U.S. patent application number 12/678026 was filed with the patent office on 2010-12-02 for acoustic nonwoven fabric for perforated ceiling elements.
This patent application is currently assigned to CARL FREUDENBERG KG. Invention is credited to Jochen Bechtum, Guenter Frey, Holger Schilling, Gerhard Stuppy.
Application Number | 20100304109 12/678026 |
Document ID | / |
Family ID | 40254559 |
Filed Date | 2010-12-02 |
United States Patent
Application |
20100304109 |
Kind Code |
A1 |
Schilling; Holger ; et
al. |
December 2, 2010 |
ACOUSTIC NONWOVEN FABRIC FOR PERFORATED CEILING ELEMENTS
Abstract
A ply has a base weight of not more than 45 g/m.sup.2 for use in
a ceiling element and includes a fiber blend in a proportion of not
more than 30 g/m.sup.2 a flame retardant in a proportion of not
more than 10 g/m.sup.2.
Inventors: |
Schilling; Holger;
(Heitersheim, DE) ; Bechtum; Jochen; (Weinheim,
DE) ; Stuppy; Gerhard; (Heltersberg, DE) ;
Frey; Guenter; (Schliengen, DE) |
Correspondence
Address: |
LEYDIG, VOIT AND MAYER
TWO PRUDENTIAL PLAZA, SUITE 4900, 180 NORTH STETSON AVENUE
CHICAGO
IL
60601
US
|
Assignee: |
CARL FREUDENBERG KG
Weinheim
DE
|
Family ID: |
40254559 |
Appl. No.: |
12/678026 |
Filed: |
May 9, 2008 |
PCT Filed: |
May 9, 2008 |
PCT NO: |
PCT/EP08/03759 |
371 Date: |
March 12, 2010 |
Current U.S.
Class: |
428/219 |
Current CPC
Class: |
D06M 11/71 20130101;
D04H 1/425 20130101; E04B 9/0485 20130101; D04H 1/587 20130101;
E04B 9/34 20130101; D04H 1/4218 20130101; D04H 1/4382 20130101 |
Class at
Publication: |
428/219 |
International
Class: |
D04H 13/00 20060101
D04H013/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 19, 2007 |
DE |
10 2007 044 906.4 |
Claims
1-9. (canceled)
10. A ply having a base weight of not more than 45 g/m.sup.2 for
use in a ceiling element comprising: a fiber blend in a proportion
of not more than 30 g/m.sup.2; and a flame retardant in a
proportion of not more than 10 g/m.sup.2.
11. The ply as recited in claim 10, wherein the flame retardant
includes diammonium hydrogenphosphate.
12. The ply as recited in claim 10, wherein the fiber blend
includes cellulosic fibers.
13. The ply as recited in claim 10, wherein the fiber blend
includes fibers of two different types of cellulosic pulp.
14. The ply as recited in claim 10, wherein the fiber blend
includes glass fibers in a proportion of not more than 10
g/m.sup.2.
15. The ply as recited in claim 10, further comprising an
acrylate-based binder in a proportion of less than 5 g/m.sup.2.
16. An acoustical nonwoven having a basis weight of less than 60
g/m.sup.2 for metal ceilings comprising: a ply having a base weight
of not more than 45 g/m.sup.2 and including a fiber blend in a
proportion of not more than 30 g/m.sup.2 and a flame retardant in a
proportion of not more than 10 g/m.sup.2; and an adhesive material
in a proportion of less than 15 g/m.sup.2.
17. The acoustical nonwoven as recited in claim 16, wherein the
flame retardant includes diammonium hydrogenphosphate.
18. The acoustical nonwoven as recited in claim 16, wherein the
fiber blend includes cellulosic fibers.
19. The acoustical nonwoven as recited in claim 16, wherein the
fiber blend includes fibers of two different types of cellulosic
pulp.
20. The acoustical nonwoven as recited in claim 16, wherein the
fiber blend includes glass fibers in a proportion of not more than
10 g/m.sup.2.
21. The acoustical nonwoven as recited in claim 16, wherein the ply
includes an acrylate-based binder in a proportion of less than 5
g/m.sup.2.
22. The acoustical nonwoven as recited in claim 16, further
comprising a weighted sound absorption coefficient .alpha..sub.w of
at least 0.75, the weighted sound absorption coefficient
.alpha..sub.w being obtained from measurement according to EN ISO
354 and conversion according to EN ISO 11654.
23. An assembly comprising: a ply having a base weight of not more
than 45 g/m.sup.2 and including a fiber blend in a proportion of
not more than 30 g/m.sup.2 and a flame retardant in a proportion of
not more than 10 g/m.sup.2; and an uncoated perforated metal
ceiling element, wherein the assembly exhibits in a measurement
according to DIN EN 13823 a SMOGRA value of not more than 30
m.sup.2/s.sup.2 and a TSP(600s) value of not more than 50 m.
24. An assembly comprising: an acoustical nonwoven having a basis
weight of less than 60 g/m.sup.2 for metal ceilings including a ply
having a base weight of not more than 45 g/m.sup.2 and including a
fiber blend in a proportion of not more than 30 g/m.sup.2 and a
flame retardant in a proportion of not more than 10 g/m.sup.2 and
an adhesive material in a proportion of less than 15 g/m.sup.2; and
an uncoated perforated metal ceiling element, wherein the assembly
exhibits in a measurement according to DIN EN 13823 a SMOGRA value
of not more than 30 m.sup.2/s.sup.2 and a TSP(600s) value of not
more than 50 m.
Description
[0001] This application is a U.S. National Phase Application under
35 U.S.C. .sctn.371 of International Application No.
PCT/EP2008/003759, filed on May 9, 2008, which claims benefit to
German Application No. DE 10 2007 044 906.4, filed Sep. 19, 2007.
The International Application was published in German on Apr. 2,
2009 as WO 2009/039900 under PCT Article 21 (2).
[0002] The invention relates to a ply for producing an acoustical
nonwoven.
BACKGROUND
[0003] Acoustical nonwovens and plies of the kind mentioned at the
beginning are already known from the prior art. These are
frequently used in perforated, viz., holed or slotted, metal or
wood ceiling elements.
[0004] With regard to their reaction to fire behavior, such
acoustical nonwovens and ceiling elements used to be assessed in
accordance with German Standard Specification DEN 4102-1 by means
of the "Brandschacht" test furnace. The acoustical nonwoven would
be tested on its own and in the assembly with the ceiling element.
The market required that the assembly of ceiling element and
acoustical nonwoven achieve a classification in fire class "A2"
("noncombustible"). The acoustical nonwoven as such was required to
achieve fire class "B1" (="low flammable").
[0005] Since July 2007, a revised, EU-wide regulation with regard
to certification and classification of suspended ceilings is in
force, viz., a CE marking regime. The regulation requires ceiling
elements to meet demands which are laid down in DIN EN 13964, which
cites DIN EN 13501-1 for the classification of the reaction to fire
behavior.
[0006] The reaction to fire behavior is no longer tested in
accordance with DIN 4102-1 ("Brandschacht"), but in accordance with
DIN EN 13823. This standard describes a single burning item (SBI)
test on a complete ceiling element construction and defines the
parameters which are classification-relevant according to DIN EN
13501-1. In contradistinction to the previous test for reaction to
fire behavior under DIN 4102-1, the testing as per DIN EN 13823
focuses increasingly on the evaluation of smoke release in the
event of a fire. DIN 13501-1 applies tougher criteria to the
assessment of smoke release than hitherto.
[0007] Prior art acoustical nonwovens are prone to a relatively
severe production of smoke and thereby make it impossible for
ceiling elements to be classified as "noncombustible"
(classification "A2/s1/d0") as per the revised requirements of DIN
13501-1. This classification is stipulated particularly for
buildings, and parts of buildings, having heightened safety
requirements, for example public buildings, escape routes, etc.
[0008] In addition, the acoustical nonwoven shall have a high
acoustical efficacy, viz., a weighted sound absorption coefficient
.alpha..sub.w of at least 0.75, the weighted sound absorption
coefficient .alpha..sub.w being obtained from measurement in
accordance with EN ISO 354 and conversion in accordance with EN ISO
11654.
[0009] Further desiderata simplicity of processing, more
particularly space-saving handling or automated incorporation in
ceiling elements. Finally, the acoustical nonwoven must have no
adverse effects on hygiene, health and environmental aspects.
[0010] Accordingly, there is an appreciable market need for
efficiently processible acoustical nonwovens which assembled with
ceiling elements meet the "A2/s1/d0" classification as per DIN EN
13501-1.
SUMMARY OF THE INVENTION
[0011] An aspect of the present invention is to provide an
acoustical nonwoven which after trouble-free processing gives very
little smoke production in the event of a fire.
[0012] A sheetlike ply having a basis weight of not more than 45
g/m.sup.2 comprises a fiber blend in a proportion of not more than
30 g/m.sup.2 and a flame retardant in a proportion of not more than
10 g/m.sup.2.
[0013] The inventors recognized that it is specifically the
combination of an astute choice of the overall basis weight and of
a proportionate reduction in flame retardant which brings about an
appreciable reduction in smoke production. The ply of the present
invention is particularly useful, once an adhesive material has
been provided thereon, for arrangement in a metal ceiling element.
As a result, the problem mentioned at the beginning is solved.
[0014] The impregnating mixture could include diammonium
hydrogenphosphate as a flame retardant because it is both halogen-
and heavy metal-free and hence is environmentally friendly.
However, it is also conceivable to use other
nitrogen-phosphorus-based flame retardants, for example ammonium
polyphosphates or nitrogenous phosphonic acid salts.
[0015] The fiber blend could include fibrous or fibrillated
cellulosic components. These components serve to adjust the
acoustical efficacy of the ply. It is conceivable against this
background for the fiber blend to comprise two different types of
cellulosic pulp which are adjusted to each other with regard to
fineness. However, it is also conceivable to use finely ground
synthetic pulps, produced from viscose, polyolefin or aramid fibers
for example.
[0016] fiber blend could further include glass fibers in a
proportion of not more than 10 g/m.sup.2. This proportion of glass
fibers endows the ply with high structural stability and low
thermal shrinkage. This suitabilizes the ply for automated
incorporation in ceiling elements. However, it is also conceivable
to use other inorganic fibers, for example fibers of basalt or
alumina. Lastly, polyester fibers could also be used.
[0017] The fiber blend could be prebonded with an acrylate-based
binder at a proportion of less than 5 g/m.sup.2. Prebonding endows
the ply with sufficient stability for homogeneous incorporation of
an impregnating mixture. It is conceivable against this background
for prebonding to be effected by means of a low-formaldehyde
acrylate binder. This satisfies heightened requirements in respect
of the formaldehyde content of the ply as per DIN EN 13964
(formaldehyde class "E1"). Also conceivable is prebonding by means
of a mono- or bicomponent binder fiber, for example with an undrawn
polyester fiber or a PET/PBT or PET/copolyester bicomponent binder
fiber.
[0018] An acoustical nonwoven for metal ceilings having a basis
weight of less than 60 g/m.sup.2 could include a ply of the herein
described kind and an adhesive material in a proportion of less
than 15 g/m.sup.2. The adhesive material makes it possible to fix
the acoustical nonwoven by moderate heating in a metal ceiling
element without damaging the constituents of the ceiling element
such as paintwork, for example, in the process. It is conceivable
against this background for the adhesive material to consist of a
thermoplastic, substantially amorphous polyester, copolyester or
copolyamide having a melting point below 100.degree. C.
[0019] The acoustical nonwoven could have a weighted sound
absorption coefficient .alpha..sub.w of at least 0.75, the weighted
sound absorption coefficient .alpha..sub.w being obtained from
measurement in accordance with EN ISO 354 and conversion in
accordance with EN ISO 11654. Such an acoustical nonwoven is a
particularly good absorber of sound.
[0020] An assembly comprising a ply or an acoustical nonwoven of
the herein described kind and also an uncoated perforated metal
ceiling element could in a measurement in accordance with DIN EN
13823 exhibit a SMOGRA value of not more than 30 m.sup.2/s.sup.2
and also a TSP(600s) value of not more than 50 m.sup.2. Such an
assembly is particularly useful for fire protection as well as for
sound protection.
[0021] There are now various ways to implement and develop the
teaching of the present invention in an advantageous manner.
Reference for this is made to the dependent claims and also to the
following elucidation of the invention by means of the drawing.
BRIEF DESCRIPTION OF THE DRAWING
[0022] In the drawing,
[0023] The single FIGURE shows a diagram which compares the DIN EN
13823 smoke production of a ceiling element construction comprising
an acoustical nonwoven of the prior art with the smoke production
of an analogous ceiling element construction comprising an
acoustical nonwoven of the present invention.
DETAILED DESCRIPTION
[0024] The single FIGURE shows a diagram in which a ceiling element
construction comprising a specimen of an acoustical nonwoven of the
prior art is compared with a ceiling element construction
comprising a specimen of an acoustical nonwoven of the present
invention. The following observations may be made in this
regard:
[0025] The curves relating to the prior art specimen are
characterized by the interrupted lines and the symbol of a square.
The curves relating to the specimen according to the invention are
characterized by the solid lines and the symbol of a circle.
[0026] The SPR.sub.av curves and the individual SPR.sub.av(t)
values ("Smoke Production Rate", left-hand y-axis, in [m.sup.2/s])
represent the current smoke production of the specimens at time t
of the measurement (or within a differential time interval [t,
t-3s]). An SPR.sub.av value is the ratio of a smoke gas volume
stream in [m.sup.3/s] to the length in [m] of the optical path
through the tube of a photometric measuring device, resulting in
the unit [m.sup.2/s].
[0027] The TSP curves and the individual TSP(t) values ("Total
Smoke Production", right-hand y-axis, in [m.sup.2]) represent the
total smoke production of the specimens up to the time t of the
measurement. A TSP(t) value corresponds to the sum total of the
individual SPR.sub.av(t) values in the time interval from the start
of the measurement to the time t, and corresponds to the associated
area under the SPR curve. A TSP value represents the product of a
sum total of SPR.sub.av values in [m.sup.2/s] and the asssociated
time interval in [s], resulting in the unit [m.sup.2].
[0028] The SPR.sub.av and TSP values of a specimen, measured in the
time window from 300 s to 900 s within the overall test length
which includes a period before and after the time window, are used
for assessment. Therefore, the time axis is scaled from 300 s to
900 s. The zero point of the actual measurement is thus at 300 s in
relation to the overall length of the test.
[0029] The TSP(600s) values ("Total Smoke Production", in
[m.sup.2]) represent the total smoke production of the specimens in
the first 600 s of measurement. In accordance with the above remark
concerning the scaling of the time axis, they correspond to the
symbol-identified points on the TSP curves at the time t=900 s in
relation to the overall length of the test.
[0030] The SMOGRA values ("SMOke GRowth RAte index", in
[m.sup.2/s.sup.2]) represent the maxima of the ratios of the
SPR.sub.av(t) values of the specimens to the associated times t of
the measurement. They characterize to some extent the gradients of
the SPR.sub.av curves at the start of the measurement ("slope
triangles"). The SMOGRA value is the ratio of an SPR.sub.av(t)
value in [m.sup.2/s] to the associated time t in [s], and hence has
the unit of [m.sup.2/s.sup.2].
[0031] According to DIN EN 13823, to determine the SMOGRA value, a
ratio of an SPR.sub.av(t) value to the associated time t of the
measurement shall be taken to be 0 by definition when the following
criteria are met:
[0032] (a) the SPR.sub.av(t) value is less than or equal to 0.1
m.sup.2/s, or
[0033] (b) the associated TSP(t) value is less than or equal to 6
m.sup.2.
[0034] This means: provided the SPR.sub.av curve does not go beyond
0.1 m.sup.2/s, or if it temporarily does, and the associated TSP(t)
values in this time interval are not above 6 m.sup.2, all the
ratios of SPR.sub.av(t) values to the associated times t of the
measurement shall be deemed to be 0 and hence the SMOGRA value
should also be deemed to be 0 by definition.
[0035] However, for low-smoke specimens to be sensibly or
comparatively assessed, the SMOGRA values were determined while
disregarding the criterion (a).
[0036] To be able to assess exclusively the influence of the
specimens of acoustical nonwoven on smoke production, it was
generally constructions of ceiling elements formed from perforated
sheets of steel without coating or other smoke-relevant
constituents which were measured in accordance with DIN EN 13823.
This is intended to eliminate disruptive influences due to other
constituents of the ceiling element, such as a paint layer for
example.
[0037] In relation to smoke behavior, DIN EN 13501-1 stipulates
that it is the SMOGRA value and the TSP(600s) value which are
crucial as parameters for determining a "smoke class" (s1, s2 or
s3). To achieve the "noncombustible" classification "A2/s1/d0"
mentioned at the beginning, which includes the "smoke class" s1 and
hence imposes the highest requirements on smoke behavior, the
following limits for the abovementioned smoke-relevant parameters
shall be observed: SMOGRA value less than or equal to 30
m.sup.2/s.sup.2 and TSP(600s) value less than or equal to 50
m.sup.2.
[0038] Measurements of the herein described type of ceiling element
constructions demonstrate that a specimen of the acoustical
nonwoven representing the prior art gives a SMOGRA value of about
30 m.sup.2/s.sup.2 and a TSP(600s) value of about 40 m.sup.2. This
is shown by the diagram of the single FIGURE.
[0039] By contrast, a specimen of the acoustical nonwoven
representing the invention only gives a SMOGRA value of about 15
m.sup.2/s.sup.2 and a TSP(600s) value of about 30 m.sup.2, i.e., an
approximately 50% reduced SMOGRA value and an approximately 25%
reduced TSP(600s) value.
[0040] Reference measurements on similar ceiling element
constructions without acoustical nonwoven but with a coating show
that commercially commonplace coatings make an, to a first
approximation, additive contribution to the SMOGRA value of at best
about 10 m.sup.2/s.sup.2, typically about 15-20 m.sup.2/s.sup.2,
and a contribution to the TSP(600s) value of at best about 15
m.sup.2, typically about 20-30 m.sup.2.
[0041] Hence commercially available ceiling element constructions
with coating and an acoustical nonwoven as per the prior art give
SMOGRA values of at best about 40 m.sup.2/s.sup.2 and TSP(600s)
values of at best about 55 m.sup.2/s.sup.2. These high values
prevent a "noncombustible" classification "A2/s1/d0" under DIN EN
13501-1.
[0042] By contrast, ceiling element constructions with an
acoustical nonwoven of the present invention and with optimum
execution of the coating give SMOGRA values of only about 25
m.sup.2/s.sup.2 and TSP(600s) values of only about 45
m.sup.2/s.sup.2. These values permit a "noncombustible"
classification "A2/s1/d0" under DIN EN 13501-1.
[0043] Example representing the prior art:
[0044] An acoustical nonwoven representing the prior art consists
of a ply and an adhesive material. The basis weight is altogether
63 g/m.sup.2. Of this, the ply accounts for 48 g/m.sup.2 and the
adhesive material accounts for 15 g/m.sup.2.
[0045] The ply includes a fiber blend composed of fibers of
cellulosic pulp and fibers of glass. The fiber blend contributes
altogether 25 g/m.sup.2 to the basis weight of the ply.
[0046] The ply further includes fiber prebonding of acrylate binder
having a basis weight contribution of 4 g/m.sup.2.
[0047] The ply additionally includes an impregnating mixture
comprising a flame retardant which accounts for a basis weight
contribution of 14.5 g/m.sup.2. The impregnating mixture further
comprises colorant grade carbon black and also an ethyl vinyl
alcohol binder which together make a basis weight contribution of
4.5 g/m.sup.2.
[0048] The adhesive material consists of
epsilon-polycaprolactone.
[0049] Embodiment representing the invention:
[0050] An acoustical nonwoven representing the invention consists
of a ply and an adhesive material. The basis weight is altogether
54 g/m.sup.2. Of this, the ply accounts for 42 g/m.sup.2 and the
adhesive material accounts for 12 g/m.sup.2.
[0051] The ply includes a fiber blend composed of fibers of two
types of cellulosic pulp and fibers of glass. The fiber blend
contributes altogether 26 g/m.sup.2 to the basis weight of the ply.
The cellulosic pulp fibers contribute 20 g/m.sup.2 to the basis
weight of the ply, the glass fibers 6 g/m.sup.2.
[0052] The ply further includes fiber prebonding of acrylate binder
having a basis weight contribution of 4 g/m.sup.2.
[0053] The ply additionally includes an impregnating mixture
comprising a flame retardant which accounts for a basis weight
contribution of 7.5 g/m.sup.2. The impregnating mixture further
comprises colorant grade carbon black and also an ethyl vinyl
alcohol binder which together make a basis weight contribution of
4.5 g/m.sup.2.
[0054] The adhesive material selected was
epsilon-polycaprolactone.
[0055] With regard to further advantageous implementations and
developments of the teaching of the present invention, reference is
made to the general part of the description and to the claims.
[0056] It may finally be particularly emphasized that the
previously purely arbitrarily selected embodiment merely serves to
discuss the teaching of the present invention, but does not
restrict it to this embodiment.
* * * * *