GB2335431A

GB2335431A - Acoustical products and coatings therefor

Info

Publication number: GB2335431A
Application number: GB9909500A
Authority: GB
Inventors: James D Pape; Darryl Lamar Sensenig
Original assignee: Armstrong World Industries Inc
Current assignee: Armstrong World Industries Inc
Priority date: 1995-11-09
Filing date: 1996-11-07
Publication date: 1999-09-22
Also published as: GB9909500D0

Abstract

The invention provides products with a plain, nonperforated, surface. The products comprise a fibreboard substrate (with or without a laminated porous nonwoven scrim) and a painted surface. The painted surface decorates or finishes the board and remains acoustically transparent to retain the sound absorption properties of the fibreboard prior to painting. The fibreboard substrate is porous or modified with hole perforations to cause it to be a good sound absorber. If the fibreboard substrate is sufficiently porous without hole perforations, then sprayable, high solids, paint can be applied directly to the substrate to provide a porous coating. If hole perforations are used to improve the sound absorption properties of the substrate, then a porous, nonwoven scrim is attached and painted using the high solids paint. The painted scrim must be sufficiently optically opaque to hide the holes punched in the board, yet sufficiently open to render it acoustically transparent.

Description

"ACOUSTICAL PRODUCTS AND COATINGS THEREFOR11 The invention relates to

improved acoustical products and coatings therefor.

2335431 Methods for obtaining products with a high noise reduction coefficient (NRC) are well known. (The NRC value of a product is measured using ASTM Test C423-90a.) Fibreglass is known to be a good sound absorber since it has high porosity. It can be decorated with a surface layer of laminated fabric or painted scrim requiring only a minimal openness in the surface layer for sound to pass through and be absorbed in the substrate.

To make an acoustically high NRC (equal to or greater than 65) product using a wood or mineral fibreboard substrate, the board porosity must be high. Paint applied directly to the board to provide a finish must not form a continuous film closing off the board surface. Normally, however, a continuous film is formed, thus lowering the NRC. Methods generally used to increase the NRC involve hole punching and the provision of surface perforations.

There is a need for a product with a high NRC and a plain, nonperforated, surface. If a sanded and painted fibreboard without surface perforations and scrim is used, then the porosity of the paint layer must be equal to or greater than the porosity of the board if the sound absorption properties of the board are to be retained.

- 2 Attaining a high porosity and an NRC equal to or greater than 65 is not easily accomplished with fibreboard without sacrificing other material properties such as strength and hardness. In accordance with the invention, it is possible to obtain high application rates to give a coating providing adequate coverage while remaining porous.

If hole punching of the fibreboard is needed to achieve an NRC equal to or greater than 65, then a facing layer is necessary in order to obtain a plain, nonperforated surface. Porous nonwoven scrims are attached for this purpose. It is necessary to cover the scrim with a paint coating to make it optically opaque. opacity is needed to hide the holes yet the paint coating must be acoustically transparent.

The present invention provides a paint coating on a fibreboard with an acceptable sound-absorbing NRC rating comprising:

(a) a fibreboard base substrate having a visual surface capable of absorbing sound; (b) at least a paint coating applied to the substrate visual surface, the paint coating being an optically opaque, discontinuous smooth paint coating means that is acoustically transparent to sound so that the sound can penetrate through the coating means and be absorbed in the substrate; (c) the paint coating means consisting essentially of (1) a latex emulsion, (2) very small size inert filler particles, and (3) water; (d) the paint coating means having a porosity of not less than about 50 to 75 cfm/square foot, preferably not less than about 75 cfm/square foot, to permit sound to penetrate therethrough.

In one embodiment of the invention, a porous material is positioned between the paint coating means and the fibreboard base substrate. The porous material is advantageously a scrim, preferably a non-woven scrim.

The invention also provides a paint coating for use with a soundabsorbing substrate, the paint coating being an optically opaque, discontinuous smooth paint coating means that is acoustically transparent to sound so that the sound can penetrate through the coating means, the paint coating means consisting essentially of:

(1) a latex emulsion, (2) very small size inert filler particles, and (3) water; the paint coating means being smooth and having a porosity of not less than about 50 to 75 cfm/square foot, preferably not less than about 75 cfm/square foot, to permit sound to penetrate therethrough, and further provides a paint and scrim coating for use with a soundabsorbing substrate comprising:

(a) a porous scrim having a porosity of not less than 100 cfm/square foot; and (b) a smooth paint coating consisting essentially of:

(1) a latex emulsion (2) very small size inert filler particles, and (3) water; the paint coating means having a porosity of not less than about 50 to 75 cfm/square foot, preferably not less than about 75 cfm/square foot, to permit sound to penetrate therethrough.

In another aspect, the invention provides a method of painting a soundabsorbing fibreboard comprisinq the steps of:

(a) providing a fibreboard with a sound-absorbing surface; (b) preparing a paint coating from a paint consisting essentially of a high solid emulsion and small mesh inert particles added to the emulsion to form a highly filled suspension; and (c) applying the paint coating to the sound absorbing surface to form an open or discontinuous coating that is acoustically transparent to sound and optically opaque.

The invention also provides an article comprising (a) a substrate having a surface capable of absorbing sound; - 5 (b) optionally, a porous material overlying the said surface; and (c) a paint coating on the said surface or, if a porous material is present, on the said material, the paint coating being smooth and having a porosity of not less than about 50 cfm/square foot, preferably not less than about 75 cfm/square foot, and having been produced from a paint comprising:

(1) a binder in the form of a emulsion; (2) relatively small inert filler particles; and (3) water.

The invention further provides a paint coating for use with a soundabsorbing substrate, the paint coatinq being an optically opaque, acoustically transparent, discontinuous smooth coating having a porosity of not less than about 50 cfm/square foot, preferably not less than about 75 cfm/square foot, the coating having been produced from a paint comprising:

(1) a binder in the form of a emulsion; (2) relatively small inert filler particles; and (3) water, and also provides a paint and porous material coating for use with a sound-absorbing substrate, the coating comprising:

(a) a porous material having a porosity of not less than 100 cfm/square foot; and (b) a smooth paint coating having a porosity of not less than about 50 cfm/square foot, preferably not less than about 75 cfm/square foot, the paint coating having been produced from a paint comprising:

In another aspect, the invention provides a method of manufacturing a painted substrate, which method comprises applying to a substrate having a soundabsorbing surface or to a porous material that overlies, or is subsequently brought into contact with, the soundabsorbing surface, a paint consisting essentially of a binder emulsion having a high solids content and small sized particles mixed with the emulsion to form a highly filled suspension, the paint forming an open or discontinuous coating that is acoustically transparent and optically opaque.

The values given for porosities herein are those measured by the Frazier Airflow Test.

Advantageously, the small particles used in accordance with the invention have a size of 325 U.S. mesh or finer. 325 U.S. mesh corresponds to a mesh opening of 44 gm.

Advantageously, a coating composition (or paint) used in accordance with the invention has a total solids content of up to about 72% by weight, based on the total weight of the composition.

The invention also provides a paint suitable for use with a soundabsorbing substrate, which paint comprises:

(1) a binder in the form of an emulsion; (2) small inert filler particles having a size of 325 U.S. mesh or finer; (3) water; the paint having a solids content of up to about 72% by weight, based on the total weight of the paint, and being such that, an application to a substrate, a paint coating with a porosity of not less than about 50 cfm/square foot, preferably not less than about 75 cfm/square foot, is obtained.

The invention makes it possible to provide a plain product comprising a substrate, for example, a wood or mineral fibre substrate, having a high NRC (equal to or greater than 65) and a surface layer that does not significantly alter the substrate sound absorption characteristics. The surface layer described herein can give a product having a plain surface without visible holes or surface perforations. This surface layer can comprise a directly applied paint or an attached painted porous material, for example, a nonwoven scrim. The critical characteristic of this surface layer is that it is acoustically transparent so that sound can penetrate through the surface layer and be absorbed in the substrate.

Paints are generally designed and applied in 8 sufficient amounts to form a continuous film. Atomized paint droplets coalesce and normally flow and wick on the substrate to spread over the surface, forming a film. The same type of wicking and spreading occurs when painting porous scrims. Acoustic transparency of the surface can be retained by applying small amounts of paint insufficient to form a film, but these small amounts are not optically opaque. Another method is to use a paint having minimal wicking and spreading characteristics. More paint can then be applied without closing off the surface. If hole perforations are needed to develop the desired NRC, these holes can be hidden by applying a porous nonwoven scrim to the board surface bridging the holes and then painting the scrim with an acoustically porous paint.

In accordance with the invention, there is used a paint which has restricted flow properties and minimized coalescence when applied, thus retaining discrete paint droplets. The paint preferably comprises a high solids/low liquid suspension having up to about 72% total solids by weight (based on the total weight of the paint before application to the substrate), the viscosity of which paint increases quickly with minimal water loss. The paint also desirably has a greater affinity for itself than for the surface to which it is applied. Fine particles with a mesh size equal to or greater than 325 (for example, conventional fine particles) can be used 9 - for the paint: a relatively low viscosity of about 3000 to 9000 cP (3 to 9 Pas) can be retained. Examples of particles that can be used are particles of limestone, silica or perlite, and glass beads. Because fine particles are used, the liquids and fine particles have an affinity for each other as a result of surface tension. This prevents wicking of the droplets into the surface of the fibreboard or the scrim. Since flow and coalescence of the paint droplets is minimal, the coating remains discontinuous allowing heavier application rates while retaining an openness essential for air and sound passage.

If desired, the porosity of the paint coating could be chosen to reduce the sound absorption of a fibreboard substrate.

The present applicants have determined that paints which preferably have a high percent of solids permit significantly higher application rates while retaining openness essential for good air and sound passage into a sound absorbing substrate. By, for example, blending extremely fine (325 mesh or finer) limestone, silica, titanium dioxide, binder and water, unusual properties are secured when this suspension is spray applied. (The titanium dioxide used here is present both as a pigment and as a small particle size filler. The silica filler assists in obtaining a smooth surface and preferably has a particle size of 8 to 20 microns)). This paint has - 10 minimal wicking and spreading characteristics. Minimal coalescence occurs, so that more discrete individual paint droplets are retained. The liquid and fine fillers have a greater af f inity f or each other than f or the surface to which they are applied. When, as is preferred, the solids content is high, even minimal water loss leads to a rapid increase in the viscosity, thus setting the paint droplets and retaining discrete paint droplets. The use of fine fillers makes it possible to obtain suspensions containing up to 72% fillers by weight, based on the total weight of the suspensions, with viscosities ranging from about 3000 to 9000 cP (3 to 9 Pas), permitting spray application via air atomized guns. Adjusting the amount of fillers and the use of viscosity altering agents will make it possible to obtain viscosities higher or lower than those specified above.

The preferred formulation at present for a paint in accordance with the invention is as follows:

Ingredients %BY Weight Range% Binder-Hycar Acrylic latex emulsion 7.2 4-20 50% solids by weight - B.F. Goodrich Filler-Omyacarb slurry limestone (325 mesh) 81.0 65-85 70% solids by we-Lght - Omya Corp.

Silica Filler - Celatom MW-27 (325 mesh) 7.0 4-10 100% solids by weight Harcross Chemicals Filler-Titanium dioxide (325 mesh) 1.7 1-10 100% solids Liquid-Water 3.1 2-8 i-0000 100.00 11 - When a paint used in accordance with the invention is applied by spraying, a smooth surface is formed. There is a limit to the amount of paint that can be applied while still retaining an openness for air and sound passage to the substrate. Higher application rates can be used with materials which absorb water from the paint droplet more quickly. Rapid absorption minimizes flow and the unwanted formation of a continuous film. Paint application rates as high as 60 gm/sf (about 650 g/m2) in one coat can be applied to high water absorption wood or mineral fibreboard and very porous nonwoven scrim, while still retaining the openness in the paint layer essential for good air and sound passage.

As the fibreboard or nonwoven scrim becomes less porous, the amount of paint has to be reduced since the water in the paint is not as readily absorbed and flooding occurs, closing off the fibreboard surface. In general, between about 30 to 50 cjm/sf (about 320 to 540 9/M2) of paint is generally ideal for retaining sufficient openness in the surface layer while not affecting the sound absorption properties of the substrate.

A paint used in accordance with the invention can be used on, for example, fibreboard substrates comprising fibres selected from the group consisting of wood, mineral, glass and mixtures of two or more thereof. The paint has utility for producing a layer for good air and 12 - sound passage. Porosity to air flow is a measure of a material's ability to pass sound. Porosity as measured by the Frazier Airflow Test or its equivalent is necessary for sound passage. The paint coating preferably has a minimum porosity of not less than 50 to 75 cubic feet per minute (cfm)/square foot (about 0.25 to 0.38 m3 per second/m2), preferably not less than about 75 cfm/square foot. This permits a substrate with an NRC rating of 65, having the above paint coating, to retain an NRC rating of 65. Lowering the paint coating porosity to, for example, about 25 cfm/square foot (about 0.10 m3 per second/m2) would reduce the substrate NRC rating to less than 65.

In one embodiment of the invention, structures of very high NRC (>75) may be obtained, by, for example, using a very porous wood or mineral fibre substrate with holes punched therein, if needed, at, for example, approximately 2000 small holes/sf (about 21530 holes/m2) A cellulose paper scrim, for example of 4 to 5 cjm/sf (about 43 to 54 g/m2), 15 mils (about 0.35 mm) thick and having a porosity of 117 cfm/square foot (about 0.6 m3 per second/m2) is laminated to this substrate using a water-based adhesive. A suitable cellulose scrim is supplied by Mlstrom Filtration, Inc. as grade 1281 with fibres of a nominal length of 2.5 to 5.0 mm and nominal diameter of 30 - 50 microns. The holes are visible through the cellulose scrim. The high solids paint is spray applied using conventional air atomized spray guns. Up to 30 gm/sf (about 323 g/m2) of paint can be applied without a decrease in the NRC. The surface obtained is optically opaque and acoustically transparent without visible surface perforations.

In general, the scrim (or other porous material) used in accordance with the invention advantageously a thickness of 15 mils (about 0.35 mm) or more. Other scrims that can be used may comprise, for example, organic fibres, glass fibres, glass/organic fibre combinations and like materials. The weight of the scrims is advantageously 6 to 12 qm/square foot (about 65 to about 130 g/m2) and the porosity is advantageously 200 to 300 cfm/square foot (about 1.0 to about 1.5 m3 per second/m2). Advantageously, the scrims are non-woven.

As the porosity of the paint layer or the paint/scrim combination layer decreases, the ability of that layer to pass sound decreases. Different layers have utility in different situations. Less porous paint layers or paint/scrim layers can be compensated for by increasing the absorption of the substrate. However, this is usually accompanied by a decrease in the strength and durability of the substrate since substrate density must be decreased to increase its absorption. The most efficient system overall is one in which the absorption loss due to the paint or paint/scrim is minimized. The paint/scrim porosity should preferably not be lower than cfm/square foot (about 0.33 M3 per second/m2). With the paint coats in accordance with the invention, the scrim itself preferably has a porosity of higher than 100 cfm/square foot (about 0.50 m3 Two embodiments of the per second/m). invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Fig. 1 is a side view of a discontinuous paint coating on a porous fibreboard; and Fig. 2 is a sectional side view of a porous scrim and discontinuous paint coating on a porous perforated fibreboard.

Fig. 1 shows a porous fibreboard substrate 2 with a discontinuous paint coating 4. Fig. 2 shows a perforated fibreboard substrate 6 with holes 8. A porous scrim 10 is used with a discontinuous paint coating 12.

Claims

CLAIMS:

1. A method of manufacturing a painted substrate, which method comprises applying to a substrate having a sound-absorbing surface or to a porous material that overlies, or is subsequently brought into contact with, the sound-absorbing surface, a paint consisting essentially of a binder emulsion having a high solids content and small sized particles mixed with the emulsion to form a highly filled suspension, the paint forming an open or discontinuous coating that is acoustically transparent and optically opaque.

2. A method as claimed in claim 1, wherein the substrate has an NRC rating equal to or greater than 65.

3. A method as claimed in claim 1 or claim 2, wherein the substrate comprises fibreboard.

4. A method as claimed in claim 3, wherein the fibreboard comprises fibres selected from one or more of wood fibres, mineral fibres and glass fibres.

5. A method as claimed in any one of claims 1 to 4, wherein the binder emulsion comprises a latex.

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6. A method as claimed in any one of claims 1 to 5, wherein the small particles have a size of 325 U.S. mesh or finer.

7. A method as claimed in any one of claims 1 to 6, wherein the small particles comprise limestone.

8. A method as claimed in any one of claims 1 to 7 wherein the paint has a total solids content of up to about 72% by weight, based on the weight of the paint before application.

9. A method as claimed in any one of claims 1 to 8, wherein the paint has a viscosity of 3000 to 9000 centipoise.

1

10. A method as claimed in any one of claims 1 to 9, wherein, when the paint is applied, the water and the relatively small particles have a greater affinity for each other than for the surface to which the paint is applied.

11. A method as claimed in any one of claims 1 to 10, wherein the paint coating or, if a porous material is present, the paint and porous material coating, has a lower porosity than the substrate surface to which the coating is applied, and the NRC rating of the coated substrate is lower than that of the uncoated substrate.

12. A method as claimed in any one of claims 1 to 11, wherein the porous material comprises a scrim.

13. A method as claimed in claim 12, wherein the scrim is a cellulose paper scrim.

14. A method as claimed in any one of claims 1 to 13, wherein the paint coating has a porosity of not less than about 25 cfm/square foot.

15. A method as claimed in any one of claims 1 to 13, wherein the paint coating has a porosity of not less than about 50 cfm/square foot.

16. A method as claimed in any one of claims 1 to 16, wherein the paint coating has a porosity of not less than about 75 cfm/square foot.

17. A method of painting a sound-absorbing fibreboard comprising the steps of:

(a) providing a fibreboard with a sound-absorbing surface; (b) preparing a paint coating from a paint consisting essentially of a high solid emulsion and small mesh inert particles added to the emulsion to form a - 18 highly filled suspension; and (c) applying the paint coating to the soundabsorbing surface to form an open or discontinuous coating that is acoustically transparent to sound and optically opaque.

18. A method as claimed in any one of claims 1 to 17, wherein the paint comprises:

(1) a binder in the form of an emulsion; (2) small inert filler particles having a size of 325 U.S. mesh or finer; (3) water; the paint having a solids content of up to about 72% by weight, based on the total weight of the paint, and being such that, on application to a substrate, a paint coating with a porosity of not less than about 50 cfm/square foot is obtained.

19. A method as claimed in claim 18, wherein the binder comprises a latex.

20. A method as claimed in claim 18 or claim 19, wherein the small particles comprise limestone particles, optionally in admixture with titanium dioxide particles.

21. A method as claimed in claim 20, wherein the paint also comprises silica particles.

19 -

22. A method as claimed in any one of claims 18 to 21, wherein the paint is such that, on application to a substrate, a paint coating with a porosity of not less than about 75 cfm/square foot is obtained.

23. A method as claimed in claim 1 or claim 17, wherein the paint has a composition substantially as described herein.

24. A method as claimed in claim 1 or claim 17, carried out substantially as described herein.

c

25. A painted substrate obtained by a method as laimed in any one of claims 1 to 24.

26. A painted substrate as claimed in claim 25, wherein the coating obtained from the paint has a porosity of at least about 25 cfm/square foot.

27. A painted substrate as claimed in claim 25, wherein the coating obtained from the paint has a porosity of at least about 50 cfm/square foot.

28. A paint coating on a fibreboard with an acceptable sound-absorbing NRC rating comprising:

(a) a fibreboard base substrate having a visual - surface capable of absorbing sound; (b) at least a paint coating applied to the substrate visual surface, the paint coating being an optically opaque, discontinuous smooth paint coating means that is acoustically transparent to sound so that the sound can penetrate through the coating means and be absorbed in the substrate; (c) the paint coating means consisting essentially of:

(1) a latex emulsion, (2) very small size inert filler particles, and (3) water; (d) the paint coating means having a porosity of not less than about 50 to 75 cfm/square foot to permit sound to penetrate therethrough.

29. A paint-coated fibreboard as claimed in claim 28, wherein the fibreboard NRC rating is equal to or greater than 65.

30. A paint-coated fibreboard as claimed in claim 28 or claim 29, wherein the particles comprise very small size particles ranging from about 325 mesh and finer.

31. A paint-coated fibreboard as claimed in any one of claims 28 to 30, wherein the fibreboard base substrate comprises fibres selected from the group consisting of 21 - wood, mineral, glass and mixtures thereof.

32. A paint-coated fibreboard as claimed in any one of claims 28 to 31, wherein the water and small size particles have a greater affinity for each other than for the substrate surface to which the paint coating is applied, so that discrete individual paint droplets are formed as an open and discontinuous coating means.

33. A paint-coated fibreboard as claimed in any one of claims 28 to 32, wherein the coating means has a lower porosity than the fibreboard and the NRC rating of the coated fibreboard is lower than that of the uncoated fibreboard.

34. A paint-coated fibreboard as claimed in any one of claims 28 to 33, wherein a scrim is positioned between the paint coating means and the fibreboard base substrate.

35. A paint coating for use with a sound-absorbing substrate, the paint coating being an optically opaque, discontinuous smooth paint coating means that is acoustically transparent to sound so that the sound can penetrate through the coating means, the paint coating means consisting essentially of: (1) a latex emulsion, (2) very small size inert filler particles, and 22 - (3) water; the paint coating means being smooth and having a porosity of not less than about 50 to 75 cfm/square foot to permit sound to penetrate therethrough.

36. A paint coating as claimed in claim 35, wherein the particles comprise very small size particles ranging from about 325 mesh and finer.

37. A paint coating as claimed in claim 35 or claim 36, wherein the water and small size particles have a greater affinity for each other than for the substrate surface to which the paint coating is applied, so that discrete individual paint droplets are formed as an open and discontinuous coating means.

38. A paint and scrim coating for use with a soundabsorbing substrate comprising:

(1) a latex emulsion, (2) very small size inert filler particles, and (3) water; the paint coating means having a porosity of not less than about 50 to 75 cfm/square foot to permit sound to penetrate therethrough.

23 -

39. An article comprising (a) a substrate having a surface capable of absorbing sound; (b) optionally, a porous material overlying the said surface; and (c) a paint coating on the said surface or, if a porous material is present, on the said material, the paint coating being smooth and having a porosity of not less than about 50 cfm/square foot and having been produced from a paint comprising:

(1) a binder in the form of an emulsion; (2) relatively small inert filler particles; and (3) water.

40. A paint coating for use with a sound-absorbing substrate, the paint coating being an optically opaque, acoustically transparent, discontinuous smooth coating having a porosity of not less than about 50 cfm/square foot, the coating having been produced from a paint comprising:

41. A paint and porous material coating for use with a sound-absorbing substrate, the coating comprising:

(a) a porous material having a porosity of not less 24 - than about 100 cfm/square foot; and (b) a smooth paint coating having a porosity of not less than about 50 cfm/square foot, the paint coating having been produced from a paint comprising: (1) a binder in the form of a emulsion; (2) small inert filler particles; and (3) water.

42. An article as claimed in any one of claims 39 to 41, having one or more features as specified in any one of claims 2 to 13.

43. A coating as specified in any one of claims 28, 35 and 38, substantially as described herein.

An article as described herein.

as c laimed in claim 39, substantially 45. A coating as claimed in claim 40 or claim 41, substantially as described herein.