CN114423915A - 锥形切口构造 - Google Patents

锥形切口构造 Download PDF

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CN114423915A
CN114423915A CN202080065873.4A CN202080065873A CN114423915A CN 114423915 A CN114423915 A CN 114423915A CN 202080065873 A CN202080065873 A CN 202080065873A CN 114423915 A CN114423915 A CN 114423915A
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M·P·施皮尔曼
P·J·古伯兰德森
S·D·赫尔卡
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USG Interiors LLC
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Abstract

一种干墙板，其中石膏芯包覆在正面纸层和背面纸层中，所述板的边缘朝向背面成锥形，该锥形由正面纸的边缘区域的翼片和附接至正面纸边缘的内侧、折叠进入由板边缘上切割到大致等于翼片的宽度的深度的狭槽形成的空间中的石膏薄层形成，所述翼片由一层连续的热熔粘合剂固定到位，该热熔粘合剂占据狭槽的没有被翼片占据的空间并具有弹性，其使得从板的正面的相关边缘具有抗紧固件穿透性。

Description

锥形切口构造
发明背景
本发明涉及干墙板或面板的改进，特别是涉及便于与类似板完成端部接头的这种板。
现有技术
传统的干墙板被制造为矩形面板，其长边为锥形，以促进平齐的胶接头。长边通常与制造工艺线对齐，使锥形易于形成。短边不那么容易成锥形，因此，大多数干墙产品具有平端或非锥形端，有时称为方形端。
干墙板，也称为石膏板，已在有限的范围内生产，具有锥形短端。在石膏板浇铸过程中或在板已硬化并被切割成一定长度之后，已经采用了各种技术。后者的一个例子在美国专利4,584,224中公开。
例如，从美国专利8,684,134、8,770,345和8,925,677中已知穿孔的和用多孔稀松布包覆的隔音干墙板。这些隔音板在安装后优选涂有相对光滑的透声油漆。这种油漆或涂层具有微不足道的表面隐藏特性，因此面板或板之间的不均匀接头可能明显，尤其是在传统的非锥形对接接头处。
隔音的穿孔干墙板存在一个额外的问题，即板边缘不是锥形的。在宽图案上应用接头化合物以隐藏邻接的平板边缘上的接缝胶，这是传统干墙的常规技术，将不利于吸音功能，因为一定比例的吸音孔会被阻塞并失去其功能。
发明内容
本发明提供了一种干墙板，其长边通常为锥形，其短边以改进板的可使用性的方式修改为锥形。本发明的干墙板的改进的短边被切开或开槽，在切口中提供粘合剂并移位成永久锥形。
该粘合剂是一种热熔产品，通过增加其硬度、弹性和伸长率特性，令人惊讶地改进了改性边缘的可使用性，使边缘与处理、运输和安装的传统锥形边缘相比更耐用。
在优选的形式中，干墙板具有传统的石膏芯，其包裹在正面和背面纸中，这些纸上穿孔有多个小孔，并在其面向房间的一侧覆盖有多孔非织造玻璃纤维稀松布或面纱，并且在其背面覆盖有非织造织物。稀松布粘合附接到干墙板的穿孔纸面上，并通过加强在切口操作中形成的翼片的附着促进本发明的锥形边缘生产，折叠起来以施加热熔粘合剂，然后向下折叠形成期望的锥度。
粘合剂施加是计量的，使得向下折叠的翼片下方的空间优选地略微未充满，以减少否则可能在翼片连接处破裂或以其他方式从预期空间逸出的液压力。
附图说明
图1是干墙板的原始非锥形或方形端部和用于在端部开槽的圆锯片和电机的示意性剖视图；
图2是开槽后的板端部的类似于图1的视图；
图3是干墙板端部的视图，其中翼片通过折叠移动以允许热熔粘合剂从分配器沉积到开槽区域中；和
图4是翼片折叠形成锥形边缘的视图。
具体实施方式
图1示出了干墙板10的非锥形端部。如传统的那样，板10被制造为具有矩形面并且具有石膏芯11，该石膏芯包覆在正面纸层12和背面纸层13中并且粘合到该正面纸层和背面纸层上。矩形板10的长边是锥形的，这在工业上是惯用的。制造的或工厂的长边锥度是通过减少芯11边缘的石膏连续体的厚度来实现的。通常，板或面板10具有4英尺乘8英尺、10英尺或12英尺的主要尺寸。在所示实例中，板10名义上为5/8英寸厚并且具有如美国专利8,684,134、8,770,345和8,925,677中所公开的声学构造。板10，包括纸包覆层12、13，被穿孔有例如直径为0.312英寸(8mm)的圆形孔，总开口面积在约12％和20％之间。板10的周边，例如5-1/2英寸宽的区域是未穿孔的。板的正面或房间侧优选地至其或靠近其四个边缘被覆盖有例如在天花板行业中使用的粘合附接的多孔非织造玻璃纤维面纱或稀松布，并且板10的背面优选地至其或靠近其四个边缘被覆盖有在天花板行业中使用的粘合附接的非织造玻璃纤维面纱或织物。
通常，板10最初被制造为具有短边，例如测量为4英尺的那些，例如，是方形的或非锥形的。本发明提供一种方法和所得产品，通过其将非锥形边缘转换为锥形边缘。
参考图1，在板10的正面在长边上的原始锥度以上部虚线14表示。圆锯片或切割器16由电动机17驱动旋转。锯片16位于平行于板10的平面的平面中，并且与板正面间隔开足够的距离以优选地低于虚线14，在该虚线处，板的长边缘处的锥度处于最小厚度。
在旋转时，锯片16和电机17由机构(未示出)在平行于并沿着原始非锥形板边缘18的路径中驱动，以在该边缘中形成切口或深槽19，如图2所示。举例来说，在所示实例中平行于板10的平面的狭槽或切口19与板10的正面(标为21)间隔约0.080英寸，深度约为2-3/4英寸和宽度大约0.090英寸，理想地对应于锯片16的齿的宽度。优选地对锯片16的切割区域施加强真空，以尽可能多地抽空石膏粉尘。如果需要，原始边缘18可以在切口切割锯片16操作之前用合适的工具例如旋转锯片进行加工或修面。
翼片22包括来自芯11的石膏材料的薄层23以及由切口19产生的正面纸12和稀松布15的共同延伸区域，其优选地通过自动操作的板26折叠到板10上或远离板10，该自动操作板进入切口并且然后围绕与靠近切口19的基部或底部的正面纸12和稀松布15相关联的铰链或折叠线27旋转翼片。纸12和稀松布15在翼片22的折叠运动期间用作“活动铰链”。石膏翼片材料23优选地具有足够的厚度，并且由纸12和稀松布15提供加强以保持完整并且可靠地折叠打开(图3)和闭合(图4)。翼片22的石膏23从石膏芯11的主体沿切口或槽19的底部处的线28断裂。正面纸12撕裂或以其他方式失效的任何趋势都被粘附在其上的非织造面纱或稀松布15抵抗。
在翼片22被板26保持远离槽19的原始区域的情况下，自动操作的分配器31沿板边缘18行进以在原始槽19的侧面33上沉积一定量的热熔粘合剂32。加热到粘合剂工作温度的分配器31可以包括多个孔口或喷嘴34。喷嘴34将精确测量体积的粘合剂32以连续珠形式施加到槽侧33上。
随着粘合剂32分配在开口槽侧33上，翼片22通过平压板自动围绕折叠线或铰链线27朝向槽侧33旋转，直到翼片的远端接触槽侧33的外端或紧邻。压板36将翼片22保持在该位置，直到粘合剂粘附到形成槽侧33和石膏层23的石膏上，冷却并凝固，从而将翼片22固定在锥形位置。
优选地，粘合剂32的分配体积略小于当翼片被压到其锥形位置时由槽侧33和翼片22界定的体积或空间。这确保粘合剂将在槽19底部附近和槽外端附近留下小的空隙区域41、42。
一个或多个粘合剂珠具有足够的直径或横截面，使得它们首先与翼片石膏层23接触，然后被该层横向移位。一个或多个粘合剂珠沿槽19的整个长度是连续的，但是优选地，在槽的两端有轻微的缺口。
可以重复开槽、翼片控制和粘合剂分配设备以同时处理板10的两端。
合适的热熔粘合剂的一个例子是EVA共聚物类型，其具有350华氏度的最佳运行温度和108摄氏度的软化点。这种粘合剂32的特征在于室温下的弹性度。
塌缩槽中的粘合剂32本身形成连续的膜或层，以及在粘合剂的两侧与石膏11粘合的一体化复合结构。由向内或向后折叠的翼片22、粘合剂32和槽19后面的石膏芯11的残余物制成的锥形板边缘已经证明了改进的抗紧固件穿透性的惊人结果。与板10的长边上的常规锥形边缘所表现出的抗紧固件穿透性相比，在台架测试中的粘合复合边缘在峰值负载之后抵抗紧固件型材的穿透约.020英寸的距离，比较而言传统锥形边缘在长板边缘上的抗穿透性约为.017英寸的距离。当边缘附接到与另一个板端部共用的托梁或吊架时，本发明的锥形含粘合剂的板边缘上这种18％改进的抗穿透性特别有益。在这种情况下，螺钉或钉子紧固件可能会朝托梁或吊架中心线翘起，特别是当板边缘没有与托梁或吊架精确位于中心时。更进一步地，以50％的增加测量的增加的硬度和热熔粘合剂的柔韧性提高了板边缘在板的处理、运输和安装期间抵抗冲击的耐久性。
应显而易见的是，本公开是借助于实例，并且可以通过在不脱离本公开中所含有的传授内容的合理范围的情况下添加、修改或消除细节来进行各种变化。因此，本发明不限于本公开的特定细节，除非所附权利要求书必要地如此限定。

Claims (6)

1.一种干墙板，其中石膏芯包覆在正面纸层和背面纸层中，所述板的边缘从板的正面向背面成锥形，该锥形由正面纸的边缘区域的翼片和附接至正面纸边缘的内侧、折叠进入由板边缘上切割到大致等于翼片的宽度的深度的狭槽形成的空间中的石膏薄层形成，所述翼片由一层连续的热熔粘合剂固定到位，该热熔粘合剂至少占据狭槽的没有被翼片占据的大部分空间并具有弹性，其使得从板的正面的相关边缘具有抗紧固件穿透性的距离大于通过朝向相应的板边缘末端逐渐减小连续石膏芯材料的厚度而形成的板的传统锥形边缘的抗穿透性。
2.根据权利要求1所述的干墙板，其中所述板被穿孔有多个孔，并且在正面纸上覆盖有非织造玻璃纤维稀松布，在背面纸上覆盖有非织造织物。
3.根据权利要求1所述的干墙板，其中所述粘合剂的体积小于没有被翼片占据的狭槽的体积，从而避免在所述翼片最终定位期间所述粘合剂中的过大液压力。
4.根据权利要求1所述的干墙板，其中所述翼片的石膏在所述狭槽的底部具有断裂线，所述断裂线是由所述翼片折叠离开原始狭槽空间而产生的。
5.一种使具有纸包覆石膏芯的干墙板的方形端形成锥形的方法，包括在平行于板的正面并与板的正面隔开的边缘末端切割深切口，使得石膏芯材料和正面纸饰面在狭槽的前侧形成翼片，折叠所述翼片，使其与正面纸饰面围绕与狭槽底部相邻的一条线铰接，并且所述翼片的石膏从靠近铰接线的石膏芯断裂，所述翼片从与狭槽相邻的原始位置折叠，同时在铰接线处保持正面纸层与板附接，沿狭槽的其余侧施加熔融的热熔粘合剂并将翼片折叠到原始狭槽的空间中并与粘合剂以确保粘合剂形成占据翼片和芯之间的大部分空间并将翼片保持在最终位置直到热熔粘合剂通过冷却固化的方式接触。
6.根据权利要求5所述的方法，其中所述粘合剂以熔融珠粒的形式沉积，所述熔融珠粒的横截面干扰关闭翼片的运动，以确保所述粘合剂被翼片接触并在珠粒的横向上被压在狭槽侧和翼片二者上。
CN202080065873.4A 2019-09-11 2020-08-21 锥形切口构造 Pending CN114423915A (zh)

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