CN105209251A - 具有一体化的空气/水阻挡膜的外部护套面板 - Google Patents
具有一体化的空气/水阻挡膜的外部护套面板 Download PDFInfo
- Publication number
- CN105209251A CN105209251A CN201480011601.0A CN201480011601A CN105209251A CN 105209251 A CN105209251 A CN 105209251A CN 201480011601 A CN201480011601 A CN 201480011601A CN 105209251 A CN105209251 A CN 105209251A
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- China
- Prior art keywords
- water barrier
- barrier film
- panel
- integrated air
- film
- 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.)
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- C—CHEMISTRY; METALLURGY
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Abstract
本发明提供了一种防止水渗透和漏气的外部护套水泥面板。也提供了用于制造具有高度有效的一体化空气/水阻挡膜的外部护套水泥面板的方法。
Description
相关申请的交叉引用
本专利申请要求2014年3月5日提交的美国专利申请14/198,093的优先权,并要求2013年3月15日提交的美国临时专利申请61/792,545的优先权,两个申请的全部公开内容以引用方式并入本文。
技术领域
本发明涉及一种具有一体化空气/水阻挡膜的建筑外部护套面板以及用于制造和安装所述面板的方法。
背景技术
作为建筑围护阻挡系统的部分的空气/水阻挡层的前提是阻止空气、水和其他元素非故意地进出建筑围护结构。外部空气/水阻挡片材膜首先被引入行业中,但由于接缝处为关键接合,因此存在与在实地安装片材相关的数个问题。片材的安装不总是匹配制造者所提供的指令。环境条件(例如风、温度、雨等)可产生成功安装片材材料的显著障碍。此外,片材背衬通常提供用于其他建造材料的差的结合表面,由此使得片材难以粘附。
流体施用的空气/水阻挡膜对于行业而言更新,并被接受为片材膜阻挡产品的替代选择。相比于片材膜阻挡产品,流体施用的膜阻挡产品在工地现场安装得更快。典型的安装人员要求比使用片材膜阻挡装置更小。流体施用的膜通常在工地现场喷雾施用,这相比于片材膜的施用大大增加了生产率。然而,可能发生施用的问题,如由于涂敷器误差、设备问题和/或环境条件(如风、温度、雨等)而导致的被施用的材料的错误的量。这些问题不仅影响空气/水阻挡装置的品质和耐久性,还可引起清理和修复由于过度喷雾而导致的对相邻建筑物和汽车的损坏的显著的额外成本。
安装外部护套、空气阻挡层和耐水阻挡层的常规方法要求在数个步骤中围绕建筑物周界完成安装的分别的工作人员:首先安装护套,然后在第二轮精整接头,然后在下一单独一轮中安装耐水阻挡层和空气阻挡层。
因此,持续需要提供一种使与安装相关的问题达到最小的空气/水阻挡膜。也持续需要在制造过程中在受控条件下用空气/水阻挡膜涂布的建筑面板。
应了解,本背景技术描述由本发明人创作以协助读者,并不被当作表示所指出的问题中的任意者本身在本领域中得以认知。尽管所描述的原理在一些方面和实施例中可缓和其他体系中所固有的问题,但应了解所保护的创新的范围由所附权利要求书限定,而不由用以解决本文记载的任何特定问题的任意公开特征的能力限定。
发明内容
在一方面,本公开涉及防止水渗透和漏气的建筑水泥面板的实施例。
一个实施例涉及一种水泥面板,其包括水泥芯、至少一个覆盖片材和一体化空气/水阻挡膜。在所述面板中,覆盖片材夹在所述水泥芯与所述一体化空气/水阻挡膜之间。所述水泥芯可包含硫酸钙材料、波特兰水泥或两者的组合。所述面板可包括第二覆盖片材,在该实施例中,水泥芯夹在第一覆盖片材与第二覆盖片材之间,且所述第一覆盖片材夹在所述水泥芯与所述一体化空气/水阻挡膜之间。
在一些实施例中,水泥面板包括纸片材或纤维垫作为覆盖片材。各种纤维可在垫中使用,包括但不限于聚合物纤维和矿物质纤维。
在一些实施例中,一种外部护套片材包括一体化空气/水阻挡膜,所述一体化空气/水阻挡膜包含30至70重量%的聚合物粘结剂和20至50重量%的碳酸钙,所述聚合物粘结剂选自聚丙烯酸酯、聚氯酯、有机硅乳液、聚苯乙烯、苯乙烯/丙烯酸共聚物以及它们的组合。所述一体化空气/水阻挡膜还可包含如下中的至少一者:分散剂、消泡剂、颜料、增稠剂、防腐剂、pH调节剂、乳液稳定剂、润湿均化剂、交联剂以及它们的组合。
另外的实施例包括一种外部护套面板,其中一体化空气/水阻挡膜具有在10至90密耳范围内的干燥厚度。
在一些实施例中,将抗微生物/抗真菌剂添加至水泥芯、覆盖片材和/或一体化空气/水膜。合适的抗微生物剂包括2-(4-噻唑基)苯并咪唑、银沸石、氧化锌和吡啶硫酮锌。
另外的实施例提供了一种制造具有一体化空气/水阻挡膜的外部护套面板的厂内方法。所述方法包括制备具有胶结材料的浆料;将所述浆料夹在两个覆盖片材之间;使所述浆料凝固,并形成水泥面板;使用配制为具有聚合物粘结剂和碳酸钙的一体化空气/水阻挡膜在至少一个表面上喷涂所述水泥面板;以及在烘箱中调节所述经喷涂的水泥面板,其中所述面板暴露于至少两个不同的温区。
附图说明
图1为具有一体化空气/水阻挡膜的本发明的外部护套面板的碎片横截面;和
图2显示了图2A中的对照面板和图2B中的通过本发明的方法获得的具有一体化空气/水阻挡膜的本发明的外部护套面板。
具体实施方式
本公开提供了外部护套面板的各个实施例,所述外部护套面板与空气/水阻挡膜物理一体化,以提供独特的阻挡部件。一体化空气/水阻挡膜护套面板可提供易安装的单个面板,其消除了在工地现场单独安装分别的耐空气和耐水阻挡层的需要。通过如此,完成建筑围护所需的步骤数降低,必须单独密封的接头数降低,从而显著降低满足建筑围护的空气/水阻挡系统性能要求所需的时间和人力。本公开也提供了涉及方法的实施例,其中具有空气/水阻挡膜的外部护套面板在受控的工厂环境中量产为具有均匀整体的阻挡性质,因此减少与在实地施用的阻挡材料的不足的量相关的问题。另外,以如本公开中提供的受控自动化工厂设置将空气/水阻挡膜施用至外部护套确保了膜施用不易受气候/环境变化或工人疲劳的变化的影响,由此提供具有空气/水阻挡膜与护套基材之间的最佳粘结的一致的涂层厚度。
特别地,在一些实施例中,水泥外部护套面板包括在面板的至少一个表面上粘合剂流体施用的空气/水阻挡层。参照图1,一些实施例包括通常指定为10的具有一体化空气/水阻挡膜的外部护套面板。面板包括水泥芯12、覆盖片材14a和任选的覆盖片材14b,和空气/水阻挡膜16。水泥芯12夹在覆盖片材14a和14b之间。覆盖片材14a上覆有空气/水阻挡膜16,使得覆盖片材14a夹在水泥芯12与一体化空气/水阻挡膜16之间。
水泥护套面板可由旨在用于外部应用的任何合适的无机芯材料组成。特别地,芯可由任何胶结材料、物质或组合物以及任何合适的添加剂组成。可用于水泥芯中的材料的非限制的例子包括:波特兰水泥;sorrel水泥;矿渣水泥;飞灰水泥;钙氧化铝水泥;水溶性硫酸钙无水石膏;硫酸钙α-半水合物;硫酸钙β-半水合物;天然、合成或化学改性的硫酸钙半水合物;硫酸钙二水合物(“石膏”、“凝固石膏”或“水合石膏”);以及它们的混合物。如本文所用,术语“硫酸钙材料”指上述硫酸钙的形式中的任意者。在某些优选实施例中,水泥芯包含硫酸钙材料、波特兰水泥、或它们的混合物。优选地,水泥芯包含石膏。
用于本公开的实施例中的合适的水泥外部护套面板的例子包括,例如,以商品名SHEETROCK 和购自伊利诺斯州芝加哥的美国石膏公司(UnitedStatesGypsum,Chicago,IL)的那些。
水泥芯可包含添加剂,如常用于制备水泥制品(例如石膏板或水泥板)的任何添加剂。合适的添加剂包括但不限于结构添加剂,如矿物棉、连续或短切玻璃纤维(也称为纤维玻璃)、珍珠岩、粘土、蛭石、碳酸钙、聚酯和纸纤维。化学添加剂包括例如发泡剂、填料、促进剂、糖、增强剂(例如磷酸盐、膦酸盐、硼酸盐)、阻滞剂、粘结剂(例如淀粉和胶乳)、着色剂、杀真菌剂和杀生物剂。这些和其他添加剂中的一些的使用的例子描述于例如美国专利No.6,342,284、No.6,410,118、No.6,632,550、No.6,800,131、No.5,643,510、No.5,714,001和No.6,774,146以及美国专利申请公布No.2004/0231916、No.2002/0045074和No.2005/0019618中,所述公开以引用方式并入本文。在某些实施例中,水泥芯还包含金属纤维、纤维素纤维、矿物纤维、玻璃纤维、聚合物纤维、碳纤维或它们的组合。
水泥芯由至少一个基材覆盖,在一些实施例中由两个基材在芯的相对面上相对于芯以上覆的方式覆盖。换言之,水泥芯夹在两个基材之间。基材可为覆盖片材,例如纸覆盖片材或垫。各种类型的纸覆盖片材是本领域已知的(例如马尼拉、牛皮、聚合物等),所有这种类型的纸覆盖片材可用于本发明中。多层纸可用于各个实施例中。如果需要,纸覆盖片材可由化学或物理添加剂处理以赋予性质,如防水、防火、抗真菌和/或抗微生物性质。在一些实施例中,覆盖片材为重量为约40至约65lb/msf(千平方英尺)的纸覆盖片材。
在其他实施例中,使用包含纤维垫的覆盖片材。垫可包含任何合适类型的聚合物纤维、矿物纤维或它们的组合。合适的纤维的非限制性的例子包括玻璃纤维、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醇酯(PET))、聚乙烯醇(PVOH)、聚乙酸乙烯酯(PVAc)、纤维素纤维(例如棉、人造纤维等)以及它们的组合。此外,垫的纤维可为疏水性或亲水性的,涂布的或未涂布的。纤维的选择部分取决于使用水泥护套面板的应用的类型。例如,当护套面板用于需要耐热性或耐火性的应用时,适当的耐热或耐火纤维应该用于纤维垫中。
纤维垫可为织造的或非织造的。非织造垫包含通过粘结剂粘结在一起的纤维。粘结剂可为通常用于垫行业中的任何粘结剂。合适的粘结剂包括但不限于脲醛、三聚氰胺甲醛、硬脂酸化的三聚氰胺甲醛、聚酯、丙烯酸类、聚乙酸乙烯酯、由聚乙酸乙烯酯或丙烯酸类改性或者与聚乙酸乙烯酯或丙烯酸类共混的脲醛或三聚氰胺甲醛、苯乙烯丙烯酸聚合物以及它们的组合。合适的纤维垫包括用作水泥外部护套面板的饰面材料的市售垫。
一体化面板可通过任何合适的方法制得。通常,将粘合剂流体施用的空气/水阻挡层施用至水泥外部护套面板的至少一个表面(例如外部饰面表面)。粘合剂流体可为任何合适的组合物,并且在一些实施例中为液体聚合物制剂的形式。施用步骤可包括将液体聚合物制剂添加至护套面板的表面的任何合适的方法。这种方法为本领域已知的,并包括例如用液体聚合物制剂喷雾、轧制(例如压力轧制)、抹灰、刷涂、擦拭、沉浸、浸泡和/或浸渍面板的表面。一旦施用,则液体聚合物制剂在表面上干燥、凝固、硬化和/或固化,以提供具有防空气和/或防湿性质的粘合剂层。该步骤可在室温下或在高温下进行指定量的时间,以获得所需的粘着性水平。
液体聚合物制剂可为用于流体施用的膜中的任何合适的材料。用于空气/水阻挡层制剂的合适的制剂方应满足或超过由CAN/ULC-S741(“StandardforAirBarrierMaterials-Specification(空气阻挡层材料的标准-规格)”)所述并根据ASTME2178(“StandardTestMethodforAirPermeanceofBuildingMaterials(建筑材料的透气性的标准测试方法)”)测试的最低要求。这种制剂包括防止或最小化通过具有一体化空气/水阻挡膜的外部护套面板的空气渗透/漏出和水穿透的那些。其他合适的空气/水阻挡层制剂包括防止或最小化通过面板的空气渗透/漏出,也最小化面板对水蒸气的渗透性的那些。
在至少一些实施例中,在干燥和/或固化之后,液体聚合物制剂在外部护套面板的至少一个表面上形成橡胶化(弹性体)膜。
至少在一些实施例中,液体聚合物制剂包含一种或多种材料(例如聚合物),所述材料用作聚合物粘结剂,并在制剂干燥和/或固化之后提供自密封效果。适用于具有一体化空气/水阻挡膜的外部护套面板的液体聚合物制剂的非限制性的例子包括聚丙烯酸酯(例如基于甲基丙烯酸酯、丙烯酸乙酯、甲基丙烯酸乙酯、丙烯酸丁酯、甲基丙烯酸丁酯、2-氯乙基乙烯基醚、丙烯酸2-乙基己酯和甲基丙烯酸羟乙酯的聚合物和共聚物)、聚苯乙烯、聚丁二烯、聚(丁二烯共-苯乙烯)、聚异戊二烯、聚丙烯腈丁二烯、聚氯丁烯、聚乙酸乙烯酯、聚氯乙烯、聚氯酯、聚乙酸乙烯酯、有机硅乳液以及它们的组合。流体施用的膜的例子由例如美国专利No.8,151,537和No.7,662,221示例,所述公开以引用方式并入本文。
在某些实施例中,液体聚合物制剂为液体乳液(例如液体聚合物乳液)的形式,如水基弹性体乳液(例如水基丙烯酸类乳液)或油基弹性体乳液(例如橡胶化(弹性体)乳液)。用于乳液中的溶剂可为水、有机溶剂或它们的组合。有机溶剂的例子包括溶剂油、矿物油、二甲苯和石油脑。
至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括由包含丙烯酸类乳液的制剂制得的膜。至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括具有5至80wt%的聚丙烯酸酯的膜。至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括具有30至70wt%的聚丙烯酸酯的膜。至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括具有40至60wt%的聚丙烯酸酯的膜。
至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括由包含聚氯酯的制剂制得的膜。至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括包含5至50wt%的聚氯酯的膜。至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括包含10至40wt%的聚氯酯的膜。至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括包含聚氯酯与选自如下有机硅和聚丙烯酸酯中的至少一者的另一聚合物的组合的膜。至少在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括包含苯乙烯共聚物的膜。
出乎意料地发现,用于外部护套面板中的一体化空气/水阻挡膜的优选聚合物粘结剂包括丙烯酸类胶乳、丙烯酸苯乙烯共聚物和苯乙烯-丁二烯分散体。这些聚合物粘结剂可以以30至70%的量使用。在一些实施例中,聚合物粘结剂可选自如下市售粘结剂:来自欧诺法公司(Omnova)的PLIOTECEL-25(丙烯酸类弹性体胶乳)、来自BASF的ACRONALS400(丙烯酸酯和苯乙烯的不含增塑剂的水性共聚物分散体)、来自陶氏公司(DOW)的UCAR9176(苯乙烯丙烯酸共聚物)、来自陶氏公司(DOW)的RHOPLEX2620(100%丙烯酸类共聚物)或来自BASF的BUTONALNS175(高固体冷聚合的阴离子苯乙烯-丁二烯分散体)。
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括由包含聚合物乳液和分散剂的制剂制得的膜。多种分散剂可用于稳定乳液,如聚乙烯醇、纤维素和它们的衍生物;含乙烯基吡咯烷酮的共聚物;乙氧基化的单烷基酚、二烷基酚和三烷基酚;乙氧基化的脂肪醇以及硫酸的烷基硫酸酯的碱金属和铵盐;乙氧基化的烷醇的单酯和烷基磺酸和烷基芳基磺酸的乙氧基化的烷基酚的单酯;十二烷基苯磺酸的碱金属和/或铵盐,以及乙氧基化的十二烷醇的硫酸单酯的碱金属和/或铵盐。分散剂可以以约0-10wt%(例如约1-9wt%之间,约2-7wt%之间,3-6wt%之间)的量添加至制剂中。
在一些实施例中,合适的分散剂包括具有颜料亲合基团(pigmentaffinicgroup)的高分子量嵌段共聚物的溶液、丙烯酸酯共聚物的铵盐的溶液、阴离子聚电解质、三聚磷酸钾和具有酸性基团的共聚物的烷基醇铵盐。这些分散剂可以以0-10%,优选0.1-5%的量使用。在一些实施例中,分散剂可选自如下市售分散剂:来自BYK的DISPERBYK-190(具有颜料亲合基团的高分子量嵌段共聚物的溶液)、来自BYK的BYK-156(丙烯酸酯共聚物的铵盐的溶液)、来自陶氏公司(DOW)的TAMOL851(阴离子聚电解质)、来自INNOPHOS的三聚磷酸钾(三聚磷酸五钾盐)、来自BYK的DISPERBYK-180(具有酸性基团的共聚物的烷基醇铵盐)。
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括配制为具有用以进一步提高阻挡材料的性能的一种或多种添加剂的膜。合适的添加剂包括例如石油沥青、石灰岩、碳酸钙、硅烷(例如二氨基硅烷、三甲氧基乙烯基硅烷)、二醇(例如乙二醇、丙二醇、二丙二醇一丁基醚)、增粘剂(例如松香或松香衍生物(如木松香)、萜烯或改性萜烯、脂族、脂环族或芳族树脂)、粘合促进剂、固化催化剂、交联剂、杀白蚁剂、真菌生长抑制剂(例如2-(4-噻唑基)苯并咪唑、银沸石、氧化锌和吡啶硫酮锌)、填料(例如高岭土、云母、重晶石、滑石、沙子、石英粉、白垩、二氧化钛、二氧化硅、飞灰)和/或相变材料。
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括配制为具有上述聚合物粘结剂和可以以20至50重量%的量使用的碳酸钙的膜。碳酸钙的合适的商业来源包括但不限于来自特种矿物公司(SpecialtyMinerals)的THIXO-CARB500TM(沉淀碳酸钙)、来自特种矿物公司(SpecialtyMinerals)的ULTRAFLEX100TM(沉淀碳酸钙)、来自胡贝尔工程材料公司(HuberEngineeredMaterials)的HUBERCARBQ6TM(碳酸钙)、来自欧米亚公司(Omya)的OMYACARB100-PTTM(碳酸钙)、来自胡贝尔工程材料公司(HuberEngineeredMaterials)的HUBERCARBQ325TM(碳酸钙)和来自竹原大生化学公司(TakeharaKagakuKogyoCo)的NEOLIGHTSSTM(沉淀涂布碳酸钙)。
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括配制为具有如上所述的聚合物粘结剂、碳酸钙和至少一种或多种添加剂(如消泡剂、颜料、增稠剂、防腐剂、pH调节剂、乳液稳定剂、润湿均化剂和交联剂)的膜。
在一些实施例中,合适的消泡剂包括但不限于链烷烃矿物油和疏水性组分的混合物、在增强矿物油体系中配混的分子、经聚醚改性的聚二甲基硅氧烷的溶液、和泡沫破坏聚硅氧烷和在聚乙二醇中的疏水性固体的混合物。这些消泡剂可以以0.1至5%的量使用。消泡剂的合适的商业来源包括来自BYK的BYK-033TM(链烷烃矿物油和疏水性组分的混合物)、来自BASF的FOAMSTARST2410TM(亦称为FOAMSTARA10TM)(在增强矿物油体系中配混的分子)、来自BYK的BYK-019TM(经聚醚改性的聚二甲基硅氧烷的溶液)、来自BYK的BYK-021TM(泡沫破坏聚硅氧烷和在聚乙二醇中的疏水性固体的混合物)。
在一些实施例中,合适的颜料包括但不限于二氧化钛、氧化锌、炭黑、微粒化沉淀二氧化硅、滑石以及它们的组合。这些颜料可以以0.1重量%至10重量%的量使用。颜料的合适的商业来源包括来自马龙公司(MaroonInc.)的HUNTSMANTR93TM(二氧化钛)、来自佐化学公司(ZochemIcc.)的ZOCO101TM(氧化锌)、来自硕泰克公司(Soltex)的SOLTEXACEBLACKTM(炭黑)、来自胡贝尔公司(Huber)的ZEOTHIX265TM(微粒化沉淀二氧化硅)和来自伊莫瑞斯公司(Imerys)的SIERRALITE402STM(滑石)。
在一些实施例中,合适的增稠剂包括但不限于如下中的至少一者:羟乙基纤维素、丙烯酸类增稠剂、阴离子反相乳液增稠剂、HASE、和经疏水改性的碱溶胀型丙烯酸类乳液。这些增稠剂可以以0.1重量%至5重量%的量使用。增稠剂的合适的商业来源包括来自亚什兰公司(AshlandInc.)的NATROSOL250HBRTM(羟乙基纤维素)、来自陶氏公司(DOW)的ACRYSOLASE-95NPTM(碱溶性丙烯酸类增稠剂)、来自斯高特巴德公司(ScottBader)的TEXIPOL63-510TM(阴离子反相乳液增稠剂)、来自阿科玛公司(Arkema)的POLYPHOBE106HETM(HASE)和来自路博润公司(Lubrizol)的SOLTHIXA100TM(经疏水改性的碱溶胀型丙烯酸类乳液)。
在一些实施例中,合适的防腐剂包括但不限于如下中的至少一者:2[(羟甲基)氨基]-2-甲基丙醇、氨基甲酸3-碘-2-丙炔基丁酯(3-iodo-2-propnynylbutylcarbamate)、n-(3,4-二氯苯基)-n,n-二甲基脲、1,2苯并异噻唑啉-3-酮和四氯间苯二甲腈。这些增稠剂可以以0.1重量%至5重量%的量使用。增稠剂的合适的商业来源包括来自特洛伊公司(TroyCorporation)的TROYSAN186TM(2[(羟甲基)氨基]-2-甲基丙醇)、来自特洛伊公司(TroyCorporation)的POLYPHASEAF1TM(氨基甲酸3-碘-2-丙炔基丁酯)、来自特洛伊公司(TroyCorporation)的POLYPHASE663TM(n-(3,4-二氯苯基)-n,n-二甲基脲)、来自特洛伊公司(TroyCorporation)的MERGAL758TM(1,2苯并异噻唑啉-3-酮)和来自亚什兰公司(AshlandInc)的NUOCIDE404DTM(四氯间苯二甲腈)。
在一些实施例中,合适的pH调节剂包括但不限于如下中的至少一者:氢氧化钙、氢氧化钠、氢氧化钾、30%氨水和2-氨基-2-甲基-1-丙醇。这些pH调节剂可以以0.1重量%至5重量%的量使用。pH调节剂的合适的商业来源包括来自约斯特化工公司(JostChemical)的氢氧化钙(氢氧化钙)、来自OXY化学公司(OXYChem)的苛性钠(氢氧化钠溶液)、来自化学第一公司(ChemOneLtd.)的氢氧化钾(氢氧化钾)、来自坦纳工业公司(TannerIndustries)的氢氧化氨溶液(30%氨水)和来自安格斯公司(Angus)的AMP95(2-氨基-2-甲基-1-丙醇)。
在一些实施例中,合适的乳液稳定剂包括但不限于如下中的至少一者:膨润土、丙烯酸和C10-C30烷基丙烯酸酯的高分子量交联共聚物、非离子辛基酚乙氧基化物表面活性剂、妥尔油树脂和天然树脂提取物。这些乳液稳定剂可以以0.1重量%至5重量%的量使用。乳液稳定剂的合适的商业来源包括来自BYK的OPTIGELLXTM(膨润土)、来自路博润公司(Lubrizol)的PEMUIEN1622TM(丙烯酸和C10-C30烷基丙烯酸酯的高分子量交联共聚物)、来自陶氏化学公司(DOWChemicalCompany)的TRITONX405TM(非离子辛基酚乙氧基化物表面活性剂)、来自亚利桑那化学公司(ArizonaChemical)的SYLVAROSTMNCY(妥尔油树脂)、和来自(Pinnova)的VINSOLTMSOAP(天然树脂提取物)。
在一些实施例中,合适的润湿均化剂包括但不限于如下中的至少一者:磺基琥珀酸酯、聚醚改性的硅氧烷、脲改性的聚氯酯、丙烯酸酯共聚物的改性脲铵盐。这些润湿均化剂可以以0.1重量%至5重量%的量使用。润湿均化剂的合适的商业来源包括来自氰特公司(Cytec)的AEROSOLTMLF-4(专有磺基琥珀酸酯共混物)、来自BYK的BYK-349(聚醚改性的硅氧烷)、BYK-425(脲改性的聚氯酯)、BYK-420(改性的脲)和BYK-154(丙烯酸酯共聚物的铵盐)。
在一些实施例中,合适的交联剂包括但不限于如下中的至少一者:氧化锌、锌金属离子、含有阴离子羟基化锆聚合物的经稳定的碳酸锆铵、和环氧基官能硅烷。这些交联剂可以以0.1重量%至5重量%的量使用。交联剂的合适的商业来源包括来自美锌公司(USZinc)的氧化锌(氧化锌)、来自明镜公司(Munzing)的ZIMPLEXTM15(锌金属离子)、来自梅尔化学公司(MelchemicalInc.)的BACOTETM20(含有阴离子羟基化锆聚合物的经稳定的碳酸锆铵的澄清碱性溶液)、来自布勒集团(BuhlerGroup)的OXYLINKTM3404(无机粒子(包括氧化锌)的水性制剂)、和来自迈图公司(Momentive)的SILANETMA-187(环氧基官能硅烷)。
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括配制为具有如上所述的合适的聚合物和如下添加剂中的至少一者的膜:石油沥青、石灰岩、碳酸钙、高岭土、云母、重晶石、滑石、沙子、石英粉、白垩、二氧化钛、二氧化硅、飞灰、石膏、或这些添加剂中的至少两者的组合。添加剂可以以不同的量使用,包括20至80重量%;25至75重量%和30至60重量%。在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括配制为具有聚丙烯酸酯和如下添加剂中的至少一者的膜:石油沥青、石灰岩、碳酸钙、高岭土、云母、重晶石、滑石、沙子、石英粉、白垩、二氧化钛、二氧化硅、飞灰、石膏、或这些添加剂中的至少两者的组合。
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括配制为具有选自2-(4-噻唑基)苯并咪唑、银沸石、氧化锌和吡啶硫酮锌的抗微生物抗真菌剂的膜。抗微生物/抗真菌剂可以以多种量使用,包括约1至约10重量%或约3至约7重量%。
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括包含颜料的膜。可使用多种颜料,包括提供黑色、棕色、蓝色、绿色、红色、黄色、橙色或白色颜料的化学化合物。
市售流体施用的空气/水阻挡层的例子包括如下商品名销售的那些:EXOAIRTM(创高公司(Tremco))、TYVEKTM(杜邦公司(DuPont))、R-GUARDTM(普罗索公司(Prosoco))、AIR-SHIELDTM(W.R.梅多斯公司(W.R.Meadows))、STOGUARDTM(思多公司(StoCorp.))和AIRBLOCTM(亨利公司(HenryCo.))。
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板包括配制为具有聚合物粘结剂、碳酸钙和其他组分的膜,如以下表1中所提供。
表1.一体化空气/水阻挡膜制剂
在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板通过控制一体化空气/水阻挡膜的厚度的方法制得。可控制厚度,使得具有一体化空气/水阻挡膜的外部护套面板显著降低通过面板的空气渗透/漏出和水穿透。一些实施例提供具有一体化空气/水阻挡膜的外部护套面板,所述外部护套面板将通过面板的空气渗透/漏出和水穿透降低至少50%。一些其他实施例提供具有一体化空气/水阻挡膜的外部护套面板,所述外部护套面板将通过面板的空气渗透/漏出和水穿透降低至少70-80%。充分降低空气渗透/漏出和水穿透的具有一体化空气/水阻挡膜的外部护套面板包括如下那些面板:其中一体化空气/水阻挡膜的干燥厚度为至少10密耳,至少20密耳,至少30密耳,至少40密耳,至少50密耳,至少60密耳,至少70密耳,且小于100密耳,小于90密耳,小于80密耳,小于70密耳,小于60密耳,小于50密耳,小于40密耳。可在使用上限值和下限值的任何合适的范围内组合前述值,例如10-90密耳,20-80密耳,40-80密耳,60-80密耳等。
为了获得具有一体化空气/水阻挡膜的外部护套面板,膜制剂可以以5-100密耳(例如至少5密耳,至少10密耳,至少20密耳,至少30密耳,至少40密耳,至少50密耳,至少60密耳,至少70密耳,且小于100密耳,小于90密耳,小于80密耳,小于70密耳,小于60密耳,小于50密耳,小于40密耳)的厚度施用至面板。可在使用上限值和下限值的任何合适的范围内组合前述值,例如10-90密耳,20-80密耳,40-80密耳,60-80密耳等。由于膜(例如液体聚合物制剂)通常作为乳液施用,因此初始层为“湿的”。随着膜干燥,膜层的厚度将取决于制剂的浓度而收缩。因此,干燥厚度从初始湿厚度尺寸降低约10%或更多(例如约20%或更多,约30%或更多,约40%或更多,约50%)的量。
在一个实施例中,如上所述在至少一个表面上具有一体化空气/水阻挡膜的水泥外部护套面板还包括粘附至一体化空气/水阻挡膜的片材膜。在一体化空气/水阻挡膜在面板上形成之后,可将具有耐空气和/或耐湿性质的片材膜施用至所述膜。可使用任何合适的方法(如敷设、轧制、层合、压延和/或压制)将片材膜施用至一体化空气/水阻挡膜。通常,将片材膜切割至与水泥外部护套面板相应的尺寸。通常可在施用至面板之前切割片材,但在一些实施例中,片材膜可以以卷材的形式施用至一系列接合面板,可随后切割所述接合面板以限定单个一体化面板。
在一些实施例中,一体化空气/水阻挡膜通常具有足够的粘合剂特性,以在无另外的一种或多种粘合剂的情况下固定片材膜。
在一些实施例中,提供一种用于安装具有一体化空气/水阻挡膜的外部护套面板的系统。这种系统可包括可被施用至外部护套面板的一体化空气/水阻挡膜的一个或多个补充粘合剂涂层和/或密封剂。另外的粘合剂可在面板的整个表面上或在表面的选定区域(例如周边、中心、平行边缘等)中施用。另外的添加剂可为任何合适的材料,如以如下商品名销售的那些:EXOAIRTM(创高公司(Tremco))、TYVEKTM(杜邦公司(DuPont))、R-GUARDTM(普罗索公司(Prosoco))、AIR-SHIELDTM(W.R.梅多斯公司(W.R.Meadows))、STOGUARDTM(思多公司(StoCorp.))和AIRBLOCTM(亨利公司(HenryCo.))。在一些实施例中,合适的密封剂包括聚氯酯基密封剂(如SPECTREM1TM(创高公司(Tremco)))和有机硅基密封剂(如DYMONIC100TM(创高公司(Tremco)))。至少在一些实施例中,安装系统包括具有空气/水阻挡膜的外部护套面板和至少一种聚氯酯基和/或有机硅基密封剂。
尽管在一些实施例中,具有一体化空气/水阻挡膜的外部护套面板可与另外的片材膜组合使用,但在其他实施例中,外部护套面板可在无片材膜的情况下使用。具有耐空气和/或耐湿性质的片材膜(也称为房屋或建筑覆盖物)可为任何合适的材料,如由如下制得的那些:沥青浸渍的纸或纤维玻璃、微穿孔交叉搭接膜、层合至纺粘非织造物的膜、层合或涂布至聚丙烯织造物的膜、超级砑光湿法聚烯烃(例如聚乙烯)原纤维非织造物(例如TYVEKTM)和可排水房屋覆盖物。在实施例中,合适的片材膜可满足或超过由ASTME2178(“StandardTestMethodforAirPermeanceofBuildingMaterials(建筑材料的透气性的标准测试方法)”)所述的最低要求。片材建筑覆盖物的例子显示并描述于例如美国专利No.7,148,160和美国专利申请公布No.2006/0040091和No.2006/0051560中,所述公开以引用方式并入本文。市售片材膜的例子包括以如下商品名销售的那些:Tri-BuiltBuildingWrap(三建公司(Tri-Built))、TYVEKTM(杜邦公司(DuPont))、HARDIEWRAPTM(詹姆斯哈迪公司(JamesHardie))、HYDROGAPTM(本杰明欧布迪克公司(BenjaminObdyke))、WEATHERMATETM(陶氏公司(Dow))、BLUESKINTM(亨利公司(HenryCo.))、FOILSKINTM(亨利公司(HenryCo.))、AIR-SHIELDTM(W.R.梅多斯公司(W.R.Meadows))和CERTAWRAPTM(瑟登帝公司(CertainTeed))。
任选地与片材膜组合的一体化空气/水阻挡膜使得面板系统(水泥面板、一体化空气/水阻挡膜和任选的片材膜)具有调节和/或改变面板的水蒸气渗透速率的通用能力。取决于外部建筑围护的设计和/或预期性能,调节耐空气和耐湿水泥外部护套面板的水蒸气渗透速率,并同时保持一致的面板厚度的能力是特别有利的。基于涉及墙组件的湿气管理和/或使用的地理和气候区域的一组特定的建筑科学设计原理,耐空气和耐湿水泥外部护套面板可需要被制造为具有不同的水蒸气渗透速率,以解决特定的建筑能量性能要求和/或建筑围护设计性能。例如,美国能源部描述了七个(7)气候区。七个区的每一个基于采暖度日(HDD)和冷却度日(CDD)的程度。使用这些度量标准来分类采暖和冷却条件用于国家的不同区域中的建筑物的严重程度。例如,气候区1(南佛罗里达)具有CDD>9000,建筑空间调节完全由冷却主导。相反,在如位于气候区6中的上中西部的区域中,建筑能量使用由热负荷主导,HDD大于7200且小于9000。湿气和湿度条件也必须在设计过程中考虑。湿度考虑对优化房屋内的能量系统具有主要影响,常常决定哪个材料或系统在能量性能和湿气控制方面最佳起作用。例如,在热和干燥气候中,蒸发冷却系统可为家庭提供空间冷却,且相比于常规蒸气压缩A/C系统通常使用更少的能量。同时,在如热/潮湿的东南的区域中,必须特别关注外部墙组件的蒸汽渗透率,以防止建筑围护的严重的湿气和霉菌问题。因此,对与防空气和防湿水泥外部护套面板相关的不同的水蒸气渗透速率的需要是重要的。
可通过调节施用的一体化空气/水阻挡膜的量和/或通过调节构造的任选的片材膜的设计水蒸气渗透速率而改变水蒸气渗透速率,所述片材膜厚度不改变,并同时可被特意构造为具有不同的水蒸气渗透速率。改变和/或调节防空气和防湿水泥外部护套面板的设计水蒸气渗透速率的一个示例性方法是提供保持厚度的尺寸一致的面板。在需要一致的面板厚度但需要不同的水蒸气渗透速率的实际应用中,一体化空气/水阻挡膜保持固定,改变任选的片材膜水蒸气渗透速率以获得广泛范围的水蒸气渗透速率的耐空气和耐湿水泥外部护套面板类型。片材膜也防止一体化面板彼此粘附(堵塞)。
在另一实施例中,水泥护套面板包括在面板的至少一个表面上的一体化空气/水阻挡膜和至少部分嵌入膜中的支架(standoff)材料。支架材料为可嵌入一体化空气/水阻挡膜以防止一体化面板彼此粘附(堵塞)的任何合适的材料。考虑到膜的橡胶化性质,即使在干燥和/或固化之后,表面可保持粘着。因此,可使用物理防止相邻的一体化面板彼此接触的支架材料来防止对一体化面板的粘附和/或损坏。
在一个实施例中,支架材料为开放编织网。网可由任何合适的材料制得。例如,网可包含天然或合成材料(例如纤维),如棉、黄麻、剑麻、羊毛、大麻、亚麻(flax)、竹子、亚麻(linen)、玻璃、金属、尼龙、聚乙烯、聚丙烯、丙烯酸类、聚酯、碳纤维以及它们的组合。如果需要,网材料可具有某些性质,如耐火性、耐霉菌性、耐水性和/或耐碱性,所述性质为材料固有的或源于化学添加剂和/或处理。
为了提供抗堵塞性质,网应该具有大于膜的干燥厚度的厚度。可选择网的股线的直径,使得网的一部分延伸超过干燥膜的表面。不特别限制编织物的尺寸(紧密性),但为了节约成本,网的股线之间的间距可为约1至1.5英寸(约2.54至3.81cm)。更开放的编织物也确保网不妨碍由膜相对于在安装一体化面板的过程中使用的紧固件而提供的自密封效果。
网优选作为与一体化面板的尺寸相应的片材施用。网可在任何合意的阶段施用至膜。例如,膜可完全湿润、部分干燥或完全干燥,只要膜保持合适量的粘合性以允许网嵌入和保持。
在另一实施例中,支架材料为至少部分嵌入膜中的丸粒或珠粒。丸粒或珠粒为提供抗堵塞效果的任何合适的材料。仅有的实际限制是丸粒或珠粒由耐久材料制得,并具有大于干燥膜的厚度的尺寸(即直径或厚度),使得每个丸粒/珠粒的一部分延伸超过干燥膜的表面。合适的材料包括聚合物(例如聚乙烯(包括HDPE)、聚丙烯、聚苯乙烯、聚氯乙烯、聚酯、丙烯酸类、橡胶和它们的组合)、木材、金属和玻璃。丸粒/珠粒也可由热熔粘合剂形成,所述热熔粘合剂例如基于乙烯乙酸乙烯酯共聚物、乙烯丙烯酸酯共聚物、聚酯、聚乙烯和聚丙烯的那些。
丸粒/珠粒可以以任何合适的方式沉积,以允许丸粒/珠粒将其自身嵌入膜中。丸粒/珠粒可在任何合意的阶段施用至膜。例如,膜可完全湿润、部分干燥或完全干燥,只要膜保持合适量的粘合性以允许丸粒/珠粒嵌入和保持。在一个优选实施例中,丸粒/珠粒以网格或阵列状图案沉积于一体化面板的整个范围上。不特别限制丸粒/珠粒的沉积频率,只要保持抗堵塞性质(例如每1英寸(2.54cm)、每2英寸(5.08cm)、每3英寸(7.62cm)等的间隔)。在一个优选实施例中,丸粒/珠粒的设置不妨碍由膜相对于在安装一体化面板的过程中使用的紧固件而提供的自密封效果。
另外的实施例提供了一种用于制造具有空气/水阻挡膜的外部护套面板的方法。所述方法包括制备水泥浆料并通过将浆料夹在两个覆盖片材之间而制造水泥面板的步骤。在水泥面板凝固之后,用空气/水阻挡膜涂布水泥面板。在一些实施例中,通过将包含石膏的水泥浆料夹在两个纤维玻璃垫之间而制造水泥面板。在水泥面板凝固之后,用如表1所提供而配制的空气/水阻挡膜喷涂、辊涂或溢流涂布水泥面板。上述方法存在许多优点。当在受控条件(包括持续监测和保持温度)下进行时,所述方法产生具有空气/水阻挡膜的外部护套面板,所述空气/水阻挡膜具有一致的厚度、均匀性和膜对水泥面板的平坦粘结。
出乎意料地发现,如上所述的具有空气/水阻挡膜的外部护套面板具有优良的膜对面板的粘合强度,并在粘合强度测试(包括标准化ASTMC297测试)中表现极好。如下表2显示了通过四种不同的喷涂方法A至D(方法A-从面板中间喷涂;方法B-从编码边缘喷涂;方法C-从4ft跨纵向方向部分喷涂;方法D-使用手持泵手动喷雾)制得的如上所述的具有空气/水阻挡膜的外部护套面板的ASTMC297结合测试结果。
表2.粘合强度
出乎意料地发现,如上所述的具有空气/水阻挡膜的外部护套面板提供了优良的膜对面板的粘合强度,并满足ASTMC297结合测试中的15psiZ-方向拉伸粘合强度的最小值。如以上表2中所示,所有面板的平均破裂点在20psi以上。此外,也出乎意料地发现,表2中所有面板的破裂点在面板本身内,即在玻璃垫面与石膏芯之间。
也出乎意料地发现,在各种测试(包括粘附、UV稳定性、透气性、喷雾施用的粘度容易度、表面粘着和堵塞以及干燥缺陷)中,配制具有根据表1配制的空气/水阻挡膜的外部护套面板表现优于配制具有市售涂层(如EXOAIRTM230、ICETM涂层、TREMGARDTMHB(全部来自创高公司(Tremco))的面板。一些对比数据在如下表3中提供。
表3.对比分析
也出乎意料地发现,在烘箱中调整具有空气/水阻挡膜的外部护套面板防止了面板堵塞的问题。这种经调整的面板获得孔堵塞性质,并可储备而无需网或其他支架材料。
进一步出乎意料地发现,当面板在具有两个不同温区的烘箱中调整时获得最佳结果。在一些实施例中,优选的是面板首先在具有较低温度的第一温区中调整,然后移动至第二温区,在第二温区中,第二温度高于第一温区中的第一温度。在一些实施例中,第一温区可设定为100至140°F之间,第二温区可设定为160至190°F之间。用于获得具有抗堵塞性质的具有一体化空气/水阻挡膜的外部护套面板的该调整方法可用于在本公开中描述的具有任何一体化空气/水阻挡膜的面板。在一些实施例中,在具有一体化空气/水阻挡膜的外部护套面板上使用调整方法,所述一体化空气/水阻挡膜配制具有如表1中提供的聚合物粘结剂和碳酸钙。如图2A所示,配制具有如表1中提供的聚合物粘结剂和碳酸钙的一体化空气/水阻挡膜仅在较高温区中经受调整。该面板产生起泡。不同于图2a中的面板,配制具有如表1中提供的聚合物粘结剂和碳酸钙的第二一体化空气/水阻挡膜通过双区方法经受调整。如图2B所示,该第二面板不产生起泡,并具有优良的防堵塞性质而无需网或任何其他另外的处理。
本文描述的一体化面板中的任意者可为包括经由紧固件(例如螺钉、钉子)附接至一个或多个墙立柱或天花板接头的一体化面板的系统的部分,其中一体化空气/水阻挡膜作为外部表面材料。使用合适的合缝带和接合配混物在接缝处接合两个相邻的面板。如果需要,可添加另外的防水层作为另外的空气和水阻挡层。将覆盖材料(例如挡板、盖板、石材)进一步附接至一体化面板的外部饰面。整个系统设计为防止空气和水渗透通过面板至结构内部。
本文引用的所有的引文均以引用方式并入本文,如同单独且特别地指出每个引文以引用方式并入、并以其全文在本文陈述那样的程度。
在描述本发明的上下文(特别是在权利要求书的上下文)中术语“一种”、“一个”和“所述/该”的使用应解释为涵盖单数和复数,除非本文另外指出或上下文明确矛盾。除非另外指出,术语“包含”、“具有”、“包括”和“含有”应解释为开放式术语(即意指“包括但不限于”)。本文数值范围的列举仅旨在用作单独提及落入该范围内的每个分立的值的速记方法,除非本文另外指出,且每个分立的值引入说明书中,就像其在本文单独列举一样。本文所述的所有方法可以任何合适的顺序进行,除非本文另外指出或上下文明确矛盾。本文提供的任何和所有实例或示例性语言(例如“如”)的使用仅旨在更好地说明本发明,而不对本发明的范围进行限制,除非另外声明。本说明书中的语言不应理解为表示对于本发明的实施为必要的任何非声称的元素。
实例1
制造具有一体化空气/水阻挡膜的外部护套面板
水泥面板制备为具有包含石膏的水泥芯,所述水泥芯夹在两个玻璃纤维垫之间。使水泥面板凝固。
空气/水阻挡膜配制为具有聚合物粘结剂、碳酸钙和抗真菌剂,如表1所示。使用空气/水阻挡膜喷涂水泥面板。平行制备第二对照涂布面板。
第一涂布面板在烘箱中在100-140°F范围内的温度下的第一温区处调节,然后移动至第二温区,并进一步在160至190°F范围内的温度下调节。
第二对照涂布面板在相同烘箱中调节,但仅在160至190°F范围内的温度下的第二温区中调节。
尽管第一涂布面板完全调节,不具有气泡并获得防堵塞性质,但第二对照面板覆盖有起球涂层的气泡,且所述对照面板未适当调节,如图2A所示。
Claims (10)
1.一种水泥面板,其包括水泥芯、至少一个覆盖片材和一体化空气/水阻挡膜,其中所述覆盖片材夹在所述水泥芯与所述一体化空气/水阻挡膜之间。
2.根据权利要求1所述的水泥面板,其中所述水泥芯包含选自硫酸钙材料、波特兰水泥和它们的混合物的胶结材料。
3.根据权利要求1所述的水泥面板,其中所述覆盖片材选自纸覆盖片材和纤维垫。
4.根据权利要求3所述的水泥面板,其中所述纤维垫包含聚合物纤维、矿物质纤维或它们的组合。
5.根据权利要求1所述的水泥面板,其中所述一体化空气/水阻挡膜包含30至70重量%的聚合物粘结剂,所述聚合物粘结剂选自聚丙烯酸酯、聚氨酯、有机硅乳液、聚苯乙烯、苯乙烯丙烯酸共聚物和它们的组合。
6.根据权利要求1所述的水泥面板,其中所述一体化空气/水阻挡膜包含20至50重量%的碳酸钙。
7.根据权利要求1所述的水泥面板,其中所述一体化空气/水阻挡膜具有在10至90密耳范围内的干燥厚度。
8.根据权利要求1所述的水泥面板,其中如下中的至少一者:所述水泥芯、所述覆盖片材和所述一体化空气/水阻挡膜包含抗微生物剂,所述抗微生物剂选自2-(4-噻唑基)苯并咪唑、银沸石、氧化锌和吡啶硫酮锌。
9.一种制造具有一体化空气/水阻挡膜的外部护套面板的方法,所述方法包括如下步骤:
-制备包含胶结材料的浆料;
-将所述浆料夹在两个覆盖片材之间;
-使所述浆料凝固,由此形成水泥面板;
-通过喷涂、辊涂或溢流涂布,使用配制为具有聚合物粘结剂和碳酸钙的一体化空气/水阻挡膜在至少一个表面上喷涂所述水泥面板;以及
-在烘箱中调节所述经涂布的水泥面板,其中所述面板暴露于至少两个不同的温区。
10.根据权利要求9所述的方法,其中在第一温区中的温度在100至140°F的范围内,其中在第二温区中的温度在约160至190°F的范围内。
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