TWI526593B - Waterproof ceiling tile and method of making the same - Google Patents

Description

Waterproof ceiling tile and manufacturing method thereof

The present invention is directed to improvements in building panels, and more particularly to ceiling tiles produced from aqueous or aqueous pastes.

Building panels, especially permeable ceiling tiles, are prone to stains when exposed to water. One mechanism that causes water droplets to contact the ceiling tiles is the condensation of the tubing and piping systems present in the space above the ceiling. The condensate can be dropped onto the back side of the ceiling tile and moved to the visible side of the ceiling tile. Since moisture can remove contaminants from the surfaces it touches, the generation of stains will occur, and, as often, water droplets will move through the ceiling tiles and are recovered from recycled newsprint or other vegetable cellulosic materials. The tannins are filtered from the stains of the other ingredients used in the ceiling tile composition, and the dyes are transported to the front surface of the ceiling tiles.

For most products, cost is important, and there is a need to provide an economical solution to stain the water stains on the sides of the exterior of the panels (especially permeable ceiling tiles). Minimized to a minimum.

The present invention provides an economical solution for treating water stains generated at the visible surface of a building panel as moisture moves through the panel. More particularly, the present invention contemplates the idea of providing water droplets locally on the back side of the panel by providing an obstacle that will be caused by the liquid component of the water droplet before it passes through the panel. evaporation.

Commercially available materials known to be used to transfer water repellency to fibers are an optimal medium for accomplishing the objectives of the present invention. Such materials are widely used, not toxic, and relatively inexpensive, and such materials are known to be effective in carrying out the invention to a limited extent. By simply applying the waterproof material to the back side of a hard mat, the preferred waterproof material can be applied with the same water transport medium from which the ceiling tiles are fabricated. The very small range and low cost of water repellent treatment, as well as the ease of application, make it suitable for use in panel manufacturers' very cheap product lines.

Preferably, the core mat or ceiling tile is capable of withstanding high temperatures to rapidly dry or harden the waterproof material before it can be absorbed through the core mat. The drying process is preferably performed simultaneously with conventional processing steps that are used to dry the last coating or coating on the visible side of the ceiling tile or panel.

The invention can be applied to different building panels for covering walls or ceilings. One suitable type of building panel is a ceiling tile or panel for suspended ceilings. Other building panel types include gypsum wall tiles and siding. It is particularly advantageous for the present invention to be made from a slurry or paste, as well as a ceiling tile that is not impervious to the film/sheet on the back. In describing the manufacturing method of the ceiling in combination with the present invention, reference may be made to Figs. 1 and 2. A rectangular ceiling tile 10 is used as a An introduction panel in a rectangular lattice in a conventional suspension ceiling system structure. The ceiling tile typically has a thickness of between about 1/2 inch and about 7/8 inch and has a surface size of 2 inches x 2 inches, 2 inches x 4 inches, and 2 1 /2 inches x 5 inches, or the metric equivalent of these panel sizes. Suspended ceiling panels or ceiling tiles are typically fabricated from a water bonding process or a similar paste-like water-based castable component. Among them, the panel 10 is produced from a water bonding process, and has a general approximate composition, based on the weight, which may include: 65% pearlite filler 18% paper fiber 7% unconditioned starch binder, and 10% mineral wool fiber.

The mineral wool component can be greatly altered, for example up to about 25%, and in this application example, the composition of the bead can be reduced. In addition to paper fibers, other sources of cellulose such as wood or wood plant material can also be employed. In the application example of the water-bonded product, when the above components have been suitably mixed into the water slurry and dispersed onto a sieve; or in the application example of the cast brick, similar components are dispersed to a panning On the plate, these ingredients are removed from moisture and/or dried to a hard board. Thus, the preformed exterior or front side of the hard or ceiling tile is coated with an outer coating or coating which is typically an aqueous material having a plurality of emulsion or other binder components. In the application example of a water bonding pad or core, the final finished side of the water bonding pad may be coated before a final or top coating is applied, if desired. Grinding to create a flat surface. Further, a primer coating film such as a clay property may be applied to the side of the surface of the water bonding mat before the final coating film is applied. The ceiling tile 10 of Figure 1 is shown in a position where it has been placed and includes a top coat 11, a primer film 12, a water bond pad or core 13 on the underside visible surface. And a waterproof coating 14 on the back or upper side surface (discussed below).

As mentioned above, the outer coating 11 on the final side of the ceiling tile 10 is typically an aqueous coating with a white pigment to provide high light reflectivity. The water-bonding mat 13 is coated by using the following materials, and it is known that such commercially available waterproof fiber materials can be used to successfully provide waterproof performance to the back portion of the ceiling tile 10. It is known that only a relatively small amount of such a waterproof material is required to obtain satisfactory results. An example of a product suitable for use in the practice of the invention is a fluorocarbon polymer emulsifier, such as a commercially available product of the brand TG-5601 by Daikin Chemical Europe, Dusseldorf, Germany. This product is an aqueous emulsifier that can be diluted in large amounts in water while maintaining its effectiveness even when the rate of application is not accurate. The result of diluting the original emulsifier is to obtain a very small amount of coating of about 1/5 to 1/4 gram of waterproof solids per square inch. Despite obtaining such low concentration solids, it is known that satisfactory water and water resistance properties can be obtained. Together with the solids coverage rates disclosed herein, the water droplets on the water repellent coating 14 simply form the beads and are ultimately evaporated.

Figure 2 illustrates an application example for carrying out the processing program of the present invention. a solid having the above-described solids produced by a conventional water bonding process The dry pad or plate 13 of the ingredients is conveyed onto a conveyor 20 into a spray booth 21 for application of a waterborne top coat or coating 11. In this processing procedure, the top coating or topcoat 11 is facing upwards, but when the ceiling tile is installed into the ceiling, the top coating is facing downward. The water bonding pad 13 is conveyed from the painting booth to a dryer 22 by a roller conveyor 23. A diffuser 22 carrying a plurality of nozzles extends between the set of rollers extending through the conveyor 23 across the width of the conveyor. The diffuser 24 spreads the diluted waterproof liquid 14 described above to the bottom side of the water bonding pad 13. The water bonding pad 13 coated with the top coating film 11 and the waterproof material 14 is conveyed by the conveyor 26 through the dryer 22, in which the above coatings are simultaneously dried and/or Or hardening is preferred, for example, at a temperature of about 220 degrees Celsius for about 45 seconds. Other methods for applying the top coating film and waterproof material can also be considered. For example, a roll coating method or an overflow method can be employed.

Condensed water dripping from the fittings and piping in the gap or space above the suspended ceiling can fall onto the back side of the prior art ceiling tile, eventually resulting in discoloration on the surface or exterior side. The mechanism of discoloration or stain formation can be attributed to the leakage of the condensate through the ceiling tiles. The condensate will withstand the contamination caused by the surface it flows before flowing to the ceiling tile. In addition, as moisture leaks through the body of the ceiling tile, stain-forming materials (such as tannic acid) present in the paper fibers or cellulose fibers will be filtered out. The contaminated water can leak through the outer coating and add the outer coating To pollution. The water flow path through a ceiling tile, wherein the ceiling tile does not employ the present invention, and since the ceiling tile must be porous or exhibit good sound absorbing characteristics, the water flow path will become a common source of moisture. Typical ceiling tiles add the required porosity to their original aqueous character and essentially render them water permeable.

The disclosure is obviously described by way of application examples, and different changes are obtained by adding, changing or deleting details without departing from the scope of the teachings contained in the disclosure. Accordingly, the invention is not limited by the specific details of the disclosure, except as the scope of the claims.

10‧‧‧Ceiling bricks/panels

11‧‧‧Appearance/Top Coating/Coating

12‧‧‧ Primer coating

13‧‧‧Water bonding pad/core/flat

14‧‧‧Waterproof coating/waterproof liquid/waterproof material

20‧‧‧Transporter

21‧‧‧ spray booth

22‧‧‧Dryer

23‧‧‧Roller conveyor

24‧‧‧ diffuser

26‧‧‧Conveyor

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic perspective view showing a ceiling tile of the present invention; and Fig. 2 is a schematic view showing a machining program according to the present invention.

10‧‧‧Ceiling bricks/panels

11‧‧‧Appearance/Top Coating/Coating

12‧‧‧ Primer coating

13‧‧‧Water bonding pad/core/flat

14‧‧‧Waterproof coating/waterproof liquid/waterproof material

Claims (8)

A method for manufacturing a waterproof ceiling tile, comprising: generating a core, the core being produced by mixing a material into water, drying the material to form a hard board, and applying a waterborne topcoat to the core On the side of the outer surface, a water-repellent aqueous coating is applied to the side of the core opposite the side of the surface. A method for manufacturing a waterproof ceiling tile according to claim 1, wherein the exterior coating and the water repellent coating are applied, and then simultaneously exposed to a high heat environment of about 220 degrees Celsius by exposing the coatings to a temperature of about 220 degrees Celsius , keep it dry for about 45 seconds. A ceiling tile manufactured by the method of claim 1, comprising a core, an outer coating on a side of the surface of the ceiling tile, and a waterproof coating on a side of the back of the ceiling tile a layer comprising a filler, a binder, and a plurality of equal fiber elements, the fiber element being produced by drying from an aqueous slurry or paste of the fiber element, the core having water permeability and comprising an easy passage through a material that filters out from the core and thereby causes the outer coating to smear, the outer coating being rendered highly reflective by the effect of containing a white component and having water permeable properties. The layer is used to waterproof and form drops of water droplets deposited on the back side of the ceiling tile. The ceiling tile of claim 3, wherein the fiber element comprises mineral fiber. Such as the ceiling tile of claim 3, wherein the exterior coating It is a dried aqueous white paint layer. The ceiling tile of claim 3, wherein the waterproof material is a dried and hardened water transport material. The ceiling tile of claim 6, wherein the waterproof material is a fluorocarbon polymer emulsifier. A ceiling tile according to item 7 of the patent application, wherein the waterproof material is applied to a solid range at a rate of about 1/5 to 1/4 gram per square inch.