CN101778703A - 垫片饰面石膏板和其制备方法 - Google Patents
垫片饰面石膏板和其制备方法 Download PDFInfo
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Abstract
本发明提供垫片饰面石膏板和其制备方法,所述石膏板具有施加在饰面垫片内表面上并且自垫片内表面部分地延伸至所述垫片中的颗粒物质。所述颗粒物质优选为可水合粉末(例如半水合硫酸钙),其可最小化并且优选地防止石膏浆液在石膏板形成期间透胶。
Description
相关申请案交叉参考
本专利申请案主张2007年7月23日申请的美国临时专利申请案第60/951,400号和2008年7月18日申请的美国专利申请案第12/176,200号的权益,所述专利是以引用方式并入本文中。
技术领域
本发明涉及石膏板和具体来说垫片饰面石膏板,以及其制备方法。
背景技术
具有主要外表面上经覆面材料或粗织品强化的石膏基芯材的壁板为业内所熟知。这些石膏板常用于形成内壁或外壁、电梯井、楼梯井、天花板、和屋顶板,此处仅提出了几个实例。在某些情形下,将纸饰面板与石膏基芯材一起使用。在其它情形下,使用纤维垫片作为覆面材料,例如非织玻璃纤维垫片。具体来说,经常使用玻璃垫片饰面石膏板作为外保温整饰系统(EIFS系统)以及其它应用的一部分。
使用所述纤维垫片制造石膏板可能较难,因为在水性石膏浆液仍呈液态时,浆液易于通过纤维垫片中的孔发生渗漏或透胶。当在进入板成型封头前先将浆液沉积至纤维垫片上时,此透胶问题尤其显著。浆液透胶可导致在纤维垫片外表面上出现不期望的石膏以及石膏在辊或其它机器设备上积累。石膏在辊上积累需要定期关闭机器以进行清除,因为辊上的石膏可转移至纤维垫片外表面上和/或导致纤维网片在进入成型封头时网片上留有痕迹的问题。垫片外表面上的石膏可降低整饰涂层的粘着性并向消费者呈现令人不愉快的外观。
人们已进行了各种尝试来防止或最小化石膏浆液透胶。例如,有人建议通过使用粘度控制剂来改变浆液粘度以使浆液通过网片渗漏的能力降至最低。也有人建议向网片外表面提供树脂和其它涂层以封阻纤维网片中的孔从而限制透胶。其它努力集中在改变纤维网片自身的特征上。例如,有人建议结合特定挤出比使用由具有介于10与15微米之间的特定直径的玻璃纤维组成的纤维网片,所述网片具有大于1.85lb/100ft2的特定基重。其它网片修改方案建议使用由短纤维与微纤维(平均直径为1微米或更小)的掺合物组成的纤维垫片来封阻浆液的透胶。其它建议包括提高纤维垫片的厚度或改变垫片纤维的表面特征以降低其可湿性。例如,参见美国专利第4,186,236号、第4,388,366号、第4,637,951号、第4,681,798号、第4,810,569号和第6,001,496号,以及美国专利申请公开案第2007/0148430 A1号和欧洲专利申请案第EP 1 801 278 A1号。然而,所提出的这些解决方案可能需要额外的处理步骤,纳入其它材料,将浆液特征改变至不期望范围,和/或指定使用定制或不标准纤维垫片。在多种情形下,上文所建议用来限制透胶的技术都因各种成本、技术和其它原因而不合意。
因此,业内需要提供石膏板和其制造方法,在所述石膏板制造期间石膏浆液的透胶程度最低或优选地不发生透胶。
发明内容
在一方面中,本发明提供形成石膏板的方法,所述方法包含提供具有内表面的多孔基材;将颗粒物质施加至多孔基材的内表面上,从而形成粉末饰面基材;将水性石膏浆液沉积至粉末饰面基材内表面上的至少一部分所施加颗粒物质上,从而形成浆液涂布基材,其中颗粒物质填充多孔基材中的一部分孔以阻碍石膏浆液通过其渗透;并且使浆液涂布基材形成石膏板。
在另一方面中,本发明提供垫片饰面石膏板,其包含石膏基芯材、具有面向石膏基芯材至少一侧的内表面的纤维垫片、和位于纤维垫片内表面上并且自纤维垫片内表面部分延伸至其中的水合颗粒材料,其中水合颗粒材料是独立于石膏基芯材来供应。
本发明涉及垫片饰面石膏板,其包含石膏基芯材、具有面向石膏基芯材至少一侧的内表面的纤维垫片、和位于纤维垫片内表面上并且自纤维垫片内表面部分延伸至其中的水合颗粒材料,其中水合颗粒材料的组成与石膏基芯材的组成不同。
根据本文所提供关于本发明的说明,可了解本发明的这些和其它优点以及其它发明特征。
附图说明
图1是使石膏浆液的透胶最小化的实例性板转换工艺的示意图;
图2是用于图1板转换工艺中的干颗粒施加系统的示意图;
图3是将干颗粒施加至部分网片上的浆液沉积站的透视图;
图4是实例性板形成工艺的流程图;
图5是市售玻璃纤维垫片的SEM照片,其以50X放大倍数显示在将干颗粒施加至垫片内表面之前所述垫片的横截面;
图6是俯视图的SEM照片,其以100X放大倍数显示在将干颗粒施加至市售玻璃纤维垫片内表面之前所述垫片的内表面;
图7是图5市售玻璃纤维垫片的SEM照片,其以50X放大倍数显示在将干颗粒施加至垫片内表面之后的横截面;
图8是俯视图的SEM照片,其以100X放大倍数显示在将干颗粒施加至图6市售玻璃纤维垫片内表面之后垫片的内表面;并且
图9是垫片饰面石膏板的照片,所制备板中饰面垫片的内面施加有或未施加干颗粒。
具体实施方式
本发明提供垫片饰面石膏板和其制备方法,所述方法可最小化并且优选地防止垫片中的浆液出现透胶。进一步来说,所述方法包括将诸如干粉末等干颗粒物质施加至用于形成石膏板饰面垫片(例如纤维垫片)的多孔基材内表面上。本文所用“内表面”是指多孔基材中沉积有石膏浆液并且另外接触整饰石膏板中的石膏芯材的表面。优选地,在即将使石膏浆液沉积至基材或垫片上之前施加干颗粒物质。干颗粒物质的一种形式是可水合粉末或颗粒,其渗透至多孔基材的孔或间隙中并且通过石膏浆液中的过量水进行水合。换句话说,颗粒物质包含可水合粉末,并且水性石膏浆液中的水实质上水合可水合粉末。水合粉末随后在垫片的孔或其它间隙中固化,并通过封阻或阻碍液体浆液穿过垫片的可能途径来阻碍浆液通过所述孔或其它间隙来渗透。
所形成垫片饰面石膏板包括石膏基芯材,其在其至少一侧上具有纤维垫片饰面。石膏基芯材可任选地包含第二纤维垫片,其中石膏基芯材配置在第一纤维垫片与第二纤维垫片之间。第二纤维垫片与第一纤维垫片可相同或不同。纤维垫片包括颗粒物质在垫片的内表面上于石膏芯材与垫片之间界面处的粉末沉积物。优选地,颗粒物质自内表面部分延伸至纤维垫片中,从而使得纤维垫片的外表面基本不含所述颗粒(例如在裸眼可见的外表面上无颗粒)。尽管粉末或颗粒可包括与石膏芯材中所发现者类似的组份,但颗粒物质是独立于石膏芯材施加至纤维垫片上并且不是自石膏芯材来供应或转移。换句话说,颗粒物质的组成与石膏浆液不同。也就是说,垫片饰面石膏板的典型构造包括通过渗透纤维垫片的芯材材料以一定程度将所述垫片机械锁闭至石膏芯材上。在本文中,颗粒物质与芯材材料相分离,例如优选地在施加芯材浆液之前将颗粒物质预施加至纤维垫片上。然而应了解,在某些情形下可在板形成后掺合颗粒物质与所渗透芯材材料。如果干颗粒物质包括优选可水合材料,则粉末在水合或固化时可通过形成与石膏芯材的额外机械锁闭来另外帮助将纤维垫片固定在石膏芯材上,其锁闭方式类似于纤维垫片通过渗透至石膏芯材中来锁闭至芯材的方式。
如上所述,干颗粒物质优选地包含诸如可水合无机粉末等可水合粉末,或基本由其组成或由其组成。例如,干颗粒物质可包括以下物质(包含以下物质、基本由其组成、或由其组成):石膏基颗粒(例如水溶性无水硫酸钙、α-半水合硫酸钙、β-半水合硫酸钙、天然、合成或化学修饰半水合硫酸钙、二水合硫酸钙(“石膏”、“固化石膏”或“水合石膏”)、和其混合物)、膨胀性粘土(例如蒙脱石(montmorillonite)、坡缕石(attapulgite)和诸如此类)、碳酸钙、其混合物、和诸如此类。干颗粒物质的特别优选形式包括以下物质(包含以下物质、基本由其组成、或由其组成)呈粉末形式的半水合硫酸钙(灰泥),使用石膏浆液中的过量水使其水合(例如部分地、实质上、或完全地)成二水合硫酸钙(石膏)。优选地,颗粒材料的平均尺寸为约10至约50微米(最优选地为约10至约40微米、约10至约25微米、或约10至约15微米),并且是以约10至约40lb/1000ft2的比率施加至纤维网片内侧。例如,可以约10lb/1000ft2或更高、约15lb/1000ft2或更高、约20lb/1000ft2或更高、或约25lb/1000ft2或更高的比率来施加颗粒材料。通常,颗粒物质可以约40lb/1000ft2或更低、例如约35lb/1000ft2或更低、或甚至约30lb/1000ft2或更低的比率来施加。根据进一步说明,颗粒材料可以约10至约20lb/1000ft2、约10至约30lb/1000ft2、约20至约30lb/1000ft2、约20至约40lb/1000ft2、或约30至约40lb/1000ft2的比率来施加。在实施例的另一方面中,颗粒材料可以约10lb/1000ft2、约15lb/1000ft2、或约20lb/1000ft2的比率来施加。然而,根据具体纤维垫片、浆液粘度和其它因素,也可使用其它施加比率和粉末尺寸。
在另一方面中,干颗粒物质可另外包括其它填料或添加剂以向石膏板提供其它功能性强化。例如,干颗粒材料可包括一定量的干聚合物或树脂,其可在垫片内表面上提供防潮障壁。所述添加剂可包括可再分散聚合物或树脂粉末,例如丙烯酸类粉末、聚乙烯醇、乙酸乙烯酯、聚乙二醇、聚氯乙烯、所述树脂的共聚物(即PVA/PVC共聚物)、其混合物、和诸如此类。进一步来说,干颗粒物质可包括约1重量%至约30重量%的所述可再分散聚合物或树脂。在施加至垫片后,这些聚合物或树脂可立即使用水性石膏浆液中的水进行再分散,从而一般在垫片的内表面上形成树脂沉积物或其它障壁和/或自垫片的内表面部分延伸至垫片中。预期任何树脂或聚合物都不会通过垫片延伸至垫片的外表面。已发现,所述树脂一般可改良EIFS或其它直接施加整饰系统材料对石膏板的抹光性,此使得最终用户可对板的外表面施加更均匀的表面整饰。尽管不欲受理论限制,但据信再分散树脂颗粒可帮助表面整饰保持湿度,从而使得其可在板上更均匀地铺展,而不出现石膏芯材在施加期间自外部整饰吸收水分的情形。
纤维垫片可包含任何适宜类型的聚合物或矿物纤维,或其组合。适宜纤维的非限制性实例包括玻璃纤维、聚酰胺纤维、聚芳酰胺纤维、聚丙烯纤维、聚酯纤维(例如聚对苯二甲酸乙二酯(PET))、聚乙烯醇(PVOH)、聚乙酸乙烯酯(PVAc)、纤维质纤维(例如棉花、人造丝等)、和诸如此类、以及其组合。纤维垫片可为织造或非织造;然而,优选者为非织垫片。非织垫片包含通过粘合剂结合在一起的纤维。粘合剂可为通常用于垫片工业中的任一粘合剂。适宜粘合剂包括(但不限于)脲甲醛、三聚氰胺甲醛、硬脂化三聚氰胺甲醛、聚酯、丙烯酸类、聚乙酸乙烯酯、经聚乙酸乙烯酯或丙烯酸改性或掺合的脲甲醛或三聚氰胺甲醛、苯乙烯丙烯酸聚合物、和诸如此类、以及其组合。适宜纤维垫片包括用作水泥性物件的覆面材料的市售垫片。
在一实施例中,多孔纤维垫片是自平均直径为约5至约20微米、例如约10至约20微米、或甚至约11至约16微米的短切玻璃纤维或连续玻璃纤维形成的玻璃纤维垫片,其基重为约20lb/1000ft2或更大。多孔纤维垫片也可包含直径为(例如)约2-8微米或4-6微米的微纤维。纤维垫片也可包含具有不同直径的纤维。例如,玻璃纤维垫片可包含约70%至约90%具有约10至约20微米直径的玻璃纤维,和约10%至约30%具有约2至约15微米较小直径的玻璃纤维,所述垫片的基重为约20lb/1000ft2或更大。在另一实施例中,纤维垫片可包含约70%至约90%具有约14微米或更大、或15微米或更大(例如约14至约16微米)直径的玻璃纤维,和约10%至约30%具有约4至约6微米直径的玻璃微纤维,所述垫片的基重为约20lb/1000ft2或更大。纤维可具有任何适宜长度。例如,微纤维可具有不同长度。其它纤维的长度通常为约1英寸或更小(例如约3/8英寸至1英寸,或约1/2英寸至约3/4英寸)。为了进一步说明,一个所述玻璃纤维垫片是由约80%具有约16微米直径(约1/2英寸长度)的纤维和约20%具有约11微米直径(约1/4英寸长度)的纤维来形成,所述垫片的基重为约22lb/1000ft2。另一适宜玻璃纤维垫片是由约90%具有约16微米直径(3/4英寸长度)的纤维和约10%具有约4至约6微米直径(不同长度)的纤维来形成,所述垫片的基重为约22lb/1000ft2。
优选地使用可将玻璃纤维粘合成非织网片的热固性树脂来形成垫片。进一步来说,热固性树脂可为丙烯酸类树脂,例如三聚氰胺甲醛与其它丙烯酸树脂的掺合物。垫片可包含任何适宜量的粘合剂,例如约5-40重量%、约10-30重量%、或约20-30重量%。上述纤维垫片只是可用于本文中的适宜垫片的一个实例。应了解,也可使用本文所述方法来利用具有不同组成的其它多孔垫片和纤维垫片。
可使用可使干颗粒或固体颗粒分散至移动网片上的任何已知施加方法将干颗粒物质沉积或施加至网片(即多孔基材或纤维垫片表面)上。参照图1至4,所述图图示说明施加系统(10)的一个实例,其中使干颗粒物质(12)自施加器、给料机或储料漏斗(13)沉积至串联在石膏板转换线中网片展开站(18)与浆液混合罐(20)之间的纤维垫片(16)的内表面(14)上。以此方式,将干颗粒物质(12)施加至网片上,随后立即使浆液沉积(22)至网片(16)上,然后进入板成型封头(24)。于是干颗粒物质可有效地最小化并优选地防止浆液在浆液沉积位点(22)与板成型封头(24)之间出现透胶。
进一步来说,施加器(13)可包括工作台、托盘、储料漏斗、给料机、或其它容器(30),其上容纳有过量颗粒(12)。包括振动式和旋转式给料机在内的适宜给料机可自市场购得。施加器(13)的配置可通过托盘(30)将颗粒(12)施加至网片上,所述托盘倾斜预定角度以容许一定量颗粒(12)在纤维网片(16)经过托盘(30)下方时筛落或自由下落至纤维网片(16)的内表面(14)上。例如,如图2所示,工作台(30)倾斜并振动或振荡以容许颗粒物质自工作台的前缘(32)下落或脱落。前缘(32)可包括计量装置(34)(例如隆起转轮)以提供受控程度更高的颗粒物质施加。应了解,可采用其它施加方法来将颗粒物质分散至网片上,例如挤出模、辊施加器、幕施加器、和类似方法。上述说明只是如何将干颗粒施加至网片上的一个实例。或者,可将干颗粒物质预施加至已由垫片厂商形成的网片上,从而使得可仅将网片展开并用于已存在的成形设备中即可。在此情形下,预期可将过量颗粒施加至网片上以补偿在装运和/或展开期间粉末的任何损失。
对于上述优选颗粒物质,颗粒在施加后由于是松散沉积至网片的内表面上,所以一般不粘着、或仅轻度粘着至网片。若需要,可在纤维垫片内表面上使用整平板、医生刀片、辊隙、刷子、辊、和诸如此类将颗粒(12)整平或铺展。进一步来说,在将颗粒施加至网片后立即使用刷子(40)铺展颗粒,且随后在浆液罐(20)处施加浆液。
可将颗粒物质仅施加至纤维网片的一部分或可将其施加至纤维网片的整个宽度上。已发现,在进入成型封头之前先将浆液沉积至网片上时,石膏浆液的透胶最为显著。因此,至少应在进入成型封头之前将干颗粒物质施加至纤维垫片(16)中接触石膏浆液的一部分(50)内表面(14)上,如图3中以示意性方式所示。以此方式,使干颗粒材料的定位可阻碍或封阻浆液通过网片孔渗透,在所述孔处最需要所述颗粒物质。或者,如果干颗粒物质包括其它添加剂以向网片提供其它功能性特性,那么优选地可将干粉末施加至垫片(16)的整个或实质上整个宽度上。当然,这些只是实例并且可根据特定应用的需要将干颗粒物质施加至网片的任一宽度上。
参照图4,其图示说明形成垫片饰面石膏板(102)的实例性方法(100),其具有最低、并且优选地不具有石膏浆液透胶。方法(100)包含首先提供多孔基材(104),例如非织玻璃纤维垫片。制备颗粒物质(106),其优选地包括无机可水合粉末(108)和任选可再分散有机树脂(110)。然后将颗粒物质(106)施加(112)至多孔基材(104)的内表面上。任选地,可在基材内表面上将所施加颗粒物质(106)整平(114)以获得更均匀的颗粒物质施加。然后将一定量的石膏浆液沉积(116)至多孔基材内表面上的至少一部分颗粒物质上。然后使经浆液沉积的多孔基材形成(118)石膏板。
石膏芯材除石膏基材料(例如水溶性无水硫酸钙、α-半水合硫酸钙、β-半水合硫酸钙、天然、合成或化学修饰半水合硫酸钙、二水合硫酸钙(“石膏”、“固化石膏”或“水合石膏”)、和其混合物)以外可包含多种添加剂中的任一种。添加剂可为常用于制造石膏板或水泥板的任一添加剂。所述添加剂包括(但不限于)结构性添加剂,例如矿棉、连续或短切玻璃纤维(也称作纤维玻璃)、珍珠岩(perlite)、粘土、蛭石(vermiculite)、碳酸钙、聚酯、和纸纤维;以及化学添加剂,例如疏水剂、发泡剂、填料、促进剂、糖、增强剂(例如磷酸盐、膦酸盐、硼酸盐和诸如此类)、缓凝剂、粘合剂(例如淀粉和胶乳)、着色剂、杀真菌剂、杀生物剂、和诸如此类。这些和其它添加剂中某些添加剂的使用的实例阐述于(例如)美国专利第6,342,284号、第6,632,550号、第6,800,131号、第5,643,510号、第5,714,001号、和第6,774,146号、以及美国专利公开案第2004/0231916 A1号、第2002/0045074 A1号和第2005/0019618 A1号中。
通过以下实例进一步阐述本文所述垫片饰面石膏板的优点和实施例;然而,不应将这些实例中所列举的具体材料和其数量、以及其它条件和细节理解为对本发明的过度限制。除非另有说明,否则所有百分比都是重量百分比。
以下实例进一步阐释本发明,但当然不应将其理解为以任何方式限制本发明的范围。
实例1
此实例阐述根据本发明将颗粒物质施加至多孔基材的内表面以形成粉末饰面基材。
以20lb/1000ft2的比率将干灰泥粉末(USG,芝加哥,伊利诺斯州)振荡至玻璃纤维垫片(约翰斯曼威尔公司(Johns Manville),丹佛,科罗拉多州)表面上。此垫片是由约80%16微米直径纤维和约20%11微米直径纤维来制造并且具有约22lb/1000ft2的基重。即使将灰泥振荡至垫片表面上,使用背散射电子成像来区分灰泥与有机粘合剂和玻璃纤维的SEM分析也显示,灰泥部分渗透至垫片的间隙中。图5和6是施加灰泥之前垫片的SEM影像,并且图7和8是在将灰泥振荡至垫片表面上之后垫片的SEM影像。图5和7展示通过用剃刀片切割垫片获得的纤维垫片的横截面。在图7影像中,将灰泥施加至垫片的右侧表面(即内表面)上。灰泥材料是图7和8影像中的明亮颗粒并且显示部分延伸至垫片的厚度中,并且相对表面基本上不含颗粒物质(图7横截面图)。
实例2
此实例展示施加至多孔基材内表面上的颗粒物质防止石膏浆液发生透胶的有效性。
使石膏浆液的2”x4”圆柱下落至位于圆柱下方约2”的玻璃垫片(约翰斯曼威尔公司)上。将所述量的石膏沉积至玻璃垫片的两个相同部分上,并且各自浇铸成小板部分。一个玻璃垫片在垫片表面上铺展有一定量的灰泥粉末,之后以20lb/1000ft2的比率施加浆液。另一玻璃垫片不具有干灰泥粉末。尽可能快地自相同批次浆液接续浇铸各板以使任何固化或水合效应最小化。如图9中所示,上面铺展有灰泥的玻璃垫片(右侧样品)不表现石膏透胶,而无灰泥玻璃垫片(左侧样品)表现石膏透胶。
实例3
此实例阐述根据本发明制备垫片饰面石膏板。
以20lb/1000ft2的比率将包含80%灰泥(USG)和20%可再分散粉末聚合物(乙酸乙烯酯共聚物,HD1501,Elotex AG,瑞士)的干颗粒物质施加至玻璃垫片上以形成颗粒填充玻璃垫片。玻璃垫片包括约80%具有16微米直径的纤维和20%具有11微米直径的纤维,所述垫片的基重为约22lb/1000ft2。将石膏浆液沉积至颗粒填充垫片上并形成为整饰石膏板。所述板不表现石膏透胶并且接受表面整饰的能力增强。
实例4
此实例阐述根据本发明制备垫片饰面石膏板。
以20lb/1000ft2的比率将包含100%灰泥(USG)的干颗粒物质施加至玻璃垫片上以形成颗粒填充玻璃垫片。玻璃垫片包括约80%具有16微米直径的纤维和20%具有11微米直径的纤维,所述垫片的基重为约22lb/1000ft2。将石膏浆液沉积至颗粒填充垫片上并在标准石膏板制造线上形成为整饰石膏板。出于比较目的,在相同制造线上使用相同石膏浆液和玻璃垫片制造石膏板,但不向垫片施加灰泥粉末。检查两种类型板中每种的垫片的外表面。在制造包含施加有颗粒物质的玻璃垫片的石膏板后,外表面洁净并且无显著石膏浆液积累,此表明颗粒填充玻璃板抑制浆液透胶。相反,在制造未向玻璃垫片施加颗粒的板后,外表面显示浆液透胶。
应理解,所属领域技术人员可在随附权利要求书中所述原理和范畴内对本文所说明并图示以阐释非织材料的性质和其制备方法的细节、材料、以及各部分与组份的布置进行各种改变。
本文所引用的所有参考文献(包括出版物、专利申请案和专利)都是以引用方式并入本文中,其并入的程度如同每一参考资料都是个别并且特别指明以引用方式并入本文中并且其全文列示于本文中一般。
除非本文另外指明或上下文明显矛盾,否则在阐述本发明的上下文(尤其在随附权利要求书的上下文)中所用术语“一(a和an)”和“所述”都应理解为涵盖单数与复数两种含义。除非另有说明,否则术语“包含”、“具有”和“包括”都应理解为无限制术语(即意指“包括,但不限于”)。除非本文另有说明,否则本文列举的数值范围仅意欲作为单独查阅此范围内各单独值的速记方法,并且各单独值是如同在本文中个别引用一般并入本说明书中。除非本文另有说明或上下文明显矛盾,否则本文所述所有方法都可以任何适宜顺序实施。除非另外阐明,否则本文所提供的任何和所有实例或实例性语言(例如“例如”)仅欲用于更好地阐述本发明而不是对本发明范畴加以限制。本说明书中的任何语言均不应理解为指示任何未主张要素对本发明实践是必不可少的。
本文阐述本发明的优选实施例,包括发明者已知用于实施本发明的最佳模式。所属领域技术人员在阅读上述说明后可了解那些优选实施例的各种变化形式。本发明的发明者期望所属领域技术人员适当使用所述变化形式,并且所述发明者期望本发明可以不同于本文具体阐述的方式来实施。因此,本发明包括适用法律所允许的本文随附权利要求书中所述标的物的所有修改形式和等效形式。此外,除非本文另有说明或上下文明显矛盾,否则在其所有可能的变化形式中,上述元素的任何组合都涵盖于本发明中。
Claims (24)
1.一种形成石膏板的方法,所述方法包含:
(a)提供具有内表面的多孔基材;
(b)将颗粒物质施加至所述多孔基材的所述内表面上,从而形成粉末饰面基材;
(c)将水性石膏浆液沉积至所述粉末饰面基材的所述内表面的至少一部分所施加颗粒物质上,从而形成浆液涂布基材,其中所述颗粒物质填充所述多孔基材中的一部分孔以阻碍所述石膏浆液通过所述孔而渗透;和
(d)使所述浆液涂布基材形成所述石膏板。
2.如权利要求1所述的方法,其中所述颗粒物质包含可水合粉末并且来自所述水性石膏浆液的水使所述可水合粉末水合。
3.如权利要求2所述的方法,其中所述可水合粉末包含石膏基颗粒。
4.如权利要求2或3所述的方法,其中所述可水合粉末包含选自碳酸钙、粘土和其混合物的填料。
5.如权利要求2或3所述的方法,其中所述可水合粉末包含半水合硫酸钙。
6.如权利要求1到5中任一权利要求所述的方法,其中所述颗粒物质包含选自由以下组成的群组的可再分散有机颗粒:丙烯酸类、聚乙烯醇、聚乙二醇、聚氯乙烯、乙酸乙烯酯、其共聚物、和其混合物。
7.如权利要求6所述的方法,其中所述颗粒物质包含约1重量%至约30重量%的所述可再分散有机颗粒。
8.如权利要求1所述的方法,其中施加颗粒物质另外包含将约10lb/1000ft2至约40lb/1000ft2的所述颗粒物质施加至所述多孔基材的所述内表面上。
9.如权利要求1到8中任一权利要求所述的方法,其中所述多孔基材是非织玻璃纤维垫片。
10.如权利要求9所述的方法,其中所述非织玻璃纤维垫片包含约70%至约90%直径为约10微米至约20微米的玻璃纤维和约10%至约30%具有约5微米至约15微米较小直径的玻璃纤维,所述垫片的基重为约20lb/1000ft2或更大。
11.如权利要求9所述的方法,其中所述非织玻璃纤维垫片包含约80%直径为约16微米的玻璃纤维和约20%直径为约11微米的玻璃纤维,所述垫片的基重为约20lb/1000ft2或更大。
12.如权利要求1到11中任一权利要求所述的方法,其另外包含在所述多孔基材的所述内表面上将所述所施加颗粒物质铺展开,随后在其上沉积所述水性石膏浆液。
13.如权利要求1到12中任一权利要求所述的方法,其中所述颗粒物质自所述多孔基材的所述内表面部分地延伸至所述多孔基材中,从而使得所述多孔基材与所述内表面相对的外表面基本不含所述颗粒物质。
14.一种垫片饰面石膏板,其包含:
(a)石膏基芯材;
(b)纤维垫片,其具有面向所述石膏基芯材的至少一侧的内表面;和
(c)水合颗粒材料,其位于所述纤维垫片的所述内表面上并且自所述纤维垫片的所述内表面部分地延伸至所述纤维垫片中;
其中所述水合颗粒材料是独立于所述石膏基芯材来供应。
15.一种垫片饰面石膏板,其包含:
(a)石膏基芯材;
(b)纤维垫片,其具有面向所述石膏基芯材的至少一侧的内表面;和
(c)水合颗粒材料,其位于所述纤维垫片的所述内表面上并且自所述纤维垫片的所述内表面部分地延伸至所述纤维垫片中;
其中所述水合颗粒材料的组成不同于所述石膏基芯材的组成。
16.如权利要求14或15所述的垫片饰面石膏板,其中所述水合颗粒材料包含石膏基颗粒。
17.如权利要求14或15所述的方法,其中所述水合颗粒包含选自碳酸钙、粘土、和其混合物的填料。
18.如权利要求14或15所述的垫片饰面石膏板,其中所述水合颗粒材料包含半水合硫酸钙。
19.如权利要求14到18中任一权利要求所述的垫片饰面石膏板,其中所述水合颗粒材料包含选自由以下组成的群组的可再分散有机颗粒:丙烯酸类、聚乙烯醇、聚乙二醇、聚氯乙烯、乙酸乙烯酯、其共聚物、和其混合物。
20.如权利要求19所述的垫片饰面石膏板,其中所述水合颗粒材料包含约1重量%至约30重量%的所述可再分散有机颗粒。
21.如权利要求14到20中任一权利要求所述的垫片饰面石膏板,其中所述垫片饰面石膏板包含约10lb/1000ft2至约40lb/1000ft2的所述水合颗粒材料。
22.如权利要求14到21中任一权利要求所述的垫片饰面石膏板,其中所述纤维垫片包含约70%至约90%直径为约15微米或更大的玻璃纤维和约10%至约30%直径为约4微米至6微米的玻璃纤维,所述垫片的基重为约20lb/1000ft2或更大。
23.如权利要求14到21中任一权利要求所述的垫片饰面石膏板,其中所述纤维垫片另外包含非织玻璃纤维垫片,其包括约80%直径为约16微米的玻璃纤维和约20%直径为约11微米的玻璃纤维,所述非织玻璃纤维垫片的基重为约22lb/1000ft2或更大。
24.如权利要求14到23中任一权利要求所述的垫片饰面石膏板,其中所述纤维垫片与其所述内表面相对的外表面基本上不含所述水合颗粒物质。
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2008
- 2008-07-18 US US12/176,200 patent/US20090029141A1/en not_active Abandoned
- 2008-07-22 EP EP20080782216 patent/EP2173527A2/en not_active Withdrawn
- 2008-07-22 CA CA 2694182 patent/CA2694182A1/en not_active Abandoned
- 2008-07-22 AR ARP080103181 patent/AR074132A1/es not_active Application Discontinuation
- 2008-07-22 CN CN200880025579XA patent/CN101778703B/zh not_active Expired - Fee Related
- 2008-07-22 JP JP2010518336A patent/JP2010534577A/ja active Pending
- 2008-07-22 BR BRPI0814637-3A patent/BRPI0814637A2/pt not_active IP Right Cessation
- 2008-07-22 WO PCT/US2008/070787 patent/WO2009015156A2/en active Application Filing
- 2008-07-22 RU RU2010101660/03A patent/RU2010101660A/ru not_active Application Discontinuation
- 2008-07-22 TW TW97127748A patent/TW200914230A/zh unknown
- 2008-07-23 CL CL2008002160A patent/CL2008002160A1/es unknown
-
2010
- 2010-01-14 CO CO10003239A patent/CO6170346A2/es not_active Application Discontinuation
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104487242A (zh) * | 2012-06-08 | 2015-04-01 | 瑟登帝石膏公司 | 粘合纤维垫的构建 |
CN106216176A (zh) * | 2016-07-22 | 2016-12-14 | 苏州芳磊蜂窝复合材料有限公司 | 一种玻璃布蜂窝涂胶方法及其使用的涂胶装置 |
Also Published As
Publication number | Publication date |
---|---|
RU2010101660A (ru) | 2011-08-27 |
TW200914230A (en) | 2009-04-01 |
WO2009015156A2 (en) | 2009-01-29 |
CA2694182A1 (en) | 2009-01-29 |
WO2009015156A3 (en) | 2009-04-09 |
EP2173527A2 (en) | 2010-04-14 |
US20090029141A1 (en) | 2009-01-29 |
CN101778703B (zh) | 2012-07-18 |
AR074132A1 (es) | 2010-12-29 |
JP2010534577A (ja) | 2010-11-11 |
CO6170346A2 (es) | 2010-06-18 |
CL2008002160A1 (es) | 2009-03-20 |
BRPI0814637A2 (pt) | 2015-06-16 |
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