WO2002058902A2 - Plaques de platre revetues et procede de fabrication - Google Patents

Plaques de platre revetues et procede de fabrication Download PDF

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Publication number
WO2002058902A2
WO2002058902A2 PCT/US2002/002106 US0202106W WO02058902A2 WO 2002058902 A2 WO2002058902 A2 WO 2002058902A2 US 0202106 W US0202106 W US 0202106W WO 02058902 A2 WO02058902 A2 WO 02058902A2
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WO
WIPO (PCT)
Prior art keywords
coating
gypsum board
gypsum
board
core
Prior art date
Application number
PCT/US2002/002106
Other languages
English (en)
Other versions
WO2002058902A3 (fr
Inventor
Elizabeth A. Colbert
Original Assignee
Lafarge Platres
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=23004422&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2002058902(A2) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority to IL15693702A priority Critical patent/IL156937A0/xx
Priority to EP02713458A priority patent/EP1358052A4/fr
Priority to MXPA03006599A priority patent/MXPA03006599A/es
Priority to CA002435574A priority patent/CA2435574A1/fr
Priority to AU2002245308A priority patent/AU2002245308B2/en
Priority to JP2002559220A priority patent/JP2004520966A/ja
Priority to BR0206941-5A priority patent/BR0206941A/pt
Application filed by Lafarge Platres filed Critical Lafarge Platres
Priority to UA2003087997A priority patent/UA76975C2/uk
Priority to KR1020037009895A priority patent/KR100842847B1/ko
Priority to NZ527112A priority patent/NZ527112A/en
Publication of WO2002058902A2 publication Critical patent/WO2002058902A2/fr
Publication of WO2002058902A3 publication Critical patent/WO2002058902A3/fr
Priority to NO20033319A priority patent/NO20033319L/no
Priority to US10/625,624 priority patent/US20040154264A1/en
Priority to US12/610,401 priority patent/US20100047461A1/en

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Classifications

    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4578—Coating or impregnating of green ceramics or unset concrete
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • 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
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • 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
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • 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
    • C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/61—Coating or impregnation
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C04B2111/00577—Coating or impregnation materials applied by spraying
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C04B2111/0062—Gypsum-paper board like materials

Definitions

  • the present invention relates generally to coatings for gypsum board products, and the production thereof. More particularly, the present invention relates to the composition of coatings for gypsum board products, and methods of producing and applying the coatings in one continuous gypsum board manufacturing process.
  • a backing sheet is applied over the slurry and the wet gypsum board product is formed to the desired thickness between forming rollers.
  • the wet gypsum sets during the conveying process is cut to the desired length, and is dried by passing the gypsum board product through a drying oven.
  • Coatings for gypsum board products may be used to impart surface homogeneity and improved surface appearance, both in the manufactured condition and after a decorative coating has been applied.
  • An example of a previously known two-step manufacturing method for coated gypsum board products is disclosed in Australian Patent Application No. 19322/92, the disclosure of which is incorporated herein by reference.
  • a surface coating is applied to the facing sheet and dried before the gypsum is applied to the facing sheet in the gypsum board manufacturing process.
  • the coating imparts desirable aesthetic qualities including surface coloration, reflectance, and absorbency.
  • the methods are capital intensive, requiring separate and dedicated production facilities in which to apply the coating and suffering inefficiencies by not being part of a larger in-line production facility.
  • a coated gypsum board which can be produced in one continuous gypsum board manufacturing process.
  • Such gypsum board can be made either with paper on both sides thereof, paper on one side thereof, or without paper on either side thereof. Further, such gypsum board coatings may be applied to wet gypsum board prior to drying.
  • a coated gypsum board comprises a gypsum core having a first side and second side and a facing sheet disposed on the first side. A coating is disposed on at least a portion of the facing sheet and at least a portion of the coating penetrates into the gypsum core.
  • the gypsum board further comprises a backing sheet on the second side of the gypsum core.
  • the coating may penetrate into the gypsum core to a substantially uniform depth across an area of the gypsum board. A gypsum board with such a coating exhibits a nail hold value of greater than 80 pounds.
  • a gypsum slurry is deposited to form a wet gypsum board, a coating is applied to the wet gypsum board, and the wet gypsum board is dried.
  • the coating can be applied directly to the gypsum core or to a facing sheet applied over the gypsum slurry.
  • the coating can penetrate into the facing sheet and/or the gypsum core and forms a coating that is up to 30 mils in thickness.
  • a coating to be applied to a gypsum board is a joint compound or a diluted joint compound.
  • the coating has a composition of 25-75 vol. % water, 30-70 wt. % calcium carbonate, 0-30 wt. % fillers, 2-10 wt. % latex emulsion, and 0-10 wt. % other additives.
  • Fillers can comprise one or more of mica, talc, clay and limestone.
  • 2-8 wt. % perlite can be added to the coating to form a lightweight product and pigment can also be added in an amount effective to provide a desired tint to the coating.
  • a coating to be applied to a gypsum board has a composition of 10-60 vol. % water, 50-90 vol. % calcined gypsum; 0.1-10 vol. % binder; 0-50 vol. % limestone; 0-10 vol. % clay; 0-30 vol. % other fillers; and 0-10 vol% additives.
  • Fillers can comprise one or more of mica and talc. 2-15 vol. % perlite can be added to the coating to form a lightweight product and pigment can also be added in an amount effective to provide a desired tint to the coating.
  • An exemplary method of making a wall deposits a gypsum slurry to form a wet gypsum board having a gypsum core, applies a coating to the wet gypsum board, and dries the wet gypsum board.
  • the step of applying the coating occurs prior to the step of drying the wet gypsum board.
  • the coated gypsum board is then fastened to a support structure to form the wall and the seams between adjacent coated gypsum boards are taped and finished using a joint compound having a composition substantially similar to the composition of the coating.
  • Figure 1 is a cross-sectional view of a coated gypsum board with a coating applied to a facing sheet.
  • Figure 2 is a cross-sectional view of a coated gypsum board with a coating applied to the gypsum core.
  • Figure 3 is a schematic of an embodiment of a production line incorporating a coating step prior to drying a gypsum board.
  • Figure 4 is a schematic plan view of the coating step showing a coating machine.
  • gypsum board is installed during construction on surfaces such as wall, ceilings, and the like, in edge abutting engagement.
  • suitable attachments e.g. , nails, screws, epoxy, and so forth
  • the seams and/or artifacts from the attachments e.g. , depressions from nails, nail heads, screw holes, and so forth
  • a coating can be used in combination with tape.
  • the coating material is sometimes referred to as joint compound.
  • Coatings for use in the gypsum board industry can be of one of two types. In a first type, the coating is applied and the evaporation of water over time produces a hard coating. In a second type, the coating is applied and allowed to set for a suitable time during which the components of the coating solidify into a hard gypsum-based coating.
  • a coating of either of the first type or the second type can be applied to one side of a gypsum board (e.g. , applied to a facing sheet or directly to a gypsum core) during the manufacturing process to form a coated gypsum board.
  • the selection of the coating can be made such that the coating of the coated gypsum board substantially matches the coating or joint compound intended to be used to cover the seams and/or artifacts of attachment associated with the affixing of the coated gypsum board to a structural support.
  • FIG. 1 An embodiment of a coated gypsum board 100 is shown in Figure 1.
  • a gypsum core 105 is disposed between a backing sheet 110 and a facing sheet 115.
  • a coating 120 is disposed on the facing sheet 115.
  • An alternative embodiment of a coated gypsum board 200 is shown in Figure 2, in which a coating 205 is directly disposed on a gypsum board 210. It should be clear that any combination of facing sheet and backing sheet may be utilized in practicing the invention. In cases where one or more sheets have been removed, the coating may be applied directly to the gypsum core with attendant penetration of the coating into the gypsum core.
  • the coating is evenly applied onto the surface of the gypsum board (e.g. , applied to the facing sheet, if used, or directly to the gypsum core) to a uniform thickness t that is preferably not sensitive to surface irregularities.
  • a typical thickness t for the coating is up to 30 mils, preferably from 3-20 mils, and more preferably from 5-15 mils. The preferred thickness can be dependent on the ultimate application. For example, for wallboards, the thickness t is preferably 10 mils; for ceiling tiles it is 20 mils. Furthermore, thicknesses outside of these ranges may also be contemplated by the present invention. However, a coating of approximately 30 mils or greater may result in cracks and grazing of the surface finish when dried.
  • the coating may penetrate into at least a portion of the facing sheet and, in some cases, all the way through the facing sheet and into sections of the gypsum core, over at least a portion of the gypsum board.
  • the coating may penetrate into the gypsum board over substantially the whole of the area to which it is applied, i.e, the whole gypsum board, or predetermined portions if selected regions of the gypsum board have been coated.
  • the depth of penetration of the coating can be influenced by the relative moisture level and/or degree of set of the gypsum board, although the coating preferably penetrates into the gypsum board to a substantially uniform depth.
  • the coating 120 is shown to have penetrated into the facing sheet 115 and into the gypsum core 110 to a depth d.
  • the coating only penetrates a certain depth into the facing sheet.
  • the depth of penetration into the gypsum core is from about 5 mils to 20 mils, preferably from 10 mils to 15 mils. In embodiments of a gypsum board without a facing sheet, the depth of penetration is from about 5 mils to 30 mils, preferably from 10 mils to 20 mils.
  • FIG. 3 A method of producing a coated gypsum board is shown in Figure 3, in which a flow chart of a coated gypsum board manufacturing line is depicted.
  • the general manufacturing steps 300 include mixing 305 the gypsum slurry and forming 310 the gypsum into a desired shape, cutting 315 the gypsum into the desired dimensions, followed by coating 320 to form a gypsum board product and then drying 325.
  • Setting of the gypsum occurs primarily between the forming step 310 and the cutting step 315.
  • the manufacturing steps from forming 310 to cutting, inclusive, are herein described as the forming and setting line; the steps following cutting 315 are herein described as the coating and drying line.
  • a formed, coated gypsum board is manufactured.
  • a gypsum core is coated on a first surface with a coating while the gypsum core is wet.
  • the gypsum board has a facing sheet and/or a backing sheet and is coated on a first surface, e.g. , on the facing sheet surface, with a coating while the gypsum core is wet.
  • a gypsum core is considered wet at any time during the manufacturing process before the gypsum board is passed through the drying oven.
  • the components of the gypsum board can be adjusted, by, for example, controlling the quantity of accelerator and the retarder used in the composition of the gypsum slurry.
  • the accelerator includes small crystal-like objects which are coated with a starch or other dissolvable substances. As the coating on the starch or other dissolvable substances is dissolved, the accelerator crystals form a starting point or seed for crystal growth of the gypsum.
  • Retarder is preferably added to the gypsum board components in order to delay the set time of the gypsum core.
  • the retarder has no long term effect on the strength or other characteristics of the final board product.
  • the gypsum board is conveyed by a conveying system along the forming and setting line to a cutting position.
  • the conveying speed and distance are chosen in combination with the set time of the gypsum to result in gypsum having a desired set or hardness for subsequent cutting and manipulation.
  • Cutting is accomplished by a cutting machine, as is conventionally known in the art.
  • the gypsum board is turned over and placed on a conveying surface and transported to a coating and drying line. Where the gypsum core has a facing and/or backing sheet, the manipulation of the gypsum board results in placing the backing sheet in contact with conveying surface and exposing the facing sheet.
  • the gypsum board On the coating and drying line, the gypsum board, with or without the facing and/or backing sheet, is conveyed by the conveying means through coating machinery, which is located prior to the drying apparatus.
  • Figure 4 schematically depicts an in-line coating process 400.
  • the coating machinery 405 is positioned over the conveying path 410 of the gypsum board 415.
  • the conveying path typically includes a conveying belt 420 on which the gypsum board to be coated has been placed, although other suitable conveying paths can be used, such as driven and nondriven rollers.
  • An uncoated and wet gypsum board 425 is passed under the coating machinery 405 and a coating is applied via a coating applicator 430.
  • the coated gypsum board 435 is then conveyed to the next manufacturing steps, if any, and is then dried in, for example, an oven.
  • the coating can be applied using traditional coating machinery, such as a curtain coater.
  • An example of a curtain coater is that provided by Hymmen International, which can be custom designed to adapt to a particular production line or manufacturing facility.
  • the curtain coater provides a continuous curtain of the coating through which the wet gypsum board is passed.
  • Alternative coating machinery may include sprayers, such as nozzle or shower sprayers, drip lines, and atomization techniques.
  • An example of a spray technology is that provided by Graco, Inc. using spray tips suspended over the wallboard line.
  • Another alternative method is a blade technology that scrapes the coating mix on to the surface of the gypsum board, i.e. , on the surface of the gypsum core or the facing sheet.
  • Coatings may be applied to the gypsum board under any condition of set of the gypsum.
  • the coating can be applied before oven drying, thus allowing the coating to penetrate into the wet facing sheet and/or the wet gypsum core during the conveying period.
  • the coated gypsum board is dried and then prepared for storage and shipping.
  • the coating can be applied after drying where, for example, the coating is heat sensitive or penetration into the facing sheet is to be minimized.
  • Coatings can be applied to the whole surface area of the gypsum board , or to predetermined portions thereof.
  • predetermined portions can be so designated by, for example, masking the gypsum board to prevent coating of the designated sections or by adjusting the coating machinery to only apply a coating to predetermined portions.
  • compositions of coating are envisioned, each affecting the end product.
  • a coating referred to herein as the "rapid coating” is a coating that hardens by evaporation of the water content.
  • the rapid coating comprises water; calcium carbonate; fillers such as limestone, mica, talc, and/or clay; binder; latex emulsion; and other additives such as preservative, and thickener.
  • the rapid coating is provided with a water content of 35-45 wt. % and is diluted in the mixture to between 10% and 60% dilution, e.g. , to between 25-70 wt. % , preferably between 39 wt. % and 56 wt. % water, by the addition of water.
  • Table 1 presents an exemplary formulation of an embodiment of the rapid coating. [0038] Table 1
  • the filler can include from 2% to 8% by weight perlite.
  • An additional embodiment of the rapid coating incorporates a pigment added in an amount effective to provide a desired tint to the coating.
  • the rapid coating may be made so as to substantially match a property of the joint compound, such as the absorbency, the reflectance, and so forth. The substantial matching of one or more properties may improve the aesthetic appearance of the gypsum board in the finished condition after a decorative coating has been applied.
  • a wall can be assembled by producing a gypsum board and coating the gypsum board before the drying step with a joint compound or a diluted joint compound. And, when the gypsum board is fastened to a supporting structure to form the wall, the seams between adjacent boards can be taped and finished using a joint compound having a substantially similar composition to the coating.
  • the setting coating forms a hard gypsum- based coating by a setting process similar to that of the gypsum in the gypsum board.
  • the setting coating comprises is a dry product comprising calcined gypsum; binder; fillers such as limestone, mica, talc, and/or clay; and other additives such as preservative, accelerator, and thickener.
  • the calcined gypsum may be either alpha or beta type or a blend of these types.
  • Prior to use the setting coating is mixed with 30-60 vol. % water to form a mixture.
  • Table 2 presents an exemplary formulation of a setting coating. [0042] Table 2
  • the filler can include from 2% to 15% by volume perlite.
  • An additional embodiment of the setting coating incorporates a pigment added in an amount effective to provide a desired tint to the coating.
  • the setting coating is generally more resilient to impact, i.e. , tougher, than the rapid coating, and may be utilized to provide an abuse resistant surface on the gypsum board, for example, for use in high traffic areas or public spaces. Additionally, the rapid coating may be made so as to substantially match a property of the joint compound, such as the absorbency, the reflectance, and so forth. The substantial matching of one or more properties may improve the aesthetic appearance of the gypsum board in the finished condition after a decorative coating has been applied.
  • Binders suitable for use in the above rapid coating and setting coating include starches, which assist the binding properties. Examples of such binders are wheat starch which can be preset between 0.01 and 5% .
  • a preservative suitable for use in the above rapid coating and setting coating can be present between 0.01 and 5 % . This additive prevents the product from spoiling prematurely, prior to application. The coatings can spoil because there can exist inside the formulations water and/or a number of organic raw materials. The preservative is also commonly known as the biocide.
  • Accelerators may be used to adjust the set time in the above setting coating. An example of an accelerator is potassium sulfate. The accelerator can be present in a suitable amount to achieve the desired set time.
  • the accelerator is present from 0.01 and 15% by solids weight.
  • Thickeners such as generic cellulose-based thickeners, may be used to adjust the rheological properties of the coatings and can be present in suitable amounts. Typical values are between 0.01 and 35 % by solids weight.
  • the penetration of the coating provided by the application of coatings to a wet gypsum board results in improved coated gypsum board properties, such as better adhesion of the facing sheet to the gypsum core.
  • a coating improves board strength, as measured by nail hold.
  • Table 3 includes nail hold values for both coated gypsum board and uncoated gypsum board. From Table 3, it is shown that the coating improves nail hold by up to 25 % of nail hold values for traditional uncoated gypsum board products.
  • Table 3 includes nail hold values for both coated gypsum board and uncoated gypsum board. From Table 3, it is shown that the coating improves nail hold by up to 25 % of nail
  • a coated gypsum board displays a mechanical or strength advantage over uncoated gypsum board products that may allow for utilization of facing sheets of lower weight with attendant cost reductions.
  • facing sheets are anywhere between 40 to 60 lbs. weight.
  • the facing sheet is a paper blended with mineral or synthetic fibers. If the facing sheet is to be coated, the improved board strength imparted by the coating allows the paper weight to be reduced. This advantage of the invention is realized while still obtaining the required handling characteristics to allow manipulation without breakage during the manufacturing process.
  • a gypsum board is produced by forming a gypsum slurry and depositing the slurry onto a facing sheet laid out on an endless conveyor belt.
  • a backing sheet is then laid on top of the gypsum slurry.
  • the facing sheet, the gypsum slurry, and the backing sheet are then formed into a wet gypsum board by passing the gypsum and optional facing and backing sheet through a forming roller or rollers to produce the desired thickness.
  • the wet gypsum board is carried by a conveyor belt until a set time expires, after which the gypsum board is cut into desired lengths with a blade cutter, and then passed through a mechanical coater.
  • a subsequent application of heat such as in a dryer or an oven, removes excess water.
  • either the facing sheet or the backing sheet or both may be removed.
  • the gypsum board product can be formed in a manufacturing line as generally known for making ceiling tiles.
  • the desired components are blended with a high shear mixer in a batch.
  • the batch is then extruded through an opening of an extruder onto an endless conveyor belt.
  • the mixture is then cut into desired lengths.
  • the cut lengths are then passed through a mechanical coater followed by a dryer to evaporate the excess water.
  • lightweight gypsum boards can be made. The density of such boards can range from as low as 1,000 lbs. per thousand square feet to about 1 ,700 lbs. per thousand square feet, or greater.
  • the wet gypsum board is transported to the coating and drying line.
  • a coating of thickness of up to 30 mils is applied which is subsequently dried in a drying process, e.g. , dried in an oven.
  • a gypsum board product of a desired thickness can be made as conventionally known.
  • a x h inch or 1/4 inch gypsum board can be made.
  • the wet gypsum board is transported to the coating and drying line.
  • a coating of thickness of up to 30 mils is applied which is subsequently dried in a drying process, e.g. , dried in an oven.

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  • Paints Or Removers (AREA)

Abstract

L'invention concerne une plaque de plâtre recouverte d'un revêtement au cours de son procédé de fabrication de manière à former une plaque de plâtre revêtue. Des revêtements sont appliqués afin d'humidifier les plaques de plâtre avant de les sécher dans le four, et pénètrent par au moins une partie de la feuille avant dans le noyau de plâtre de la plaque de plâtre. La résistance de la plaque et, s'il y a lieu, l'adhérence au papier sont améliorées par l'application d'un revêtement. Les compositions de revêtement rapide permettent une installation plus rapide, et les compositions à prise rapide permettent d'obtenir des finitions plus durables. Les revêtements peuvent être légers grâce à l'addition de perlite et peuvent présenter une finition améliorée grâce à l'incorporation de pigments. Une plaque de plâtre revêtue peut être fixée à une structure de support pour former une paroi et les joints entre les plaques de plâtre revêtues adjacentes peuvent être pontés et finies à l'aide d'un joint dont la composition est sensiblement semblable à la composition du revêtement. Dans l'ensemble, la plaque de plâtre revêtue obtenue et le procédé de fabrication utilisé permettent d'améliorer l'apparence de la finition finale et de réduire le temps et le coût de fabrication.
PCT/US2002/002106 2000-08-04 2002-01-25 Plaques de platre revetues et procede de fabrication WO2002058902A2 (fr)

Priority Applications (13)

Application Number Priority Date Filing Date Title
NZ527112A NZ527112A (en) 2001-01-26 2002-01-25 Coated gypsum board products and method of manufacture
BR0206941-5A BR0206941A (pt) 2001-01-26 2002-01-25 Produtos de chapa de gesso revestida e método para fabricação de uma chapa de gesso revestida e método para a produção de uma parede
MXPA03006599A MXPA03006599A (es) 2001-01-26 2002-01-25 Productos de tablero recubiertos de yeso y metodo para su fabricacion.
CA002435574A CA2435574A1 (fr) 2001-01-26 2002-01-25 Plaques de platre revetues et procede de fabrication
UA2003087997A UA76975C2 (en) 2001-01-26 2002-01-25 Gypsum board, method of its production and method for production of a wall
JP2002559220A JP2004520966A (ja) 2001-01-26 2002-01-25 コーティングされた石膏ボード製品及び製造方法
EP02713458A EP1358052A4 (fr) 2001-01-26 2002-01-25 Plaques de platre revetues et procede de fabrication
IL15693702A IL156937A0 (en) 2001-01-26 2002-01-25 Coated gypsum board products and method of manufacture
AU2002245308A AU2002245308B2 (en) 2001-01-26 2002-01-25 Coated gypsum board products and method of manufacture
KR1020037009895A KR100842847B1 (ko) 2001-01-26 2002-01-25 피복 석고보드 제품들 및 이의 제조 방법
NO20033319A NO20033319L (no) 2001-01-26 2003-07-23 Belagte gipsplateprodukter og fremgangsmåte ved fremstilling
US10/625,624 US20040154264A1 (en) 2000-08-04 2003-07-24 Coated gypsum board products and method of manufacture
US12/610,401 US20100047461A1 (en) 2000-08-04 2009-11-02 Coated gypsum board products and method of manufacture

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US26406801P 2001-01-26 2001-01-26
US60/264,068 2001-01-26

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US10/625,624 Continuation-In-Part US20040154264A1 (en) 2000-08-04 2003-07-24 Coated gypsum board products and method of manufacture

Publications (2)

Publication Number Publication Date
WO2002058902A2 true WO2002058902A2 (fr) 2002-08-01
WO2002058902A3 WO2002058902A3 (fr) 2002-09-19

Family

ID=23004422

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2002/002106 WO2002058902A2 (fr) 2000-08-04 2002-01-25 Plaques de platre revetues et procede de fabrication

Country Status (16)

Country Link
EP (1) EP1358052A4 (fr)
JP (1) JP2004520966A (fr)
KR (1) KR100842847B1 (fr)
CN (1) CN1317123C (fr)
AU (1) AU2002245308B2 (fr)
BR (1) BR0206941A (fr)
CA (1) CA2435574A1 (fr)
IL (1) IL156937A0 (fr)
MX (1) MXPA03006599A (fr)
NO (1) NO20033319L (fr)
NZ (1) NZ527112A (fr)
PL (1) PL363475A1 (fr)
RU (1) RU2280560C2 (fr)
UA (1) UA76975C2 (fr)
WO (1) WO2002058902A2 (fr)
ZA (1) ZA200305485B (fr)

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WO2004025045A1 (fr) 2002-09-09 2004-03-25 Lafarge Platres Cloison seche comprenant un materiau de protection multicouches et procede de fabrication correspondant
WO2005099907A1 (fr) 2004-04-13 2005-10-27 Lafarge Platres Chaine de fabrication de plaques de platre
WO2005100279A1 (fr) * 2004-04-13 2005-10-27 Lafarge Platres Systeme utilisant une cloison seche et un compose de jointement, revetement pour la construction d'un mur
JP2006524143A (ja) * 2002-10-15 2006-10-26 ビーピービー ピーエルシー 多層セメント系生成品を生成するための方法および装置
US7208225B2 (en) 1995-06-30 2007-04-24 Lafarge Platres Prefabricated plaster board
WO2009058292A1 (fr) * 2007-10-29 2009-05-07 Eastman Chemical Company Incorporation d'une dispersion de résine pour améliorer la résistance à l'humidité de produits à base de gypse
CN1867721B (zh) * 2003-10-17 2010-05-05 G-P石膏公司 内墙板及其制造方法
CN102776995A (zh) * 2012-07-27 2012-11-14 嘉兴博隆铝装饰板有限公司 一种吊顶胚料自动生产流水线
WO2017184945A1 (fr) * 2016-04-22 2017-10-26 Sproule Iii Charles G Isolation rigide renforcée
WO2018022819A1 (fr) 2016-07-28 2018-02-01 United States Gypsum Company Procédés de fabrication de panneaux de plâtre à revêtement polymère et panneaux de plâtre fabriqués selon ce procédé
WO2018057456A1 (fr) 2016-09-22 2018-03-29 United States Gypsum Company Plaques de gypse ayant un revêtement polymère et leurs procédés de fabrication
US10344478B2 (en) 2013-08-27 2019-07-09 Axalta Coating Systems Ip Co., Llc Coating and binder compositions for gypsum boards

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US8404365B2 (en) * 2006-03-23 2013-03-26 Hercules Incorporated Paper for gypsum wallboard
CN107285724A (zh) * 2017-08-09 2017-10-24 苏州雪原风知识产权服务有限公司 一种墙面装饰石膏板的制备方法
CN109928706B (zh) * 2019-03-29 2023-11-03 河北科技大学 一种利用石膏浆液制成三维图案的方法及设备
US11993054B2 (en) 2019-11-05 2024-05-28 United States Gypsum Company Method of preparing gypsum wallboard from high salt gypsum, and related product
US11891336B2 (en) 2019-11-22 2024-02-06 United States Gypsum Company Gypsum board containing high absorption paper and related methods

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US4205041A (en) * 1977-09-19 1980-05-27 Hymes Richard H Tapeless joint compound
US5207830A (en) * 1990-03-21 1993-05-04 Venture Innovations, Inc. Lightweight particulate cementitious materials and process for producing same
US5746822A (en) * 1994-05-12 1998-05-05 United States Gypsum Company Ready-mixed setting type joint compound

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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7208225B2 (en) 1995-06-30 2007-04-24 Lafarge Platres Prefabricated plaster board
US8151532B2 (en) 1995-06-30 2012-04-10 Lafarge Platres Construction assembly of skim coated prefabricated elements and jointing material, a kit therefor, and method of assembling the same
WO2004025045A1 (fr) 2002-09-09 2004-03-25 Lafarge Platres Cloison seche comprenant un materiau de protection multicouches et procede de fabrication correspondant
JP2006524143A (ja) * 2002-10-15 2006-10-26 ビーピービー ピーエルシー 多層セメント系生成品を生成するための方法および装置
CN1867721B (zh) * 2003-10-17 2010-05-05 G-P石膏公司 内墙板及其制造方法
WO2005099907A1 (fr) 2004-04-13 2005-10-27 Lafarge Platres Chaine de fabrication de plaques de platre
WO2005100279A1 (fr) * 2004-04-13 2005-10-27 Lafarge Platres Systeme utilisant une cloison seche et un compose de jointement, revetement pour la construction d'un mur
US7214411B2 (en) 2004-04-13 2007-05-08 Lafarge Platres Coating spray apparatus and method of using same
US7897660B2 (en) 2007-10-29 2011-03-01 Eastman Chemical Company Incorporation of a resin dispersion to improve the moisture resistance of gypsum products
WO2009058292A1 (fr) * 2007-10-29 2009-05-07 Eastman Chemical Company Incorporation d'une dispersion de résine pour améliorer la résistance à l'humidité de produits à base de gypse
US8741989B2 (en) 2007-10-29 2014-06-03 Eastman Chemical Company Incorporation of a resin dispersion to improve the moisture resistance of gypsum products
CN102776995A (zh) * 2012-07-27 2012-11-14 嘉兴博隆铝装饰板有限公司 一种吊顶胚料自动生产流水线
US10344478B2 (en) 2013-08-27 2019-07-09 Axalta Coating Systems Ip Co., Llc Coating and binder compositions for gypsum boards
WO2017184945A1 (fr) * 2016-04-22 2017-10-26 Sproule Iii Charles G Isolation rigide renforcée
US11123956B2 (en) 2016-04-22 2021-09-21 Charles G. Sproule, III Reinforced rigid insulation
US11787155B2 (en) 2016-04-22 2023-10-17 Charles G. Sproule, III Reinforced rigid insulation
WO2018022819A1 (fr) 2016-07-28 2018-02-01 United States Gypsum Company Procédés de fabrication de panneaux de plâtre à revêtement polymère et panneaux de plâtre fabriqués selon ce procédé
US9945119B2 (en) 2016-07-28 2018-04-17 United States Gypsum Company Methods for making gypsum boards with polymer coating and gypsum boards made by the method
WO2018057456A1 (fr) 2016-09-22 2018-03-29 United States Gypsum Company Plaques de gypse ayant un revêtement polymère et leurs procédés de fabrication

Also Published As

Publication number Publication date
WO2002058902A3 (fr) 2002-09-19
CN1317123C (zh) 2007-05-23
PL363475A1 (en) 2004-11-15
MXPA03006599A (es) 2004-10-15
JP2004520966A (ja) 2004-07-15
KR100842847B1 (ko) 2008-07-02
BR0206941A (pt) 2004-02-25
EP1358052A2 (fr) 2003-11-05
AU2002245308B2 (en) 2006-04-06
KR20030082575A (ko) 2003-10-22
UA76975C2 (en) 2006-10-16
NZ527112A (en) 2004-03-26
EP1358052A4 (fr) 2007-10-24
NO20033319L (no) 2003-09-26
RU2003125961A (ru) 2005-02-20
CA2435574A1 (fr) 2002-08-01
ZA200305485B (en) 2004-06-23
RU2280560C2 (ru) 2006-07-27
CN1498161A (zh) 2004-05-19
IL156937A0 (en) 2004-02-08
NO20033319D0 (no) 2003-07-23

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