RU2552268C2 - Water-resistant ceiling tiles and method of production - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to the means for improving structural panels, in particular to ceiling tiles designed based on aqueous slurry or water-based slurry. Ceiling tiles comprise a core, outer coating on the front side of tiles and waterproof coating on the rear side of tiles, in this case the core has a filler, binding component and fibrous elements formed during drying of water-based suspension or slurry of their fibrous elements, is made water-permeable and contains colour spot forming materials, used during its manufacture, subjected to water washout during its passage through the core. The outer coating has high reflecting power due to the content of white-painted components and implementation of moisture-resistant coating with possibility of water passage, capable to repel water droplets, accumulating on the rear side of tiles. Method for manufacturing the waterproof ceiling tiles is also described.

EFFECT: increase of water-repellent properties of building tiles.

8 cl, 2 dwg

Description

FIELD OF TECHNOLOGY

The present invention relates to means for improving the design of panels, and in particular to a ceiling tile made on the basis of an aqueous suspension or a paste-like mixture based on water.

BACKGROUND

Building panels, especially permeable ceiling tiles, tend to stain when water gets on them. One of the ways water droplets get on the ceiling tiles is condensate, which forms on the surface of pipes and ducts located in the inter-ceiling space. Condensation can drip onto the back of the ceiling tile and then migrate to its visible portion. Stains on the surface of the tile arise due to the fact that water brings with it various contaminants from the surfaces with which it comes into contact, and also because drops of water seeping through the ceiling tile wash the tannins out of recycled newsprint or other plant-based cellulosic materials as well as coloring additives from other components used in the composite material for the manufacture of tiles, and transfer these coloring additives to the front surface of the tile. Since this product is a typical of many other products on the market, its price is a very important indicator, and there is a need for an economical solution to minimize the formation of water stains on the front surface of building panels, especially on permeable ceiling tiles.

SUMMARY OF THE INVENTION

This invention provides an economical solution to the problem of water stains on the front surface of building panels due to the flow of water through the panels. More specifically, the present invention provides an embodiment which, by creating an impermeable insulating layer on the rear side of the panel, eliminates the accumulation of water and ensures its evaporation, preventing water from flowing through the panels.

It has been found that commercially available material used to incorporate water-repellent properties into tile manufacturing is an excellent medium for implementing the objectives of this invention. This material is widely available, non-toxic, and has a relatively low cost for a limited area of research, and has proven to be very effective for the practice of this invention. A preferred waterproof material may be applied together with the aqueous base to the back side of the rigid substrate from which the tile is made. A very light coating and relatively low cost of processing with waterproof material, as well as ease of use of steel, are the result of using this product to cover a less expensive range of tiles. Preferably, the core or the tile itself is subjected to elevated temperatures to accelerate the drying or hardening of the water-resistant material before the water seeps and saturates the base layer. Preferably, this drying process was carried out simultaneously with the implementation of the standard technology step used to dry the finish coat or paint on the outer visible side of the tile or panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic isometric view of a ceiling tile according to the present invention; and

FIG. 2 is a flowchart of a process using the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is applicable to various building panels used to cover walls or ceilings. One of the possible forms of such building panels is ceiling tiles or panels used in suspended ceilings. Other forms of building panels are gypsum wall panels and wall panels. The use of the proposed invention is especially recommended for ceiling tiles made on the basis of an aqueous suspension or a pasty mixture, the back side of which is not covered with a layer of waterproof film or sheet.

A description of a ceiling tile manufacturing process using the present invention is made with reference to FIG. 1 and 2. In the system of suspended ceilings of a well-known design, the rectangular tile 10 of a rectangular shape is made with the possibility of using it as a embedded panel in the rectangular lattice of a suspended ceiling system of known design. Tiles typically have a thickness of about 1/2 inch to 7/8 inches and nominal two-dimensional dimensions of 2 × 2 feet, 2 × 4 feet, and 2-1 / 2 × 5 feet or metric equivalents of these sizes. Tiles or panels for suspended ceilings are typically made by wet wetting or by casting a paste-based water-based mixture. In the case where the panel 10 is made by wet wetting, a typical approximate composition, depending on the weight, may include:

65% perlite filler,

18% paper fiber

7% binder from unmodified starch and

10% mineral wool fiber.

The mineral wool content can vary significantly, say, to about 25%, and therefore the perlite content can be reduced. In addition to paper fiber, other cellulose-based materials can be used, such as, for example, materials from wood or woody plants. After thoroughly mixing these components, converting them into an aqueous suspension and applying to the screen, in the case of tiles made by the wet-drying method, or introducing similar components into the mold in the case of molded tiles, they are dehydrated and / or dried to form a rigid panel. After that, an outer coating or paint, usually water-based, containing latex or other binder, is applied to the outer or front side of the sheet or panel blank. In the case of a substrate or a core made by the wet-wetting method, the finish side of the substrate, if necessary, can be sanded to create a smoother surface before applying a finish or topcoat. Also, before applying the finishing coating on the front side of the substrate, a primer layer, for example, clay-based, must be applied. The tile 10 shown in FIG. 1 in the mounting position, has an outer coating 11 on its lower visible side, a soil layer 12, a substrate or core 13 made by wet wetting, as well as a waterproof coating 14 on its rear or upper side, discussed below.

The outer coating 11 on the fine side of the tile 10, as already noted, is usually a water-based white pigment coating with high reflectivity.

It has been found that a commercially available waterproof material can be used to protect against leakage of the rear side of the tile 10 by coating the substrate or core of the tile 13 with such a material. Surprisingly, it was found that to achieve a satisfactory result requires a relatively small amount of such material. As an example for the practical application of this invention was taken fluoropolymer emulsion, as, for example, manufactured by Daikin Chemical Europe GmbH, Dusseldorf, Germany, under the brand name TG-5601. This product is a water-based emulsion that is highly soluble in water and remains effective even with an undetermined utilization rate. The result of the dissolution of this emulsion is a very light coating of a waterproof solid with a coating capacity of from 1/5 to 1/4 g / sq. foot. Despite such a low concentration of solid, it was found that the required level of water resistance and resistance of the material was achieved. In this case, the moisture drops are easily repelled from the coating 14 and subsequently evaporate.

In FIG. 2 shows a process for putting the present invention into practice. The dried substrate or panel 13, made by the traditional method of wet wetting using a solid substance, as described above, is conveyed onto the conveyor 20 into a spray painting chamber 21, where an aqueous-based outer coating or paint 11 is applied. The upper or outer coating 11 is facing up, but when installing the tile in the frame of the false ceiling, it will be turned face down. Substrate 13 is then moved from the spray booth to the dryer 22 using a roller conveyor 23. A spray 24 having a plurality of spray nozzles is positioned between a pair of conveyor rollers 23 across the entire width of the conveyor. The sprayer 24 sprays the lower part of the substrate 13 with the dissolved waterproof liquid 14, which was mentioned earlier. A sheet 13 coated with an outer coating 11 and a water-resistant material 14 is conveyed by conveyor 26 through a drying device 22, in which all these coatings are preferably subjected to a simultaneous drying and / or, for example, curing process at a temperature of about 220 ° C for about 45 seconds. Other methods of applying the outer coating and waterproof material are also possible. For example, coating using a roller or pouring method.

Water condensate that forms on the surface of pipes and ducts located in the inter-ceiling space can drip onto the back of the ceiling tiles, which ultimately leads to stains on the outer face of the tile. The reason for the formation of spots can be that the water brings with it various impurities and dirt from the areas and areas through which it flows before reaching the tile. In addition, spots appear due to the fact that water droplets seeping through the ceiling tiles wash out some of the components and substances used in the manufacture of tiles, such as tannin contained in paper and cellulose fibers. Contaminated water seeps through the tiles and leaves dirty stains. The flow of water through the ceiling tile then, if this invention is not applied, is a common occurrence in the presence of a water source and evaporation, since the ceiling tile is preferably made porous to provide good sound absorption characteristics.

It should be obvious that the disclosure of the present invention is only an example and various changes can be made to it by adding, improving or eliminating individual details without going beyond the scope of the present invention. Therefore, the present invention is not limited to the specific details of the present description, unless certain points are limited by the claims.

Claims (8)

1. Ceiling tile containing a core, an outer coating on the front side of the tile and a waterproof coating on the back side of the tile made of a waterproof material, the core containing a filler, a binder component and fibrous elements formed by drying a water-based suspension or a paste-like mixture of these fibrous elements, made permeable and contains colored stain-forming materials, subject to leaching with water when it passes through the core, the outer coating has a high The light reflecting ability due to the content of the components painted in white is made with the possibility of transmitting water, and the waterproof coating helps to repel water droplets that accumulate on the back of the tile. 2. Ceiling tile according to claim 1, characterized in that the fibrous element includes mineral fiber. 3. Ceiling tile according to claim 1, characterized in that the outer coating is a layer of dried water-based white. 4. The ceiling tile according to claim 1, characterized in that the waterproof material is a dried and hardened water-conducting material. 5. Ceiling tile according to claim 4, characterized in that the waterproof material is a fluoropolymer emulsion. 6. Ceiling tile under item 5, characterized in that the waterproof material is applied with a coating ability of solid particles in the range from 1/5 to 1/4 g / sq. foot. 7. A method of manufacturing a waterproof ceiling tiles according to any one of paragraphs. 1-6, containing the manufacture of the core by mixing materials in an aqueous medium, drying these materials with the formation of a rigid panel, applying an external water-based coating to the outside, as well as a water-based waterproof coating to the side opposite to the front side. 8. The method according to p. 7, characterized in that after applying the specified external and waterproof coatings, they are simultaneously dried, exposing them to a temperature of approximately 220 ° C for 45 s.

Images