TWI586877B - 建構連結纖維毯的系統與方法 - Google Patents

建構連結纖維毯的系統與方法 Download PDF

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TWI586877B
TWI586877B TW102119400A TW102119400A TWI586877B TW I586877 B TWI586877 B TW I586877B TW 102119400 A TW102119400 A TW 102119400A TW 102119400 A TW102119400 A TW 102119400A TW I586877 B TWI586877 B TW I586877B
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Taiwan
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thin
fiber blanket
thermoplastic plastic
wire
composite building
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TW102119400A
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TW201350653A (zh
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羅伯 號博
傑拉 波頓
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確頂石膏有限公司
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1018—Coating or impregnating with organic materials
    • C04B20/1029—Macromolecular compounds
    • C04B20/1033—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
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    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
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    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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    • B32B37/08—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • 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
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Finishing Walls (AREA)
  • Civil Engineering (AREA)
  • Composite Materials (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Description

建構連結纖維毯的系統與方法
本發明係有關一種建構纖維毯(fibrous mats)的系統，特別是一種將纖維毯結合於複合建築板的製造方法。
背景技術包含有許多建構纖維毯的製造方法，譬如賽門(Simmons)等人所提出的美國專利公告第5,565,049號專利，揭露一種由切細纖維材料製作纖維毯的方法，該方法使用長條環狀的傳輸皮帶來延伸並環繞於一對滾輪。在初始階段，一串線軸連續地將纖維絞線傳遞至切割平臺，然後切割後的絞線會被放置在皮帶上形成鬆散的纖維毯結構，接續傳送至噴霧平臺，在此，噴嘴會於纖維毯結構上噴灑超細的水霧，接著，黏著粉末均勻地鋪設在纖維毯結構的上表面，藉由黏著劑施加器的計量使得粉末狀的黏著劑形成細粒泰樣。緊接著加熱平臺上，上皮帶可施加壓力於纖維毯上，同時，加熱平臺也具有加熱單元，其設於纖維毯結構的上、下方，因此，藉由施加的壓力與加熱，使得纖維毯結構平坦化，並使黏著劑具有可塑性；然後冷卻平臺可將纖維毯的溫度降低至低於黏著劑的初始可塑溫度之下，而可使黏著劑重新固化而將纖維連結在一起。
其他製造纖維毯的方法，如瑞絲(Reese)等人所提出的美國專利公告第5,051,122號專利，其提出一種製作連續玻璃絞線毯的方法，其中利用加熱的壓延式滾輪以及連續性皮帶來壓緊纖維毯；複數個絞線饋 送器橫跨於具有穿孔的移動輸送帶，且每一饋送器會由供應源頭拉動至少一股連續性絞線，並將其射出至輸送皮帶的表面，以形成鬆散的纖維毯結構。接續將粉末狀的橡膠顆粒分佈於鬆散的纖維毯上，然後通過第二移動輸送帶或皮帶與至少一個壓延滾輪之間；較佳實施例中，係可以水來濕潤纖維毯來使橡膠材料更易於分佈。當纖維毯到達第二輸送皮帶時，會於其表面與分開驅動、轉動且加熱的壓延式滾輪之間予以修剪，而當其移動至環繞在滾輪表面時，則會受到皮帶張力的壓緊，隨著皮帶的轉動，會將壓緊的纖維毯由壓延式滾輪分離並延續其路徑，而纖維毯因加熱所產生的蒸氣則會由壓延式滾輪上透過遮罩裝置予以洩漏。
儘管上述索引述的皆為有效的建構方法，然而其也面臨到不同的缺點，譬如上述每一前案所採用的橡膠或是黏著劑是微粒或是顆粒的型態，就技術上來看需要相當多的步驟且仍舊不足以塗佈於底下的纖維，導致相鄰纖維之間的連結力不足；同時其也並沒有展示將纖維毯結合至複合建築板的方法，本發明主要乃鎖定解決上述先前技術的缺失而提出之系統與方法。
本發明的主要目的在於提供一種建構纖維毯的系統與方法，同時亦揭露了相關的纖維毯結合於複合建築板的系統與方法。
本發明之優點在於藉由細線長度所建構之纖維毯乃先行予以塗佈熱塑性塑膠。
本發明之另一優點在於使連續性細線，於結合至纖維毯之前，完整塗佈有液化的熱塑性塑膠。
本發明之進一步的優點在於細線於置放在成型平臺後，藉由加熱來達成液化預先塗佈的熱塑性塑膠，使其作為細線之間的結合劑。
本發明之另一個潛在的優點在於完成建構纖維毯，並於後續將其結合至複合建築板內。
本發明也提出另一種優點係於建構纖維毯時，無需使用前頁紙或是背紙即能結合於建築用板材。
為使對本發明的目的、特徵及其功能有進一步的瞭解，茲配合圖式詳細說明如下：
10‧‧‧製造系統
20‧‧‧生產線
22‧‧‧成型平臺
24‧‧‧初始部份
26‧‧‧細線
32‧‧‧後端部份
34‧‧‧塗佈工作站
36‧‧‧應用滾輪
38‧‧‧溝槽
42‧‧‧供給滾輪
44‧‧‧液化熱塑性塑膠
46‧‧‧束緊滾輪
48‧‧‧計量塊
52‧‧‧開孔
54‧‧‧溢流邊緣
56‧‧‧導引滾輪
58‧‧‧線軸
62‧‧‧成型皮帶
64‧‧‧加熱工作站
66‧‧‧加熱元件
68‧‧‧成型平臺
72‧‧‧開口
74‧‧‧泥漿混合器
76‧‧‧第二纖維毯
78‧‧‧複合板材
80‧‧‧成型工作站
82‧‧‧細線切割器
84‧‧‧堆積槽
86‧‧‧搖晃器
第1圖為本發明所揭露之建構複合建築板之製造程式的側視示意圖。
第2圖為本發明所揭露之建構複合建築板之製造程式的另一實施例之側視示意圖。
第3圖為本發明所揭露之建構複合建築板之製造程式的預先塗佈機構的側視示意圖。
第4圖為本發明所揭露之建構複合建築板之製造程式的利用線軸來收集細線的側視示意圖。
第5圖為本發明所揭露之建構複合建築板之個別細線連接的微觀示意圖。
第6圖為本發明所揭露之建構複合建築板之個別細線連接的微觀示意圖。
第7圖為本發明所揭露之建構複合建築板之個別細線連接的微觀示意圖。
本發明揭露一種建構纖維毯的系統與方法，根據所揭露之內容，連續長度的細線係預先塗佈有液化的熱塑性塑膠，接著置放於皮帶上來形成纖維毯，其中細線可以連續性長度的置放、亦可將其切割為不連續的長度。置放於皮帶後，將細線予以加熱，使得熱塑性塑膠重新液化，並 於交纏的纖維間形成連結；同時本發明更揭露一種結合纖維毯至複合建築板的系統與方法，更多本發明之特徵、相關之方式將會於底下做更詳盡的說明。
根據本發明所揭露之較佳的製造系統10，請參閱第1圖，包含一單一生產線20，其具有一系列的成型平臺22，生產線20的初始部份24係用以將連續長度的細線26製作為纖維黏著毯，在此做更詳盡之描述，細線26係於成型纖維毯28預先塗佈熱塑性塑膠，生產線20的後端部份32用以將纖維毯28結合至複合建築板，此後端部份32可結合相同發明人郝柏(Hauber)所提出之美國專利公告第6,524,679號專利(玻璃強化石膏板；Glass Reinforced Gypsum Board)所提出之方法，該專利的內容根據此一目的可完全引入。
第2圖係提出另一種選擇性的實施例，就生產線10的許多方面近似於第1圖所繪示之實施例；亦即是，生產線20的初始部份24係用以將連續長度的細線26製作為纖維黏著毯，生產線20的後端部份32用以將纖維毯28結合至複合建築板；然後第2圖所繪示的生產線乃係將細線與以切割為不連續的長度，然後再隨機置放於成型平臺，特別的是兩個實施例中的初始連續長度細線26都預先塗佈有熱融的熱塑性塑膠。
塗佈熱塑性塑膠於細線之系統
複數個別長度的細線26初始係以未塗佈的狀態由對應之複數個細線饋送器來加以分配，另一方面，纖維也可以由細線製造程式來直接提供，在此較佳實施例中，細線26之線徑範圍最小約為1微米、最大約為5000微米，在此所稱的細線包含有單絲或是複數細線結合而成的粗紡，其更可包含紡織的單絲絞線以及編織的單絲絞線，所使用細線26的數量取決於所要建構的纖維毯28之尺寸與密度，且本發明並未特別限定任何特殊數 量的細線26，然而，數量在2至2000的個別細線26都可以被利用；在細線26由饋送器分配後，將會藉由導引滾輪來運送至塗佈工作站34，見第3圖，於塗佈工作站34中，未塗佈的細線26將會被浸入要預先塗佈的熱塑性塑膠中。
在較佳實施例中，每一細線都塗佈有一定量的液化熱融熱塑性塑膠接著劑，此接著劑可以是有機、無機或是兩者混合，提供此接著劑的目的在於維持纖維的位置、並提供其張力抗性以及彈性。熱塑性塑膠接著劑可為以下單獨、或混合的成份，包含有丙烯腈-丁二烯-苯乙烯(Acrylonitrile butadiene styrene；ABS)、賽璐珞(Celluloid)、醋酸纖維素(Cellulose Acetate)、丁基乙烯(Ethylene-Butyl)、丙烯酸鹽(Acrylate)、乙烯-丙烯酸甲酯(Ethylene-Methyl Acrylate)、乙烯醋酸乙烯共聚物(Ethylene Vinyl Acetate；EVA)、乙烯-丙烯酸(Ethylene-Acrylic-Acid-copolymer；EAA)、乙烯-乙烯醇(Ethylene Vinyl Alcohol；EVAL)、氟碳塑膠(Fluoroplastics；PTFEs，包含有氟化乙烯丙烯共聚物(FEP)、過氟烷基化合物(PFA)、三氟氯乙烯共聚物(CTFE)、乙烯-三氟氯乙烯共聚物(ECTFE)、乙烯-四氟乙烯共聚物(ETFE))、離子交聯聚合物(ionomers)、液晶高分子(Liquid Crystal Polymer；LCP)、聚縮醛樹脂(Polyacetal；聚縮醛(POM)或乙縮醛(Acetal))、聚丙烯酸(Polyacrylates；融化或硬化丙烯酸樹脂)、聚丙烯腈(polyacrylonitrile；PAN或丙烯腈(Acrylonitrile)、聚醯胺(Polyamide；PA或尼龍)、聚醯胺醯亞胺(Polyamide-imide；PAI)、聚芳醚酮(Polyaryletherketone；PAEK或酮)、聚丁二烯(Polybutyadiene；PBD)、聚丁烯(Polybutylene；PB)、聚對苯二酸丁二酯(Polybutylene Terephthalate；PBT)、聚對苯二甲酸乙二酯(Polybutylene Terephthalate；PET)、聚對苯二甲酸環乙酯(Polycyclohexylene Dimethylene Terephthalate；PCT)、聚碳酸酯(Polycarbonate；PC)、聚酮(Polyketone；PK)、聚酯纖 維(Polyester)、聚乙烯(Polyethylene/Polythene/Polyethane)、聚醚嵌段醯胺(Polyether Block Amide；PEBA)、聚醚醚酮(Polyetheretherketone；PEEK)、聚醚醯亞胺(Polyetherimide；PEI)、聚醚(Polyethersulfone；PES)、氯化聚乙烯(Polyethylenechlorinates；PEC)、聚亞醯胺(Polyimide；PI)、聚乳酸(Polyactic Acid；PLA)、聚甲基戊烯(Polymethylpentene；PMP)、聚苯醚(Polyphenylene Oxide；PPO)、聚苯硫醚(Polyphenylene Sulfide；PPS)、聚鄰苯二甲醯胺(Polyphthalamide；PPA)、聚丙烯(Polypropylene；PP)、聚苯乙烯(Polystyrene；PS)、聚醚(Polysulfone；PSU)、聚氯乙烯(Polyvinyl Chloride；PVC)、Spectralon以及熱塑性聚烯烴橡膠(thermoplastic Olefinic Elastomers；TPO)。在本發明的較佳實施例中，熱塑性塑膠接著劑的熔點範圍最小蓋略為100℉至最大蓋略為500℉，其中也可以添加矽烷耦合劑(Y-Si(OR)3)於上述熔點的熱塑性塑膠接著劑，以增加其黏著強度，且其亦可增加耐久度、機械特性、電子特性以及接著劑的分佈。
熱塑性塑膠可包含有填充化合物，來增加或改變下列特性，包含但不限定有顏色(不可透光或特明)、紫外線抗性、增黏特性強化、熱絕緣性、熱導性、導電性、非導電性、防水性、透溼性強化或抑制、吸光性、反光性、聲音傳播性、隔音效果、彈性強化、剛性強化、衝擊抗性、穿刺抗性、磨耗抗性、增厚、提高密度、抗火性、聲音反射以及氣體、液體、有毒氣體化合物的吸收。
塗佈工作站34的詳細描細將結合第3圖來說明，所繪示的特殊塗佈工作站34僅為範例來說明細線26如何被塗佈，其他塗佈的技術當然也包含於本發明之範圍內。塗佈工作站34包含有應用滾輪36，其外表麵具有一連串週緣溝槽38，每一溝槽38之尺寸恰可容置單一股的細線26，較佳實施例中，細線饋送器的數量將配合應用滾輪36之溝槽38的數量來設計配 置。
塗佈工作站34更包含有供給滾輪42，其係為公知技術，一部份接觸於液化熱塑性塑膠44，另一部份接觸於應用滾輪36；藉此，供給滾輪42可將一定量的液化熱塑性塑膠44由供給滾輪42傳送至應用滾輪36的表面，因此，應用滾輪36之溝槽38內的個別定位的細線26將可以透過供給滾輪42來被塗佈液化熱塑性塑膠44。
塗佈工作站34更包含有束緊滾輪46，其設置於應用滾輪36相對操作上的頂面，此束緊滾輪46維持與應用滾輪36強制接觸於其外部週緣表面，其主要功能在於確保每一個別的細線26於應用滾輪36轉動時能保持在對應的溝槽38內。
計量塊48可以選擇性地設於塗佈工作站34的末端，用以將過多的熱塑性塑膠由細線26上刮除；計量塊48包含有複數個個別的開孔52，其尺寸恰可容置個別的細線26，而計量塊48的出口處設計具有溢流邊緣54，允許由開孔52所刮除的過量熱塑性塑膠流出，而流出的熱塑性塑膠可加以回收再利用或是丟棄。因此，計量塊48用以控制細線26所需的接著劑的覆蓋範圍以及速率，而上述所提到熱融熱塑性塑膠的塗佈厚度，蓋略為0.01密爾(mils)至50密爾，而其厚度可為均勻或是不均勻的厚度。
塗佈工作站34的操作說明如下，一連串未經塗佈的細線26經由細線饋送器送入，然後藉由導引滾輪將細線26送入塗佈工作站34，接著，細線26會被導引進入應用滾輪36之溝槽38內；當應用滾輪36轉動時，就會透過供給滾輪42持續將液化熱塑性塑膠44予以供給，應用滾輪36持續轉動來確保細線26的整個外圍區域都完全浸入熱塑性塑膠內，多出的熱塑性塑膠會由計量塊48予以去除，計量塊48的規格取決於所欲應用的纖維毯。塗佈必須維持足夠的週緣覆蓋率，以確保其與各方向周圍的纖維能有 足夠的黏結力，其覆蓋率可維0.1%至100%。
最後，塗佈後的細線26會藉由導引滾輪56來離開塗佈工作站34，見第4圖，當細線26離開後，熱塑性塑膠44將會冷卻並固化，而此冷卻的步驟，可以直接或間接透過冷卻機構來達成。最後每一塗佈後的細線26會被捲繞於線軸58上，其可以堆積於線軸58上，或是連續性地供應給生產線。本實施例而言，塗佈後的細線26係儲存於線軸58上，接續後面的描述，塗佈後的細線26將會於建構纖維毯28由線軸58上配送。
連續性細線纖維毯
當細線26以上述方式完成塗佈後，可接續來進行製作纖維毯28，如第1圖所示，預先塗佈的細線26之線軸58設於生產線20之初始位置，線軸58亦可為細線饋送器的型態，然後其開始鬆開而將細線26置放於成型平臺68上，同時，為了產生隨機圖樣，線軸58可以前後、或左右移動來達成。理想狀態下，纖維(細線)26以相同的重量分佈來置放，因此，個別的細線26將會其他(一個或數個)細線26交纏，細線26交纏的密度，將取決於個別細線26的置放數量，而其數量則決定於所欲生產的纖維毯28。
細線26所置放的成型皮帶62係由堅固、篩網或連結的構造組成，其也可具有保水的特性，因此提供不會沾黏熱塑性塑膠的表面，而更可進一步促進纖維間的黏結；成型皮帶62可以是有機、無機或其混合物所組成。
接著，隨機圖樣的細線26將會被皮帶運送到加熱工作站64，其包含有複數個位於上方的加熱元件66，較佳實施例中，加熱元件66可以將細線圖樣加熱至蓋略為100℉至1000℉，直接、間接或其混合的加熱方式皆可被採行。加熱工作站64可將細線26加熱至熱塑性塑膠44重新液化、或使其具有可塑性，然後可與周圍細線26的塗層相互混合、黏結，然後被運 送至皮帶外冷卻、固化，緊接著加熱工作站64，可藉由室溫予以冷卻。其優點在於熱融的熱塑性塑膠無需要再增加額外的冷卻步驟來使其重新固化，然而，如果需要的話，也可增加冷卻成型生產線來使其冷卻；加熱、冷卻的步驟可以間歇、或是連續性地來增加/降低溫度。因此，藉由加熱以及接續冷卻的程式，可使其相互交纏黏結而形成纖維毯。
較佳實施例中，其表面的硬度可為15至150洛氏硬度(Rockwell R Hardness scale)、或是10至70的蕭氏硬度(Shore A and D Hardness scale)，而熱塑性塑膠塗佈層的空氣滲透度可為0.01CFM(ft2/sec)至1500CFM(ft2/sec)(雷澤型測試法(Frazier Permeability Test)使用噴嘴範圍8微米至2微米)，因此，此塗佈層可視為防水或是完全透氣。
所形成的纖維毯，可以結合入複合建築板，可結合相同發明人郝柏(Hauber)所提出之美國專利公告第6,524,679號專利(玻璃強化石膏板；Glass Reinforced Gypsum Board)所提出之方法，該專利的內容根據此一目的可完全引入。其步驟首先將石膏泥漿由位於纖維毯28上方的開口72倒下，泥漿可藉由泥漿混合器74來供應，此石膏泥漿後續將形成建築板的核心部份，接著第二纖維毯76會被配置匹覆於此核心部份上方來形成複合板材78，第二纖維毯76可用上述的方法來加以製成，當然也可以用現有其他製程技術來加以完成；最終，複合板材78會被運送到成型工作站80,然後予以壓延成均勻的厚度，如習知技術，複合板材78可以切割成所需要的長度。
非連續性細線纖維毯
本發明的另一實施例繪示於第2圖，其具有與上述第1圖蓋略相同的製程，然而，第2圖中的實施例是利用不連續的細線來建構纖維毯。為達成此一目的，連續、但未經塗佈的細線26由線軸56供應，然後運送進 入細線切割器82來將其切割，單一個細線切割器82或是一組平型配置的多個細線切割器82也可採用。細線切割器82會將其切割為許多隨機長度的纖維，其個別長度範圍蓋略為0.1公分至45,720公分；切割後將由堆積槽84以及搖晃器86予以收集儲存，搖晃器86主要用以確保個別切割後的細線26能夠以隨機圖樣的狀態來運送至成型皮帶62。理想狀態下，細線26將會以相同的重量分佈來置放、配置於成型皮帶62上，其也可以利用秤量皮帶(weighing belt)來加以驗證其密度，此隨機圖樣的纖維將會有許多細線的交纏。
用來建構纖維毯的細線可以是有機纖維、無機纖維或是兩者混合的纖維，且纖維可以是有編織、無編織或是其混合的排列，當藉由熱塑性塑膠接著時，纖維毯將會於+X、-X、+Y、-Y、+Z、-Z等方向展現張力抗性，纖維毯也可以提供各方向上的拉伸抗性。進一步來說，纖維毯將具有提高的彈性、斷裂以及破壞的抗性、複合吸收性以及熱抗性，並可製成各種不同的態樣，譬如為墊子、薄紗、布料、或是窗簾等。
纖維毯可特別應用於複合建築板，作為玻璃強化石膏板來使用，然而，纖維毯也可以用於複合石膏建築板、石膏纖維建築板、水泥板、纖維水泥板、石膏纖維側板、纖維水泥側板、水泥側板、石膏飛簷、纖維石膏飛簷、水泥飛簷、纖維飛簷、氧化鎂建築板、氧化鎂飛簷、氧化鎂側板、氧化鎂屋頂、灌注瀝青屋頂、塗佈瀝青屋頂、灌注瀝青建築覆蓋物、塗佈有機/無機聚合物之建築覆蓋物、塗佈混合有機/無機聚合物之建築覆蓋物、結合連續、不連續或其混合材料之帶狀物(墊子、薄紗、布料、或是窗簾)、邊角護條、地毯、強化的夾板、強化複合層板、強化鑄模或擠壓之有機、無機或其混合材料(包含強化幾何基板、強化硬/軟塑膠管、以及強化的圓柱)。
本發明所揭露的纖維毯可以不需要額外增加前板、後板即能加以建構，相對於習知纖維毯的建構，其具有低成本的優勢，製造成本約可降低30%至50%。
第5-6圖係繪示本發明熱塑性塑膠塗層不同密度的應用，第5圖所繪示僅有纖維交叉部份具有熱塑性塑膠來接著，而第6圖則繪示具有更大密度的熱塑性塑膠來降低或封閉纖維毯的滲透性，多孔性可於0%至95%之間變化。第7圖繪示個別纖維完全塗佈有熱塑性塑膠，根據所想要的結果，增加纖維/細線之間的剪力抗性、或是強化徑向的彈性、降低空氣、液體的滲透度等，熱融熱塑性塑膠接著劑可以提供部份或是完整的纖維/細線的覆蓋程度，或是可以形成於纖維/細線間的交纏、交叉的部份；這些特性可以藉由化學公式的變化或是簡單由成型皮帶的熱融溫度調整而達成。本發明所提出的一大優點在於單獨溫度的變化，而不是不斷地針對習知接著劑技術來重新制定/變化配方公式，因此而能產生令人注目的產品，且不需要增加而外制定接著劑配方的成本，僅需於成型為墊子、薄紗、布料、或是材料前，藉由每一纖維/細線預先塗佈熱融熱塑性塑膠即可達成。
雖然本發明以前述之實施例揭露如上，然其並非用以限定本發明。在不脫離本發明之精神和範圍內，所為之更動與潤飾，均屬本發明之專利保護範圍。關於本發明所界定之保護範圍請參考所附之申請專利範圍。
10‧‧‧製造系統
20‧‧‧生產線
22‧‧‧成型平臺
24‧‧‧初始部份
26‧‧‧細線
32‧‧‧後端部份
62‧‧‧成型皮帶
64‧‧‧加熱工作站
66‧‧‧加熱元件
68‧‧‧成型平臺
72‧‧‧開口
74‧‧‧泥漿混合器
76‧‧‧第二纖維毯
78‧‧‧複合板材
80‧‧‧成型工作站

Claims (7)

  1. 一種製造複合建築板的方法，該複合建築板包含一個或一個以上的纖維毯，該方法包含下列步驟：提供複數個細線饋送器，每一細線饋送器包含有一連續性長度的細線，且係預先塗佈有一熱融的熱塑性塑膠；以一隨機圖樣將每一該細線置放於一成型平臺上，該隨機圖樣包含有複數個交纏細線；於該成型平臺上將隨機圖樣的細線予以加熱至概略100℉至1000℉之間，使得該熱塑性塑膠予以融化；將該隨機圖樣的細線予以冷卻至一室溫，使該熱塑性塑膠因加熱、冷卻效果而作為交纏細線間的接著劑來形成一第一纖維毯；將一石膏漿(gypsum slurry)置放於該第一纖維毯上，來形成該複合建築板之核心；置放一第二纖維毯來覆蓋該形成該複合建築板之核心的該第一纖維毯，而形成一複合板材；以及傳送該複合板材至一成型工作站，並將其沖壓成型為一均勻厚度。
  2. 一種製造複合建築板的方法，該複合建築板包含一個或一個以上的纖維毯，該方法包含下列步驟：提供一連續長度的細線；塗佈一熱塑性塑膠接著劑於該細線；將該塗佈後之細線以一隨機圖樣饋送至一成型平臺，該隨機圖樣包含有複數個交纏細線； 加熱位於該成型平臺上之該隨機圖樣，使該接著劑融化；冷卻該隨機圖樣至一室溫，使該接著劑因加熱、冷卻效果而黏著該交纏細線來形成一第一纖維毯；將一石膏漿(gypsum slurry)置放於該第一纖維毯上，來形成該複合建築板之核心；以及置放一第二纖維毯來覆蓋該形成該複合建築板之核心的該第一纖維毯，而形成一複合板。
  3. 如請求項2所述之製造複合建築板的方法，其中於置放至該成型平臺的步驟前，更包含有將該塗佈細線切割為不連續片狀的步驟。
  4. 如請求項2所述之製造複合建築板的方法，其中於塗佈該細線的步驟前，更包含有添加一矽烷耦合劑(Y-Si(OR)3)於該熱塑性塑膠接著劑的步驟。
  5. 如請求項2所述之製造複合建築板的方法，其中該熱塑性塑膠接著劑的厚度蓋略為0.01密爾(mils)至50密爾。
  6. 如請求項2所述之製造複合建築板的方法，其中該熱塑性塑膠接著劑的熔點蓋略為100℉至500℉。
  7. 一種塗佈連續性長度細線的系統，包含有：複數個細線饋送器，每一該細線饋送器提供一細線；一熱融熱塑性塑膠供應器，該熱塑性塑膠係加熱並呈現液化狀態；一應用滾輪，具有溝槽狀的外周圍表面，每一該溝槽用以接收一該細線饋送器所供給之一該細線；一供給滾輪，相鄰於該應用滾輪，該供給滾輪供應一定量的該液化熱塑性塑膠至該應用滾輪之該外周圍表面，使得位於該溝槽內的該細線 得以塗佈該液化熱塑性塑膠；一束緊滾輪，接觸於該應用滾輪之該外周圍表面，該束緊滾輪用以維持該溝槽內的該細線之長度，以確保該細線得以塗佈該熱塑性塑膠；以及一計量塊，包含有複數個開孔用以接收一長度之該細線，且更包含有一溢流邊緣，藉以吸收該細線中之超量的該液化熱塑性塑膠。
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