约60重量%至约80重量%、约65重量%至约80重量%、约65重量%至约75重量%或约60重量%至约75重量%的量提供。在实施方案中,基于基垫的总重量,矿棉以约65重量%至约95重量%的量存在。
基垫还包括矿物填料。术语“矿物填料”和“填料”应当被认为是可互换的。如本领域普通技术人员所理解的,矿棉和矿物填料是浆料的不同组分,它们中的每一者都是形成基垫所必需的。矿物填料的合适示例包括但不限于粘土、珍珠岩、蛭石以及它们的组合。在实施方案中,矿物填料不含玻璃珠。在实施方案中,矿物填料包括珍珠岩,诸如膨胀珍珠岩。
通常,基于基垫的总重量,矿物填料可以以约5重量%至约25重量%的量存在。例如,所包括的矿物填料的量可为至少约5重量%、至少约8重量%、至少约10重量%、至少约12重量%、至少约15重量%、至少约17重量%或至少约20重量%和/或至多约10重量%、至多约12重量%、至多约15重量%、至多约17重量%、至多约20重量%、至多约22重量%或至多约25重量%,诸如约5重量%至约25重量%、约5重量%至约22重量%、约10重量%至约20重量%、约8重量%至约15重量%、约8重量%至约12重量%、约12重量%至约17重量%或约15重量%至约20重量%。
本公开的基垫包括纤维素。纤维素或纤维素纤维是向最终基垫提供结构元素的有机纤维的示例。纤维素纤维通常使用回收的新闻纸作为纸纤维提供。除了回收的新闻纸或作为回收的新闻纸的替代,可以使用过度发行的报纸(OIN)和旧杂志(OMG)。纸纤维以约1重量%至约3重量%纤维素的量存在,例如约1重量%、约1.5重量%、约2重量%、约2.5重量%,诸如1.5重量%至约3.0重量%。令人惊讶地,当纤维素以大于约1重量%的量存在时,该基垫具有足够的湿强度以经受得住在使用富迪尼耶型垫成形设备的水制毡基垫制造期间进行的去湿和干燥,同时继续表现出可接受的可切割性。
本公开的基垫包括粘合剂。合适的粘合剂的示例包括但不限于淀粉、胶乳、再生纸制品以及它们的组合。在实施方案中,粘合剂选自淀粉、胶乳和再生纸制品的组中的一种或多种粘合剂。在实施方案中,粘合剂包括淀粉和胶乳。
基于基垫的总重量,粘合剂可以以约5重量%至约20重量%的总重量存在。例如,基于基垫的总重量,粘合剂可以以至少约5重量%、至少约8重量%、至少约10重量%、至少约12重量%、至少约15重量%或至少约17重量%和/或至多约12重量%、至多约15重量%、至多约17重量%或至多约20重量%的总重量存在。例如,粘合剂可以以约5重量%至约20重量%、约5重量%至约15重量%、约8重量%至约17重量%、约8重量%至约15重量%、约12重量%至约15重量%或约15重量%至约20重量%的量提供。
在粘合剂包括淀粉和胶乳的实施方案中,基于基垫的总重量,淀粉可以以约7重量%至约15重量%,例如约10重量%的量存在,并且胶乳可以以约0.5重量%至约4重量%,例如约1重量%的量存在。淀粉和胶乳可以以约5:1至约15:1,例如约7:1至约15:1、约7:1至约12:1或约10:1的重量比存在。
本公开的基垫可以任选地包括石膏以促进在基垫形成中涉及的传送和干燥过程期间增加的保水和排水。基于基垫的总重量,石膏可以以约0.01重量%至约2重量%的总重量存在。例如,石膏可以以约0.25重量%至约2.0重量%、约0.25重量%至约1.75重量%或约0.25重量%至约1.5重量%的量提供。
如本文所用,术语“低密度”是指密度小于15pcf或小于12pcf的基垫。例如,基垫可具有小于约15pcf、14pcf、13pcf、12pcf、11pcf、10pcf、7pcf或6pcf的密度。在实施方案中,基垫具有介于约7pcf与12pcf之间、例如介于约10pcf与约12pcf之间的密度。
基垫可具有约0.75英寸至约1.5英寸的厚度。例如,基垫可具有至少约0.75英寸、1.0英寸或1.25英寸和/或至多约1.0英寸、1.25英寸或1.5英寸,诸如约0.75英寸至约1.5英寸、约1英寸至约1.5英寸、约1英寸至约1.25英寸或约1.25英寸至约1.5英寸的厚度。
在实施方案中,基于基垫的总重量,矿棉以约65重量%至约85重量%的量存在,矿物填料包括珍珠岩并且以约8重量%至约15重量%的量存在,纤维素包括回收的新闻纸纤维,并且粘合剂包括淀粉和胶乳并且以约8重量%至约15重量%的量存在。在此类实施方案中,淀粉和胶乳可以以约7:1至约12:1的重量比存在。
基垫可具有至少约1.3lbf,例如至少约1.3lbf、约1.35lbf、约1.4lbf、约1.45lbf、约1.5lbf、约1.55lbf或约1.6lbf的湿强度。在实施方案中,基垫具有约1.3lbf至约1.6lbf或约1.35lbf至约1.6lbf的湿强度。基垫的湿强度可以使用常见拉伸测试来测量。在形成后但在烘箱中干燥之前对基垫进行拉伸测试。将样品切割成一定大小(约3"长度),夹在通用测试机器中,然后在张力下拉动直至断裂。将峰值载荷记录为湿强度值。
基垫可具有大于约9磅力英尺(lbf)但小于约10lbf、例如约9lbf、约9.3lbf、约9.5lbf、约9.8lbf或约10lbf的最大切割载荷。在实施方案中,基垫具有约9lbf至约10lbf、约9.3lbf至约10lbf或约9.3lbf至约9.8lbf的最大切割载荷。切割最大载荷可根据以下程序测量:将完全形成的、干燥的并且任选地精整的(面罩、油漆等)基垫样品切割成约3"长度并且加载到具有切割夹具的通用测试机器中。夹具使用在安装期间通常用于切割吊顶板的实用刀片。夹具将样品和刀片定向以获得可重复性。通用测试机器拉动刀片穿过样品,同时记录阻力。将峰值记录为切割最大载荷。
基垫可具有10的可切割性等级。在1至10的量表上测量的可切割性等级(其中10是最佳等级)是通过视觉检查和比较切割边缘与参考样品来确定。在切割后的边缘粗糙度方面,在连续等级10与9之间存在明显的视觉差异。在美学和功能性方面,等级越高导致生产越均匀,浪费越少。
纤维面板
本公开还提供了包括如本文所述的基垫的纤维面板。纤维面板还包括具有第一表面和第二表面的多孔面罩,其中第一表面与基垫的饰面侧接触。如本文所用,术语“面板”和“板”相对于所公开的方法应被认为是可互换的,因为所公开的方法可以相应地应用于两种形式。此外,如本文所用,术语“纤维面板”包括“吊顶板”和“吸音板”两者。
合适的面罩及用于制造该面罩的方法在本领域是已知的。在美国专利申请公开2005/0181693号中描述了代表性的面罩组合物以及用于制造该面罩组合物的程序,该专利申请公开以引用方式并入本文。在实施方案中,面罩包括多孔非织造玻璃纤维或玻璃纤维共混材料。面罩可以是非织造的、短的或中股的、连续的玻璃纤维型材料,其具有多方向的和随机的、重叠纤维取向,这允许显著的透气性和在其所有方向上的流动。多孔面罩可以层压到基垫。
由于使用相对较粗的纤维,由于在表面中和整个面罩包括许多相对较大的孔,面罩通常非常具有渗透性。面罩优选地具有合适的孔隙率,以允许到基垫的气流传输和声传输。
在实施方案中,纤维面板还包括在多孔面罩的第二表面上的涂层。涂层可以包括帘式涂层和/或喷涂涂层。在实施方案中,涂层包括帘式涂层。在实施方案中,涂层包括喷涂涂层。在实施方案中,涂层包括帘式涂层,并且喷涂涂层沉积在其上。
帘式涂布是这样的过程,在该过程中,帘式涂布机创建来自涂布室的液体涂料组合物的不间断的、自由下落的竖直帘式流动,并且液体涂料组合物被沉积到移动基底上。在传送器上以各种速度将基底移动通过帘式涂布机。在实施方案中,基底是纤维面板,优选地是吊顶板。
首先将液体涂料组合物混合并加入到涂料贮存器中。在实施方案中,液体涂料组合物是包含水、粘合剂、填料和添加剂的水基涂料组合物。在实施方案中,粘合剂是胶乳聚合物。在实施方案中,合适的填料包括但不限于碳酸钙、二氧化钛、粘土等。在实施方案中,添加剂可以包括但不限于分散剂、水软化剂、表面活性剂(例如,非离子表面活性剂)、杀生物剂、消泡剂、触变剂、流动剂以及它们的组合。
在一些实施方案中,用于通过帘式涂布施加的本发明的液体涂料组合物包含约30重量%至约65重量%的水、约1.5重量%至约7.5重量%的粘合剂(特别是胶乳聚合物粘合剂)、约30重量%至约65重量%的填料以及约0.01重量%至约10重量%的添加剂。涂料组合物组分在适用的情况下以固体的质量进行描述(因此,在前述液体涂料组合物中,胶乳聚合物组分仅被表示为固体,并且可以存在的任何水包括在水组分中)。
涂层重量是添加到基底上的涂料的量的测量。涂层重量可以通过调节传送器的速度和/或调节帘式涂布头的狭槽开口的大小来控制,该狭槽开口可以如本领域已知的那样加压。在实施方案中,通过帘式涂布沉积的涂料组合物的涂层重量为约5g/ft2至约25g/ft2,优选地约8g/ft2至约22g/ft2,并且更优选地约10g/ft2至约18g/ft2。用于特定涂布过程的涂层重量可以通过使已知面积和重量的基底以与吊顶板相同的方式穿过涂布装备来测量,其中将紧接在涂布后的基底的湿重与涂布前的基底的(干燥、未涂布)重量进行比较。涂层重量被报告为重量方面的差(湿基底重量和未涂布的基底重量之间)除以基底的表面积。因此,对于特定纤维面板,涂层重量可以通过从经涂布的基垫和层压到基垫的面罩的重量中减去基垫和层压到基垫的面罩的组合的重量,并且除以纤维面板的正面的表面积来确定。一般来讲,不需要使用纤维面板,并且任何已知重量的基底可以用于测量用于特定涂布过程的涂层重量。
在实施方案中,涂层包括喷涂涂层。喷涂涂布频繁用于将涂料施涂到各种基底上。常规喷涂涂布过程包括将涂料组合物泵送通过过滤器进入喷头中。在实施方案中,喷头可以垂直于基底的移动方向往复运动,如本领域已知的那样。在喷涂涂布中,涂料从喷头以液滴的形式创建并涂布基底,同时留下未涂布的空间,这可能导致不均匀的斑点外观。在实施方案中,喷涂涂布用于在经由帘式涂布施涂的先前施涂的底涂层层面的顶部上施涂饰面涂层层面。
在根据本发明的喷涂涂布过程中使用的涂料组合物典型地是包括水、粘合剂、填充剂以及添加剂的水性涂料组合物。在一个优选的实施方案中,在相对重量百分比的基础上,用于喷涂涂布过程的涂料组合物包含比用于帘式涂布过程的涂料组合物中存在的胶乳聚合物粘合剂更大量(例如多50重量%以上、多60重量%以上或多70重量%以上)的胶乳聚合物粘合剂。
在一些实施方案中,用于喷涂涂布的涂料组合物包含约30重量%-65重量%的水、约2.5重量%-10重量%的粘合剂(特别是胶乳聚合物粘合剂)、约30重量%-65重量%的填料和约0.01重量%-10重量%的添加剂。涂料组合物组分在适用的情况下以固体的质量进行描述(因此,在前述液体涂料组合物中,胶乳聚合物组分仅被表示为固体,并且可以存在的任何水包括在水组分中)。在实施方案中,通过喷涂涂布施加的涂层重量在约8g/ft2至约25g/ft2和/或约10g/ft2至约22g/ft2的范围内。
如本文所用,术语“高吸音”是指具有相对高的降噪系数值、相对高的吊顶衰减级别等级或两者的基垫,任选地精整为纤维面板。例如,在一个方面,术语“高吸音”是指根据本公开的具有至少约0.75的NRC的基垫或纤维面板。声音吸收通常通过其降噪系数(“NRC”)测量,如ASTM C423“用混响法测定声音吸收和声音吸收系数的标准试验方法(StandardTest Method for Sound Absorption and Sound Absorption Coefficients by theReverberation Method)”中所描述的那样。NRC值是撞击特定表面时所吸收的声能量的量表表示,NRC值为0表示完全反射,并且NRC为1表示完全吸收声能量。其是从特定表面在250Hz、500Hz、1000Hz和2000Hz的频率下的四个声音吸收系数的平均值确定,这些频率覆盖了典型的人类讲话的范围。具有0.6的NRC值的吸音面板吸收撞击该吸音面板的声音中的60%并且偏转该声音中的40%。在一些情况下,可以获得大于1的NRC,但是这是由于衍射/边缘到区域效应的测试方法的假象。在根据ASTM C423的实验室中的材料的实验室测试中,仅样品的面暴露于声能量,如在典型安装中的情况。在实施方案中,本公开的高吸音基垫或纤维面板可具有至少约0.75,例如约0.75至约0.95、约0.75至约0.90、约0.80至约0.90或约0.80至约0.85的NRC。
在另一个方面,术语“高吸音”是指根据本公开的具有至少约35的CAC的基垫或纤维面板。吊顶衰减级别(CAC)等级量化当声音通过一个房间的吊顶通过公用集气室传输到相邻房间时损失的声音量。CAC等级越高表示吊顶***允许的声音传输越少。使用测试标准ASTM E 1414-16测量CAC,其中在源室和相邻室中测量声级。在实施方案中,本公开的基垫或纤维面板可具有至少约30,例如约35、约40、约45或约50,例如介于约30与约50之间,或介于约35与约45之间的CAC等级。
实施例
实施例1-基垫的制备和评估
使用表1中提供的配方在湿制毡机上制造根据本发明的基垫。
表1:基垫组合物
组分 | 量(重量%) |
矿棉 | 75.5 |
珍珠岩 | 10 |
纸纤维 | 3.0 |
淀粉 | 10 |
胶乳 | 1.0 |
石膏 | 0.5 |
将基垫研磨,用玻璃纤维面罩层压,然后经由帘式涂布接着喷涂涂布,涂布在基垫的饰面侧上。用包含约12g/ft2粘土的溶液涂布基垫的背衬侧。成品纤维面板的NRC经测定为0.75。成品纤维面板的CAC等级测定为35。基垫的密度为约10.3pcf。
实施例2-基垫中的纤维素量的评估
为了评估实验室规模的样品,将水性浆料提供给Tappi成形机(一种类似地加工水性浆料以形成基垫的设备),尽管在较小的规模上,提供给本文前述的已知的富迪尼耶型成形机。
制造五个实验室吊顶板。这五个吊顶板含有不同量的范围为0重量%至10重量%的纤维素纤维(以回收的新闻纸的形式)。实验室吊顶板材的湿强度和可切割性以及用于制造吊顶板的详细配方示于表2中。
表2:纤维素对湿强度和可切割性的作用
组分 | 板1 | 板2 | 板3 | 板4 | 板5 |
矿棉(重量%) | 78.0 | 77.0 | 75.0 | 73.0 | 68.0 |
珍珠岩(重量%) | 10.0 | 10.0 | 10.0 | 10.0 | 10.0 |
纤维素纤维(重量%) | 0 | 1.0 | 3.0 | 5.0 | 10.0 |
淀粉(重量%) | 10.0 | 10.0 | 10.0 | 10.0 | 10.0 |
胶乳(重量%) | 1.0 | 1.0 | 1.0 | 1.0 | 1.0 |
石膏(重量%) | 1.0 | 1.0 | 1.0 | 1.0 | 1.0 |
湿强度(lbf) | 1.20 | 1.36 | 1.59 | 1.71 | 2.02 |
切割最大载荷(lbf) | 8.67 | 9.32 | 9.79 | 10.94 | 17.64 |
可切割性等级 | 10 | 10 | 10 | 9 | 7 |
从表2中的数据可以看出,纤维素纤维的浓度对于提供足够的湿强度(至少约1.35lbf)同时保持有利的可加工特性是关键的。从前述内容可以看出,当在基垫组合物中包含少至1重量%的纤维素纤维时,提供了大于13%的湿强度的出乎意料且令人惊讶的改善。此外,当包含3重量%纤维素纤维时,湿强度甚至进一步令人惊讶地改善超过32%,而不会成比例地增加所形成的基垫的可切割性。在1%和3%纤维素纤维下,吊顶板的可切割性是可接受的,并且相对于没有任何纤维素纤维形成的基垫分别增加了小于8%和13%。然而,在5%纤维素纤维下,可切割性显著劣化(相对于没有任何纤维素纤维形成的基垫增加超过26%),并且在10%纸纤维下变得更差(相对于没有任何纤维素纤维形成的基垫增加超过100%),这证实了湿强度和可加工性的特别令人惊奇和有利的平衡,我们将该平衡归因于包含1重量%-3重量%纤维素纤维和超过70重量%矿棉的基垫。
Claims (18)
1.一种用于纤维面板的基垫,所述基垫包括:
矿棉,基于所述基垫的总重量,所述矿棉以至少约60重量%的量存在;
矿物填料;
纤维素,基于所述基垫的总重量,所述纤维素以约1重量%至约3重量%的量存在;和,
粘合剂,
其中所述基垫具有背衬侧和饰面侧。
2.根据权利要求1所述的基垫,其中基于所述基垫的总重量,所述矿棉以约60重量%至约95重量%、约60重量%至约90重量%、约60重量%至约80重量%、约65重量%至约95重量%、约65重量%至约80重量%、约65重量%至约75重量%或约60重量%至约75重量%的量存在。
3.根据权利要求1或2所述的基垫,其中所述矿物填料选自粘土、珍珠岩和蛭石的组中的一种或多种矿物填料。
4.根据任一前述权利要求所述的基垫,其中基于所述基垫的总重量,所述矿物填料以约5重量%至约25重量%、约5重量%至约22重量%、约10重量%至约20重量%、约8重量%至约15重量%、约8重量%至约12重量%、约12重量%至约17重量%或约15重量%至约20重量%的量存在。
5.根据任一前述权利要求所述的基垫,其中所述纤维素包括纸纤维。
6.根据任一前述权利要求所述的基垫,其中所述粘合剂选自淀粉、胶乳和再生纸制品的组中的一种或多种粘合剂。
7.根据权利要求6所述的基垫,其中所述粘合剂包括淀粉和胶乳。
8.根据任一前述权利要求所述的基垫,其中基于所述基垫的总重量,所述粘合剂以约5重量%至约20重量%、约5重量%至约15重量%、约8重量%至约17重量%、约8重量%至约15重量%、约12重量%至约15重量%或约15重量%至约20重量%的量存在。
9.根据任一前述权利要求所述的基垫,其中所述基垫具有小于约15磅/立方英尺(pcf)的密度。
10.根据任一前述权利要求所述的基垫,其中所述基垫具有约10pcf至约12pcf的密度。
11.根据任一前述权利要求所述的基垫,其中:
基于所述基垫的总重量,所述矿棉以约65重量%至约85重量%的量存在;
所述矿物填料包括珍珠岩并且基于所述基垫的总重量以约8重量%至约15重量%的量存在;
所述纤维素包括纸纤维;并且,
所述粘合剂包括淀粉和胶乳并且基于所述基垫的总重量以约8重量%至约15重量%的量存在,
其中所述淀粉和所述胶乳以约7:1至约12:1的重量比存在。
12.一种纤维面板,所述纤维面板包括:
根据任一前述权利要求所述的基垫;和,
多孔面罩,所述多孔面罩具有第一表面和第二表面,其中所述第一表面与所述基垫的所述饰面侧接触。
13.根据权利要求12所述的纤维面板,其中所述多孔面罩包括无纺玻璃纤维或玻璃纤维共混材料。
14.根据权利要求12或13所述的纤维面板,其中所述多孔面罩被层压到所述基垫。
15.根据权利要求12至14中任一项所述的纤维面板,所述纤维面板还包括在所述多孔面罩的所述第二表面上的装饰涂层。
16.根据权利要求13至15中任一项所述的纤维面板,所述纤维面板还包括在所述基垫的背衬表面上的背涂层。
17.根据权利要求13所述的纤维面板,所述纤维面板具有至少约0.75的降噪系数(NRC)。
18.根据权利要求13所述的纤维面板,所述纤维面板具有至少约35的吊顶衰减级别(CAC)。
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