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CN105178462A - Panels Including Renewable Components And Methods For Manufacturing - Google Patents

Panels Including Renewable Components And Methods For Manufacturing Download PDF

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Publication number
CN105178462A
CN105178462A CN201510532756.5A CN201510532756A CN105178462A CN 105178462 A CN105178462 A CN 105178462A CN 201510532756 A CN201510532756 A CN 201510532756A CN 105178462 A CN105178462 A CN 105178462A
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CN
China
Prior art keywords
plate
water
weight
base wad
slurry
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201510532756.5A
Other languages
Chinese (zh)
Inventor
曹邦继
特华·罗
戴维·W·宋
马丁·W·布朗
柯特·马隆
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
USG Interiors LLC
Original Assignee
USG Interiors LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US12/106,077 external-priority patent/US7935223B2/en
Priority claimed from US12/414,313 external-priority patent/US8133357B2/en
Application filed by USG Interiors LLC filed Critical USG Interiors LLC
Publication of CN105178462A publication Critical patent/CN105178462A/en
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • 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
    • C04B28/24—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 alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/52—Sound-insulating materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/745—Vegetal products, e.g. plant stems, barks
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/746—Recycled materials, e.g. made of used tires, bumpers or newspapers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B2001/8245—Machines for manufacturing, shaping, piercing or filling sound insulating elements
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/24—Structural elements or technologies for improving thermal insulation
    • Y02A30/244—Structural elements or technologies for improving thermal insulation using natural or recycled building materials, e.g. straw, wool, clay or used tires
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Landscapes

  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Electromagnetism (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Building Environments (AREA)
  • Paper (AREA)
  • Laminated Bodies (AREA)
  • Panels For Use In Building Construction (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

A panel includes about 0.1% to about 95% by weight of a renewable component and has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. In an embodiment, the panel has a core including 0.1% to 95% by weight of the renewable component; 0.1% to 95% by weight fibers; and 1% to 30% by weight binders, all based on dry panel weight. The renewable component optionally has a particle size distribution whereby less than 5% of the particles are retained by a mesh screen with openings of 0.312 inches and less than 5% of the particles pass through a mesh screen with openings of 0.059 inches. A method for manufacturing such panels is also provided.

Description

Comprise plate and the manufacture method thereof of renewable component
To be the applying date be the application on 04 01st, 2009 and denomination of invention is the divisional application of No. 200980113651.9 applications for a patent for invention of " plate and the manufacture method thereof that comprise renewable component ".
Technical field
The present invention relates to the plate for building trade, it comprises renewable component to improve acoustics and the physical property of plate.The present invention also provides the method manufacturing this plate.
Background technology
Plate as ceramic tile or wall belongs to the classification of building products, and for interior of building provide art of building to be worth, sound absorption properties, acoustic attenuation and utility function.Usually, plate, as abatvoix, is be used in the region needing control noise.The example in these regions is office building, department stores, hospital, hotel, auditorium, airport, restaurant, library, classroom, theater and cinema and residential building.
Such as, in order to provide art of building to be worth and utility function, abatvoix is smooth substantially and can self-sustained, to be suspended in typical ceiling grid system or similar structures.Therefore, abatvoix has hardness to a certain degree and rigidity, usually weighs abatvoix with its modulus of rupture (MOR).For obtaining required acoustic characteristic, abatvoix also has absorption of sound and propagates attenuating performance.
Absorption of sound is generally weighed by the noise reduction coefficient (NRC) described in ASTMC423.The number of NRC between 0 and 1.00 represents, it represents the mark of its sound of absorbed arrival.NRC value be 0.60 abatvoix absorb 60%, and 40% of reflect sound of the sound impacting it.Another kind of method of testing is the NRC (" eNRC ") of the use impedance tube estimation as described in ASTMC384.
The ability reducing sound transmission is weighed (" CAC ") by the ceiling class of attenuation value described in ASTME1414.CAC value measures with decibel form (" dB "), the amount that when representing that sound is propagated by material, sound reduces.Such as, CAC be 40 abatvoix make the sound of propagation reduce by 40 decibels.Similarly, sound transmission reduction also can be weighed by the Sound Transmission Class (" STC ") described in ASTME413 and E90.Such as, STC value be 40 plate make the sound of propagation reduce by 40 decibels.
Abatvoix according to multiple industrial standard and norm of construction manufacture has category-A fire-protection rating.According to ASTME84, flame spread index is required to be less than 25 and smoke index is less than 50.Gas-flow resistance, the measurement of pad porosity tests according to ASTMC423 and the C386 standard revised.In addition, the MOR of abatvoix, hardness and sag are tested according to ASTMC367.The increase of base wad degree of porosity improves sound absorption properties, but it is not measured through any concrete industrial standard or norm of construction.
Current, most of abatvoix or ceramic tile use water felting technique to prepare, because its speed and efficiency are preferred in this area.In water felting technique, base wad is formed by the method similar to papermaking.Authorize the U.S. Patent No. 5,911 of Baig, describe a version of this technique in 818, be hereby incorporated by.First, the water-based slurry comprising mineral wool dilution aqueous dispersion and aglite is transported on the foraminous conveyer of fourdrinier wire formula pad forming machine.Water is drained from slurry by gravity, then alternatively further by vacuum draw and/or the dehydration of squeezing means.Then, by the base wad of dehydration, it may still hold some water, dry to remove residual moisture in the baking box or drying stove of heating.The all qualified plate of size, outward appearance and acoustic properties is obtained by the dry base wad of finishing.Finishing comprises surface grinding, cutting, perforation/cracking, roller/spraying, trimming and/or is pressed on thin cloth or screen cloth by flaggy.
Typical abatvoix base wad composition comprises inorfil, cellulose fibre, adhesive and filler.As known in the art, inorfil can be mineral wool (it can exchange with mineral wool, rock wool and asbestos) or glass fiber.Mineral wool is by first being formed at 1300 DEG C (2372 °F) to 1650 DEG C (3002 °F) fusing slag or rock wool.Melting mineral are rotated into woollen via continuous print air-flow again in fibroblast circulator.Inorfil is stiff, for base wad provides volume and degree of porosity.On the contrary, cellulose fibre serves as structural element, for wet and dry base wad provides intensity.This intensity is that this is the hydrophilic result of cellulose fibre because form countless hydrogen bonds with various composition in base wad.
Normally used base wad adhesive is starch.Typical starch for abatvoix is unmodified uncooked amylum particle, and they are dispersed in the plate slurry of water-based and are also usually evenly distributed in base wad.Once heating, this starch granules becomes ripe and dissolves, and provides the adhesive power to plate composition.Starch not only contributes to the flexural strength of abatvoix, and contributes to hardness and the rigidity of plate.Have in the plate composition of the inorfil of high concentration at some, latex binder is used as main adhesive.
Typical base wad filler comprises the inorganic matter of heavy and lightweight.The major function of filler is to provide the flexural strength of plate, and contributes to the hardness of plate.Although this specification employs term " filler ", it should be understood that often kind of filler all has character and/or the feature of the uniqueness that rigidity, hardness, sag, the sound absorption properties and sound transmission that can affect plate reduces.The example of high-gravity filler comprises calcium carbonate, clay or gypsum.The example of light filler comprises expanded perlite.As filler, the advantage of expanded perlite is that volume is large, reduces amount of filler required in base wad thus.
A shortcoming of expanded perlite is that perlite particle is often filled in the hole of base wad, and seals its surface, and this damages the sound-absorbent of plate.And swelling fiber is relatively fragile and frangible in the fabrication process.Generally speaking, the amount of the expanded perlite of use is larger, and plate sound absorbing capabilities is poorer.Perlitic expansion consumes a large amount of energy.Just expanded perlite is formed when being incorporated into by perlite ore in the expanding tower being heated to about 950 DEG C (1750 °F).Water in perlitic structure is transformed into steam, and consequent expansion causes perlite " to pop " as puffed rice, makes density be down to about 1/10th of non-expanding material.The lower bulk density of expanded perlite to upper reaches in expanding tower, and can be filtered device collection.This process uses relatively a large amount of energy to make all perlites be heated to enough to vaporize the temperature of wherein moisture.
Consider the trend of current builing industry, need environment-friendly products, global warming, acidifying, smog, the eutrophication of water, solid waste, primary energy consumption and/or effluent discharge that namely the manufacture process of this product produces reduce.The recyclable materials of self-sow may be used for the building products of production environmental protection.In construction industry, widely used recyclable materials is timber, but it provides absorption of sound hardly.Similarly, also have a large amount of agricultural residues and byproduct, and timber and furniture industry waste material, they are all easy to obtain but purposes in production of construction materials is limited.
In order to utilize the recyclable materials of self-sow, need the fiber extracting it.This passes through by ligno-cellulosic materials as slurrying such as timber, straw, bamboos, so that single fibrocyte vegetable material chemically or mechanically being resolved into it realizes.Common chemical pulp processes utilizes vulcanized sodium, NaOH or sodium sulfite to dissolve timber at about 150 DEG C (302 °F) to 180 DEG C (356 °F), makes the living beings of fiber reduce about 40-60%.On the contrary, wood is carried out high temperature (about 130 DEG C (266 °F)) and high pressure (an about 3-4 atmospheric pressure (304-405kPa)) process by heat-mechanical pulp-making method, makes lignin softening and is mechanically torn apart by fibrocyte.The division that lignin connects makes raw material go fibrillatable, causes biotin to lose about 5-10%.Chemistry and heat-mechanical pulping process all need a large amount of energy, with the single fiber making ligno-cellulosic materials become it.And the loss of large number of biological element adds raw-material cost.
Several sections of US patent teaches use reproducible material in constructional materials.U.S. Patent No. 6,322,731 disclose a kind of method forming the structural slab of endless, comprise a kind of organic fine particles matrix material formed primarily of rice husk and adhesive.Because the requirement of structural integrity, this technique needs the combination of high temperature and high pressure, to form the plate of sufficient intensity.The plate obtained has relative low sound absorption value because of its high density and low porosity.Heat and sound insulation characterisitic are realized by parcel chamber.
U.S. Patent No. 5,851,281 disclose a kind of technique manufacturing cement-waste composite, and wherein waste material is rice chaff.Rice chaff is heated to about 600 DEG C (1112 °F) to produce particulate when anaerobic.
U.S. Patent No. 6,443,258 disclose a kind of by solidify, water-based, the porous sound absorption plate that formed of cementitious materials of foaming.This plate provides good acoustical behavior, the durability of enhancing and moisture resistance.Add the integral hardness that rice hull ash strengthens cement board.
Summary of the invention
The invention provides a kind of as constructional materials use there is the acoustics of improvement and the plate of physical characteristic.Plate of the present invention comprises a kind of renewable component, such as rice husk, and the acoustic characteristic with improvement, comprise CAC or STC keeping relative constancy.Achieve the NRC of improvement in addition, keep simultaneously or improve other physical characteristics of plate, comprise MOR, hardness, gas-flow resistance and sag.
In one embodiment, plate of the present invention comprises the renewable component of about 0.1% to about 95% weight.This plate has the CAC value at least about 25, the NRC value at least about 0.25 and at least about at least one item in the STC value of 25.
Some other the embodiment of plate of the present invention comprises plate core, this plate core comprises the renewable component through grinding of about 0.1% to about 95% weight, one or more fibers of about 0.1% to about 95% weight, one or more adhesives of about 1% to about 30% weight, and about 3% to about 80% one or more filler of weight, above all based on the plate weight of drying.Renewable component through grinding has a domain size distribution, makes the particle lower than 5% be retained by the mesh screen of Kong Weiyue 0.312 inch thus, and the particle lower than 5% is through the mesh screen of Kong Weiyue 0.059 inch.
In another embodiment, preparation comprises step as the method for the plate of constructional materials: formed and comprise the renewable component of about 0.1% to about 95% and the water-based slurry of water.Then base wad is formed with foraminous conveyer by slurry.Water in removing base wad, and finishing base wad is to form the plate being used as constructional materials.The plate manufactured by this method has at least one item in the CAC value at least about 25 and the NRC value at least about 0.25.
At least another kind of embodiment is a kind of method of producing the plate being used as constructional materials, comprises step: select the renewable component through grinding; By renewable component, the fiber of about 1% to about 50% weight, the adhesive of about 1% to about 30% weight of water with about 0.1% to about 95% weight, and the filler of about 3% to about 80% weight combines, to form water-based slurry; On foraminous conveyer, base wad is formed by this water-based slurry; Remove the moisture in base wad and this base wad of finishing.Renewable component is separated to obtain domain size distribution as above.The plate made by the method has at least one item in the CAC value at least about 25 and the NRC value at least about 0.25.
It is useful for adding through the renewable component of grinding or mill, because compared with other packing materials, the preparation of renewable component needs less energy.Preferably, renewable component is through grinding or being directly incorporated in abatvoix.This technique only has the ability consumed energy when renewable component is through grinding and/or sieving, and uses less energy compared with expanded perlite.
Another benefit of recyclable materials is used to be that its preparation does not have obvious living beings to lose.Recyclable materials through grinding or mill keeps its bulk structure, and does not experience the change of chemical modification or chemical constitution, such as, go fibrillatable.The reservation of living beings makes the raw material of purchase more effectively use, thus reduces its cost.
The selection of the different fillers used in construction panel does not change plate character with usually conforming to people's will.But the use of the renewable component of the present invention reduces the energy and the cost of raw material, keep simultaneously or improve other physical propertys of plate.
Especially, the present invention relates to the following:
1, be used as a plate for constructional materials, comprise:
The renewable component of about 0.1% to about 95% weight; Wherein said plate has the CAC value at least about 25, at least one item in the NRC value at least about 0.25 and the STC value at least about 25.
2, the plate as described in the 1st, wherein said renewable component comprises rice husk, buckwheat shell, shuck, comprise peanut and walnut shell, wheat shell, oat shell, rye are stroked, cotton seed hulls, cocoanut shell, corn bran, corn ear, sunflower seeds, rice stalk, wheat stalk, Barley straw, oat straw, rye stalk, Spanish grass (Esparto), Chinese sorghum straw, reed, bamboo, sisal hemp, India's grass, ramie, bagasse, flax, bluish dogbane, jute, hemp, abaca, sawdust, wood chip or its combine.
3, the plate as described in the 1st, it has the eNRC at least about 0.20.
4, the plate as described in the 1st, it has the MOR value at least about 80psi.
5, the plate as described in the 1st, it has the flame spread index lower than about 25.
6, the plate as described in the 1st, wherein said renewable component comprises mesh screen through perforate about 0.312 inch (8000 μ) and the particle be retained on second mesh screen of perforate about 0.0059 inch (655 μ).
7, the plate as described in the 1st, comprises one or more fibers of about 0.1% to about 95% weight based on dry plate weight further, and one or more adhesives of about 1% to about 30% weight.
8, manufacture a method for the plate described in the 1st, the method comprising the steps of:
Select renewable component;
By renewable component and one or more fibers and an adhesive and hydration also, water-based slurry is formed;
On guipure, base wad is formed by described water-based slurry;
Remove the water in described base wad; And
Base wad described in finishing.
9, the method as described in the 8th, wherein said renewable component comprises rice husk, buckwheat shell, shuck, comprise peanut and walnut shell, wheat shell, oat shell, rye are stroked, cotton seed hulls, cocoanut shell, corn bran, corn ear, sunflower seeds, rice stalk, wheat stalk, Barley straw, oat straw, rye stalk, Espart, Chinese sorghum straw, reed, bamboo, sisal hemp, India's grass, ramie, bagasse, flax, bluish dogbane, jute, hemp, abaca, sawdust, wood chip or its combine.
10, the method as described in the 8th, comprises the step of sieving described renewable component further.
Detailed description of the invention
Product described herein, method and composition are intended to be applied to the plate used as constructional materials.More specifically, this plate also can be used as ceiling product, abatvoix or ceramic tile.Below discussing is for the abatvoix as one embodiment of the present invention, but and limits the scope of the invention never in any form.
Fiber is present in abatvoix with inorfil, organic fiber or its combination.Inorfil can be mineral wool, mineral wool, rock wool, asbestos, glass fiber or its mixture.Inorfil is hard, for substrate provides volume and degree of porosity.Inorfil is present in abatvoix with the amount of about 0.1% to about 95% based on plate weight.At least one embodiment of abatvoix uses mineral wool as preferred fiber.As the example of in organic fiber, cellulose fibre serves as structural element, for wet provides intensity with dry base wad.This intensity is that this is the hydrophilic result of cellulose fibre because form hydrogen bond with the various compositions in base wad.Cellulose fibre in base wad accounts for about 1% of plate weight to about 50%, and preferably about 5% to about 40%, most preferably from about 10% to about 30%.A kind of preferred sources of cellulosic fibers is from the newsprint recycled.
It is renewable component that plate comprises at least one composition.Renewable component is defined as timber or non-wood plant, or a part for timber or non-wood plant.These renewable components are preferably lignocellulosic, and it comprises cellulose and lignin.The potential source of these materials is waste material from aquaculture, agricultural, forestry and/or builing industry or byproduct.
Rice husk or rice chaff are the examples of renewable component.The example of other renewable components includes but not limited to: wheat shell, oak bark, rye is stroked (ryewhisk), cotton seed hulls, cocoanut shell, corn bran, corn ear, rice stalk, wheat stalk, Barley straw, oat straw, rye stalk, bagasse, reed, Spanish grass (Esparto) (Esparto), India's grass (Sabai), flax, bluish dogbane, jute, hemp, ramie, abaca, sisal hemp, wood sawdust, bamboo, wood chip, Chinese sorghum straw, sunflower seeds, buckwheat shell, shuck, comprise peanut and walnut shell, other similar materials and their mixture.
Before mixing with other plate compositions, preferably the size of renewable component is reduced.The particle diameter that recyclable materials preferably has is: through 0.312 inch aperture mesh screen (as ASTM sieve figure definition 2.5 orders) and on the mesh screen of 0.0059 inch aperture (as ASTM sieve figure definition 100 orders) retain.In some embodiments, renewable component uses by whole use or by former state when receiving from supplier.The term " renewable component " used is intended to the particle that comprises whole particle or size is reduced by any means known in the art, comprises through pulverizing, shredding, grind, mill, particle that sieving or its combination obtain.Size reduces to be realized by machining alternatively, such as, grind or mill, to obtain required size.At least one embodiment uses hammer type crushing type equipment.
Alternatively, renewable component can carry out sieving with the screen cloth in specific order footpath, to obtain required domain size distribution.Selectively will remove by the coarse fraction of required maximum screen cloth too greatly and not, and then process, until the material obtained is through screen cloth.In one embodiment, first by the rice husk #30 mesh sieve sieving of grinding, to remove large particle, subsequently by #80 mesh sieve, to remove too thin particle.Rice husk by #30 mesh sieve and after being retained in the processing on #80 mesh sieve is for the manufacture of abatvoix.In this embodiment, need not be in the plate by the particle of #80 mesh sieve.#30 mesh sieve has the perforate of 0.022 inch or 0.55mm.#80 mesh sieve has the perforate of 0.007 inch or 180 μm.In another embodiment, by the rice husk after the direct processing obtained from rice mill for the manufacture of abatvoix.The size distribution of recyclable materials pulverized have alternatively at least about 95% particle through #30 mesh sieve, and the particle being no more than about 5% is by #80 mesh sieve (U.S.'s bushing screen).
As in background technology discuss, expanded perlite is the material often used in construction panel.When used for a ceiling, expanded perlite often forms a kind of structure lacking interconnective hole.Contribute to interrupting expanded perlite structure by introducing in abatvoix through the renewable component of grinding or mill, thus increase interconnective hole.Compared with the plate of the renewable component of grinding without other with containing perlite or mill, the plate hole comprising the renewable component of the grinding except perlite is more, and produces higher sound absorption properties.
Have been observed that, the particle diameter of renewable component is larger, and sound absorption value is higher.For any one embodiment, best domain size distribution depends on required sound absorption value.
It should be understood that renewable component domain size distribution is preferably compatible with other compositions, as cellulose, expanded perlite etc., to form the slurry of uniformity.The formation of even slurry makes the base wad producing uniformity.Domain size distribution preferably passes through and selects, to maintain or to improve the physical integrity of plate.
In some embodiments, reproducible composition comprises the particle lower than about 5% weight retained by #6 mesh sieve.In other embodiments, the renewable component of use comprises the particle lower than about 5% weight retained by #20 mesh sieve.Also have in some embodiments, the grinding of use or the renewable component of milling comprise the particle lower than about 5% weight retained by #30 mesh sieve.Preferably, the bulk density that has of renewable component between about 5 to about 50lbs/ft 3(80 to 800kg/m 3), preferred bulk density is about 10 to about 40lbs/ft 3(160 to 640kg/m 3), most preferred bulk density is about 20 to about 35lbs/ft 3(320 to 560kg/m 3).#6 mesh sieve has the perforate of 0.132 inch or 3.35mm, and #20 mesh sieve has the perforate of 0.0312 inch or 800 μm, and #30 mesh sieve has the perforate of 0.022 inch or 0.55mm.
Comprise starch alternatively in the base pad as adhesive.Typical starch is unmodified uncooked amylum, and it is dispersed in water-based slurry, and is substantially evenly distributed in whole base wad.Heating base wad, boils and dissolves starch granules, with by plate members bound together.Starch not only contributes to the flexural strength of abatvoix, and improves hardness and the rigidity of plate.In addition, base wad comprises the starch of about 1% to about 30% of plate weight alternatively, and more preferably from about 3% to about 15%, and most preferably from about 5% to about 10%.
Typical base wad filler comprises lightweight and heavy inorganic material.The example of heavy fiber comprises calcium carbonate, clay or gypsum.Also other fillers can be considered to be used for abatvoix.In one embodiment, the calcium carbonate of use is about 0.5% of plate weight to about 10%.Also the calcium carbonate of about 3% to about 8% of plate weight can be used.
The example of light fibre is expanded perlite.Expanded perlite volume is large, decreases the amount of the filler used in base wad.The major function of filler improves flexural strength and the hardness of plate.Although entirety employs term " filler " in this discussion, it should be understood that often kind of filler has unique character and/or feature, it can affect the reduction of the rigidity of plate, hardness, sag, sound absorption properties and sound transmission.Expanded perlite in the base wad of this embodiment exists with the amount of about 5% to about 80% of plate weight, is more preferably about 10% of plate weight to about 60%, and most preferably is about 20% of plate weight to about 40%.
In a preferred embodiment, this base wad comprises renewable component, mineral wool, expanded perlite, starch, calcium carbonate and/or clay.A kind of preferred renewable component is wherein the rice husk of grinding.The percentage of renewable component is about 0.1% of plate weight to about 95%, is more preferably about 5% to about 60%, most preferably is about 7% to about 40%.
In abatvoix, another kind of optional composition is clay, and it is included to improve refractoriness usually.When exposed to a fire, clay does not burn; On the contrary, it can sinter.Abatvoix comprises the clay of about 0% to about 10% of plate weight alternatively, and preferably about 1% to about 5%.Eurypalynous clay perhaps can be used, include but not limited to SpinksClay and BallClay (Gleason, TN.) and OldHickoryClay (Hickory, KY).
Alternatively, also flocculant is added in abatvoix.Flocculant preferably uses with about 0.1% of plate weight to about 3%, is more preferably about 0.1% to about 2%.Useful flocculant includes but not limited to: aluminum chlorohydrate, aluminum sulfate, calcium oxide, iron chloride, ferrous sulfate, polyacrylamide, sodium aluminate and silicate of soda.
In a kind of embodiment manufacturing the base wad being used for abatvoix, be mixed to form water-based slurry mutually preferably by by water and renewable component, mineral wool, expanded perlite, cellulose fibre, starch, calcium carbonate, clay and flocculant.Married operation is preferably with batch mode or carry out in stock tank in a continuous mode.The water yield of adding makes the total solids content of gained or the scope of denseness be the denseness of about 1% to about 8%, is preferably about 2% to about 6%, and is more preferably about 3% to about 5%.
Once form the even slurry comprising mentioned component, just this slurry is transported in the headbox of the slurry Commodity flow providing stable.To form wet basis pad on the foraminous conveyer that the slurry flowed out from headbox is distributed to movement.First water discharged from guipure by gravity.Can expect, in some embodiments, can simultaneously or being combined low vacuum pressure after draining by gravity from slurry.Understood as those of ordinary skill in the art, then alternatively by pressurizeing and/or utilizing vacuum servo to dewater, extra water removed.Residual water generally evaporates to form shaping base wad in baking box or drying stove.
Once shaping, base wad preferably has about 7 to about 30lbs/ft 3(112 to 480kg/m 3) bulk density, more preferably from about 8 to about 25lbs/ft 3(128 to 400kg/m 3), and most preferably from about 9 to about 20lbs/ft 3(144 to 320kg/m 3).
Then by the finishing procedure that those of ordinary skill in the art know, shaping base wad is cut and changes into abatvoix.Some preferred finishing procedures comprise surface grinding, coating, perforation, cracking, edge thinning and/or packaging etc.
Perforation and cracking obviously contribute to the sound absorption value improving above-mentioned base wad.Perforating application provides multiple hole with the controlled degree of depth and density (number of perforations on per unit area) on the surface of base wad.Perforation carries out on base wad surface by one being equipped with the flat-plate compressed subscribing pin number.Cracking is the impression providing unique model at shaping base wad on the surface, such as, with the roller of metal sheet that patterning is housed.Perforation and cracking step open base wad surface and internal construction thereof, thus make air pass in and out plate.Perforate in base wad also can make sound enter and be received by base wad wicking.
In addition, alternatively, abatvoix cloth or curtain are carried out lamination.Also should be taken into account, abatvoix of the present invention can use cutter hand cut.
Once shaping, abatvoix of the present invention preferably has about 9 to about 32lbs/ft 3(144 to 513kg/m 3) bulk density, more preferably from about 10 to about 27lbs/ft 3(160 to 433kg/m 3), most preferably from about 11 to about 22lbs/ft 3(176 to 352kg/m 3).In addition, this plate preferably has about 0.2 inch of thickness to 1.5 inches (5 to 38mm), and more preferably from about 0.3 inch to 1.0 inches (8 to 25mm), and most preferably from about 0.5 inch to about 0.75 inch (13 to 19mm).
The abatvoix comprising the renewable component of at least one preferably reaches the NRC value at least about 0.25 and the CAC value at least about 25.And this abatvoix reaches the eNRC value at least about 0.15.In addition, abatvoix reaches the MOR value at least about 80psi, at least about the hardness number of 100lbf, reaches the maximum sag value of in 90%RH humidity chamber 1.5 inches (38mm) simultaneously.Further, this abatvoix reaches the flame spread index lower than about 25 and the smoke index lower than about 50.This abatvoix also has the STC value at least about 25.
Embodiment 1
Rice husk obtains from RicelandIndustries, Jonesborough, AR, and wherein unpolished rice separates the grain of rice through milling from rice husk.According to slot size, #6 mesh sieve, #10 mesh sieve (perforate is 0.066 inch or 1.7mm), #16 mesh sieve (perforate is 0.039 inch or 1mm) and #30 mesh sieve, classify rice husk.The size distribution of rice husk comprises about 18.3% and is retained on #10 mesh sieve, and about 58.0% is retained on #16 mesh sieve, and about 20.1% is retained on #30 mesh sieve, and about 3.6% through #30 mesh sieve simultaneously.The bulk density of rice husk is about 8.51lbs/ft 3(136kg/m 3).
Mixed mutually by the perlite of Jiang Shui and the different amounts described in plate composition and table 1 and rice husk, form the slurry with about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: the rice husk of newsprint paper pulp, starch, calcium carbonate, grinding, mineral wool and expanded perlite.Stir slurry about 2 minutes.At the end of stirring, in slurry, add the flocculant of the concentration of about 0.1% of slurry weight.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill makes slurry water freely discharge, and retains most of solid simultaneously.Other water is removed by applying low-voltage vacuum (1 " Hg (25mmHg)) to shaping box.Then wet basis pad is pressed onto a constant humidity thickness, to remove other water and to consolidate base wad structure.Finally, wet basis pad dewaters further by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)).By shaping base wad again in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In the following embodiments, employ the mineral wool of about 10% of plate weight, also have an appointment 19% newsprint fiber, the starch of about 8% and the calcium carbonate of about 6%.The amount of perlite and rice husk is described as follows.List file names with the character of the dry base wad of gained.
Table 1
As implied above, the base wad with higher rice husk percentage by weight also has lower gas-flow resistance value, shows that base wad is porous more.Therefore, the base wad comprising more rice husk is sound absorption properties stronger, and this is reflected in imperforated eNRC value.
Embodiment 2
Rice husk obtains from RicelandIndustries, Jonesborough, AR, and wherein unpolished rice separates the grain of rice through milling from rice husk.Further with diameter 0.109 is housed " (0.028m) porous sieve size Fritz mill grinding rice husk.Grinding rice husk is until all material passes through screen cloth.Other rice husk through grinding, and is 0.079 with perforate " with 0.050 " mesh screen of (being respectively 0.002m with 0.0013m) is separated.For 0.109 " (0.028m), 0.079 " (0.002m) and 0.050 " sieve aperture of (0.0013m), the bulk density of above-mentioned sample is respectively about 14.62lbs/ft 3(234kg/m 3), 16.31lbs/ft 3(261kg/m 3) and 21.77lbs/ft 3(349kg/m 3).
Mixed mutually by the perlite of Jiang Shui and the different amounts described in plate composition and table 2 and rice husk, form the slurry with about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: newsprint paper pulp,
The rice husk of starch, calcium carbonate, grinding, mineral wool and expanded perlite.Stir slurry about 2 minutes.At the end of stirring, in slurry, add the flocculant of about 0.1% weight.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill allows slurry water freely to discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is pressed onto a constant humidity thickness to remove other water and to consolidate base wad structure.Finally, wet basis pad dewaters further by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)).Then by shaping base wad in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 2, by the mineral wool of about 10% of plate weight, and the newsprint fiber of about 19%, the starch of about 8% and the calcium carbonate of about 6% are for the formation of plate.The amount of perlite and rice husk is described as follows.List file names with the character of the dry base wad of gained.
Table 2
As implied above, have and can have through the base wad of rice husk of larger sieve aperture stronger sound absorption properties, this is reflected in higher eNRC value.
Embodiment 3
Rice husk obtains from RiceHullSpecialties, Stuttgart, AR, is wherein through grinding from the rice husk of rice-hulling mill.First with the rice husk of #20 mesh sieve sieving grinding to remove larger particle, subsequently with the sieving of #80 mesh sieve to remove less particle.The grinding rice husk that will retain through #20 mesh sieve and by #80 mesh sieve is for the manufacture of base wad.Bulk density is about 22.96lbs/ft 3(368kg/m 3).
Mixed mutually by the perlite of Jiang Shui and the different amounts described in plate composition and table 3 and rice husk, form the slurry with about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: the rice husk of newsprint paper pulp, starch, calcium carbonate, grinding, mineral wool and expanded perlite.Stir slurry about 2 minutes, at the end of stirring, in slurry, add the flocculant of about 0.1% of slurry weight.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill allows slurry water freely to discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is pressed onto a constant humidity thickness, to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.Then by shaping base wad in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 3, by the mineral wool of about 10% of plate weight, and the newsprint fiber of about 19% of plate weight, plate weight about 8% starch and the calcium carbonate of about 6% weight for the formation of plate.The amount of perlite and rice husk is described as follows.List file names with the character of the dry base wad of gained.
Table 3
With the test No. 1 in embodiment 1 with 2 reference substance compare, all three samples obviously porous more in the present embodiment, and sound absorption properties stronger.
Implement profit 4
Rice husk obtains from RiceHullSpecialties, Stuttgart, AR, is wherein through grinding from the rice husk of rice-hulling mill.First use the rice husk of #30 mesh sieve sieving grinding to remove larger particle, then with the sieving of #80 mesh sieve to remove less particle.The grinding rice husk that will retain through #30 mesh sieve and by #80 mesh sieve is for the manufacture of base wad.Bulk density is about 28.56lbs/ft 3(457kg/m 3).According to the composition in table 4, in stock tank, Jiang Shui mixes with plate composition and prepares slurry:
Table 4
Newsprint fiber Clay Grinding rice husk Starch Mineral wool Expanded perlite
% plate weight 18.8 2.7 29.4 8.2 9.7 31.2
Except the composition of table 4, add the abatvoix (or " damage plate ") of the reprocessing of 20% weight in addition.The finished product that the abatvoix of reprocessing (re-claimed) is those defectiveness, quality is low or grind.The abatvoix of reprocessing can form identical or different.
The denseness of slurry is about 3.0%.Even slurry containing table 4 composition is transported in the headbox of the slurry Commodity flow providing stable.Then, to form wet basis pad on the foraminous conveyer that the slurry flowed out from headbox is distributed to movement.First water discharged from guipure by gravity.Other water is removed by applying low vacuum pressure (4 " Hg (100mmHg)) under guipure.After pressing the base wad between two rollers, by apply under guipure relatively high vacuum pressure (7-15 " Hg (178-381mmHg) removes other water.Water residual in wet basis pad and moisture are evaporated in drying stove.
After drying, this base wad is through cutting, grinding, rolling and spraying, punching press split into abatvoix attractive in appearance, and these plates are 2 ' × 4 ' (0.61m × 1.22m) or 2 ' × 2 ' (0.61m × 0.61m).Table 5 lists the character of base wad:
Table 5
Test No. Mat thickness, inch (mm) Density, lbs/ft 3(kg/m 3) eNRC(unperf.) Gas-flow resistance, mPa.s/m 2
1 0.617(15.67) 12.98(207.92) 0.40 1.12
2 0.615(15.62) 13.00(208.24) 0.41 1.09
3 0.607(15.42) 14.69(235.31) 0.33 1.68
4 0.614(15.60) 15.60(249.89) 0.30 2.21
In addition, table 6 shows the character of finished product abatvoix:
Table 6
Embodiment 5
Rice husk obtains from RiceHullSpecialties, Stuttgart, AR, is wherein through grinding from the rice husk of rice-hulling mill.First with the rice husk of #20 mesh sieve sieving grinding to remove larger particle, subsequently with the sieving of #80 mesh sieve to remove less particle.Will through #20 mesh sieve and the grinding rice husk be retained on #80 mesh sieve for the manufacture of base wad.Bulk density is about 24.37lbs/ft 3(390kg/m 3).Substantially according to the composition of table 7, in stock tank, Jiang Shui mixes with plate composition and prepares slurry:
Table 7
Newsprint fiber Clay Grinding rice husk Starch Mineral wool Expanded perlite
% plate weight 18 3 30 8 9 32
Except the composition in table 7, add the damage plate of (with plate weighing scale) 15% in addition.
The denseness of slurry is about 3.0%.Even slurry containing table 7 composition is transported in the headbox of the slurry Commodity flow providing stable.The slurry flowed out from headbox is distributed on foraminous conveyer to form wet basis pad again.First water discharged from guipure by gravity.Other water is removed by applying low vacuum pressure (1 " Hg (25mmHg)) under guipure.After squeezing the base wad between two rollers, by apply under guipure relatively high vacuum pressure (5-9 " Hg (127-229mmHg) removes other water.Water residual in wet basis pad and moisture are evaporated in drying stove.
After drying, this base wad is through cutting, grinding, rolling and spraying, punching press split into abatvoix attractive in appearance, and these plates are 2 ' × 4 ' (0.61m × 1.22m) or 2 ' × 2 ' (0.61m × 0.61m).Table 8 lists the character of base wad:
Table 8
Test No. Mat thickness, inch (mm) Density, lbs/ft 3(kg/m 3) eNRC(unperf.)
1 0.581(14.76) 13.43(215.28) 0.36
In addition, table 9 shows the character of finished product abatvoix.
Table 9
Embodiment 6
Buckwheat shell obtains from ZafuStore, Houston, TX.Further with diameter 0.05 is housed " (1.27mm) porous sieve size Fritz mill grinding buckwheat shell.By buckwheat shell grinding until all material is through screen cloth.The buckwheat shell bulk density of grinding is about 24.5lbs/ft 3(392kg/m 3).The domain size distribution of buckwheat shell of grinding is: 21.0% is retained on 20 mesh sieves, and 47.4% is retained on 30 orders, and 21.0% is retained on 40 orders, and 5.6% is retained on 50 orders, and 2.8% to be retained on 100 orders and 2.3% through 100 orders.
Mixed mutually by the perlite of Jiang Shui and the different amounts described in plate composition and table 10 and buckwheat shell, form the slurry with about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: newsprint paper pulp, starch, calcium carbonate, grinding wheat straw shell, mineral wool and expanded perlite.Stir slurry about 2 minutes, at the end of stirring, in slurry, add the flocculant of about 0.1% weight.Slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill allows slurry water freely to discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is squeezed to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.Then by shaping base wad in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 10, by the mineral wool of about 10% of plate weight, and the newsprint fiber of about 19% of plate weight, the starch of about 8% of plate weight and the calcium carbonate of about 6% of plate weight are for the formation of plate.The amount of perlite and rice husk is described as follows.List file names with the character of the dry base wad of gained.
Table 10
As implied above, the base wad containing buckwheat shell absorbs sound more, and this shows as has higher eNRC value compared with reference substance (testing #1).
Embodiment 7
The wood chip being used as pine bedding is obtained from AmericanWoodFiberInc., Columbia, MD.Further with diameter 0.050 is housed " (1.27mm) porous sieve size Fritz barreling ground wood bits.By wood chip grinding until all materials are through screen cloth.The bulk density of grinding wood chip is about 8.9lbs/ft 3(143kg/m 3).The domain size distribution of grinding wood chip is: 5.5 are retained on 20 mesh sieves, and 37.6% is retained on 30 orders, and 24.3% is retained on 40 orders, and 13.6% is retained on 50 orders, and 12.6% is retained on 100 orders, and 6.4% passes 100 orders.
Mixed mutually by the perlite of Jiang Shui and the different amounts described in plate composition and table 11 and wood chip, form the slurry with about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: the wood chip of newsprint paper pulp, starch, calcium carbonate, grinding, mineral wool and expanded perlite.Stir slurry about 2 minutes, at the end of stirring, in slurry, add the flocculant of about 0.1% weight of slurry.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill allows slurry water freely to discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is squeezed to constant humidity thickness, to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.Shaping base wad again in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 11, by the mineral wool of about 10% of plate weight, and the newsprint fiber of about 19% of plate weight, the starch of about 8% of plate weight and the calcium carbonate of about 6% of plate weight are for the formation of plate.The amount of perlite and wood chip is described as follows.List file names with the character of the dry base wad of gained.
Table 11
As implied above, the base wad containing grinding wood chip has stronger sound absorption properties, and this shows there is higher eNRC value compared with reference substance (testing #1).
Embodiment 8
Wheat Straw obtains from GalushaFarm, Warrenville, IL.Further with diameter 0.050 is housed " (1.27mm) porous sieve size Fritz mill grinding Wheat Straw.The Wheat Straw of grinding is until most of material is through screen cloth.The Wheat Straw bulk density of grinding is about 7.7lbs/ft 3(123kg/m 3).The domain size distribution of the Wheat Straw of grinding is: 3.6% is retained on 20 mesh sieves, and 25.3% is retained on 30 orders, and 25.4% is retained on 40 orders, and 19.8% is retained on 50 orders, and 17.1% is retained on 100 orders, and 8.9% passes 100 orders.
Mixed mutually by the perlite of Jiang Shui and the different amounts described in plate composition and table 12 and Wheat Straw, form the slurry with about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: the Wheat Straw of newsprint paper pulp, starch, calcium carbonate, grinding, mineral wool and expanded perlite.Stir slurry about 2 minutes, at the end of stirring, in slurry, add the flocculant of about 0.1% of slurry weight.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill makes slurry water freely discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is squeezed to constant humidity thickness, to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.By shaping base wad again in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 12, by the mineral wool of about 10% of plate weight, also have the newsprint fiber of about 19% of plate weight, the starch of about 8% of plate weight and the calcium carbonate of about 6% of plate weight are for the formation of plate.The amount of perlite and Wheat Straw is described as follows.List file names with the character of the dry base wad of gained.
Table 12
As implied above, the base wad of Wheat Straw containing grinding has stronger sound absorption properties, and this shows as has higher eNRC value compared with reference substance (testing #1).
Embodiment 9
The sawdust as material of sweeping the floor is obtained from ZEP, Carterville, GA.The bulk density of sawdust is about 24.0lbs/ft 3(384kg/m 3).Domain size distribution is: 9.0% is retained on 20 mesh sieves, and 24.3% is retained on 30 orders, and 22.7% is retained on 40 orders, and 19.1% is retained on 50 orders, and 21.4% is retained on 100 orders, and 3.6% passes 100 orders.
Mixed mutually by the perlite of Jiang Shui and the different amounts described in plate composition and table 13 and sawdust, form the slurry with about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: newsprint paper pulp, starch, calcium carbonate, sawdust, mineral wool and expanded perlite.Slurry stir about 2 minutes, at the end of stirring, adds the flocculant of about 0.1% weight in slurry.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill makes slurry water freely discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is squeezed to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.By shaping base wad again in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 13, by the mineral wool of about 10% of plate weight, also have the newsprint fiber of about 19% of plate weight, the starch of about 8% of plate weight and the calcium carbonate of about 6% of plate weight are for the formation of plate.The amount of perlite and sawdust is described as follows.List file names with the character of the dry base wad of gained.
Table 13
As implied above, the base wad containing sawdust has stronger sound absorption properties, and this shows there is higher eNRC value compared with reference substance (testing #1).
Embodiment 10
The corn ear of grinding is obtained from KramerIndustriesInc., Piscataway, NJ.The bulk density of the corn ear of this grinding is about 18.5lbs/ft 3(296kg/m 3).The domain size distribution of the corn ear of grinding is: 0.0% is retained on 20 mesh sieves, and 0.1% is retained on 30 orders, and 1.6% is retained on 40 orders, and 94.1% is retained on 50 orders, and 4.1% is retained on 100 orders, and 0.2% passes 100 orders.
By the perlite of Jiang Shui and the different amounts described in plate composition and table 14 with grind corn ear and mix mutually, formation has the slurry of about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: newsprint paper pulp, starch, calcium carbonate, grinding corn ear, mineral wool and expanded perlite.Stir slurry about 2 minutes, at the end of stirring, in slurry, add the flocculant of about 0.1% weight.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill allows slurry water freely to discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is squeezed to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.By shaping base wad again in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 14, by the mineral wool of about 10% of plate weight, also have the newsprint fiber of about 19% of plate weight, the starch of about 8% of plate weight and the calcium carbonate of about 6% of plate weight are for the formation of plate.The amount of perlite and corn ear is described as follows.List file names with the character of the dry base wad of gained.
Table 14
As implied above, the base wad containing grinding corn ear has stronger sound absorption properties, and this shows there is higher eNRC value compared with reference substance (testing #1).
Embodiment 11
The walnut shell of grinding is obtained from KramerIndustriesInc., Piscataway, NJ.The bulk density of the walnut shell of this grinding is about 44.2lbs/ft 3(708kg/m 3).The domain size distribution of the walnut shell of grinding is: 0.0% is retained on 20 mesh sieves, and 0.0% is retained on 30 orders, and 3.9% is retained on 40 orders, and 72.5% is retained on 50 orders, and 23.2% is retained on 100 orders, and 0.3% passes 100 orders.
By the perlite of Jiang Shui and the different amounts described in plate composition and table 15 with grind walnut shell and mix mutually, formation has the slurry of about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: newsprint paper pulp, starch, calcium carbonate, grinding walnut shell, mineral wool and expanded perlite.Stir slurry about 2 minutes, at the end of stirring, in slurry, add the flocculant of about 0.1% weight.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill allows slurry water freely to discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is squeezed, to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.By shaping base wad again in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 15, by the mineral wool of about 10% of plate weight, also have the newsprint fiber of about 19% of plate weight, the starch of about 8% of plate weight and the calcium carbonate of about 6% of plate weight are for the formation of plate.The amount of perlite and walnut shell is described as follows.List file names with the character of the dry base wad of gained.
Table 15
As implied above, the base wad containing grinding walnut shell has stronger sound absorption properties, and this shows there is higher eNRC value compared with reference substance (testing #1).
Embodiment 12
Peanut shell is obtained from local grocery store.Further with diameter 0.05 is housed " (1.27mm) porous sieve size Fritz mill grinding peanut shell.Grinding peanut shell is until all material is through screen cloth.The bulk density of the peanut shell of grinding is about 15.2lbs/ft 3(243kg/m 3).The domain size distribution of the peanut shell of grinding is: 0.2% is retained on 20 mesh sieves, and 13.1% is retained on 30 orders, and 31.5% is retained on 40 orders, and 19.8% is retained on 50 orders, and 29.2% is retained on 100 orders, and 6.1% passes 100 orders.
By the perlite of Jiang Shui and the different amounts described in plate composition and table 16 with grind peanut shell and mix mutually, formation has the slurry of about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: newsprint paper pulp, starch, calcium carbonate, grinding peanut shell, mineral wool and expanded perlite.Stir slurry about 2 minutes, at the end of stirring, in slurry, add the flocculant of about 0.1% weight.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill allows slurry water freely to discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is squeezed, to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.Then by shaping base wad in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 16, by the mineral wool of about 10% of plate weight, also have the newsprint fiber of about 19% of plate weight, the starch of about 8% of plate weight and the calcium carbonate of about 6% of plate weight are for the formation of plate.The amount of perlite and peanut shell is described as follows.List file names with the character of the dry base wad of gained.
Table 16
Test Perlite Peanut shell Mat thickness Density MOR Hardness eNRC Gas-flow resistance
Numbering ％wt ％wt Inch (mm) lbs/ft 3(kg/m 3) psi lbf (unperf.) mPa·s/m 2
13 0 57 0.423(10.7) 18.0(288) 240.7 184 0.32 2.09
As implied above, the base wad containing grinding peanut shell has stronger sound absorption properties, and this shows there is higher eNRC value compared with reference substance (testing #1).
Embodiment 13
Sunflower seed shell is obtained from ArcherDeniels, Midland, ND.The bulk density of the sunflower seed shell of grinding is about 12.4lbs/ft 3(199kg/m 3).The domain size distribution of the sunflower seed shell of grinding is: 0.1% is retained on 20 mesh sieves, and 8.9% is retained on 30 orders, and 30.3% is retained on 40 orders, and 29.3% is retained on 50 orders, and 23.9% is retained on 100 orders, and 7.5% passes 100 orders.
By the perlite of Jiang Shui and the different amounts described in plate composition and table 17 with grind sunflower seed shell and mix mutually, formation has the slurry of about 4.5% denseness.Continuous stirring water, adding ingredient in the following order: the sunflower seed shell of newsprint paper pulp, starch, calcium carbonate, grinding, mineral wool and expanded perlite.Stir slurry about 2 minutes, at the end of stirring, in slurry, add the flocculant of about 0.1% weight.Then slurry is poured into and is of a size of 14 " × 14 " × 30 " in the shaping box of (0.36m × 0.36m × 0.76m).
In the bottom of shaping box, the glass fabric supported by metal grill allows slurry water freely to discharge, and retains most of solid simultaneously.By applying to shaping box the water that low-voltage vacuum (1 " Hg (25mmHg)) removes other.Then wet basis pad is squeezed, to remove other water and to consolidate base wad structure.Finally, by applying higher pressure vacuum (5-9 " Hg (127-229mmHg)), wet basis pad is dewatered further.Then by shaping base wad in baking oven or drying box in 315 DEG C (600 °F) dry 30 minutes and in 149 DEG C (300 °F) dry 3 hours to remove residual moisture.
In table 17, by the mineral wool of about 10% of plate weight, also have the newsprint fiber of about 19% of plate weight, the starch of about 8% of plate weight and the calcium carbonate of about 6% of plate weight are for the formation of plate.The amount of perlite and sunflower seed shell is described as follows.List file names with the character of the dry base wad of gained.
Table 17
As implied above, the base wad of sunflower seed shell containing grinding has stronger sound absorption properties, and this shows there is higher eNRC value compared with reference substance (testing #1).
Although the display of this manual and the detailed description of the invention comprising the plate of renewable component described as constructional materials use, but it should be appreciated by those skilled in the art, do not deviating from situation of the present invention and can carry out changing and revising, as following proposed claim in widely.

Claims (9)

1. be used as a plate for constructional materials, comprise:
Described plate is formed by water-based slurry, and described water-based slurry comprises:
The inorfil component of about 1% to about 50% weight, wherein said inorfil component is mineral wool,
The starch of about 1% to about 30% weight,
The filler of about 3% to about 80% weight,
Newsprint paper pulp,
Water, and
Renewable component, after the described water of removing, about 5% to about 60% weight of described plate is renewable component;
Wherein said plate has the ceiling class of attenuation (CAC) value at least about 25, noise reduction coefficient (NRC) value at least about 0.25 and at least about at least one item in the Sound Transmission Class (STC value) of 25, wherein said renewable component is selected from rice husk, buckwheat shell, shuck, comprise peanut and walnut shell, wheat shell, oat shell, rye is stroked, cotton seed hulls, cocoanut shell, corn bran, corn ear, sunflower seeds, rice stalk, wheat stalk, Barley straw, oat straw, rye stalk, Spanish grass (Esparto), Chinese sorghum straw, reed, bamboo, sisal hemp, India's grass, ramie, bagasse, flax, bluish dogbane, jute, hemp, abaca, sawdust, wood chip or its combination.
2. plate as claimed in claim 1, wherein said filler is selected from expanded perlite, calcium carbonate and clay.
3. plate as claimed in claim 1, it has the NRC (eNRC) of estimation at least about 0.20.
4. plate as claimed in claim 1, it has the modulus of rupture (MOR) value at least about 80psi.
5. plate as claimed in claim 1, it has the flame spread index lower than about 25.
6. plate as claimed in claim 1, wherein said renewable component comprises mesh screen through perforate about 0.312 inch (8000 μ) and the particle be retained on second mesh screen of perforate about 0.0059 inch (655 μ).
7. plate as claimed in claim 1, wherein said renewable component is the rice husk of grinding.
8. a method for the plate described in manufacturing claims 1, the method comprising the steps of:
Select described renewable component;
By described renewable component, described inorfil component and described starch and hydration also, water-based slurry is formed;
On guipure, base wad is formed by described water-based slurry;
Remove the water in described base wad; And
Base wad described in finishing.
9. method as claimed in claim 8, comprises the described renewable component of screening further.
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CN108687928A (en) * 2018-05-25 2018-10-23 柳州市林道科技有限公司 A kind of environment friendly artificial board and its manufacturing process
CN110757917A (en) * 2019-11-08 2020-02-07 中南林业科技大学 A kind of eucalyptus veneer veneer wood-based composite board and preparation method thereof
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