EP2257666A2 - Toile de renforcement pliable - Google Patents

Toile de renforcement pliable

Info

Publication number
EP2257666A2
EP2257666A2 EP08866360A EP08866360A EP2257666A2 EP 2257666 A2 EP2257666 A2 EP 2257666A2 EP 08866360 A EP08866360 A EP 08866360A EP 08866360 A EP08866360 A EP 08866360A EP 2257666 A2 EP2257666 A2 EP 2257666A2
Authority
EP
European Patent Office
Prior art keywords
web
binder composition
fibers
precursor
foldable
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.)
Granted
Application number
EP08866360A
Other languages
German (de)
English (en)
Other versions
EP2257666B1 (fr
EP2257666A4 (fr
Inventor
Glenn Stevens
Charles Herbert
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Adfors Canada Ltd
Original Assignee
Saint Gobain Technical Fabrics America Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Saint Gobain Technical Fabrics America Inc filed Critical Saint Gobain Technical Fabrics America Inc
Publication of EP2257666A2 publication Critical patent/EP2257666A2/fr
Publication of EP2257666A4 publication Critical patent/EP2257666A4/fr
Application granted granted Critical
Publication of EP2257666B1 publication Critical patent/EP2257666B1/fr
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • D04H1/62—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently at spaced points or locations
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/66—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions at spaced points or locations
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • E04F13/04—Bases for plaster
    • E04F13/042—Joint tapes

Definitions

  • the invention relates to a reinforcing web to reinforce a cementitious wallboard or to reinforce a wallboard joint compound, and a method of making the reinforcing web, as well as, a reinforcing web in a wallboard or in a wallboard joint.
  • wallboard refers to one or more panels or panel sections having major surface areas, which form gypsum wallboard or, alternatively, portland cement wallboard or alternatively, in situ polymeric foam panels of US 2007/0099524 Al.
  • U.S. 5,017,312 discloses chopped glass fiber mats tested for flexure and tensile properties according to ASTM D 790-84a "Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials," and ASTM D 638-84 “Standard Test Method for Tensile Properties of Plastics.” The tests are performed on mats having random oriented chopped fibers and mats having directionally oriented chopped fibers.
  • US 7,141,284 B2 discloses a reinforcing web having a rewettable coating to solubilize in a slurry of a joint compound and form an adhesive bond with the joint compound.
  • Open wallboard seams are formed between abutting sections of gypsum wallboard that meet side-by-side, or that meet at inside corners.
  • a wallboard joint is constructed, by applying a joint compound reinforced with an imbedded reinforcing tape. Additional seams can appear as cracks in the wallboard, which are repaired by constructing wallboard joints.
  • the joint compound is in the form of a shapeable slurry that fills the seam.
  • the reinforcing tape is applied to extend across the filled seam, and to overlap the edge margins of the wallboard abutting the filled seam. It is desirable that the reinforcing tape is foldable to
  • DM2U505651.3 form a lengthwise crease.
  • the crease is needed for conformance at an inside corner of a wall meeting another wall or a wall meeting a ceiling, wherein wallboard sections of the walls and ceiling meet one another at an angle less than 180 degrees.
  • a wallboard joint is constructed at the inside corner by applying joint compound to imbed the creased reinforcing tape.
  • a joint tape made of paper is capable of forming a crease for installation at inside corners wherein wallboard sections meet one another at an angle of less than 180 degrees.
  • commercial tooling has been developed to use paper tape for machine construction of a wallboard joint. The tooling continuously dispenses the paper tape and continuously dispenses a joint compound slurry to imbed the tape.
  • a drawback of paper tape is that the paper is weakened by becoming saturated with water from the slurry, and is incapable of passing air bubbles that are trapped behind the paper tape during construction of a wallboard joint.
  • a fabric tape has been used to reinforce a joint compound.
  • a thin porous fabric has been manufactured with random laid glass fibers adhered to one another with a urea-formaldehyde binder. The tips of the glass fibers tend to poke out, which is irritating to the touch when handled by a worker.
  • a binder coated fabric resists being folded, and is not able to form a crease for conformance to an inside corner. Further, the binder covered fabric is not adaptable as is paper for handling by machine tooling for fabricating a wallboard joint. Such drawbacks deter using a binder coated fabric for reinforcing a joint compound.
  • a reinforcing web for imbedding at least partially in a cementitious material that hardens from a slurry form includes multiple fibers joined together by a binder. At least some of the fibers have foldable portions, wherein the foldable portions have less binder composition thereon to increase flexure while folded without forming a crease or while folded to form a crease, and the foldable portions extend over a lengthwise central section of the web.
  • the reinforcing web reinforces either a cementitious board or a wallboard joint compound.
  • a planar section of the web reinforces a major surface of a wallboard, and foldable portions of the web are of increased flexure to be foldable over lateral edges of a wallboard to reinforce the lateral edges.
  • a lengthwise central section of the web is foldable to form a crease for conformance to an inside corner formed by a wallboard joint compound.
  • a method of making a reinforcing web comprises, applying a binder onto multiple fibers, wherein the fibers are oriented lengthwise in multiple directions, including random directions, predetermined directions, or a combination thereof to form a non- woven web, removing at least some of the binder from foldable portions of at least some of the fibers to increase flexure of the foldable portions at a fold of the foldable portions, and joining the fibers to one another by curing the binder thereon to resist tensile forces exerted in said multiple directions.
  • the method includes, removing substantially all of the binder from foldable portions of at least some of the fibers to increase flexure of the foldable portions at a fold of the foldable portions and to form a crease in the fold.
  • Fig. 1 is a schematic view of a first embodiment of a reinforcement tape.
  • Fig. 2 is a schematic view of a roll of tape according to one of the embodiments of a reinforcement tape.
  • FIG. 3 A is schematic view of a portion of a manufacturing system and apparatus.
  • Fig. 3B is a schematic view of another portion of a manufacturing system and apparatus.
  • Fig. 4 is a schematic view of a vacuum table of a manufacturing system and apparatus.
  • Fig. 4A is a view similar to Fig. 4 of another embodiment of a vacuum table.
  • Fig. 5 is a schematic view of a slitting apparatus of a manufacturing system and apparatus.
  • Fig. 6 is a schematic view of a second embodiment of a reinforcement tape.
  • Fig. 7 is a schematic view of another embodiment of a reinforcement web.
  • Fig. 8 is a schematic view of the reinforcing web of Fig. 7 providing a facing on a cementitious material to form a board.
  • Fig. 9 discloses a boxplot of test data in a test for Gurely Stiffness by Sample.
  • Fig. 10 discloses a boxplot of test data in a test for Flexural Strength (PSI) by
  • the invention relates to a fiber reinforcement web to at least partially imbed in a cementitious material, and methods for making the same.
  • the reinforcement web is at least partially embedded in the cementitious material that is hardened from a slurry form to form a wallboard.
  • the fiber reinforcement web permeability enables penetration by the cementitious material in slurry form to at least partially imbed the web in the cementitious material to reinforce the cementitious material.
  • the imbedded web reinforces the hardened cementitious material, adding to its flexural strength and its tensile strength, i.e. resistance to deflection and resistance to cracking and fracture due to strain induced by external tensile forces and/or due to internal strain.
  • the relative permeability of the web due to the sizes of pores or spaces between the fibers, and the relative viscosity of the slurry determine to what extent the web becomes imbedded in the slurry.
  • a web of lower permeability, smaller pores or spaces between the fibers promotes penetration of a lower viscosity slurry and tends to imbed at the surface of a lower viscosity slurry, particularly for a slurry mixture of the lower viscosity slurry and a higher viscosity slurry.
  • a web of higher permeability, larger pores or spaces between the fibers can promote penetration of a lower viscosity slurry, and can embed deeper, below the surface of the slurry. Further, a web of higher permeability is required to promote penetration of a higher viscosity slurry.
  • a slurry wetting agent applied to coat the fibers further promotes wetting of the fibers by the slurry together with penetration of the web by the slurry.
  • a solvent activated adhesive coating on the fibers further promotes adherence of the fibers to a hardened cementitious material.
  • water is a solvent of a gypsum cementitious slurry or of an alkali cementitious slurry, which activates a water activated adhesive coating on the fibers to and adhesive state for adherence to a hardened wallboard or hardened joint compound.
  • the invention relates to a reinforcement web to reinforce a cementitious material, wherein the web is constructed with a varied flexibility for foldability and creasability and for achieving a result including but not limited to, bending the web and/or folding the web and/or creasing the web to conform the web to the shape or shapes of the cementitious material being reinforced by the web.
  • the fiber reinforcement web is constructed for flexibility or flexure, foldability and creasability at one or more selected locations on the web.
  • the flexibility or flexure, foldability and creasability varies across the width of the web or alternatively in another direction.
  • the fiber reinforcement web is constructed with chopped reinforcement fibers bonded together by a binder composition dispersed among the fibers and cured, i.e., solidified, to bond the fibers together.
  • the binder composition is dispersed with a lower binder mass distribution and a higher binder mass distribution in respective continuous lines or continuous areas that extend lengthwise of the web or alternatively in another direction.
  • the lines or areas extend continuously throughout a dimensional measurement of the web area to include the web thickness, such that a section of the web within the lines or areas including the web thickness is constructed with relatively less binder composition to adjust or induce flexibility, foldability and creasability. Alternatively, the section of the web is constructed with substantially less binder composition to adjust or induce foldability and/or creasability.
  • the binder composition is dispersed with a relatively lower binder mass distribution than elsewhere in the web.
  • the fiber reinforcement web is made with a selected thicknesses.
  • a fiber reinforcement web having a maximum thickness of a paper drywall tape is adapted for use in fabricating a drywall joint.
  • the dry wall tape is creased lengthwise for conformance to an inside corner.
  • a fiber reinforcement web having a thickness of a wallboard facing sheet is adapted for use in fabricating a cementitious wallboard.
  • the fiber materials, lengths and thickness, the web permeability and thickness, and the binder composition viscosity are selective to promote penetration of the intended slurry composition and adherence of the fibers to the cementitious composition.
  • the fiber materials, lengths and thickness, and the web thickness are selected to promote flexure strength and tensile strength of the fiber reinforced cementitious.
  • Fig. 1 discloses a thin non- woven reinforcement web 104 of multiple fibers
  • the fibers 102 comprise a high tensile strength material, including but not limited to glass or a polymer, for example, a polyester. Further, the fibers 102 are water resistant when manufactured of glass, a crystalline polymer or a thermoset polymer. The fibers 102 are alkali resistant when manufactured of either AR glass or polymer coated glass. [0029] According to an embodiment of the invention, the fibers 102 are chopped or severed to lengths of about 0.75 inch (19.05 mm.) to about 1.5 inch (38.100 mm.).
  • the fiber diameters comprise one of about, 11 ⁇ mm., 13.5 ⁇ mm. or 16 ⁇ mm.
  • the distribution of the fibers 102 in the web 104 provides a web thickness preferably equal to that of a commercially available, cellulosic paper joint tape, about 0.18 mm., plus or minus allowable dimensional tolerances.
  • the web 104 has a width of about 2 inches (5 mm.) desirably about equal to or less than that of a commercially available, paper joint tape. Thereby, the web 104 has dimensions capable of substituting for a paper tape that is used in commercial tooling to fabricate a wallboard joint.
  • the distribution of spaces between adjacent fibers 102 provides the web 104 with openings for passage of a commercially available joint compound in slurry form during a process of imbedding the web 104 in the slurry to make a wallboard joint.
  • the web 104 in the form of a joint tape 100 is of continuous length, and has lengthwise lateral sections 106, 108 adjoining a lengthwise central section 110 that encompasses a lengthwise central axis 112 of the web 104.
  • the fibers 102 in the lengthwise lateral sections 106, 108 are joined together by a binder composition 114 thereon.
  • the binder composition 114 joins the fibers 102 with one another.
  • the fibers 102 in the web 104 are laid flatly and extend in multiple directions, including random directions, predetermined directions, or a combination thereof to resist tensile forces exerted in such multiple directions. Thereby, the fibers 102 resist tensile forces exerted in said directions when the fibers 102 are imbedded in a joint compound.
  • the joint compound will be reinforced by the imbedded fibers 102 of the web 104 to resist cracking under stress when forces are exerted on a wallboard joint formed by the reinforced joint compound.
  • Spaces among the fibers 102 provide passages through the web 104 for passage of joint compound slurry. As an advantage compared to paper joint tape, the passages permit escape of air from being trapped behind the
  • the fibers 102 provide a web 104 that comprises a non- woven mat or fleece in which the fiber lengths lie flatly in the thickness plane of the web 104, and extend lengthwise in multiple directions, including random directions, predetermined directions, or a combination thereof.
  • the lengthwise central section 110 of the web 104 is about 1 mm. to about 3 mm. wide.
  • the lengths of respective fibers 102 are less than the overall width of the web 104.
  • the lengths of respective fibers 102 are greater than the width of the central section 110 of the web 104.
  • the web 104 of the present invention must be capable of lengthwise folding to form a crease. The crease is needed for conformance at an inside corner where two sections of wallboard meet at an angle less than 180 degrees.
  • the lengthwise central section 110 is foldable to form a lengthwise crease, extending preferably along the axis 112.
  • the fibers 102 that have the binder composition 114 thereon tend to resist being creased.
  • some of the fibers 102 have foldable portions 116 that extend over the central section 110, and are free of the binder composition 114 so as to crease upon being folded.
  • the foldable portions 116 of at least some of the fibers 102 in the lengthwise central section 110 have less binder composition 114 thereon than do the fibers 102 in the lengthwise lateral sections 106, 108, so as to crease upon being folded.
  • the lengths of the fibers 102 are less than the overall width of the web 104.
  • the lengths of the fibers 102 are greater than the width of the central section 110, such that the fiber lengths extend in the central section 110, further project outwardly from the central section 110, and into at least one lateral section 106, 108, wherein they are joined with other fibers 102 by having the binder composition 114 thereon.
  • Construction of a wallboard joint is performed either by manipulating hand tools, or by using commercial machine tooling.
  • a paper type joint tape can be manually handled by a human worker who applies the tape by hand, and uses hand tools to imbed the tape in a slurry of joint compound, and to spread and smooth the joint compound to make a wallboard joint.
  • commercial machine tooling continuously applies a joint compound slurry and a paper type joint tape while continuously imbedding the paper type joint tape in the slurry, and spreading and smoothing the joint compound to make a wallboard joint.
  • An embodiment of the tape 100 according to the invention is intended as a replacement for paper type joint tape for use in commercial machine tooling or for manual
  • an embodiment of the web 104 has about the same dimensions as the paper type joint tape, or less. Further, the web 104 has a suppleness about that of paper tape for ease in handling and constructing a wallboard joint by hand tools or commercial machine tooling. Further, the web 104 of the present invention is rolled up on itself, Fig. 2, while in the form of a reinforcing tape 100, and undergoes unrolling from a roll 200 of the tape 100, for application onto a wallboard joint and imbedding in a joint compound slurry.
  • the web 104 must be capable of forming a crease for installation and conformance at an inside corner. Further, the web 104 of the present invention must have smooth fiber surfaces to avoid irritation to a human skin while being handled by a worker. [0039] A process of making the reinforcement web 104 or tape 100 will now be described.
  • the fibers 102 are chopped or severed to lengths of about 0.75 inch (19.05 mm.) to about 1.5 inch (38.100 mm.).
  • the fibers 102 are commercially purchased as chopped fibers 102.
  • Figs. 3A and 3B disclose a system and apparatus 300 to manufacture the web
  • the short length fibers 102 are commercially purchased and are amassed into a slurry 302 by mixing with a slurry solution comprised of water enhanced with a surfactant and a viscosity increaser.
  • the slurry 302 comprises 0.1212 % solids of a soluble surfactant and 0.0072% solids of a soluble viscosity enhancer and water to total 102,000 gallons (386,112 liters)of slurry solution mixed with fibers 102.
  • the slurry 302 comprises an agglomerate of the fibers 102 and slurry solution, and is capable of settling or slumping to form a thin and uniform layer.
  • the slurry 302 emerges from a head box dispenser 304 that uniformly distributes the slurry 302 in a uniform layer on a forming wire 306.
  • the forming wire 306 comprises a perforated, non-woven flat fabric of a non-stick material, such as, polytetrafluoroethylene (PTFE).
  • PTFE polytetrafluoroethylene
  • the non- woven fibers 102 of the slurry 302 are wet laid flatly on the forming wire 302, and extend lengthwise in multiple directions, including random directions, predetermined directions, or a combination thereof to form the non- woven web 104.
  • the fibers 102 in the web 104 are held together by the slurry solution, and by support against the forming wire 306, while the web 104 and forming wire 306 are conveyed by industry standard conveyers 308 to pass over a first vacuum box 310.
  • the first vacuum box 310 removes excess solution by suction, impelling the water in the web 104 and ambient air downwardly, as indicated by the arrows, through the perforated forming wire 306.
  • the removed solution is collected in a collection tank 312 for recycled use in the system
  • the fibers 102 are drawn against the forming wire 306 by the suction to form a web thickness about equal to that of a paper joint tape.
  • the conveyed web 104 is then transferred from the forming wire 306 onto a saturator wire 314, of similar construction as the forming wire 306.
  • the web 104 on the saturator wire 314 is conveyed by industry standard conveyors 316 and passes under a curtain coater 318 of the system and apparatus 300, which applies a falling, flowing curtain of fluent binder composition 114 onto the web 104.
  • the binder composition 114 distributes among the fibers 102.
  • the fluid binder coats the web 104 and adheres to the tips of the fibers 102, as well, to smooth the surfaces of the fibers 102 for non-irritating contact with a person's skin.
  • the web 104 is conveyed continuously lengthwise while being coated with a solution of the binder composition 114.
  • Fig. 3B the web 104 while on the saturator wire 314 passes over a second vacuum box 320, directly aligned vertically under the curtain coater 318.
  • the second vacuum box 320 draws a vacuum (reduced air pressure) to remove excess fluent binder composition 114 by suction from the fibers 102.
  • the removed binder composition 114 is collected in a collection tank 322 for recycled use in the system 300.
  • Essential amounts of the binder composition 322 remain on the fibers 102 for subsequent joining of the fibers 102 together in the binder coated portions of the web 104.
  • saturator wire 314 and the conveyed, binder coated web 104 pass over a top surface 324 of a vacuum table 326.
  • a motor driven vacuum pump 328 draws air from an interior 330 of the vacuum table 326, which draws a vacuum (reduced air pressure) in the interior 330 of the vacuum table 326, while one or more water jet nozzles 332 focus a stream of water 334 from above.
  • the surface 324 of the vacuum table 326 has a lengthwise, narrow slot 400 over which the lengthwise central section 110 of the web 104 is conveyed.
  • the nozzles 332, in Fig. 3, focus the stream of water 334 in a narrow pattern aligned with the lengthwise slot 400 to impinge the lengthwise central section 110 of the web 104.
  • Water is a solvent for the uncured binder composition 114.
  • a solvent 334 other than water can be dispensed to impinge a binder composition 114 that is soluble in the solvent 334 other than water.
  • Water dispenses from each water jet nozzle 322 and passes through the foldable portions 116 of the fibers 102 that extend into the narrow central section 110 of the web 104.
  • the water is vacuum drawn by the reduced air pressure of the vacuum
  • Fig. 4A discloses the narrow slot 400 transverse or crosswise to the lengthwise central section 110.
  • the stream of water 334 is focused in a narrow pattern by an appropriate number of the nozzles 332 of Fig. 4, to impinge the lengthwise central section 110 of the web 104.
  • the web 104 is conveyed lengthwise at a speed sufficient to avoid spreading of the stream of water 334 beyond the narrow central section of the web 104 before the water is vacuum drawn into the slot 400 of the vacuum table 36.
  • the water flows through the central section 110 of the web 104, which dilutes the water soluble binder composition 114 and removes at least some of the binder composition 114 from at least some of the foldable portions 116 of the fibers 102 to increase flexure and reduce stiffness thereof by reducing the amount of binder composition 114, and alternatively, removing substantially all of the binder composition 114 from such foldable portions 116 to permit folding and creasing of the foldable portions 116.
  • the binder composition 114 is completely removed from the foldable portions 116 of the fibers 102 that are in the central section 110 of the web 104.
  • the removed binder composition 114 is collected in a collection tank 336 for recycled use in the system 300.
  • the binder removing operation is narrowly focused on, and confined to, the longitudinal central section 110 of the web 104 by the combined, focused water jet and the width of the narrow slot 400 through the surface 324 of the vacuum table 326.
  • the non-removed binder composition 114 remains adhered to respective fibers 102.
  • the web 104 is conveyed through a curing oven 338 at elevated temperature, such that the binder composition 114 on the fibers 102 is heated to a curing temperature, which drives off the solvent and solidifies the binder composition 114 to a thermoset state.
  • the binder 114 is cured and set to a thermoset state, wherein the binder 114 is solidified and becomes insoluble in water and other solvents, and joins the fibers 102 together in the web 104.
  • the web 104 is rolled up to form the roll 200 of reinforcement tape 100.
  • the binder composition 114 is cooled to ambient temperature after the web 104 leaves the curing oven 338.
  • the binder composition renders the fibers 102 more supple to the touch.
  • the binder coated fibers 102 resist flexure when folded and resist forming a crease when folded.
  • the binder composition is applied to the fibers 102 accumulated on a shaped conveyor belt surface, straight or curved, to form a web 104 having a shape formed by and conforming to the shape of the conveyor belt surface.
  • the binder composition render the binder coated fibers 102 sufficiently stiff to retain the web 104 with a shape as formed.
  • the binder coated fibers 102 form a flat web 104 to provide a flat major surface of a gypsum board or cement board.
  • the foldable portions 116 of at least some of the fibers 102 have less binder composition thereon to increase its flexure while folded, and preferably have substantially or essentially all of the binder composition removed, so as to form a crease while folded and creased.
  • the foldable portions 116 are in the section 110 of the web 104 that is foldable.
  • a non- irritating binder composition 114 coats the fibers 102.
  • An embodiment of a non-irritating binder composition 114 comprises 3-10 grams of a matting agent, for example, a polymethyl urea resin with about 0.6% reactive methyl groups and primary particles of about 0.1 to 0.15 mian. forming agglomerates of about 3.5 to 6.5 mwm.
  • GP Resi-Mat a urea formaldehyde copolymer forming resin soluble in water
  • the preferred solid is marketed as PERGOPAK m5 a trademark of Albemarle Corporation, which refers to a polymethyl urea resin having a water content of 15 weight % H 2 O corresponding to the m5 designation and forming a thermosetting urea-formaldehyde copolymer, condensation product or reaction product.
  • a non-formaldehyde fluid binder composition 114 comprises Acrodur 950L, a water soluble thermosetting acrylic polymer binder cut to a range of 15% - 25% solids from 50%-55% solids, for example, 20Og of water as a solvent for 20Og of Acrodur.
  • the web 104 for use as a joint tape 100 is preferably about equal to the width of a paper joint tape.
  • Fig. 5 discloses another embodiment of the invention, wherein the web 104 is conveyed through a slitter apparatus 500. The web 104 is conveyed by a tow chain or by industry standard conveyors 504.
  • a slitting blade 502 is disclosed, which may be circular or flat.
  • the slitting blade 502 slits the web 104 lengthwise to a desired width corresponding to the width of a wallboard joint tape, preferably about equal to the width of a paper joint tape or less than the width of a paper joint tape, to substitute for paper joint tape in applicator tooling. Slitting with a sharp blade would leave sharp edges on the severed fibers 102, which would provide a source of skin irritation.
  • the slitter apparatus 500 has a blunt edge slitting blade 502 to slit through the web 104, while the blunt edge makes crushed edges on the fiber ends along the sections 106, 108, Fig. 1, of the web 104.
  • the crashed edges are less irritating to sldn than are sharp edges.
  • the slitter apparatus has a sufficient number of blades 502 to slit the web 104 lengthwise to form one or more joint tapes 100, side by side.
  • the vacuum table 326 is provided with one or more lengthwise slots 400 corresponding to the number of central sections 110 of respective joint tapes 100 to be manufactured, side by side.
  • the vacuum table 326 is provided with one or more lengthwise slots 400 corresponding to the number of foldable portions 116 are intended for the same single reinforcement web 104 of the type disclosed by Fig. 7 below.
  • the slitter apparatus 500 slits the web 104 to form the lengthwise lateral sections 106, 108 adjoining each lengthwise central section 110.
  • the central section 110 is equidistant from lateral edges of the web 104.
  • the tape 100 is rolled up on itself to provide a roll 200 of tape. Thereafter, the tape 100 is dispensed by unrolling from the roll 200, either by hand operation or by tooling operation.
  • Fig. 6 discloses another embodiment of the invention, wherein the tape 100 is provided with a fold line 600 that provides a guide for folding the tape 100 with ease.
  • the tape 100 is folded along the central longitudinal axis 112 to provide a crease 600 along the tape axis.
  • the tape 100 is then unfolded for the crease 600 to lie essentially flat and provide a fold line.
  • the unfolded tape 100 is rolled up on itself to provide a roll 200 of tape, as in Fig. 2, having a fold line 600 as a guide for folding and creasing the tape 100 in the future. Thereafter, the tape 100 is dispensed by unrolling from the roll, either by hand operation or by tooling operation.
  • the fold line 600 provides a guide for folding the tape 100 with ease along the fold line 600 to conform the tape 100 to an inside corner in preparation for imbedding in a wall board joint.
  • the tape 100 can be folded, for example, ninety degrees, and return to its original flat shape without losing tensile strength.
  • the fibers are free of the binder and are free to flex without fracturing in response to being folded.
  • This feature differs from tapes in which their fibers are held by a binder, which resists flexure of the fibers, and which causes the fibers to become weakened or fractured when the fibers are flexed.
  • the fibers in the foldable portions 116 of the lengthwise central section 110 extend into the binder coated lateral sections 106, 108 for the binder to bond the fibers to other fibers in the tape 100, and to resist pull-out of the fibers
  • DM2M505651.3 from a hardened joint compound. Further, a hardened joint compound adheres to the fibers that bridge across the foldable portions 116 to the binder coated lateral sections 106, 108 to reinforce the joint compound and provide resistance to cracking.
  • Fig. 7 discloses an alternative embodiment of a reinforcement web 104 to imbed at least partially in a surface of a cementitious material, for example, a cementitious board formed by hardening a slurry of a gypsum mixture or portland cement mixture or in situ foamed polymeric material.
  • the reinforcement web 104 provides a facing or facing layer of the cementitious material.
  • the fibers of the reinforcement web are fabricated of polymeric material, AR glass fibers or an alkali resistant polymer coating applied to chopped glass fibers intended to imbed at least partially in alkaline cementitious material, for example, portland cement.
  • the reinforcement web 104 has a flat central section 110 of binder coated fibers 102 to form a flat surface of a wallboard. Adjacent to and contiguous with the central section 110, the reinforcement web 104 has lengthwise foldable portions 116, wherein at least some of the binder composition 114 is removed from at least some of the foldable portions 116 of the fibers 102 to increase flexure and reduce stiffness thereof by reducing the amount of binder composition 114. Alternatively, removing substantially or essentially all of the binder composition 114 from such foldable portions 116 permits folding and creasing of the foldable portions 116.
  • the foldable sections are adjacent to lateral web sections 700 adjacent to respective lateral edges 702 of the web 104.
  • the web sections 700 are coated with the binder composition 114, or alternatively, the binder composition 114 is removed partially or fully removed to adjust the flexure and/or foldability of the web sections 700.
  • Fig. 8 discloses a cementitious composite material 802 forming a facing layer of a cementitious board 800 reinforced by the reinforcement web 104 of Fig. 7.
  • the entire web 104 is at least partially imbedded in the cementitious material 802 that is hardened from a slurry form.
  • the foldable portions 116 are of reduced flexure to fold in conformity with the lateral edges 804 of the board 800.
  • the flexure is increased by removal of a corresponding amount of at least some of the binder composition 114 from the foldable portions 116.
  • the foldable portions 116 are capable of wrapping around the edges and creasing along each of the foldable portions 116 by removal of substantially or essentially all of the binder from the foldable portions 116.
  • the foldable portions 116 are folded by flexure thereof to wrap by flexure around corresponding
  • edges 804 of the board 800 to reinforce the edges 802 against damage due to impact or thermal expansion and contraction.
  • the foldable portions 116 are foldable with creases to form substantially or essentially sharp edges 804 on the board 800.
  • the foldable portions 116 are foldable without creases for the edges 804 on the board 800 to have rounded configurations.
  • a flat central section 110 of the web 104 covers a flat major surface of the board 800.
  • the opposite major surface of the board 800 is covered by another reinforcement web 104a that is at least partially embedded in the cementitious material 802.
  • the web sections 700 of the web 104 overlap and cover corresponding edge sections 700a of the other reinforcement web 104a, and the overlapped sections 700 and 700a are at least partially imbedded in the cementitious material 802.
  • Gurley stiffness test a standard glass mat was tested against a glass mat with a "folding point" or seam or area with reduced binder. A typical Gurley Stiffness testing apparatus was used. The glass mat with seam shows a Gurley Stiffness of 106.47 which is lower than the glass mat without seam 257.43. Using Statistical Analysis a one-way ANOVA shows a statistically significant difference or P value of less than 0.05. With the glass mat with seam being less stiff/more flexible than the glass mat without the seam.
  • DM2 ⁇ 1505651 3 secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
  • Patents, patent applications and publications referred to herein are hereby incorporated by reference in their entireties. Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Textile Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Paper (AREA)
  • Laminated Bodies (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

La présente invention concerne une toile de renforcement comportant de multiples fibres jointes ensemble par un liant. Au moins quelques-unes des fibres présentent des parties pliables, les parties repliables comportant sensiblement moins de liant afin d'augmenter la flexion de pliage de la toile. Un procédé de réalisation de toile de renforcement comprend l'application d'un liant sur la toile et le retrait total ou partiel de ce liant d'une partie pliable de la toile avant le traitement thermique du liant restant sur la toile.
EP08866360.4A 2007-12-19 2008-12-18 Toile de renforcement pliable Not-in-force EP2257666B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US1494207P 2007-12-19 2007-12-19
PCT/US2008/087343 WO2009085901A2 (fr) 2007-12-19 2008-12-18 Toile de renforcement pliable

Publications (3)

Publication Number Publication Date
EP2257666A2 true EP2257666A2 (fr) 2010-12-08
EP2257666A4 EP2257666A4 (fr) 2012-10-03
EP2257666B1 EP2257666B1 (fr) 2016-03-23

Family

ID=40825008

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08866360.4A Not-in-force EP2257666B1 (fr) 2007-12-19 2008-12-18 Toile de renforcement pliable

Country Status (5)

Country Link
EP (1) EP2257666B1 (fr)
AU (1) AU2008343161B2 (fr)
CA (1) CA2708963C (fr)
NZ (1) NZ586545A (fr)
WO (1) WO2009085901A2 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9297098B2 (en) 2007-12-19 2016-03-29 Saint-Gobain Adfors Canada, Ltd. Foldable reinforcing web

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1214154A (en) * 1967-08-10 1970-12-02 Fibreglass Ltd Improvements in or relating to the manufacture of impregnated fibre material
GB2247031A (en) * 1988-06-13 1992-02-19 Ruberoid Building Products Lim Reinforcement of tissue
US5418027A (en) * 1994-03-03 1995-05-23 Conboy; John S. Wall board tape having fibrous surface
US5486394A (en) * 1994-08-26 1996-01-23 E-Z Taping System, Inc. Self-release self-adhesive drywall tape
US5865003A (en) * 1997-09-05 1999-02-02 Owens Corning Fiberglas Technology, Inc. Reinforced glass fiber mat and methods of forming
US20030186037A1 (en) * 2002-04-02 2003-10-02 Edge Barry Nelson Mat and a method of making the mat

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2116081C (fr) * 1993-12-17 2005-07-26 Ann Louise Mccormack Materiau permeable a l'air constitue d'une pellicule et d'un non-tisse colles
US7560398B2 (en) * 2003-07-18 2009-07-14 3M Innovative Properties Company Cleaning wipe and method of manufacture
US20060258249A1 (en) * 2005-05-11 2006-11-16 Fairbanks Jason S Elastic laminates and process for producing same

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1214154A (en) * 1967-08-10 1970-12-02 Fibreglass Ltd Improvements in or relating to the manufacture of impregnated fibre material
GB2247031A (en) * 1988-06-13 1992-02-19 Ruberoid Building Products Lim Reinforcement of tissue
US5418027A (en) * 1994-03-03 1995-05-23 Conboy; John S. Wall board tape having fibrous surface
US5486394A (en) * 1994-08-26 1996-01-23 E-Z Taping System, Inc. Self-release self-adhesive drywall tape
US5865003A (en) * 1997-09-05 1999-02-02 Owens Corning Fiberglas Technology, Inc. Reinforced glass fiber mat and methods of forming
US20030186037A1 (en) * 2002-04-02 2003-10-02 Edge Barry Nelson Mat and a method of making the mat

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO2009085901A2 *

Also Published As

Publication number Publication date
CA2708963C (fr) 2015-05-05
AU2008343161B2 (en) 2011-04-21
WO2009085901A3 (fr) 2009-09-03
CA2708963A1 (fr) 2009-07-09
NZ586545A (en) 2012-12-21
AU2008343161A1 (en) 2009-07-09
WO2009085901A2 (fr) 2009-07-09
EP2257666B1 (fr) 2016-03-23
EP2257666A4 (fr) 2012-10-03

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