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CN103443219A - 用于实现隔音的涂层材料及其方法 - Google Patents

用于实现隔音的涂层材料及其方法 Download PDF

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CN103443219A
CN103443219A CN2011800695556A CN201180069555A CN103443219A CN 103443219 A CN103443219 A CN 103443219A CN 2011800695556 A CN2011800695556 A CN 2011800695556A CN 201180069555 A CN201180069555 A CN 201180069555A CN 103443219 A CN103443219 A CN 103443219A
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约翰·比罗托
老理查德·J·普契尼
小理查德·J·普契尼
凯里·R·莱恩
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Abstract

描述了一种包括底涂层和外涂层的隔音材料，以及通过施涂这样的材料使表面隔音的方法。所述底涂层包括约20-50％的橡胶乳液，约10-20％的碳酸盐填料，约3-10％的阻燃剂，约3-10％的不透明填料，和约10-64％的用于影响所述底涂层的特征的其它组分。同样地，外涂层包括约40-80％的橡胶乳液，约10-20％的碳酸盐填料，约3-10％的阻燃剂，约3-10％的不透明填料，和约0-44％的用于影响所述外涂层的特征的其它组分。施涂方法包括：施涂底涂层至约25-30mil范围内的厚度，使底涂层干燥，然后在底涂层上施涂外涂层至约7-10mil范围的厚度。

Description

用于实现隔音的涂层材料及其方法
相关申请
本发明要求2011年2月14日提交的U.S.临时申请号61/442,425的优先权，并在此将其引入作为参考。
技术领域
本发明涉及提供隔音的表面如墙或者天花板的方法以及隔音涂层材料。
背景技术
传声等级(STC)是公认的标准，并且是现在在北美最普遍使用的隔离声音的标准。STC是设立于1961年的方法，用于在125-4000Hz频率范围内评级墙壁的“降噪”能力，假定所述墙壁试图阻止的噪声在整个频谱内通常均匀。通过使用“轮廓线(contour)”计算所述等级，所述轮廓线上下移动到两个条件都满足的最高点。为了计算STC，必须从认证的实验室得到所谓的传输损耗的性能数据。一旦得到传输损耗(TL)数据，则可以计算STC。
下表1中说明了一些普遍接受的用于墙壁结构的STC等级：
表1
Figure BDA00003867648300031
在较新的家庭结构中，在木螺栓框架的每一侧上使用2张1/2″干墙(drywall)的典型内墙具有大约33的STC。当要求对这些墙的声学性能评级时，人们常常将它们描述为“薄如纸”。因此，此类墙体结构在隔音或者隐私方面提供很少。
在墙壁空腔中加入吸收隔离材料(如玻璃纤维棉絮)通常使典型墙壁的STC增加至落入36-39的范围内，这取决于螺栓和螺钉的间距。除了绝缘之外，将干墙加倍可以产生在大约41-45范围内的STC等级，只要合适地密封壁间隙和渗入口。
重要的是要注意，加倍隔板的质量并没有使STC等级加倍。将质量加倍(例如从总共两张干墙到四张)一般仅仅使STC等级增加大约5-6个点。与简单地向单片墙/地板/天花板部件增加越来越多的质量相比，通过使面板彼此分离以打破振动路径将更有效地增加传输损耗。
对于双螺栓墙，结构上使干墙面板彼此分离(通过使用弹性通道、钢螺栓、交错式螺栓墙或者双螺栓墙)可以产生高达63或更高的STC等级，以及具有良好的低频传输损耗。与STC33的基准墙相比，STC63墙将仅仅传送其的大约1/1000的声音能量，看来更安静大约88%，并将使得听不见大多数的频率。然而，这样的墙壁部件可能给整体结构价格增加显著的成本。
由于它们的高质量，混凝土和混凝土砌块墙体具有良好的TL值(对于4-8″厚度在40s和50s内的STC等级)，但是它们的重量、增加的结构复杂性和差的隔热性会限制它们作为大部分住宅墙结构中的可行的材料，除了在温带气候和飓风或者龙卷风多发区域。各种绝缘选择可以导致更高的STC等级，然而，与墙结构的其它方面相比，绝缘往往增加很少。
可以提高墙壁中的STC等级的材料包括质量加载的乙烯基材料(mass-loaded vinyl)(MLV)，标准干墙，“隔音”干墙，如QuietRockTM、SupressTM、SoundBreakTM和ComfortGuardTM，或者阻尼复合物，如Green GlueTM。然而，这些产品各自具有缺点，如成本、应用或结构的复杂性以及其它问题。本发明的材料和公开的方法解决了这些问题以及在现有技术的隔音中发现的其它问题。
发明内容
公开了一种包括单独的底涂层和分开的外涂层的隔音涂层材料，以及通过施涂该材料使表面隔音的方法。
在一个实施方式中，底涂层材料包括约20wt％至约50wt％的橡胶乳液，约10wt％至约20wt％的碳酸盐填料，约3wt％至约10wt％的阻燃剂，约3wt％至约10wt％的不透明(opacity)填料，和约10wt％至约64wt％的用于影响所述底涂层材料的特征的其它组分。
在一个实施方式中，外涂层材料包括约40wt％至约80wt％的橡胶乳液，约10wt％至约20wt％的碳酸盐填料，约3wt％至约10wt％的阻燃剂，约3wt％至约10wt％的不透明填料，和约0wt％至约44wt％的用于影响所述外涂层材料的特征的其它组分。
施涂方法的实施方式包括以下步骤：向表面上施涂底涂层材料至约25-约30mil范围内的厚度，使底涂层干燥，然后在底涂层上施涂外涂层材料或者面涂层材料至约7-约10mil范围的厚度。
在下面的附带附图的说明书中详细描述所述材料、各个涂层和施涂方法的这些和其它实施方式。
附图说明
为了便于理解寻求保护的主题的目的，在附图中示例说明其的实施方式。由这些实施方式的研究，当结合下列描述进行考虑时，将容易地理解和领会寻求保护的主题、其的结构和操作以及它的许多优点。
图1是涂覆有本发明的隔音材料实施方式的基底的横截面。
具体实施方式
尽管本发明容许有许多不同形式的实施方式，但在附图中显示并将在本文中详细描述本发明优选的实施方式，理解的是本公开将被看作是本发明原理的范例，并非旨在将本发明的广义方面限制到示例的实施方式。
本发明的隔音组合物10优选由两个涂层—底涂层12和外涂层14组成。如果适宜应用，所公开的组合物10具有提升如墙、天花板、地板等表面的STC等级的能力，以提供需要的隔音。“隔音”意指由认证的声音实验室测量的“噪音”的传输在125-4000Hz频率范围内降低，假定通常均匀的频谱。
在由日内瓦,IL的Riverbank声学实验室的独立测试中，对由两个在绝缘的钢螺栓上的5/8″石膏板组成的并适当涂有所公开的隔音组合物的墙壁测量STC为52。如上所指出，这样的表面通常具有在43-44范围内的STC。两个单独的涂层12和14的优选组合物10在以下表2(底涂层12)和表3(外涂层14)中说明：
表2
底涂层配方-优选的组合物
Figure BDA00003867648300061
表3
外涂层配方-优选的组合物
Figure BDA00003867648300071
两种配方各自优选包括约55%至约70%范围内的固体，最优选约62%的固体。如本领域的技术人员将理解的，将组合物的所有组分一起充分混合。虽然各个组分更大的重量百分比范围可以制得合适的隔音材料，但在表1中列出的独特的优选组合物当施涂于表面上时被认为提供了最大的隔音。
例如，底涂层12可以具有下列重量百分比变化，同时仍然产生合适的隔音特性，尽管不一定是最佳的：约20wt％至约50wt％的橡胶乳液，约10wt％至约20wt％的碳酸盐填料，约3wt％至约10wt％的阻燃剂，约3wt％至约10wt％的不透明填料，和约10wt％至约64wt％的用于影响所述底涂层材料的特征的其它组分。
同样，外涂层14可以具有下列重量百分比变化，同时仍然产生合适的隔音特性，尽管不一定是最佳的：约40wt％至约80wt％的橡胶乳液，约10wt％至约20wt％的碳酸盐填料，约3wt％至约10wt％的阻燃剂，约3wt％至约10wt％的不透明填料，和约0wt％至约44wt％的用于影响所述外涂层材料的特征的其它组分。
对于底涂层12，“其它组分”包括消泡剂、冻结/解冻添加剂、表面活性剂、抗微生物剂、分散剂、杀真菌剂、增粘剂、颜料分散体、稀释剂、增稠剂和pH调节剂。对于外涂层14，“其它组分”选自由消泡剂、冻结/解冻添加剂、表面活性剂、抗微生物剂、分散剂、杀真菌剂、稀释剂、增稠剂和pH调节剂组成的组。
图1举例说明用本发明涂覆的表面。为了最好的结果，在干净的干燥表面上施涂底涂层12至约25-约30mil范围内的优选厚度，并施涂外涂层或者面涂层14至约7-约10mil范围内的厚度。应当在湿的时候测试涂层的厚度，因为在干燥期间发生收缩。
优选通过具有3.17至3.19mm喷嘴的商购无空气喷雾器施涂涂层12和14，以实现高质量的表面覆盖，因为该覆盖可能直接影响材料的隔音品质。然而，在这样的喷雾器是不可得的或者不可用的情况下，可以使用辊或者刷施涂各个涂层。使用者应当勤勉地在整个表面施涂各个涂层12和14并至期望的厚度。
前述说明书和附图中列出的事项仅仅以列举的方式提供而非限定。虽然显示和描述了特定的实施方式，但是对于本领域那些技术人员来说，只要不背离申请人的贡献的更广泛方面而做出改变和改进将是显而易见的。当基于现有技术从他们合适的角度观察时，下列权利要求旨在定义寻求保护的实际范围。

Claims (18)

1.一种隔音涂层材料，其包含：
具有下列配方的底涂层材料：
约20wt％至约50wt％的橡胶乳液，
约10wt％至约20wt％的碳酸盐填料，
约3wt％至约10wt％的阻燃剂，
约3wt％至约10wt％的不透明填料，和
约10wt％至约64wt％的用于影响所述底涂层材料的特征的其它组分；
具有下列配方的外涂层材料：
约40wt％至约80wt％的橡胶乳液，
约10wt％至约20wt％的碳酸盐填料，
约3wt％至约10wt％的阻燃剂，
约3wt％至约10wt％的不透明填料，和
约0wt％至约44wt％的用于影响所述外涂层材料的特征的其它组分。
2.根据权利要求1所述的隔音涂层材料，其中用于影响所述底涂层材料的特征的其它组分选自由消泡剂、冻结/解冻添加剂、表面活性剂、抗微生物剂、分散剂、杀真菌剂、增粘剂、颜料分散体、稀释剂、增稠剂和pH调节剂等组成的组。
3.根据权利要求1所述的隔音涂层材料，其中用于影响所述外涂层材料的特征的其它组分选自由消泡剂、冻结/解冻添加剂、表面活性剂、抗微生物剂、分散剂、杀真菌剂、稀释剂、增稠剂和pH调节剂等组成的组。
4.根据权利要求1所述的隔音涂层材料，其中所述橡胶乳液是苯乙烯化丁二烯橡胶乳液。
5.根据权利要求1所述的隔音涂层材料，其中所述冻结/解冻添加剂是丙二醇。
6.根据权利要求1所述的隔音涂层材料，其中所述分散剂是三聚磷酸钾。
7.根据权利要求1所述的隔音涂层材料，其中所述碳酸盐填料是碳酸钙。
8.根据权利要求1所述的隔音涂层材料，其中所述阻燃剂是三水合铝。
9.根据权利要求1所述的隔音涂层材料，其中所述不透明填料是二氧化钛。
10.根据权利要求1所述的隔音涂层材料，其中所述稀释剂是水。
11.根据权利要求1所述的隔音涂层材料，其中所述增稠剂是丙烯酸类乳液增稠剂。
12.一种使表面隔音的方法，所述方法包括以下步骤：
向表面上施涂底涂层材料至约25-约30mil范围内的厚度，所述底涂层材料具有下列配方：
约20wt％至约50wt％的橡胶乳液，
约10wt％至约20wt％的碳酸盐填料，
约3wt％至约10wt％的阻燃剂，
约3wt％至约10wt％的不透明填料，和
约10wt％至约64wt％的用于影响所述底涂层材料的特征的其它组分；
向所述表面上施涂外涂层材料或者面涂层材料至约7-约10mil范围内的厚度，所述外涂层材料或者面涂层材料具有下列配方：
约40wt％至约80wt％的橡胶乳液，
约10wt％至约20wt％的碳酸盐填料，
约3wt％至约10wt％的阻燃剂，
约3wt％至约10wt％的不透明填料，和
约0wt％至约44wt％的用于影响所述外涂层材料的特征的其它组分。
13.根据权利要求12所述的方法，其中使用无空气喷雾器施涂所述底涂层和外涂层或者面涂层。
14.根据权利要求13所述的方法，其中所述无空气喷雾器包括在约3.17至约3.19mm范围内的喷嘴。
15.一种用于使表面隔音的底涂层材料，所述底涂层包含：
约20wt％至约50wt％的橡胶乳液，
约10wt％至约20wt％的碳酸盐填料，
约3wt％至约10wt％的阻燃剂，
约3wt％至约10wt％的不透明填料，和
约10wt％至约64wt％的用于影响所述底涂层材料的特征的其它组分。
16.根据权利要求15所述的底涂层材料，其中影响所述底涂层材料的特征的其它组分选自由消泡剂、冻结/解冻添加剂、表面活性剂、抗微生物剂、分散剂、杀真菌剂、增粘剂、颜料分散体、稀释剂、增稠剂和pH调节剂等组成的组。
17.一种用于使表面隔音的外涂层材料，所述外涂层包含：
约40wt％至约80wt％的橡胶乳液，
约10wt％至约20wt％的碳酸盐填料，
约3wt％至约10wt％的阻燃剂，
约3wt％至约10wt％的不透明填料，和
约0wt％至约44wt％的用于影响所述外涂层材料的特征的其它组分。
18.根据权利要求17所述的外涂层材料，其中影响所述外涂层材料的特征的其它组分选自由消泡剂、冻结/解冻添加剂、表面活性剂、抗微生物剂、分散剂、杀真菌剂、稀释剂、增稠剂和pH调节剂等组成的组。
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