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TWI668351B - 以石膏爲底質之吸音板 - Google Patents

以石膏爲底質之吸音板 Download PDF

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TWI668351B
TWI668351B TW104107211A TW104107211A TWI668351B TW I668351 B TWI668351 B TW I668351B TW 104107211 A TW104107211 A TW 104107211A TW 104107211 A TW104107211 A TW 104107211A TW I668351 B TWI668351 B TW I668351B
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vinyl acetate
gypsum
polymer
copolymer
olefin
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卡塔齊娜 胡達
卡洛琳 蒂瑪洛
凡龍尼克 蕭邦
卡羅 雷德
傑若米 賽門斯
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法商聖戈本建材公司
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
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    • B32B5/022—Non-woven fabric
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本發明係關於以石膏為底質之板，特別是包含位在兩片紙或不織布之間的以石膏為底質之核心的類型，其中該核心含有選自下列之至少一種聚合物：聚乙烯丁醛(PVB)；乙酸乙烯酯與烯烴之共聚物，該等共聚物具有玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。
本發明亦關於一種製造該板之方法、該聚合物用於改善該板之吸音性能的用途及上述以石膏為底質之組成物。

Description

以石膏為底質之吸音板
本發明係關於賦予吸音性質的以石膏為底質之板。此種板特別可用於製造牆、天花板或地板覆蓋物、及隔間牆。
以石膏為底質之板通常為包含位於兩層紙或由玻璃纖維或聚合物纖維組成的不織布之間的石膏核心之複合板。 該等板具有滿足力學方面之標準的機械性質，特別是對於在負重下變形之良好抵抗力。
此種以石膏為底質之板不會展現特別的吸音性能。當需要改善此等性能時，已知結合該板與隔音材料(諸如玻璃或岩絨或聚合物)，以視目標用途形成可利用形材、黏著劑、螺釘或定位銷固定在適當位置之複合產品。
最常見的以石膏為底質之板的平均厚度為12.5mm，且通常以「BA 13」之名銷售。該等板的表面密度為約9kg/m2。當然眾所周知的是，可藉由提高其表面密度(例如至高達12kg/m2)而不修改厚度來改善吸音性能，但此必 然會造成該板中之石膏量增加。
因此，該板之成本較高。
安裝表面密度較高之板亦具有缺點：因重量增加，該板更難以處理，以及因其密度更高，更難以使用螺釘附接該板。當該板必須在高處(隔間或天花板)附接時，此等缺點成為重大缺點。
本發明目的係提供具有經改良吸音性質，同時保持良好機械性質的以石膏為底質之板。
特別是，尋求獲得一種吸音性質至少等於相同厚度的慣用板之吸音性質但具有較高表面密度(約12kg/m2)的以石膏為底質之板。本發明目標特別鎖定之表面密度從4至11kg/m2，較佳為約9kg/m2。
根據本發明，該目的係因該以石膏為底質之板而達成，特別是包含位在兩片紙或不織布之間的以石膏為底質之核心的類型，其特徵在於該核心含有至少一種聚合物。
更具體而言，該板之核心包含石膏及選自下列之至少一種聚合物：聚乙烯丁醛(PVB)；乙酸乙烯酯與烯烴之共聚物，該等共聚物具有玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。
根據本發明之聚乙烯丁醛具有玻璃轉化溫度較有利為 40℃至100℃，較佳為50℃至90℃，更佳為60℃至80℃，其係藉由微差熱量測定法根據ISO 11357-1：2009標準測量。
較佳之聚乙烯丁醛係呈粉末形式，該粉末係由具有介於20與1000μm，特別是50至100μm、150至400μm或400至1000μm之尺寸的粒子組成。
根據本發明之乙酸乙烯酯與烯烴的共聚物係例如乙酸乙烯酯與至少一種選自乙烯、丙烯、丁烯及異丁烯之單體的共聚物。該等共聚物之玻璃轉化溫度較佳為-5℃至+20℃，有利地為0℃至+10℃。該等共聚物之玻璃轉化溫度係藉由微差熱量測定法根據ISO 11357-1：2009標準測量。以乙酸乙烯酯與乙烯之共聚物(EVA)為佳。
乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物為例如乙酸乙烯酯、如前述段落中所界定之烯烴及丙烯酸烷酯或甲基丙烯酸烷酯的三元共聚物。
乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物為例如乙酸乙烯酯、支鏈烷烴羧酸(versatic acid)之乙烯基酯(稱為VeoVa10)及丙烯酸酯的三元共聚物。
乙酸乙烯酯及丙烯酸系單體之共聚物為例如乙酸乙烯酯與丙烯酸烷酯或甲基丙烯酸烷酯的共聚物。
聚合物佔由石膏與該聚合物所構成的混合物之1重量%至4重量%，較佳為3重量%至30重量%，較有利為5重量%至20重量%。
根據本發明之聚合物有利地呈平均尺寸為0.01至1200μm，較佳為0.1至1000μm，及更佳為0.2至400μm之粒子形式。
根據本發明之板的核心可額外含有改善最終產品之物理化學性質且使得能獲得良好應用狀態的添加劑。該核心因而包含根據100重量份石膏計的下列重量比例之下列添加劑：- 0.1至15份之黏著劑，其角色係增加紙塗層與石膏之間的黏著，例如澱粉(特別是經酸預處理)、糊精或植物粉，特別是麥粉或玉米粉，- 0.001至10份之固化加速劑，例如水合硫酸鈣或硫酸鉀，- 0.001至10份之固化延遲劑，- 0至10份之殺生物劑，例如吡硫鎓鈉(Sodium Omadine)，- 0.0001至1份之發泡劑，其角色係產生孔以降低該最終產品的密度。例如，可提及者為硫酸鈉烷基醚及硫酸月桂酯鈉所製者，- 0至10份之至少一種拒水劑，例如矽氧烷或聚矽氧烷，- 0至20份之至少一種阻燃劑，例如蛭石、矽石，特別是微米尺寸者，黏土或金屬纖維，- 0至20份之至少一種強化劑，例如聚合物纖維、礦物纖維，特別是玻璃纖維，及動物或植物纖維。
本發明另一目的係關於製造如前文所述之該以石膏為底質之板(特別是包含位在兩層紙或不織布之間的核心之類型)的方法。
該方法特徵在於，為了製造板之核心，將選自下列之至少一種聚合物添加至燒石膏：聚乙烯丁醛(PVB)；乙酸乙烯酯與烯烴之共聚物，該等共聚物具有玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。
該以石膏為底質之板之製造本身係已知。該石膏板係根據連續方法形成，該連續方法包括混合粉末狀燒石膏(硫酸鈣半水合物)與水以形成糊劑，該糊劑係連續沉積在兩片紙或含有礦物纖維(特別是玻璃纖維)或聚合物纖維的不織布之間。
壓製將所形成之產品以獲得所要厚度，然後在輸送帶上將其連續輸送能使該糊劑達到充分硬化程度的距離，以使得切成既定長度之板。然後在烘箱中乾燥該等板，以消除過量水。
以往，不論是天然或合成(亦即，特別是從火力發電廠氣體脫硫所衍生)之硫酸鈣半水合物(CaSO4‧0.5H2O；燒石膏)於水存在下經歷水合反應，且轉化成硫酸鈣脫水物(CaSO4‧2H2O；石膏)。
用以形成糊劑之燒石膏的量通常根據100重量份水計 為50至150重量份，及較佳為60至120份。
聚合物可呈水溶液或分散液、粉末或丸粒形式。在溶液或分散液之情況下，該聚合物係添加至用以製備糊劑的水中。其於粉末或丸粒情況時成為問題，該添加係在燒石膏與水混合形成糊劑之前與該燒石膏一起進行。分散液及粉末為佳。
雖然以石膏為底質之板的厚度更特別鎖定在等於12.5mm，但不排除較小厚度，特別是降至6毫米，或較大厚度，特別是高達25毫米。
根據本發明之以石膏為底質之板可以原樣使用或與其他材料組合，例如礦絨或木毛、或聚合物，以形成吸音及/或隔熱板(thermal panel)，或者提供兩個以石膏為底質之板之間的結合之層間聚合物膜以形成複合板。
該板可用以形成壁覆蓋物、假天花板、地板及隔間牆。
本發明其他主題係關於聚合物之用途，其係用於意欲製造以石膏為底質之板的以燒石膏為底質之組成物以改善該板之吸音性能，該聚合物係選自聚乙烯丁醛(PVB)；乙酸乙烯酯與烯烴之共聚物，該等共聚物之玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。
適於製造上述以石膏為底質之板的組成物亦形成本發 明一主題。該以石膏為底質之組成物包含燒石膏及選自下列之至少一種聚合物：聚乙烯丁醛(PVB)；乙酸乙烯酯與烯烴之共聚物，該等共聚物具有玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。該組成物可特別用於製造接頭。
以下實例能說明本發明但不限制彼。
實施例1至15
以石膏為底質之板係從表1給定之組成物製備。
將硫酸鈣半水合物、聚合物及水導入混合器。
該混合物係在600rpm下攪拌15秒及在1850rpm下攪拌45秒。然後添加發泡劑且以250rpm攪拌該混合物50秒以獲得糊劑。
將該糊劑倒入包含四個平行六面體穴(長度：300mm；寬度：30mm；深度：13mm)且其且內壁已預塗覆一層油之黃銅模。於20分鐘後從該模移出樣本，然後於露天下留置40分鐘，及最後於烘箱中以40℃乾燥，直到其重量保持固定為止。
經由比較，在相同條件下製備兩個不含聚合物且表面密度等於9.0及11.9kg/m2之板(對照實例10及11)以及四個含有不包括在本發明中之聚合物的板(對照實例12至 15)。
該等板之吸音性能係藉由在ISO 16940：2008(E)標準下測量其機械阻抗MIM(機械阻抗測量)來評估。從與頻率(Hz)有關之加速頻率(dB)曲線計算動態楊氏模數(以GN/m2計)及損失因數(以%計)。
樣本為長度300mm、寬度30mm且厚度13mm之條。
針對來自對照實例10及11之參考板計算的楊氏模數、損失因數及吸音增益之值係示於表1。

Claims (13)

  1. 一種以石膏為底質之板，特別是包含位在兩片紙或不織布之間的以石膏為底質之核心的類型，特徵在於該核心含有選自下列之至少一種聚合物：乙酸乙烯酯與烯烴之共聚物，該等共聚物具有玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。
  2. 如申請專利範圍第1項之板，其中該乙酸乙烯酯與烯烴之共聚物具有玻璃轉化溫度為-5℃至+20℃。
  3. 如申請專利範圍第1項之板，其中該乙酸乙烯酯與烯烴之共聚物具有玻璃轉化溫度為0℃至+10℃。
  4. 如申請專利範圍第1或2項之板，其中該聚合物佔由該石膏與該聚合物所構成之混合物的1重量%至40重量%。
  5. 如申請專利範圍第1或2項之板，其中該聚合物佔由該石膏與該聚合物所構成之混合物的3重量%至30重量%。
  6. 如申請專利範圍第1或2項之板，其中該聚合物佔由該石膏與該聚合物所構成之混合物的5重量%至20重量%。
  7. 如申請專利範圍第1或2項之板，其中該聚合物係呈具有平均尺寸為0.01至1200μm之粒子形式。
  8. 如申請專利範圍第1或2項之板，其中該聚合物 係呈具有平均尺寸為為0.1至1000μm之粒子形式。
  9. 如申請專利範圍第1或2項之板，其中該聚合物係呈具有平均尺寸為0.2至400μm之粒子形式。
  10. 如申請專利範圍第1或2項之板，其中其額外包含根據100重量份石膏計的下列重量比例之下列添加劑：- 0.1至15份之黏著劑，例如澱粉(特別是經酸預處理)、糊精或植物粉，- 0.001至10份之固化加速劑，例如水合硫酸鈣或硫酸鉀，- 0.001至10份之固化延遲劑，- 0至10份之殺生物劑，例如吡硫鎓鈉(sodium omadine)，- 0.0001至1份之發泡劑，例如硫酸鈉烷基醚及硫酸月桂酯鈉，- 0至10份之至少一種拒水劑，例如矽氧烷或聚矽氧烷，- 0至20份之至少一種阻燃劑，例如蛭石、矽石、黏土或金屬纖維，- 0至20份之至少一種強化劑，例如聚合物纖維、礦物纖維或動物或植物纖維。
  11. 一種製造板，特別是包含位在兩片紙或不織布之間的核心之類型，之方法，其中將粉末狀燒石膏與水混合以形成糊劑，將該糊劑係連續沉積在該等片材之間，所形成之產品係經壓製以獲得所希望厚度，將該等板切成所希 望長度，特徵在於，為了製造該板之該核心，將選自下列之至少一種聚合物添加至該燒石膏：乙酸乙烯酯與烯烴之共聚物，該等共聚物具有玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。
  12. 一種聚合物之用途，其係用於意欲製造以石膏為底質之板的以燒石膏為底質之組成物以改善該板之吸音性能，該聚合物係選自乙酸乙烯酯與烯烴之共聚物，該等共聚物具有玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。
  13. 一種以石膏為底質之組成物，特徵在於其包含燒石膏及選自下列之至少一種聚合物：乙酸乙烯酯與烯烴之共聚物，該等共聚物具有玻璃轉化溫度從-10℃至+25℃；乙酸乙烯酯、烯烴及乙烯基酯單體之三元共聚物；乙酸乙烯酯、乙烯基酯單體及(甲基)丙烯酸酯單體之三元共聚物；及乙酸乙烯酯及丙烯酸系單體之共聚物。
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