MX2013003872A

MX2013003872A - Water resistant ceiling tile.

Info

Publication number: MX2013003872A
Application number: MX2013003872A
Authority: MX
Inventors: Fares Saghbini
Original assignee: Usg Interiors Llc
Priority date: 2010-10-18
Filing date: 2010-10-18
Publication date: 2013-06-28
Also published as: JP2013544990A; HK1181830A1; US20130196151A1; RU2013120405A; EP2630312A4; CA2813558A1; EP2630312A1; BR112013008123A2; JP5740001B2; CN103154400A; RU2552268C2; CN103154400B; WO2012054014A1; AU2010362657A1

Abstract

A ceiling tile comprising a core, an appearance coating on a face side of the tile, and a waterproof coating on a backside of the tile, the core including a filler, binder, and fiber elements dried from a water based slurry or paste of said elements, the core being water permeable and containing a non-white stain producing material susceptible to being leached out of the core by water percolating through the core, the appearance coating exhibiting a high light reflectivity by virtue of containing a white colored constituent and being pervious to water, the waterproof coating serving to repel and bead- up water droplets deposited on the backside of the tile.

Description

WATER RESISTANT ROOF TILE FIELD OF THE INVENTION The invention relates to improvements in building panels and, in particular, roof tiles made of a water suspension or a water-based paste.

BACKGROUND OF THE INVENTION Construction panels, in particular, water-permeable roof tiles have a tendency to become stained when exposed to water. A mechanism that occurs when putting water droplets in contact with a roof tile is the condensation in pipes and network of ducts in the space above the ceiling. The condensate can drip on the back of the roof tile and migrate to the visible-looking side of a tile. Staining can occur because water can carry contaminants from contacting surfaces and, frequently, because water droplets migrate through a roof tile and leach tannin from recycled newspaper or other cellulose materials based on plants and agents. staining of other components used in the tile composition that carry the dyeing agents towards the front surface of the tile.

As is typical of most products, the cost is critical and there is a need for an economical solution to minimize water spots on the sides of appearance REF.240363 of construction panels, particularly roof tiles permeable to water.

BRIEF DESCRIPTION OF THE INVENTION The invention provides an economical solution to water staining on the visible side of building panels due to migration of water through the panel. More specifically, the invention involves mode by creating a barrier for water droplets locally at the rear of a panel, droplets can be caused by evaporation before their liquid content can migrate through a panel.

It has been discovered that commercially available material used to impart water repellency to the fabric is an excellent means to achieve the objective of the invention. The material is widely available, non-toxic, and relatively inexpensive in the limited coverage found to be effective in the practice of the invention. The preferred waterproof material can be applied with a water carrier by a single application thereof to the back of a rigid mat from which the tile is manufactured. The very light and consequent low cost coverage of the waterproofing treatment and the simplicity of application is practical for use in even the least expensive product lines of a panel manufacturer.

The central mesh or tile is preferably subjected to an elevated temperature to rapidly dry rapidly or cure the waterproofing material before the carrier water can be absorbed through the central mesh. Preferably, this drying process can be done simultaneously with the conventional process step used to dry a finish or paint layer on the visible side of the tile or panel.

BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a diagrammatic isometric view of a roof tile embodying the invention; Y Figure 2 is a schematic diagram of a process using the invention.

DETAILED DESCRIPTION OF THE INVENTION The invention is applicable to various building panels that can be used to cover walls or ceilings. A suitable form of a construction panel; It is a roof tile or panel used in suspended ceilings. Other forms of building panels include wall tiles based on plaster and drywall. Ceiling tiles made of a suspension of water or paste and not supported with a waterproof film or sheet are especially benefited by the present invention. In describing the manufacture of a roof tile incorporating the invention, reference is made to Figures 1 and 2 of the figure. A rectangular roof tile 10 is adapted to be used as a panel stored in a rectangular grid in a suspended ceiling system of generally known construction. The tile, usually, will have a thickness between approximately (1.27 cm to approximately 2.22 cm (1/2"to approximately 7/8") and nominal planar dimensions of .609 x .609 cm, .609 x 1.22 cm and .609 cm- 0.152 cm x 1.5 cm (2 'x 2', 2 'x 4' and 2-1 / 2 'x 5') or metric equivalents of these panel sizes Suspended ceiling tiles or tiles are typically made from a process of Liquefied with water or a moldable formulation based on paste-type water When the panel 10 is derived from a water felting process, a typical approximate formulation, on a weight basis, may comprise: 65% perlite filling 18% fiber paper 7% unmodified starch binder, and 10% mineral wool fiber.

The content of mineral wool can vary considerably, that is to say above about 25% and in this case, the perlite can be reduced accordingly. In addition to paper fiber, other sources of cellulose can be used such as wood or woody plant materials. When these constituents have been correctly mixed in a suspension of water and sprayed on a sieve, in the case of a product infelled with water, or similar constituents are sprayed on a tray in the case of a molten tile, they are dried and / or dried in a rigid cardboard. Thereafter, the appearance or front side of the tile carton or preform is covered with an appearance or paint coating generally a water-based material having some latex or other binder component. In the case of water-fed or center meshing, the meshing finish side, if necessary, can be ground to create a flat surface before coating with a topcoat or topcoat. Furthermore, before the application of the finishing layer, an initiating layer, which can be clay-based, for example, can be applied to the front side of the mesh. The tile 10 of Figure 1 is shown in its installed orientation and includes an appearance coating 11 on its visible, lower face, an initiator layer 12, a water-filled or central mesh 13 and an impermeable coating 14, discussed below, in its back or top face.

The appearance layer 11 on the finishing side of the tile 10, as mentioned, is normally a water-based coating with a white pigment color to provide high light reflectivity. It has been discovered that commercially available fabric waterproofing material can be used to properly waterproof the backside of the tile 10 by coating the mesh 13 with the material. Surprisingly, it has been found that only relatively small amounts of the materials need to be used to achieve satisfactory results. An example of a suitable product for the practice of the invention is an emulsion of fluorocarbon polymer such as that marketed by Daikin Chemical Europe GmbH, Dusseldorf, Germany, under the trademark TG-5601. This product is a water-based emulsion that can be greatly diluted with water while remaining effective even when the speed of application is imprecise. The result of the dilution of the original emulsion is a very light coating of waterproofing solids from about 2,153 g / m2 to 2,690 g / m2 (1/5 to 1/4 grams / square feet). Despite a low concentration of solids, it has been found that a surprising degree of waterproofing and resistance are achieved. With the described solids coverage rate, water droplets in the coating 14 simply spill and eventually evaporate.

Figure 2 illustrates an example of a process for practicing the invention. A dry mesh or cardboard 13 made by a conventional water felting process with a solids content, as described above, is carried out a conveyor 20 in a spray booth 21 where a water or paint-based top coat is used. applies The top layer or appearance layer 11 faces up in this process, but when the tile is installed on a roof, the top layer faces downward. The mesh 13 is transported from the spray booth to a dryer 22 by a roller conveyor 23. A sprinkler 24 carrying a plurality of spray nozzles extends between a pair of rollers of the conveyor 23 across the width of the conveyor. The sprinkler 24 sprays the bottom of the mesh 13 with diluted waterproofing liquid 14 described above. The mesh 13 is coated with the upper layer 11 and the impermeable material 14 is transported by a conveyor 26 through the dryer 22 where these coatings are preferably simultaneously dried and / or cured for example, at a temperature of about 220 ° C, for a duration of about 45 seconds. Other methods of application of the upper layer and waterproofing material are contemplated. For example, the roller coating or flood can be used.

Condensate from water falling from pipes and ducts into the space or plenum above a suspended ceiling can fall on the back of a roof tile of the prior art eventually causing discoloration: on the face or side of appearance. This mechanism of discoloration or staining can be attributed to the infiltration of condensed water through a tile. The condensate can be contaminated by the surfaces that pass over the above reaching the tile. Additionally, as water infiltrates through the body of the tile, it can leach the stain producing material such as tannins present in the paper or cellulose fibers. Contaminated water can escape through the appearance coating and thus be dyed. Water passing through a tile, where the invention is not used, is the common place where there is a water source, since it is desirable that the roof tile be porous to exhibit good sound absorption characteristics. The addition to the desired porosity of a usual roof tile is its original water-based character which is inherently permeable to water.

It should be evident that this description is by way of example and that several changes can be made by adding, modifying or deleting details without deviating from the clear scope of the teaching contained in this description. The invention is therefore not limited to the particular details of this description except insofar as the following claims are necessarily then limited.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Claims

CLAIMS Having described the invention as above, the content of the following claims is claimed as property:

1. - A roof tile characterized in that it comprises a center, an appearance coating on one face side of the tile, and a waterproof coating on a back of the tile, the center including a filler, binder and dried fiber elements of a suspension based on water or paste of the elements, the center that is permeable to water and that contains a non-white spot that produces material susceptible to being leached from the center by the water that infiltrates through the center, the coating of appearance which exhibits a high reflectivity of light because it contains a constituent of white color and which is permeable to water, the impermeable coating that serves to repel and spill the drops of water deposited on the back of the tile.

2. - The roof tile according to claim 1, characterized in that the fiber element includes mineral fiber.

3. - The roof tile according to claim 1, characterized in that the appearance coating is a layer of white paint based on dried water.

4. - The roof tile according to claim 1, characterized in that the impermeable material is a material carried with dried and cured water.

5. - The roof tile according to claim 4, characterized in that the impermeable material is an emulsion of fluorocarbon polymer.

6. - The roof tile according to claim 5, characterized in that the impermeable material is applied with a solids cover at a speed of approximately 2,153 g / m2 to 2,690 g / m2 (1/5 to 1/4 grams / square feet) ).

7. - A method for making an impermeable roof tile comprising creating a center by mixing materials in the presence of water, drying the materials to form a rigid board, applying a water-based appearance coating on the appearance side of the center, and an impermeable water-based coating on one side of the center opposite the car side.

8. - The method for making a suspended ceiling tile according to claim 7, characterized in that the coating of appearance and impermeable coating are applied and are therefore simultaneously dried by exposing the coatings to a heated environment at approximately 220 ° C for about 45 seconds.