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CN109642095A - 透声涂层 - Google Patents

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CN109642095A
CN109642095A CN201780051419.1A CN201780051419A CN109642095A CN 109642095 A CN109642095 A CN 109642095A CN 201780051419 A CN201780051419 A CN 201780051419A CN 109642095 A CN109642095 A CN 109642095A
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coating
droplets
formulation
substrate
acoustically transparent
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R·伯里
D·李
S·D·赫尔卡
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USG Interiors LLC
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Priority to CN202310242592.7A priority Critical patent/CN116063874A/zh
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Abstract

一种用于吸声衬底上的透声涂层的制剂，其包括水可分散性粘合剂和相对大的填料颗粒，并且具有高颜料体积浓度、高粘度、高剪切稀化和快速干燥的特征，以使得所述制剂能够以在相互接触时保持其特性的液滴形式喷涂。

Description

透声涂层
技术领域
本发明涉及一种用于改善吸声衬底的外观的透声涂层。
背景技术
美国专利8,684,134,8,770,345和8,925,677公开了用于构造整体式吸声天花板的干墙板或面板。这些面板是穿孔的并且包覆有薄的多孔半透明网，例如非织造半透明玻璃纤维网纱或稀松布。面板之间的接合部可以用胶带和接缝化合物完成，其方式与胶粘普通干墙相同，对于每个美国石膏协会出版物GA-216-2013。
需要一种可以涂覆在干墙面板上，以隐藏胶粘接合部和穿过网纱可见的穿孔，并且不会显着降低面板所提供的吸音性的涂层。重要的是涂层可以在不需要油漆工或商人的额外技能的情况下涂覆，并且完整的涂层将在有限的时间内干燥，优选地小于一个工作日的一半。
发明内容
本发明提供一种用于吸声衬底的饰面或外观涂层，其特征在于高孔隙度和由此产生的高透声度。所述涂层特别适用于隐藏包覆有半透明或半透明非织造网纱的干墙板中的穿孔，以及在整体式吸声天花板构造中的此些板之间的胶站接合部。
所公开的涂层材料适于以液滴形式喷涂成多个层，在涂覆连续层之前使所述多个层干燥。所得涂层结构是残余液滴和中间空隙或孔隙的三维矩阵。涂层材料的特征在于相对大的填料颗粒、高颜料体积浓度、显着的剪切稀化和快速干燥性质。
涂层材料以相对较大的液滴形式喷涂。由于材料的物理性质，一旦沉积在衬底或材料的前一层上，液滴就保留了它们各自的特性中的至少一些。由于粘度和快速干燥性质，液滴不会与相邻的液滴完全融合。液滴保持足够的个体性以在同一涂层以及前一涂层的液滴之间提供开放空间。在天花板应用中小到足以被不经意的观察者的肉眼忽略的开放空间通过单独的涂层互连，从而提供贯穿整个涂层厚度之孔隙度。
附图说明
图1是采用本发明的石膏面板整体式吸声天花板的局部示意性等距视图；
图2是图1的整体式吸声天花板的放大的局部横截面图；
图3是本发明涂层的一面的扫描电子显微照片；
图4是本发明涂层的优选制剂的粘度图；以及
图5是本发明涂层的气流阻力图。
具体实施方式
现在参考图1，示出了整体式吸声天花板装置10的示意性局部视图。将天花板10的各层的部分剥离以露出构造细节。天花板10是悬挂系统，包含本领域已知的干墙网格11，所述干墙网格包括在4英尺中心间隔开的主T形件12和在16英寸或2英尺中心间隔开的相交的副T形件13。本文中使用的尺寸通常是标称尺寸，并且旨在包含工业公认的度量等价物。与副T形件13互锁的主T形件12通过附接到上部结构(未示出)的金属丝14进行悬挂。网格11的边界通常通过固定到相应壁16的通道模制件15形成。
吸声面板20通过自钻螺钉21附接到网格T形件12、13的下部侧。所示的吸声面板的平面尺寸为4英尺×8英尺，但是根据需要或实际可以更长、更短和/或具有不同的宽度。面板20的大小和网格T形件12和13的间隔允许板的边缘位于网格T形件之下并且直接附接到网格T形件上，从而确保这些边缘得到良好的支撑。
参考图2，吸声面板20的特征在于穿孔石膏芯24。提供芯24的一种方法是通过使标准的市售干墙板穿透前纸面23、石膏芯24和后纸侧或面25来改进所述标准的市售干墙板。穿孔28可以通过钻孔、冲孔或其它已知的制孔技术形成。穿孔28优选地均匀间隔开；举例来说，穿孔可以是16mm中心上直径为8mm的圆孔。这种布置使穿孔的总面积基本上等于面板20的整个平面面积的20％。可以使用其它孔大小、形状、图案和密度。例如，测试表明，孔密度为总面积的9％可以获得良好的结果。边缘区域以及与板的支撑网格、托梁或螺柱的中心相对应的中间区域可以保持不穿孔，以维持紧固点处的强度。
将板29、30层压到穿孔干墙板的两个完整侧面上，从而至少部分地封闭穿孔28的两端。在干墙的后侧，背衬板或腹板30优选地是吸声天花板面板领域中已知的吸声非织造织物。举例来说，背衬织物可以是由Freudenberg Vliesstoffe KG以商标销售的背衬织物。
在干墙板22的前侧，用合适的粘合剂附接非织造织物稀松布层29形式的板或腹板。面层或板29是多孔的；用于此应用的合适材料是商业上用作传统吸声天花板面板的盖或面的材料。这种类型的网纱材料的实例是由Owens Corning Veil Netherlands B.V.以产品代码A125EX-CH02销售的材料。
具有其它相同面板的面板20以与安装普通干墙相同的方式悬挂在网格11上。类似地，如图1所示，接合部33以与胶粘普通干墙相同的方式胶粘。使用干墙接缝化合物或类似材料34将胶带或类似材料35粘附到两个邻接面板20的相邻边缘，方法是将其直接施加到板29上和胶带35上以隐藏胶带。
在将接缝化合物34打磨或擦拭光滑之后，将前板29和剩余的接缝化合物涂上本发明的透声涂层31。当在本文中使用术语整体式时，表示基本上天花板或墙壁的整个可见表面看起来是无缝展开而无接合部。
根据本发明，将涂层31喷涂到包覆有稀松布或网纱29的面板20的面向房间的一侧上，所述面板构成涂层的衬底。理想地，涂层31具有若干物理性质，包含相对大的填料颗粒、高颜料体积浓度(PVC)、高粘度、剪切稀化和快速干燥性能。当用作天花板结构的外观涂层时，涂层31应该是干燥的白色。
用于合适涂层的制剂包含粘合剂和相对大的颗粒，其用作颜料或填料，其大小大于常规涂料状涂层中通常使用的大小。粘合剂可以是树脂或聚合物粘合剂，或可用作水性分散液，例如但不限于丙烯酸、苯乙烯或乙烯基聚合物胶乳或油基介质，例如醇酸树脂、聚氨酯、聚酯或环氧树脂及其组合。
相对大的颗粒包含但不限于玻璃球、珍珠岩、陶瓷、飞灰、聚合物球、硼硅酸盐、粗砂、二氧化硅和粗碳酸盐。相对大的颗粒是球形或三维形状的，而没有突出的板状特性或没有主要的柱状形状。大颗粒的大小可以在20与900微米的范围内。
下表1列出了用于本发明透声涂层31的合适制剂的实例。
表1
各成分的功能或作用见最右列。水、增稠剂、粘合剂和大颗粒填料是必不可少的，且当制剂存在于罐中时，杀生物剂是必不可少的。其余成分可被视为任选的。出于参考目的，二氧化钛的平均粒度为约0.6微米；碳酸钙可具有约12微米的平均粒度，并且板状云母可具有约20微米的主要尺寸。
3M K1材料是碱石灰硼硅酸盐的玻璃气泡(空心球)，据报道真实密度通常为0.125克/立方厘米且平均粒度为65微米。3M K1材料在本发明的实践中特别有用。由于其中空球结构导致其相对低的密度，此材料占据了制剂的大部分体积。另外，K1材料的吸油量相对较低，每ASTM D281-84为0.2到0.6克油/立方厘米的产品。此外，K1材料具有天然白色，这在天花板应用中是有用的。二氧化钛用作改善不透明性的填料和增白颜料。碳酸钙增加了涂层的固体和密度，以进一步改善干燥时间和干燥涂层的硬度。
基于所有固体，涂层制剂的颜料体积浓度(PVC)相对较高，且理想地为75％到95％，而替代制剂将落入约50％到约99％的较宽范围内。通常，当涂层干燥时，粘合剂不足以填充涂层中的颗粒之间的空隙，从而允许涂层中存在气隙。相对大颗粒填料的体积与更常规大小较小的填料的体积的比率可在约0.1到约10的范围内。
表1的涂层制剂在室温下具有约190BBU(布拉本德单位)到约265BBU的相对高粘度。替代制剂在室温下可具有约66BBU到约1450BBU的粘度。
表1的涂层制剂以高剪切稀化率为特征，且替代制剂应以高剪切稀化率为特征。表1制剂的剪切稀化特性示于图4中，其中测得的粘度下降超过40:1。粘度部分由制剂的增稠剂组分贡献。列出的增稠剂是纤维素，但可以使用已知的合成和天然增稠剂。增稠剂还用于使各成分保持悬浮状态。图4的粘度图表是使用T-bar:C锭子在Brookfield HA粘度计上进行测量。替代的涂层制剂应具有高剪切稀化性质，使得在剪切条件下粘度可降低至少10比1。
表1的涂层或等同物优选在单独喷涂层的喷涂过程中涂覆到胶粘的网纱包层、穿孔干墙面板或其它衬底上。在涂覆后续涂层之前，允许每一层或涂层基本上干燥。优选地，使用例如Graco销售的常规料斗纹理喷涂器以大液滴喷涂润湿的涂层材料。理想地，调节喷枪和/或其空气供应，使得液滴的大小为约1到约4mm，优选地大小为约2mm。润湿涂层的如图4中所示的剪切稀化性质允许其易于以液滴形式喷涂，尽管其具有高粘度。单个涂层应涉及以两个垂直方向或阶段喷涂衬底，以便实现层的均匀覆盖。可以涂覆两到七个层，优选为四个层，以隐藏天花板的穿孔和胶粘接合部。总涂层的覆盖率可以是每加仑15到35平方英尺，优选为25平方英尺。表1的制剂或类似的制剂具有每加仑4到11磅的密度，优选范围为每加仑5到6.5磅。
图3显示了当涂覆于吸声衬底时本发明涂层的多孔性质。检查图3示出：液滴保持个体性的性质，而粘合剂将固体粘合到第一层的衬底且粘合到层之间和层当中的相邻液滴。图3右下角的刻度指示1毫米的量度且可在图中以大于或小于1毫米的量度观察液滴。优选地，干燥液滴的范围在1/2与2-1/2mm之间。当水分蒸发时，原始液滴大小将缩小。
随着涂层的沉积，建立了三维液滴矩阵。图3中的空隙、暗区可以在残留的液滴形式之间观察到。这些空隙通过涂层的厚度互连，从而形成多孔且透声的涂层。图3中的空隙或孔隙的大小通常小于0.5mm，使得在天花板高度处，站立在相关地板上的人不容易观察到它们。在由3M K1大颗粒提供的表1制剂中，涂层的主要固体体积的低吸收率确保涂层将快速干燥。润湿涂层的剪切稀化性质使其易于以液滴形式喷涂。
高粘度和快速干燥性质的结合使液滴能够有利地保持其个体性并避免与相邻液滴完全融合。将在特定层中应用的表1的公开制剂干燥到不会转移到手指上的程度，即指触干燥，最优选在75℉和50％相对湿度的环境下第一涂层在20分钟后且后续涂层在30分钟后干燥到所述程度。优选地，具有快速干燥性质的替代制剂将在第一涂层中在60分钟内变为指触干燥。涂层的这种快速干燥性质也很重要，因为它使油漆工能够在同一天完成工作。
图5示出了针对表1材料的每个连续干涂层单独测量的气流阻力。在每分钟2升的气流通过3.14平方英寸的表面积的情况下测定阻力。在图5中测试的涂层的总干燥厚度是0.031英寸。“0涂层”处的初始阻力读数是网纱29的阻力的量度。干涂层的厚度优选为0.03到0.15英寸。
应显而易见的是，本公开是借助于实例，并且可以通过在不脱离本公开中所含有的传授内容的合理范围的情况下添加、修改或消除细节来进行各种变化。因此，本发明不限于本公开的特定细节，除非所附权利要求书必要地如此限定。

Claims (10)

1.一种用于吸声衬底上的透声涂层的制剂，其包括水可分散性粘合剂和相对大的填料颗粒，并且具有高颜料体积浓度、高粘度、高剪切稀化和快速干燥的特征，以使得所述制剂能够以在相互接触时保持其特性的液滴形式喷涂。
2.根据权利要求1所述的制剂，其在室温下呈现的粘度在66与1450BBU之间。
3.根据权利要求1所述的制剂，其中所述大填料颗粒的大小为20与900微米之间。
4.根据权利要求1所述的制剂，其中所述颜料体积浓度在40％与99％之间。
5.根据权利要求1所述的制剂，其中在75℉和50％相对湿度的环境中以每25平方英尺四分之一加仑的速率沉积的所述制剂的喷涂层在30分钟内达到指触干燥。
6.一种用透声材料涂布吸声衬底的方法，其包括以下步骤：在所述衬底上以液滴形式喷涂根据权利要求1所述的制剂，喷涂速率允许在所述液滴基本上完全融合在一起之前通过蒸发水来干燥所述液滴，从而使所述干燥液滴之间仍有空隙。
7.根据权利要求6所述的方法，其中以大于1mm的液滴大小喷涂所述液滴。
8.一种吸声衬底上的透声涂层，其包括结合到所述衬底和相邻液滴的多层干燥液滴，所述液滴具有足够的不与相邻液滴接触的部分，以提供延伸通过所述涂层的整个厚度的互连孔隙。
9.根据权利要求8所述的透声涂层，其中所述干燥液滴的平均大小在约1/2与2-1/2mm之间。
10.根据权利要求8所述的透声涂层，其中所述涂层的厚度在0.03英寸与0.15英寸之间。
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