CN107075857A - 具有改良表面特性的聚酯层压建筑板 - Google Patents

具有改良表面特性的聚酯层压建筑板 Download PDF

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CN107075857A
CN107075857A CN201580004520.2A CN201580004520A CN107075857A CN 107075857 A CN107075857 A CN 107075857A CN 201580004520 A CN201580004520 A CN 201580004520A CN 107075857 A CN107075857 A CN 107075857A
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building panel
panel according
polyester film
felt
core
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杰里·D·波依兹顿
布莱恩·J·威尔特齐乌斯
迈克尔·J·伦贝格尔
钟-杭·赖
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Saint Gobain Placo SAS
Compagnie de Saint Gobain SA
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    • 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
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
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    • 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
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    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
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Abstract

本发明涉及在建筑板上使用聚酯膜以获得改良的表面涂层。所述聚酯膜优选通过粘着剂施覆至玻璃毡以形成层压物。接着将所述层压物与石膏板的外表面结合。所述聚酯膜因其允许施覆外表面涂层而有利。在一个实施例中，将丙烯酸系外涂层施覆至所述聚酯膜。根据本发明建构的板允许达成外部修整，而不需要过多的修整材料或步骤。

Description

具有改良表面特性的聚酯层压建筑板
技术领域
本发明涉及一种聚酯层压物于建筑板中的用途。更特定来说，本发明涉及使用聚酯层压物以改良建筑板的表面特性。
背景技术
壁板已用作内壁覆盖层超过一个世纪。壁板的最常见类型为石膏壁板。基本构造包括安置在两个相对的纸内衬之间的胶结石膏核。所述纸内衬之一形成外壁修整。纸覆盖的石膏板的一个实例说明于范哈兹伯格(Von Hazmburg)的美国专利案第2,806,811号中。范哈兹伯格揭示一种主要由厚石膏核组成的板，所述石膏核被包装在由马尼拉纸薄片(manila sheet)和新闻纸薄片所组成的纤维封套中。所述薄片层可由常规多缸造纸工艺来制造。
也已知改用对置的玻璃纤维毡替代纸面薄片。所述构造称作玻璃强化石膏板(或“GRG”)。一种GRG板揭示于贝赫(Baehr)等人的美国专利案第4,265,979号中。另一改良是通过在制造工艺期间将一块或多块玻璃纤维毡略微嵌入所述板的核浆料中来实现。此使得在板外表面上形成浆料薄膜。具有所述构造的建筑板称作嵌入式玻璃强化石膏(EGRG)板。EGRG板不存在暴露纤维，或大大地减少暴露纤维的存在。
然而，纸面板、GRG板和EGRG板均需要大量的修整材料和劳动密集步骤以达成期望的外壁修整。根据石膏协会(Gypsum Association)，壁修整的测量是基于范围自最不平滑(0级)至最平滑(5级)的标度进行。0级是指板的外表面粗糙和/或纹理化外观。扭曲和起伏在板上轻易可见。5级是指板的外表面具有近似玻璃的极平滑外观。
在不并入专用密封剂和多个修整化合物撇渣面层(skim coat)下，纸面石膏板不能达成5级修整。随着各级别增大，还需要砂纸打磨。因此，以纸面板达成5级修整是需要多种外加材料的劳动密集过程。
虽然出于不同原因，但在GRG或EGRG板上形成5级修整可证实同样地存在问题。GRG和EGRG板具有填充类干燥剂材料的胶结表面和/或核。因此，当添加修整化合物至这些板的表面时，其很快被吸收。为了有效，必须使用大量的修整化合物。修整化合物的吸收也会造成孔隙、碎裂、过早去饱和以及所得物快速硬化。所有这些均无法在GRG或EGRG板上形成5级修整。
在最近几年，已做出各种努力来减少适当修整外表面壁板所需要的材料、劳动和时间。例如，已开发可喷射化合物以提供具有4级或5级修整的壁板。然而，这些可喷射化合物具有所有前述缺点。纸面板的饱和不够快速。因此，可喷射修整在施覆至纸面板时进行。相比之下，玻璃强化板吸收液体过于快速。因此，必须使用非必要地大量喷洒以达成所需修整。这些问题仅可通过使用撇渣面层或专用底漆来克服，此仅增加修整工作的时间和费用。
本发明复合建筑板被设计成通过使用聚酯膜以最少的修整材料、时间或费用达成平滑外部修整来克服所述缺点。
发明内容
本发明允许以最少的修整材料、时间和费用施覆平滑外部修整至壁板。
本发明的一个优点是通过使用聚酯层压物制造具有平滑外部修整的壁板来达成。
另一优点是通过使用自身可提供令人满意的表面的聚酯层压物作为外部丙烯酸系涂层的基底来达成。
又一优点是通过经由热熔融粘着剂将聚酯膜粘附至纤维毡，借以制造可有利于形成平滑外表面的层压物来达成。
另一优点是通过经由热熔融粘着剂将内衬丙烯酸系物的聚酯膜粘附至纤维毡，借以制造提供平滑外表面的层压物来达成。
另一优点是通过在产生具有期望的表面修整的建筑板时使用穿孔聚酯膜来达成。
本发明的建筑板可形成5级修整，无需额外的修整材料且同时使时间、劳动和费用减到最少。
本发明的各种实施例可不具有或具有部分或所有所述优点。本发明的其它技术优点将易于为本领域技术人员所了解。
附图说明
为了更完全地理解本发明和其优点，现结合附图提及以下描述，其中：
图1为根据本发明制造的建筑板的横截面视图。
图2为用于制造根据本发明的建筑板的生产线的侧视图。
图3为从图2截取的生产线的详细视图。
图4为用于制造根据本发明的建筑板的替代生产线的侧视图。
图5为从图4截取的生产线的详细视图。
图6为自图3的线6-6所截取的剖面图。
图7为自图5的线7-7所截取的剖面图。
在附图的若干视图中，类似参考符号是指类似组件。
具体实施方式
本发明涉及使用聚酯膜以利于改良建筑板的表面修整。所述聚酯膜优选通过粘着剂施覆至玻璃毡以形成毡/膜层压物。随后将所述层压物与石膏板的表面结合。所述聚酯膜因其允许施覆外表面涂层而有利。在一个实施例中，将丙烯酸系外涂层施覆至所述聚酯膜。根据本发明建构的板允许达成外部修整，而不需要过多的修整材料或步骤。
参照图1，聚酯膜22形成复合多层建筑面板24的一层。面板24可由相对的纸薄片与内部石膏核26形成。在另一实施例中，改用相对的纤维毡28代替纸薄片。纤维毡28是由以粘结剂固持在一起的随机对齐的有机或无机纤维形成。与常规的EGRG板相同，毡28是多孔的以容许毡28在组装期间略嵌入石膏核26中。使用石膏纤维板也在本发明范围内。
核26是由在上纤维毡和下纤维毡28的内表面之间完全延伸并结合至所述内表面的硬化结晶石膏基质形成。在一个特定但非限制性实例中，核26紧邻上纤维毡和下纤维毡28的部分的密度大于核26其余部分的密度。换句话说，核26的最内部区域不如上部和下部外围致密。此有助于强化板的表面，同时不会过度增加总板重量。
核26可任选地包括高含量的纤维和淀粉。所述纤维可为玻璃纤维、木纤维、衍生自木材的纤维、合成聚合物纤维、或纸和木纤维的聚结物。在一个优选但非限制性实例中，纤维可占板重量的约1％以上。淀粉也可占板重量的约1％以上。任选地，淀粉可部分地或完全地被合成聚合物替代。
假若使用玻璃纤维，则其可包含约3至50毫米(mm)的长度与5至80微米(μ)的宽度。假若使用衍生的木纤维，则其可由具有介于约0.1mm至0.5mm之间的平均长度与小于20微米(μ)的宽度的再生纤维素纤维形成。纤维聚结物的最长尺寸将为约1mm至15mm。
优选的淀粉可为迁移性或非迁移性的，包括天然、酸解(acid thinned)、氧化、取代(例如，阳离子淀粉、乙基化淀粉)或糊化的淀粉。优选的合成聚合物将包括聚乙酸乙烯酯、聚乙酸乙烯酯-乙烯共聚物、与聚苯乙烯磺酸酯交联的聚乙烯吡咯烷酮、聚乙烯醇、甲基纤维素、羟乙基甲基纤维素、苯乙烯-丁二烯共聚物乳胶、丙烯酸酯乳胶、丙烯酸系共聚物乳胶、聚酯树脂、环氧树脂、聚甲基丙烯酸甲酯或聚丙烯酸。
在所述优选实施例中，聚酯膜22是由聚对苯二甲酸乙二酯(PET)形成。然而，使用其它聚酯膜也在本发明范围内。采用聚合物膜，诸如(但不限于)聚乙烯、聚丙烯、聚苯乙烯、聚氨基甲酸酯、聚乙酸乙烯酯、或聚乙烯醇膜也在本发明范围内。膜22的内表面可进行改性以改良其粘附至下层和促进形成层压物的能力。例如，所述内表面可通过电晕或火焰处理进行改性。
使用粘着剂32来将聚酯膜22粘附至上毡28的外表面。优选的粘着剂为热熔融聚合物粘着剂。粘着剂可为热活化的。也可使用其它聚合物基树脂。粘着剂组合物可包含用于抗紫外线(UV)、抗微生物抗性的添加剂、或其它促进粘附的添加剂。可使用夹钳或辊来活化粘着剂32并因此使膜22接合至上毡28的外表面。所述步骤可在制造最终复合板24需要的其它步骤前且分开地进行。或者，膜22和毡28可在顺着板成型台44的某一点处接合在一起(参见图2)。上毡28与所粘附的聚酯膜22共同形成层压薄片42。粘着剂32形成纤维毡28上的外层，其为平滑的且大体上不含构成毡28的纤维。因此，膜22产生出外观平整的平滑外部施覆表面。膜22因此呈现针对随后修整材料，诸如丙烯酸系物或类似材料的极佳表面。在实践中，膜22的外表面可由范围自.001英寸的最小深度至约0.01英寸的最大深度的微小构形不一致组成。在一个可行替代例中，膜22可具有粘着剂施覆至其两个外表面，使得膜22可结合至多个不同层。
此后将修整涂层34施覆至膜22的暴露表面。在所述优选实施例中，修整涂层34为丙烯酸系物。将丙烯酸系涂层34施覆至聚酯膜22的表面以使板24具有平滑外表面修整。丙烯酸系涂层34也有益，因为其可提供涂漆粘着性和无光泽修整。在一个替代实施例中，可在将层压物递送至板成型线44前将丙烯酸系涂层34粘附至膜22和毡28。
穿孔可于膜22和/或毡28中形成以避免在随后干燥板24期间起泡。此可通过在将膜22粘附至毡28前对其穿孔来达成。或者，毡28和膜22可一起在形成层压物后穿孔。在任一情况中，穿孔容许在随后干燥复合板24期间传输蒸气，包括(但不限于)水蒸气。更具体来说，在板通过一个或多个干燥机时，水蒸气从部分或完全水合的石膏释出。在无穿孔下，从核26中驱赶出来的水蒸气会导致上纸或纤维毡起泡或变形。
图2说明一种可行的用于制造根据本发明的建筑板的制造方法。毡28自供给辊(未显示)松开，继而与膜22接触。毡28和膜22一起被带至夹辊38与冷硬辊36之间。在毡28和膜22并在一起时，模具将粘着剂32供给至辊隙。粘着剂32使膜22结合至毡28的外表面。毡28和膜22共同形成层压物42，随后递送至生产线44。接着供给石膏浆料至毡28的与所粘附膜22相对的表面。石膏浆料是自混合器46递送。膜/毡层压物42优选是嵌入沉积浆料中。可包括振子以确保足够程度的穿透。穿透程度可在0.5％至101％范围内。也就是说，所沉积的浆料可穿透层压物42厚度介于0.5％至101％之间。可自供给辊48递送另外供应的纤维毡28以形成建筑板的相对侧。图3为夹辊38和冷硬辊36的更详细视图。图6的横截面也显示所得层压物42。具体来说，层压物42是由纤维毡28、粘着剂32和膜22形成。
作为共挤出物以液化形式施覆粘着剂32和膜22是在本发明范围内。膜22可在到达生产线44前施覆至毡28。或者，如图2描绘，膜22和毡28可粘附作为单一制造方法的一部分。膜22可类似地在位于生产线44下游的某一点处粘附。例如，膜22可在干燥机之前或之后施覆。膜22可经化学预处理以与粘着剂32中的化合物、软化剂、酸、碱化剂、蜡或其组合化学结合。这种化学结合改良膜与粘着剂32之间的机械和/或化学粘附。
图4和5说明一种替代制造方法。所述方法与上述参考方法在大多数方面相同。然而，在形成毡28和膜22层压物后，在膜22顶部上施覆丙烯酸系涂层34。图7为所得层压物的横截面视图，其是由毡28、粘着剂32、膜22和丙烯酸系涂层34组成。
虽然本发明已就特定实施例和一般相关联的方法进行描述，但本领域技术人员当明了所述实施例和方法的变动和置换。据此，上文的示例实施例的描述不限定或约束本发明。在不脱离本发明的精神和范围下，其它改变、替代和改动也可行。

Claims (24)

1.一种复合多层建筑面板，其包括：
对置的上纤维毡和下纤维毡，所述毡是多孔的且各毡具有内表面和外表面；
硬化石膏核，其在所述上纤维毡和下纤维毡的所述内表面之间延伸并与其结合，所述硬化石膏核紧邻所述上纤维毡和下纤维毡的部分具有比所述硬化石膏核其余部分更大的密度；
具有内表面和外表面的聚对苯二甲酸乙二酯PET膜，所述内表面经由电晕处理改性以改良结合；
热熔融聚合物粘着剂，其将所述PET膜的改性内表面粘附至所述上毡的外表面，借以使所述PET膜与所述上纤维毡结合；
施覆至所述PET膜的外表面的丙烯酸系涂层，所述丙烯酸系涂层提供对所述复合多层建筑面板的表面修整。
2.一种建筑面板，其包括：
至少一个具有内表面和外表面的毡；
结合至所述毡的所述内表面的硬化核；
具有内表面和外表面的聚酯膜；
粘着剂，其将所述聚酯膜的所述内表面粘附至所述毡的所述外表面，借以使所述聚酯膜与所述上纤维毡结合。
3.根据权利要求2所述的建筑面板，其中所述建筑面板包括上毡和下毡，其各自由通过粘结剂固持在一起的随机对齐的无机纤维形成。
4.根据权利要求2所述的建筑面板，其中所述硬化核紧邻所述毡的部分具有比所述硬化石膏核其余部分更大的密度。
5.根据权利要求2所述的建筑面板，其中所述聚酯膜的所述内表面经改性以改良粘着剂结合。
6.根据权利要求5所述的建筑面板，其中所述聚酯膜的所述内表面是通过电晕处理来改性。
7.根据权利要求5所述的建筑面板，其中所述聚酯膜的所述内表面是通过火焰处理来改性。
8.根据权利要求2所述的建筑面板，其中所述粘着剂为热熔融聚合物粘着剂。
9.根据权利要求2所述的建筑面板，其进一步包括施覆至所述聚酯膜的所述外表面的丙烯酸系涂层，所述丙烯酸系涂层提供对所述建筑面板的表面修整。
10.根据权利要求2所述的建筑面板，其中所述聚酯膜为聚对苯二甲酸乙二酯PET膜。
11.根据权利要求2所述的建筑面板，其中所述聚酯膜是穿孔的。
12.一种建筑面板，其包括：
包括粘结至薄片的穿孔聚酯膜的层压物；
硬化石膏核；
嵌入所述硬化石膏核中的所述层压物。
13.根据权利要求12所述的建筑面板，其中所述聚酯膜和所述薄片二者都是穿孔的。
14.根据权利要求12所述的建筑面板，其中所述聚酯膜为聚对苯二甲酸乙二酯PET膜。
15.根据权利要求12所述的建筑面板，其进一步包括施覆至所述聚酯膜的外表面的丙烯酸系涂层，所述丙烯酸系涂层提供对所述建筑面板的表面修整。
16.根据权利要求12所述的建筑面板，其进一步包括用于将所述聚酯膜结合至所述薄片的压敏粘着剂。
17.根据权利要求12所述的建筑面板，其中所述薄片包括纸内衬。
18.根据权利要求12所述的建筑面板，其中所述薄片包括通过粘结剂固持在一起的纤维毡。
19.根据权利要求12所述的建筑面板，其中所述层压物嵌入所述石膏中的程度是介于所述层压物总厚度的约0.5％至101％之间。
20.根据权利要求2所述的建筑面板，其中所述核包含高含量的纤维和淀粉。
21.根据权利要求20所述的建筑面板，其中所述纤维占所述核重量的1％以上。
22.根据权利要求20所述的建筑面板，其中所述淀粉占所述核重量的1％以上。
23.根据权利要求20所述的建筑面板，其中改用合成聚合物替代所述淀粉。
24.根据权利要求2所述的建筑面板，其中所述核包括硬化石膏。
CN201580004520.2A 2014-01-13 2015-01-12 具有改良表面特性的聚酯层压建筑板 Pending CN107075857A (zh)

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US11268277B2 (en) 2022-03-08
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EP3094791A1 (en) 2016-11-23
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US20190277029A1 (en) 2019-09-12
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