[go: up one dir, main page]

CN102196903A - 塑性材料涂布的复合建筑板材及其制备方法 - Google Patents

塑性材料涂布的复合建筑板材及其制备方法 Download PDF

Info

Publication number
CN102196903A
CN102196903A CN2009801429115A CN200980142911A CN102196903A CN 102196903 A CN102196903 A CN 102196903A CN 2009801429115 A CN2009801429115 A CN 2009801429115A CN 200980142911 A CN200980142911 A CN 200980142911A CN 102196903 A CN102196903 A CN 102196903A
Authority
CN
China
Prior art keywords
layer
coating
slurry
polymer
building board
Prior art date
Legal status (The legal status 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 status listed.)
Granted
Application number
CN2009801429115A
Other languages
English (en)
Other versions
CN102196903B (zh
Inventor
杰里·D·博伊兹顿
罗伯特·J·郝伯
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Certainteed Gypsum Inc
Original Assignee
Certainteed Gypsum Inc
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
Application filed by Certainteed Gypsum Inc filed Critical Certainteed Gypsum Inc
Publication of CN102196903A publication Critical patent/CN102196903A/zh
Application granted granted Critical
Publication of CN102196903B publication Critical patent/CN102196903B/zh
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
    • 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
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • 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
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • 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
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/12—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/10—Interconnection of layers at least one layer having inter-reactive properties
    • 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
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/24—Macromolecular compounds
    • C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B24/2623—Polyvinylalcohols; Polyvinylacetates
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/44—Number of layers variable across the laminate
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/044—Water-setting substance, e.g. concrete, plaster
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202—Conductive
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/414—Translucent
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/536—Hardness
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/58—Cuttability
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/582—Tearability
    • B32B2307/5825—Tear resistant
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/71—Resistive to light or to UV
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • 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
    • B32B2419/00—Buildings or parts thereof
    • 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
    • B32B2607/00—Walls, panels
    • 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
    • C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
    • C04B2111/00405—Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/24992—Density or compression of components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249955—Void-containing component partially impregnated with adjacent component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31993—Of paper
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2926—Coated or impregnated inorganic fiber fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/603—Including strand or fiber material precoated with other than free metal or alloy
    • Y10T442/604—Strand or fiber material is glass

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明公开了复合建筑板材以及相关制造方法。所述复合板材可以包含例如一个或多个具有嵌入的纤维垫的浆料层。将外部塑性材料涂层机械地附着到在下层的浆料层。塑性材料层与浆料层内的聚合物添加剂化学结合和交联。结果是产生具有大大改进的耐久性和表面强度的成为整体的聚合物基体。

Description

塑性材料涂布的复合建筑板材及其制备方法
发明背景
相关申请数据
本申请要求在2008年8月29日提交的名称为“用于玻璃增强的饰面石膏板的热塑性涂层(Thermoplastic coatings for Glass Reinforced Faced Gypsum Board)”的临时申请序列号61/093,167的优先权，所述临时申请的内容通过引用结合在此。
发明领域
本发明涉及复合建筑板材的改进构造。更具体地，本发明涉及包括外部塑性材料涂层和用于增加所得板材的耐久性和表面强度的预涂布纤维垫的复合建筑板材。
背景技术描述
建筑板材，也称为墙板，石膏板或干式墙，是当今全世界最普遍使用的建筑部件之一。建筑板材频繁用于居室内部，在那里它同时起到最终墙体覆盖和结构空间分隔的作用。建筑板材还可以在居室外部使用，在那里它起到用于提供防潮和保温的覆盖物的作用。建筑板材还可以用作其它结构如楼梯井，电梯和内部管道的内部饰面。
建筑板材的一种特别流行的形式称为石膏板。石膏板通过在两个相对的纸衬垫之间沉积黏结石膏浆料的层而制造。石膏浆料是硫酸钙的半含水形式并且具有许多使得其适于用作建筑部件的物理特性。例如，石膏板通常具有平滑的外表面，一致的厚度，并且允许涂敷装饰增强物，例如油漆。石膏板也是期望的，因为它提供一定程度的耐火性和消声。
覆纸的石膏板的实例公开在Von Hazmburg的美国专利2,806,811中。Von Hazmburg公开了一种主要由装入到纤维包封物中的厚石膏芯组成的板材，所述纤维包封物由蕉麻片和新闻纸片组成。这些片层可以由常规的圆网抄纸造纸工艺制造。
尽管常规纸饰面石膏板如由Von Hazmburg公开的纸饰面石膏板对于许多应用是可以接受的，但是它也具有显著的缺点。最大的缺点是耐久性。石膏板与其它建筑材料如木材或砖石建筑类材料相比更脆。因此纸饰面石膏板在压缩和拉伸负荷下碎裂和/或粉碎。结果，常规石膏板容易被居室内的正常磨损和撕扯如人和/或家具的冲击而破坏。常规石膏板构造通常具有差的负荷承载能力和不合适的拔钉强度(nail pull strengh)。结果，传统石膏板通常不能支持用于悬挂图片或安装架子所需的负荷。
作为这些这些缺点的结果，多年来对于改进石膏板的耐久性和表面强度进行了努力。一种特别有用的进展被称为玻璃增强石膏(GRG)板。一种这样的板材的实例公开在Baehr等的美国专利4,265,979中，Baehr公开了一种无纸石膏板构造。更具体地，Baehr采用部分地由玻璃纤维垫形成的相对层代替纸饰面层。此构造提供了更强且更硬的外表面并且是相对于纸饰面板的改进。尽管从耐久性观点方面得到了改进，但是暴露的纤维垫的使用存在问题。即，操作这样的板材的工人暴露于遗漏的纤维束。这致使了健康风险以及使用保护性手套和/或面具的必要性。因为，使用暴露的饰面片的GRG板材不是理想的。
随后的改进描述于Pilgrim的共同拥有美国专利4,378,452中。Pilgrim专利的内容通过引用完全结合在此。Pilgrim公开了一种用多孔无纺玻璃垫在一个或两个侧面上饰面的GRG板材。然而，Pilgrim的玻璃垫稍微嵌入到浆料芯(slurry core)中。这通过振动石膏浆料以致使其通过垫中的多孔开口而实现。
将垫嵌入在芯内部，导致了在板材的外表面上形成浆料的薄膜。具有此构造的建筑板材称为嵌入玻璃增强石膏(EGRG)板。EGRG板消除了，或极大地减少了暴露纤维的存在，并且另外提供了平滑的加工表面。尽管消除了围绕GRG板材的安全问题，但是Pilgrim最终未能提供具有足够强度和耐久性的板材。
进一步改进的EGRG板材公开在Hauber的共同拥有美国专利6,524,679中。Hauber专利的内容通过引用完全结合在此。Hauber的EGRG板材向石膏浆料中加入聚合物化合物。合适的聚合物化合物可以包括例如聚1，2-二氯亚乙烯(PVDC)，或聚氯乙烯(PVC)，或类似聚合物。聚合物添加剂提高了耐久性和板强度，并且还在其固化以后在浆料内产生基体。尽管的确相对于现有EGRG技术得到了改进，但是Hauber不能解决与外部面的耐久性或外部面与下面的石膏浆料的完全机械和化学结合相关的问题。
因而，在现有技术中仍存在着对改进的建筑板材构造的需求。更具体地，在现有技术中存在着对具有提供增强的耐久性，耐冲击性，防水性，防火性和负荷承载能力的聚合物基体的板材的需求。在现有技术中还存在着对在没有不适当地增加所产生的板材的重量或成本的情况下提供这些物理性质的板材的需求。本发明旨在实现这些目的。
发明概述
因此，本发明的目的之一是增强常规建筑板材的物理特性。
本发明的另一个目的是在重量和成本的增加最小的情况下增加建筑板材的耐久性和负荷承载能力。
本发明的另一个目的是具有取决于板材的期望应用而产生特定物理性质的聚合物的涂布建筑板材。
本发明的另一个目的是通过包含具有热塑性预涂层的纤维垫而提供具有有利物理特性的建筑板材。
本发明的再另一个目的是提供一种具有这样的外部涂层的建筑板材，所述外部涂层被设计用于增强一种或多种物理性质，例如耐紫外性，导电性，耐EMF性，消声以及耐水和耐火性。
本发明的另一个目的是将外部聚合物涂层与在石膏板的芯内存在的聚合物添加剂交联。
本发明的再另一个目的是提供一种建筑板材构造体，所述建筑板材构造体包括热塑性涂层，所述热塑性涂层被敷贴到在下层的聚合物改性稠密浆料层上，从而产生低成本，轻重量、耐久的板材。
本发明的又另一个目的是提供方法改进，所述方法改进显著地减小制造成本并且允许建筑板材的经济生产。
本发明的另一个目的是结合外部热塑性涂层使用预涂布纤维垫。
本发明的再另一个目的是利用嵌入到稠密浆料层内的玻璃垫上的热塑性预涂层，从而生产真正的复合建筑板材。
本发明的另一个目的是，与常规热固性粘合剂相反，将有机和/或无机纤维与热熔(holt melt)的热塑性聚合物结合在一起。
本发明的又另一个目的是，与常规热固性粘合剂相反，将连续的和/或非连续的纤维的垫与热熔的热塑性聚合物结合在一起。
本发明的另一个目的是提供一种具有显著的成本优点和性能特性的建筑板材。
本发明的另一个目的是在垫的纤维上涂布热塑性材料(thermoplastic)的连续且均匀的层，由此热塑性材料立即冷却，从而消除与传统板材制造工艺中所必需的干燥步骤相关的能量成本。
本发明的再又另一个目的是经由涂敷热塑性层而消除纤维损失和/或脱离，从而消除与传统板材制造中所必需的粉尘(dust)和/或碎屑移除步骤相关的成本。
最后，本发明的目的是使用热塑性材料以立即产生强的且结合的纤维垫，从而可以极大地增大制造速度。
通过提供包括具有热塑性材料预涂层的多孔垫的复合建筑板材而实现这些和其它目的。所述板材还包括这样的黏结浆料层，所述黏结浆料层渗透所述多孔垫，从而形成基本上覆盖垫的外表面的边界层。所述板材还包括外部聚合物涂层，所述外部聚合物涂层机械地和化学地附着于边界层，并且其在复合建筑板材内形成聚合物基体。
上述内容已经相当宽泛地略述了本发明的更相关和重要的特征，使得可以更好地理解随后的本发明的详细描述，从而可以更完全地认识到本发明对现有技术的贡献。本发明的另外的特征将在以后描述，其形成的本发明的权利要求的主题。
本领域技术人员应当理解，所公开的概念和具体实施方案可以容易地用作用于更改或设计用于实施本发明的相同目的的其它结构的基础。本领域技术人员还应当认识到，这样的等价构造不背离如在后附权利要求中阐述的本发明的精神和范围。
附图简述
为了更全面地理解本发明的属性和目的，必须结合附图参考下列详细描述，在所述附图中：
图1是根据本发明构造的建筑板材的透视图。
图2a是沿图1的线2-2取得的建筑板材的横截面图。
图2b是沿图1的线2-2取得的备选建筑板材构造的横截面图。
图3是可以用于构造本发明的建筑板材的制造方法的图。
图4a-4c是从图3取得的细节图。
图5是可以用于构造本发明的建筑板材的备选制造方法的图。
图6a-6c是从图5取得的细节图。
图7是用于涂敷本发明的塑性材料涂层的辊涂机的细节图。
图8是用于涂敷本发明的塑性材料涂层的幕涂机的细节图。
图9是用于涂敷本发明的塑性材料涂层的刀涂机的细节图。
图10是用于涂敷本发明的塑性材料涂层的喷涂机的细节图。
贯穿若干附图，类似的附图标记指代类似的部分。
优选实施方案的详细描述
本发明涉及复合建筑板材及相关制造方法。具体地，本发明涉及复合板材，所述复合板材可以包括如嵌入有纤维垫的一个或多个浆料层。根据本发明，外部塑性材料涂层被机械地附着到在下层的浆料层。塑性材料涂层与浆料层内的聚合物添加剂化学结合和交联。另外的优点通过在嵌入浆料层内之前对一个或多个纤维垫进行预涂布而实现。结果是在仅最小地增加成本或重量的情况下的具有大大改进的耐久性和表面强度的完全成为整体的聚合物基体。
复合板材构造
现在参考图1，描述本发明的复合建筑板材20。建筑板材典型地在连续生产线工艺中以长片材的形式形成。其后将片材切割成所需长度。取决于期望用涂，板材以4或9英尺的标准宽度形式制备。然而，本发明绝不限制于任何特定板材尺寸或几何形状。如在以下更详细指出的，板材20包括上表面22，所述上表面22包括塑性材料涂层。可以将塑性材料涂层同样地涂敷到板材20的底部24和侧面边缘26。
图2a示例板材20的复合材料横截面。即，板材20包括嵌入到多层石膏浆料内的上和下纤维垫(28和32)。描绘的实施方案示例了2个纤维垫(28，32)，但是本领域技术人员应当理解可以使用任何数量的垫。在优选的实施方案中，这些垫(28，32)由以粘合剂保持在一起的非织造的且无序排列的纤维的组形成。合适的粘合剂包括树脂，例如脲-甲醛树脂。垫的纤维优选是长的无机纤维，例如玻璃纤维。纤维还可以是连续的，或非连续的，或它们的混合形式。纤维可以由有机或无机长丝形成。在一个实施方案中，使用矿物纤维。优选小直径纤维；即，具有介于约13-16μm之间的平均直径的纤维。所产生的垫充分多孔以允许石膏浆料在各根纤维之间通过，从而可以用石膏浆料涂敷或基本上涂敷垫的内部面和外部面。尽管多孔，但是垫(28，32)起到了加强所产生的板材20的面的作用。合适的纤维垫更全面地描述在Hauber的共同拥有美国专利6,524,679中，该美国专利的内容全部结合在此。此外，如以下所述，可以预涂布垫(28，32)以增加复合材料结合和板材强度。
下部垫32任选包括在每一边内的一对折角(34，36)。第一折角(fold)34产生下部垫32的直立侧边38。侧边38通常相对于垫32的剩余部分以90°角形成，从而起到了增强板材20的侧边26的作用。第二折角36形成下部垫32的向内指向的上边42。上边42有时称为机器边。上边42优选彼此隔开以形成间隙44。结果是部分封闭的通道。上边42提供了用于支持上部垫28的表面。如在以下更详细地描述的，下部垫32内的折角(34，36)在制造工艺过程中由折叠器轮(creaser wheels)形成。
除加强板材20以外，下部垫32的侧边38还形成用于接受浆料体积的通道。一旦已经将充分量的浆料沉积到通道中，就在向内指向的上边42的顶部上方固定上部垫28。结果得到增强建筑板材20的所有4个侧面(22，24，26)的封闭纤维垫。
复合板材20，在优选的实施方案中，由3个不连续的黏结石膏浆料层形成。更具体地，板材20包括上和下浆料层(46和48)以及中间芯层54。如在Hauber的美国专利6,524,679中所述，上层和下层(46和48)由比中间芯层54更稠密的浆料形成。此构造具有的另外优点在于在没有不必要地增加总重量的情况下加强了板材20的外部面。
在制造工艺过程中，上部稠密浆料层和下部稠密浆料层(46，48)分别被涂布并附着到上部垫和下部垫(28，32)。然后使用辊推动稠密浆料(46，48)通过垫(28，32)内的孔。由于垫(28，32)是多孔的，因此允许稠密石膏浆料完全渗透垫(28，32)。结果，并且如在图2a中所描绘的，稠密石膏浆料(46，48)的层基本上覆盖上部垫和下部垫(28，32)的内部面和外部面。稠密石膏浆料(46，48)在内表面上通常形成较厚层。如在图2a-2b中指出的，内部稠密浆料层(46，48)与浆料芯54交界。稠密浆料层(46，48)还形成介于从纤维垫(28，32)的外表面测量的.01至2.0毫米(mm)之间的薄边界层52。
边界层52从而形成这样的形貌结构(topographically)，其以波动状态进入并离开在下层的玻璃垫(28，32)，但是其仍然覆盖垫(28，32)的各根纤维。备选地，边界层52可以在垫(28，32)上方形成均匀且平滑的覆盖表面。在任一情况下，作为浆料渗透的结果都实现了垫(28，32)的完全埋入。在优选的实施方案中，浆料在垫(28，32)的95％至100％之间渗透并且形成平滑且相对均匀和统一的聚合物改性的复合密实石膏外表面层。
如在图2a中所示，边界层52还与外部塑性材料涂层接界。备选地，在塑性涂层没有在所有表面上使用的情况下，如在图2a中所示的，边界层52弯曲以形成板材20的外表面。在此情况下，边界层52防止来自垫(28，32)的纤维免于暴露。
外部稠密浆料层(46，48和52)全部优选包含聚合物添加剂以增强板材的总体耐久性和表面强度。聚合物添加剂还优选促进其本身与外部塑性材料涂层56之间的强的化学结合。合适的聚合物添加剂将提供涂层56可以附着在其上的固定(root)结构。合适的聚合物化合物可以包括例如聚1，2-二氯亚乙烯(PVDC)，或聚氯乙烯(PVC)，或类似的聚合物。另一种合适的聚合物添加剂是购自俄亥俄州Fairlawn的Omnova Solutions的功能化的苯乙烯丁二烯(SBD)胶乳。又另一种合适的添加剂是硅烷或功能化的硅烷(SiH4)。硅烷化合物理想地与其它聚合物结合使用以促进聚合物与玻璃纤维之间的结合。硅烷还称为稳定剂。合适的硅烷化合物由Down Corning出售。再其它的聚合物添加剂描述在Hauber的美国专利6,524,679中。无论使用怎样的添加剂，所述添加剂都应当能够提供与外部塑性材料涂层56的共价、烯丙基、范德华、单键和双键结合。
芯浆料层54通常占板材20的大部分，并且在上部稠密浆料层和下部稠密浆料层(46，48)之间完全延伸并且与上部稠密浆料层和下部稠密浆料层(46，48)结合。在一种可能的制造方法中，芯浆料层54被沉积到下部浆料层48(与嵌入的下部纤维垫32一起)的顶部上方。其后，在芯浆料54上涂敷上部稠密浆料层46(与嵌入的上部纤维垫28一起)。与上部浆料层和下部浆料层(46，48)相同，芯浆料54为了增加耐久性和表面强度的目的而可以同样地包含聚合物添加剂。在芯浆料54内的聚合物添加剂优选与其它浆料层(46，48和52)内的聚合物添加剂化学结合和交联。
外部塑性材料涂层
在已经组装各个浆料层以后，将外部塑性材料涂层56涂敷到稠密浆料边界层52。可以将涂层56任选涂敷到任意或所有的板材表面。在图2a中描绘的实施方案中，将塑性材料涂层56涂敷到顶部和底部表面(22，24)以及周边26。在图2b中描绘的实施方案中，将塑性材料涂层56仅涂敷到最顶部表面22。涂布表面的数量将取决于板材的期望用途。期望用途还将确定涂层56的组成。理想地选择塑性材料涂层56以对外表面(22，24和26)提供增强的表面强度和负荷承载能力。由涂层56提供的其它适宜特性包括挠性、消声、耐水性、抗霉菌和霉病性，以及各种建筑效果。
为了实现以上内容，涂层56可以是各种合成、半合成或有机聚合物中的任一种。既可以使用反应性聚合物又可以使用非反应性聚合物。可以同样地使用全同立构和无规立构聚合物。
另外，可以使用多层层压聚合物涂层以提供甚至更大的强度和耐久性。当已经将根据本发明的聚合物涂层涂敷到板材上时，最顶部涂层然后可以起到可以在其上应用其它涂层和/或层压体的另外基础结构体的作用。可以使得不同层的性质相容，从而在连续涂敷的层之间形成强的化学结合。这导致具有强的结合能力的层压体。还可以将层压的层结合到完全复合的结构中或制备形成完全复合的结构。另外指出的是，可以在不包括纤维垫(28，32)的板材上使用外部热塑性层56。例如，可以使用纸饰面层代替垫(28和32)。
下列内容是可以单独地或以彼此组合的形式用于聚合物涂层56的各种聚合物的名单：丙烯腈丁二烯苯乙烯(ABS)，赛璐珞，乙酸纤维素，乙烯-丙烯酸丁基酯，乙烯-丙烯酸甲酯，乙烯乙酸乙烯酯(EVA)，乙烯-丙烯酸-共聚物(EAA)；乙烯乙烯醇(EVAL)，氟塑料(PTFE，包括FEP，PFA，CTFE，ECTFE，ETFE)，离聚物，液晶聚合物(LCP)，聚缩醛(POM或缩醛(Acetal))，聚丙烯酸酯(熔融和固化丙烯酸类)，聚丙烯腈(PAN或丙烯腈)，聚酰胺(PA或尼龙)，聚酰胺-酰亚胺(PAI)，聚芳醚酮(PAEK或酮)，聚丁二烯(PBD)，聚丁烯(PB)，聚对苯二甲酸丁二醇酯(PBT)，聚对苯二甲酸丁二醇酯(PET)，聚对苯二甲酸亚环己基二甲酯(PCT)，聚碳酸酯(PC)，聚酮(PK)，聚酯，聚乙烯(Polyethylene)/聚乙烯(Polythene)/聚乙烯(Polyethane)，聚醚嵌段酰胺(PEBA)，聚醚醚酮(PEEK)，聚醚酰亚胺(PEI)，聚醚砜(PES)，氯化聚乙烯(Polyethylenechlorinates)(PEC)，聚酰亚胺(PI)，聚乳酸(PLA)，聚甲基戊烯(PMP)，聚苯醚(PPO)，聚苯硫醚(PPS)，聚邻苯二甲酰胺(PPA)，聚丙烯(PP)，聚苯乙烯(PS)，聚砜(PSU)，聚氯乙烯(PVC)，Spectralon，和热塑性烯属弹性体(TPO)。
在这些中，优选使用熔点介于100℉至500℉之间的热熔热塑性材料。可以使用天然或合成的热熔热塑性材料。另外，本发明人确定的是，具有在规定范围内的熔点的热熔热塑性材料允许在不煅烧在下层的石膏的情况下以液化形式涂敷塑性材料涂层。优选的热熔热塑性材料包括EVA和EAA聚合物，因为它们都具有适当的熔点并且另外对板材的稠密石膏层中的聚合物添加剂提供足够的结合点。
除上述内容以外，还可以使用聚烯烃聚合物，包括极性或非极性聚烯烃化合物，结晶或非晶聚烯烃化合物，作为聚烯烃化合物的一部分的天然或合成粘性树脂，以及低粘度聚烯烃化合物。还可以将选择的聚合物用于产生各种膜，包括设计用于分子水渗透性的微观连续和/或非连续膜，非取向聚合物膜，平面取向聚合物膜，无规取向聚合物膜，和具有低导热性的膜。
使用无论怎样的聚合物涂层56，它都应当提供与在下层的稠密浆料层的优异机械粘合，还有对其中所包含的聚合物添加剂的化学结合。机械粘合可以通过聚合物涂层56对在下层的稠密浆料边界层52的形貌镜像反映(topographic mirroring)而实现。此形貌镜像反映可以通过控制涂敷辊的硬度和压力而实现。形貌镜像反映还可以通过下列方法实现：改变施加热，从而在冷却时使用类似真空的力(vacuum like forces)，将涂层拉成所述的形貌结构(topography)，这是本发明人在开发过程中发现的出乎意料的结果。
涂层56和在下层的浆料层46，48，52和54之间的化学结合通过下列方法实现：将聚合物涂层56与在各种浆料层，即，上部浆料层46，下部浆料层48，浆料边界层52和芯浆料层54内所含的聚合物添加剂交联。选择相应的聚合物以保证适当的交联以及在整个聚合物材料板材20中延伸的长的高分子量聚合物链的产生。例如，聚合物涂层56的正确选择允许了离子、化合价和共价结合，以及经由范德华力的结合的产生。而且，如果选择非反应性聚合物涂层，则在将涂层56进行相变以后，涂层56将与在下层的聚合物添加剂结合(initiate)。备选地，如果选择反应性聚合物涂层，则涂层56将在应用到在下层的边界层52时聚合。
还可以向聚合物涂层56中加入性能增强填料和/或改性剂。这些填料和改性剂可以提供下列物理增强中的任一种：耐紫外性，导电性，耐电磁力(EMF)性，降低的聚合物密度，消声，耐水性，和阻燃性，耐传热性，弹性体性能增强剂，强度改性，气候稳定性，改进的美学性，和磷光，彩色照相(photochromatic)和多色增强。
阻燃性质可以是化学的，起泡的、膨胀的，天然的或合成的。密度改性剂和消声剂可以包括气体如氮气，固体，液体或纳米粒子，以及微小的粒子橡胶。强度改性可以由作为金属，有机或无机化合物的填料或改性剂提供，包括纤维或合成纤维化合物，薄片或纳米材料。气候稳定可以包括用于提供对抗红外线、可见光和紫外光的保护的合成和天然的光稳定剂。为了改进的性能，还可以加入其它的稳定剂，例如自由基清除剂，氧清除剂等。
如在图2的横截面图中所示的，将塑性材料涂层56直接涂敷到形成在垫28和32的外表面上的浆料边界层52上。聚合物涂层56可以通过广泛的各种热熔涂布应用中的任何一种进行设置(laid down)。以下结合图7-10更全面地描述适当的涂层敷贴。在优选的实施方案中，以介于.01至500密耳之间的厚度涂敷聚合物涂层56。
尽管优选地公开了.01至500密耳，但是不同的应用可能要求不同的厚度。例如，对于用于盖板的玻璃增强的石膏板，优选介于.25至3密耳之间的涂层。类似地，对于更坚固的应用，例如衬底或井筒支护(shaft lining)，涂层增加到以重量计的1.8g至3.5g的范围。对于砖背衬应用，其要求更大的完整性和耐水性，需要约1-10密耳的厚度。对于改变内部石膏板的平整度等级，等级2的成品板(finish board)可能要求0.25-0.9密耳的涂层，等级3的成品板可能要求1.0-1.9密耳的涂层；等级4的成品板可能要求2.0-2.9密耳的涂层；并且等级5的成品板可能要求2.5-5.0密耳的涂层。另外的非常粗糙的(very rugged)，结构的，或高度绝热的产品可能具有更厚的涂层。基于最终产品中所需的性能标准以及对具体产品施加的具体涂层的内在化学和物理性质，涂层的重量和所得厚度可以随意改变。
介于.01至500密耳之间的涂层将导致具有如下外表面硬度的建筑板材：基于洛氏(Rockwell)硬度尺度的介于50至150的外表面硬度，或基于肖氏(Shore)A和D硬度尺度的约15的最小值至约70的最大值之间的外表面硬度。最终涂层56的优选的水蒸气渗透性介于约.01的最小值(接近水不可渗透的)至约98的最大值(接近完全水透过)之间的某值。而且，取决于板材的期望用途，涂层56可以被涂敷成从平滑至粗糙，或者甚至波动成为削边(chamfered)的形貌结构(topography)。还可以将添加剂包含在聚合物涂层56内，以提供.001％至100％的膜半透明性。
另一个可能的改进是通过在板材20的面或背表面中具有抵消的图案和或形状或衬里的所致的消声。因而，当将两块以上的板材20以面对的关系放置时，抵消部分彼此接触，从而在两块板材20之间产生空气袋(air pockets)。空气袋提供了优异的保温和声衰减以及用于防火目的的绝热。
另外，在将热塑性涂层56涂敷到聚合物改性的石膏表面之前，在熔融热塑性材料中引入微小气泡或热活化膨胀聚合物孔或膨胀聚合物孔，这导致了在本文中公开的本发明的另一个出乎意料的发现。这是夹带的气泡或浅孔，其可以在复合板材20的涂敷表面提供被固定(built in)的消声。任何填料往熔融热塑性材料中的引入导致在处于熔融或冷却的状态下，填料变得永久地悬浮在热塑性材料内。为了降低密度而在涂布工艺过程中将微小气泡引入到热塑性材料中还导致其上已经涂敷涂层56的暴露表面的显著消声。在本文中使用的空气应当理解为包括任何类型的气态物质，例如氮气或惰性气体。
纤维垫的预涂布
在本发明的另一个实施方案中，在嵌入到稠密浆料层46和48之前，将纤维垫(28和32)用热熔热塑性材料预涂布。其后将热塑性材料涂层56涂敷到如上所述的板材20的外表面上。预涂布垫28和32与化学基体一起产生强的轻重量的复合板材，所述化学基体互相连接纤维垫(28和32)，稠密浆料层(46，48)，外部石膏涂层56，和石膏芯54。
如上所示，可以将宽范围的材料用于构成(comprising)纤维垫28和32的长丝(有机的和无机的)；然而，优选无规排列的玻璃纤维。类似地，垫28和32可以由连续和/或非连续的长丝形成。单根的纤维通过粘合剂如脲-甲醛保持在一起。
尽管可以将上部和下部纤维垫(28和32)预涂布，但是预涂布优选限于下部垫32。这是因为下部垫32位于在覆面侧板(the facing side board)20的下面，因此具有较大的强度要求。可以将多种塑性材料中的任何一种用于预涂布垫32的纤维。合适的塑性材料包括上述结合外部塑性材料涂层56而描述的聚合物中的任何一种。为了简洁，没有复制该名单，但是通过引用将其结合在此。在优选的实施方案中，塑性材料预涂层是熔点介于100℉至500℉之间的热熔热塑性材料；并且更具体地是乙烯乙酸乙烯酯(EVA)或乙烯甲基丙烯腈(EAA)。
热塑性预涂层可以以平滑层的形式涂敷，或可以以遵循在下层的垫的形貌结构的层的形式涂敷。在优选的实施方案中，将热塑性材料以厚度介于.1至10密耳之间的涂层的形式涂敷。热塑性材料预涂层还可以是加填料的，或未加填料的，着色的或半透明的。
在涂敷预涂层之前，将垫32用酸、异丙醇和硅烷偶联剂的组合处理。此预处理步骤有效地制备用于随后的热塑性材料涂层的垫32的各根纤维。预处理步骤的酸活化在垫32内存在着的粘合剂，从而促进结合。酸还允许垫32的纤维与硅烷偶联剂结合。硅烷偶联剂进而保证了垫32的各根纤维和周围的热塑性材料之间的紧密结合。硅烷是促进聚合物和玻璃纤维之间的结合的已知偶联剂。硅烷还称为稳定剂。合适的硅烷化合物由Dow Corning销售。
在预处理步骤以后，以液化状态涂敷热塑性材料预涂层。在此步骤中可以利用在图7-10中描绘的热熔涂布技术中的任何一种。如在图6a中所示，预涂层附着到垫32的单根纤维，从而保持垫32的多孔性。因而，即使在涂敷预涂层的情况下，垫32也可以嵌入到稠密浆料层48内。一旦涂敷，硅烷就促进各根玻璃纤维和周围的热塑性材料之间的结合。以此方式，热熔热塑性材料预涂层与垫32的各根纤维形成强的化学和机械结合。
硅烷还促进其它结合。即，硅烷促进热塑性材料预涂层和在垫32内存在的粘合剂之间的结合。还促进热塑性材料预涂层和稠密浆料层(46，48)内存在的聚合物，石膏芯54和外部热塑性涂层56之间的结合。再进一步地，促进热塑性材料预涂层与周围石膏内的钙和硫之间的另外结合。结果是产生真正的复合建筑板，其中板材20的所有组分被化学地和机械地结合在一起。而且，可以在具有或没有上述热塑性表面涂层的情况下获得复合板。
本发明考虑用热熔热塑聚合物完全代替传统热固性粘合剂(用于粘合有机和/或无机纤维垫)。完全热塑性结合的纤维垫，尽管预期改善制造成本，但是出乎意料地提供了另外的优点。这些新近发现的优点包括显著改进的垫的“X”，“Y”和“Z”轴强度，以及相当程度的延展性和挠性改进，其优于在结合了传统热固性粘合剂的垫中看到的那些。
本发明人另外发现，在涂敷热熔热塑性粘合剂之前经硅烷预处理的有机和/或无机纤维导致垫强度增加。硅烷预处理还增加在热熔热塑性材料和有机和/或无机纤维之间的界面处的结合。这进而对垫提供了“拉伸”样特性，其可比较地类似于关于弹性体拉伸和精确回弹的有机肌肉纤维和已知的分子记忆图案倾向的“拉伸”样特性。
除以上内容以外，热塑性材料预涂层可以包含各种填料和添加剂，以赋予期望的物理特性。例如，可以将预涂层与气体复合以增加塑性材料的体积，从而减少用于完全涂布垫32所需的塑性材料的量。可以使用再另外的其它填料以产生成本节约。如本领域技术人员将意识到的，可以将其它的添加剂包含在预涂层内，以产生其它性质以及用于快速的(instant)产品变化。在将填料结合到热熔热塑性材料中时，或将填料与热熔热塑性材料混合时，还可以将填料用硅烷预处理。这样的预处理填料将通过周围的热塑性材料机械结合，并且还将随后化学结合并原位锁定(locked into place)。
最后，应当指出，垫(28，32)的预涂布可以在涂敷或不涂敷外部塑性材料涂层56的情况下进行。例如，可以将在本文中描述的预涂布垫(即，不常见地涂布有热塑性材料或涂布有包含硅烷和/或填料的热塑性材料的垫)与常规石膏饰面板结合使用。备选地，预涂布垫可以与纤维素或纸饰面板结合使用。简言之，可以将预涂层有利地结合到任何常规建筑板材构造中。
制造方法
用于本发明的建筑板材的合适制造方法描绘在图3-6中。图3公开了具有用于制备(compiling)复合板材的具体工艺58的设备。此工艺更全面地描述于Hauber的共同拥有美国专利6,524,679中，该美国专利的内容通过引用完全结合在此。为了清楚，在本文中提供此优选制造工艺的简略综述。本领域普通技术人员将意识到适用于制备根据本发明的塑性材料涂布板的其它制造方法。
工艺58包括形成下部纤维垫32的纤维垫的第一供给辊60。如在图4a的细节图中所示的，垫32是从单根纤维的组形成的多孔结构。尽管优选纤维，但是还可以使用较长的纤维粗纱。在铺开以后，上部和下部折叠器轮62用于形成第一和第二折角(34，36)。这些折角(34，36)进而产生下部垫32的向上侧面38和向内边42。向上侧面38起到产生用于接收石膏浆料芯54的通道的作用。
其后将第一石膏层48沉积到垫32上。石膏浆料从混合器68和浆料出口64供给。从此出口64分配的浆料优选是较稠密的石膏浆料。浆料被直接沉积在成型台66上方的下部垫32上。其后，将辊涂机72用于压制沉积的浆料48通过下部垫32。垫32的多孔性允许稠密浆料层48完全穿透并涂布垫32的内表面和外表面。图4b描绘在通过辊涂机72以后嵌入在浆料48内的垫32。理想地，稠密石膏48的薄层附着于垫32的内表面和外表面上。
其后经由第二浆料出口74在下游位置沉积芯浆料层54。芯浆料层54来自于稠密浆料层48相同的混合器68。然而，如上所述，芯浆料层54与上部和下部浆料层(46，48)相比较不稠密，并且形成所得板20的大部分。一个或多个振动器76，其位于邻近成型台66之间，用于迫使空气离开沉积的石膏浆料。
然后从第二供给辊78供给纤维垫28的另外供给。纤维垫28形成复合板材20的上部纤维垫。包括第三浆料出口82，以将稠密的上部浆料层46释放到纤维垫28。这是在分开的成型台84上完成的。将垫28经由一系列的导辊88导向成型台84。辊涂机86用于压制稠密浆料层46通过多孔纤维垫28以涂布内表面和外表面。其后将涂布的纤维垫28经由导辊88传送到芯石膏的上表面。然后将上部垫28在成型岗位固定至芯浆料层54和下部浆料层48。成型岗位包括具有相连的铰链94的成型板92。成型岗位保证将各个层压制在一起以产生具有均匀厚度的平滑复合石膏板20。图4c是显示板20的组装部件的细节图。如在Hauber专利中更完全地描述的，将下游修边组件96用于使板材20的边缘平滑。
图5示例其中将垫32首先用热塑性材料层预涂布的改造工艺。此预涂布工艺在以上内容中更详细地描述。除预涂布步骤以外，在图5中描绘的工艺与在图3中描绘的工艺相同。预涂布岗位61位于供给辊60的直接下游。因而，当将垫32从供给辊60展开时，将其经由一系列导辊传送到岗位61。在岗位61，一系列辊涂机用于涂敷液化的热熔热塑性材料预涂层。此预涂层以连续流动且均匀的层的形式涂敷到垫32的各根纤维上。然后将热塑性材料立即冷却，从而消除任何干燥步骤。图6a显示涂布有预涂层的垫32的各根纤维。图6b是显示在已经涂敷浆料48以后的涂布纤维的细节图。如所示出的，预涂层理想地在各根纤维之间留下间隙以允许浆料48通过。最后，图6c是显示垫(28，32)，以及芯54和上部和下部稠密浆料层(46，48)的横截面图。
对于预处理步骤而言，还可以包括另外的岗位(未示出)。即，涂布机可以位于岗位61的上游，以涂敷如上所述的酸、异丙醇和硅烷偶联剂。备选地，预处理步骤可以在将垫32卷绕到供给辊60之前进行。
热熔涂敷器
在形成步骤完成以后，然后将板材20传送到下游的用于涂敷聚合物涂层56的热熔涂敷器。聚合物涂层56可以在浆料层(46，48，54)固化之前并且在板材20通过相关的干燥器之前涂敷到板材20上。聚合物涂层56在固化之前的涂敷可以增强机械和化学结合，因为涂层56与在下层的浆料层(46，48，52，54)一起干燥，从而导致更强且更耐久的表面涂层。
备选地，可以在浆料层(46，48，52，54)已经固化并干燥以后将聚合物涂层56涂敷到板材20上。这也可以提供涂层56和在下层的边界层52之间的强的结合。该结合足够强，使得认为涂层56与板材20成为整体。
在任一情况下，在涂敷聚合物涂层56之前，都使板材20通过清洁岗位。清洁岗位保证在涂敷聚合物涂层56之前移除灰尘和碎屑。其后可以通过多种涂敷器方法中的任何一种涂敷聚合物涂层56。理想地，涂敷器将聚合物涂层56加热到介于100至500℉之间的温度，从而在涂敷过程中保持聚合物处于液态。各种涂敷器公开在图5-7中。尽管图5-7公开了单个的涂敷器，但是应当理解，可以类似地使用一系列涂布涂敷器，或者以串联或并联的形式，或者以串联和并联的组合的形式。
一种适当的涂敷器是在图5中描绘的辊涂机。辊涂机98包括计量辊102和相邻的涂敷辊104。辊104位于板材组装线的顶部，优选处于匹配板材20的厚度的高度。将加热的液化聚合物的供给递送到计量辊和涂敷辊(102，104)之间的间隙。计量辊102保证将均匀的聚合物层附着到涂敷辊104。涂敷辊104经由内部加热元件(未示出)加热。例如，可以将加热的油通过辊内部的管线。这保证了维持聚合物的温度并且防止了早期的固化或凝固。涂敷辊104然后将液体均匀的聚合物层涂敷到在下层的板材20的稠密浆料边界层52上。在涂敷辊104下面使用支持辊106。聚合物层的厚度由计量辊102和涂敷辊104之间的间隙确定。在优选的实施方案中，在固化时，聚合物层56介于.01至500密耳之间。辊涂机98的优点在于涂敷辊104仅短时间与板材20接触。因而，在下层的浆料没有长时间暴露于高温。这有助于避免不适宜地煅烧在下层的石膏浆料。
图6公开了幕型涂布机108。此涂布机包括加热的涂敷器112，其具有细长的狭缝或开口114。使得狭缝114的宽度与所制备的板材的宽度相匹配。然而，稍微增加或减小狭缝的宽度可以赋予有利效果，例如平滑，纹理，或建造建筑学特征。液体聚合物的供给在重力下释放通过狭缝114并且直接沉积在稠密浆料边界层52上。在此实施方案中，聚合物涂层56的厚度部分地由涂敷器开口114的尺寸和在下面的输送器的速度确定。
在图7中，描绘了刀或修边涂布机116。刀涂机116包括用于液化聚合物的出口供给部118。此出口供给部118将一定体积的液体聚合物直接释放到稠密浆料边界层52上。其后在液体组合物遇到刮刀122时，产生障碍(dam)。刮刀122，其可以被加热，然后被用于作为涂敷器以将均匀的聚合物薄层涂敷到板材20上。在此情况下，聚合物涂层56的厚度由刮刀122和在下层的板材之间的间距确定。最后，图10示例了经由常规喷涂机124涂敷涂层56。
还可以使用除以上所述的那些以外的其它涂敷器类型。例如，可以通过热熔溢流涂布机，热熔浸没涂布机，热熔共挤出涂布机或上述各项的任何组合涂敷聚合物涂层56。
不论涂敷方法如何，结果均是用于将聚合物涂层56涂敷到板材20的表面上的连续工艺。而且，将涂层56以连续流动和均匀层的形式涂敷到板材20的整个表面上。然后将热塑性材料立即冷却，从而消除任何干燥步骤。通过改变聚合物或通过包含聚合物添加剂，可以在制备过程中容易地更改所制备的板材的物理特性。这使得能够在单个生产线上有利地制备各种的不同板材，其关于不同的应用各自具有独特的物理特性。
本公开内容包括在后附权利要求中含有的内容，以及前述说明书的内容。尽管已经以其具有一定的具体程度的优选形式描述了本发明，但是应当理解，优选形式的本公开内容仅经由实施例进行，并且在不背离本发明的精神和范围的情况下，可以对构造细节和若干部分的组合和排列进行众多变化。
现在已经描述了本发明。

Claims (34)

1.一种复合建筑板材，所述复合建筑板材包括：
上部垫和下部垫，所述上部垫和下部垫由通过粘合剂保持在一起的非织造的无序排列的玻璃纤维形成，所述垫是多孔性的并且具有内表面和外表面；
热塑性材料预涂层，所述热塑性材料预涂层被涂敷到所述上部垫和下部垫的所述无序排列的玻璃纤维上；
上部稠密浆料层和下部稠密浆料层，所述上部稠密浆料层和下部稠密浆料层分别涂布并渗透所述上部垫和下部垫，从而每一个垫的外表面基本上被浆料覆盖，由所述浆料限定的浆料边界层覆盖每一个垫的外表面，所述边界层具有介于约.01至2.0mm之间的厚度，所述上部稠密浆料层和下部稠密浆料层包含聚合物添加剂，所述聚合物添加剂增加所述复合板材的强度并且与所述热塑性材料预涂层结合；
芯浆料层，所述芯浆料层在所述上部稠密浆料层和下部稠密浆料层之间延伸并且与所述上部稠密浆料层和下部稠密浆料层结合，所述芯浆料层的密度小于所述上部稠密浆料层和下部稠密浆料层的密度，所述芯浆料层包含聚合物添加剂，所述聚合物添加剂与所述上部浆料层和下部浆料层的聚合物添加剂以及所述热塑性材料预涂层结合；
热熔热塑性材料涂层，所述热熔热塑性材料涂层的熔点介于100°至500℉之间，所述热熔热塑性材料涂层机械地附着于所述浆料边界层，所述热塑性材料涂层还与所述上部浆料层、下部浆料层和芯浆料层的所述聚合物添加剂以及所述热塑性材料预涂层交联，以形成复合聚合物基体，所述热塑性材料涂层的厚度介于.01至500密耳之间。
2.一种复合建筑板材，所述复合建筑板材包括：
多孔垫，所述多孔垫具有内表面和外表面；
黏结浆料层，所述黏结浆料层渗透所述多孔垫并且基本上覆盖所述外表面，由所述浆料限定的边界层基本上覆盖所述多孔垫的所述外表面；
聚合物涂层，所述聚合物涂层机械地和化学地附着到所述边界层，并且在所述复合建筑板材内形成聚合物基体。
3.根据权利要求2所述的复合建筑板材，其中所述聚合物为乙烯乙酸乙烯酯(EVA)聚合物。
4.根据权利要求2所述的复合建筑板材，其中所述聚合物为乙烯丙烯酸(EAA)聚合物。
5.根据权利要求2所述的复合建筑板材，其中所述聚合物是热固性的。
6.根据权利要求2所述的复合建筑板材，其中所述聚合物是热塑性的。
7.根据权利要求2所述的复合建筑板材，其中所述聚合物涂层和边界层交联以形成具有高分子量的聚合物链。
8.根据权利要求2所述的复合建筑板材，其中所述聚合物涂层冷却以形成外部板材表面，所述外部板材表面具有基于洛氏R硬度尺度的介于50至150之间的硬度。
9.根据权利要求2所述的复合建筑板材，其中所述聚合物涂层具有介于.01至500密耳之间的厚度。
10.根据权利要求2所述的复合建筑板材，其中所述垫由通过树脂粘合剂保持在一起的非织造的无序排列的玻璃纤维形成。
11.根据权利要求2所述的复合建筑板材，其中所述多孔垫包含热塑性材料涂层。
12.根据权利要求2所述的复合建筑板材，其中所述聚合物涂层是熔点介于约100℉至500℉之间的热熔热塑性材料。
13.一种复合建筑板材，所述复合建筑板材包括：
至少一个具有外表面的黏结浆料层，其中所述黏结层通过聚合物增强；
热塑性材料涂层，所述热塑性材料涂层与所述黏结层化学结合，从而在所述复合建筑板材内形成聚合物基体。
14.根据权利要求13所述的复合建筑板材，其中所述黏结浆料层由石膏形成。
15.根据权利要求14所述的复合建筑板材，其中所述黏结浆料层包含聚合物添加剂。
16.根据权利要求15所述的复合建筑板材，其中所述纤维垫嵌入在所述黏结浆料层内。
17.根据权利要求16所述的复合建筑板材，其中所述纤维垫通过树脂粘合剂保持在一起，并且其中所述纤维垫被包含在所述聚合物基体中。
18.根据权利要求13所述的复合建筑板材，其中在所述浆料层和所述热塑性材料涂层之间设置介入层。
19.根据权利要求13所述的复合建筑板材，其中所述热塑性材料涂层是熔点介于约100℉至500℉之间的热熔热塑性材料。
20.根据权利要求16所述的复合建筑板材，其中对所述纤维垫涂敷热塑性材料预涂层。
21.根据权利要求13所述的复合建筑板材，其中所述板材包括纸覆面。
22.一种复合结构板，所述复合结构板包括：
浆料层，所述浆料层具有嵌入的垫，所述垫基本上由通过热熔热塑性材料结合在一起的纤维组成。
23.根据权利要求22所述的复合结构板，其中所述纤维是有机的。
24.根据权利要求22所述的复合结构板，其中所述纤维是无机的。
25.根据权利要求22所述的复合结构板，其中所述纤维是连续的。
26.根据权利要求22所述的复合结构板，其中所述纤维是非连续的。
27.根据权利要求22所述的复合结构板，其中所述热熔热塑性材料以遵循在下层的垫的形貌结构的层的形式涂敷。
28.根据权利要求22所述的复合结构板，其中所述热熔热塑性材料以平滑层的形式涂敷。
29.根据权利要求22所述的复合结构板，其中所述热熔热塑性材料以厚度介于.1至10密耳之间的层的形式涂敷。
30.根据权利要求22所述的复合结构板，其中所述热熔热塑性材料由乙烯乙酸乙烯酯(EVA)形成。
31.根据权利要求22所述的复合结构板，其中所述热熔热塑性材料由乙烯甲基丙烯腈(EAA)形成。
32.根据权利要求22所述的复合结构板，其中所述热熔热塑性材料是半透明的。
33.根据权利要求22所述的复合结构板，其中所述热熔热塑性材料是着色的。
34.一种复合结构板，所述复合结构板包括：
第一石膏浆料层和第二石膏浆料层，其中所述第二浆料层比所述第一层具有更高的密度；
多孔垫，所述多孔垫包含由热熔热塑性粘合剂保持在一起的一系列单根纤维，所述垫嵌入到第二浆料层内，从而所述垫的外表面基本上被石膏浆料覆盖，从而产生石膏边界层；
热熔热塑性材料的表面层覆盖在边界层上面；
硅烷偶联剂，所述硅烷偶联剂促进所述各根纤维之间，所述各根纤维和所述热塑性粘合剂之间，所述各根纤维和所述第一及第二浆料层之间，所述表面层和所述边界层之间，以及所述表面层和所述第一及第二浆料层之间的结合。
CN200980142911.5A 2008-08-29 2009-08-27 塑性材料涂布的复合建筑板材及其制备方法 Expired - Fee Related CN102196903B (zh)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US9316708P 2008-08-29 2008-08-29
US61/093,167 2008-08-29
US12/480,159 2009-06-08
US12/480,159 US8486516B2 (en) 2008-08-29 2009-06-08 Plastic coated composite building boards and method of making same
PCT/US2009/055113 WO2010025207A1 (en) 2008-08-29 2009-08-27 Plastic coated composite building boards and method of making same

Publications (2)

Publication Number Publication Date
CN102196903A true CN102196903A (zh) 2011-09-21
CN102196903B CN102196903B (zh) 2016-01-06

Family

ID=41721900

Family Applications (1)

Application Number Title Priority Date Filing Date
CN200980142911.5A Expired - Fee Related CN102196903B (zh) 2008-08-29 2009-08-27 塑性材料涂布的复合建筑板材及其制备方法

Country Status (8)

Country Link
US (4) US8486516B2 (zh)
EP (1) EP2323842A4 (zh)
CN (1) CN102196903B (zh)
CA (1) CA2735409C (zh)
MX (1) MX353351B (zh)
MY (1) MY160549A (zh)
RU (1) RU2511365C2 (zh)
WO (1) WO2010025207A1 (zh)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104487242A (zh) * 2012-06-08 2015-04-01 瑟登帝石膏公司 粘合纤维垫的构建
CN104936772A (zh) * 2012-09-06 2015-09-23 爱克斯莫克斯工业股份有限公司 复合片材料及其形成方法
US9566769B2 (en) 2012-09-06 2017-02-14 Xamax Industries, Inc. Composite sheet material and method for forming the same
CN111779749A (zh) * 2016-06-17 2020-10-16 佐治亚-太平洋石膏有限责任公司 自密封紧固件、建筑面板、系统和方法
CN112207968A (zh) * 2020-09-08 2021-01-12 故城北新建材有限公司 石膏板的上纸硬面设备和上纸硬面方法、石膏板生产线
CN113442268A (zh) * 2021-06-17 2021-09-28 长春市建林教育咨询有限公司 一种双面纤维网水泥板的生产线及应用

Families Citing this family (45)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090087616A1 (en) * 2001-06-06 2009-04-02 Hennis Mark E Coatings for glass reinforced faced gypsum board
US20050159057A1 (en) * 2001-06-06 2005-07-21 Bpb Plc Exterior sheathing weather barrier construction and method of manufacture
US7435369B2 (en) * 2001-06-06 2008-10-14 Bpb Plc Method for targeted delivery of additives to varying layers in gypsum panels
US8070895B2 (en) 2007-02-12 2011-12-06 United States Gypsum Company Water resistant cementitious article and method for preparing same
US9186869B2 (en) 2008-08-29 2015-11-17 Certainteed Gypsum, Inc. Composite floor underlayment with thermoplastic coatings
US8486516B2 (en) 2008-08-29 2013-07-16 Certainteed Gypsum, Inc. Plastic coated composite building boards and method of making same
US9346244B2 (en) 2008-08-29 2016-05-24 Certainteed Gypsum, Inc. Composite building boards with thermoplastic coatings and cementitious precoated fibrous mats
US20100239816A1 (en) * 2009-02-23 2010-09-23 Kinkade Jerald E Composite building panel and method of making same
US8329308B2 (en) 2009-03-31 2012-12-11 United States Gypsum Company Cementitious article and method for preparing the same
DE102010016048B4 (de) * 2010-03-19 2012-06-28 Düspohl Maschinenbau Gmbh Bauplatte mit Beschichtung und Verfahren zum Beschichten von Bauplatten
US20110225911A1 (en) * 2010-03-22 2011-09-22 Battisti Peter L Self-bailing interior frame
CN102844283A (zh) 2010-04-15 2012-12-26 亨利有限责任公司 用于为石膏组合物提供强度的混合物和乳液
US9096036B2 (en) 2010-06-07 2015-08-04 Certainteed Gypsum, Inc. System and method for constructing composite building boards using thermoplastic films
US8409391B2 (en) 2010-06-07 2013-04-02 Certainteed Gypsum, Inc. Method for constructing composite building boards using dissolvable films
CA2824508C (en) * 2011-01-14 2019-07-30 Certainteed Gypsum, Inc. Composite building boards with thermoplastic coatings and cementitious precoated fibrous mats
NZ613436A (en) 2011-02-24 2015-07-31 Henry Co Llc Aqueous wax emulsions having reduced solids content for use in gypsum compositions and building products
RU2599519C2 (ru) * 2011-09-27 2016-10-10 Дай Ниппон Принтинг Ко., Лтд. Лист для покрытия стен сейсмостойких сооружений, способ его отбора и способ строительства с его использованием
ITMI20120148A1 (it) * 2012-02-03 2013-08-04 Eleda S R L Pannello fonoassorbente e relativo metodo di realizzazione
US9168701B2 (en) * 2012-10-16 2015-10-27 Abss Manufacturing Co., Inc. Fiberglass reinforced plastic lightweight heavy-duty ladder and method of making same
US20140273687A1 (en) * 2013-03-15 2014-09-18 Certainteed Gypsum, Inc. Building Board with Acoustical Foam
US10336036B2 (en) 2013-03-15 2019-07-02 United States Gypsum Company Cementitious article comprising hydrophobic finish
CN105705600B (zh) * 2013-08-27 2019-04-05 威士伯采购公司 用于石膏板的涂料和粘合剂组合物
US11433645B2 (en) * 2013-12-30 2022-09-06 Saint-Gobain Placo Sas Building boards with increased surface strength
US20150184386A1 (en) * 2013-12-30 2015-07-02 Saint-Gobain Placo Sas Non-Uniform Coatings for Building Boards
US10053860B2 (en) 2015-07-31 2018-08-21 United States Gypsum Company Gypsum wallboard with reinforcing mesh
WO2017120611A1 (en) * 2016-01-10 2017-07-13 Georgia-Pacific Gypsum Llc Fibrous mats and panels having a gypsum-based coating and methods for the manufacture thereof
US20170225426A1 (en) * 2016-02-08 2017-08-10 Certainteed Gypsum, Inc. System, method and apparatus for gypsum board with embedded structure having open cells that are substantially filled
DE102016104071B4 (de) * 2016-03-07 2018-10-25 Groz-Beckert Kg Verfahren zum Biegen eines Bewehrungsstabes eines Bewehrungselements sowie Biegevorrichtung
CA3019563C (en) * 2016-04-01 2021-06-08 Certainteed Gypsum, Inc. Building board and method of forming the building board
US10472293B2 (en) 2016-04-29 2019-11-12 Certainteed Gypsum, Inc. Building assembly containing a water barrier coating film and method of making the building assembly
US10273682B2 (en) * 2016-10-24 2019-04-30 Firefree Coatings, Inc. Fire protection retrofits for high-rise buildings
CA2988547C (en) 2016-12-15 2021-01-26 Certainteed Gypsum, Inc. Plaster boards and methods for making them
RU179119U1 (ru) * 2017-09-14 2018-04-26 Российская Федерация, от имени которой выступает ФОНД ПЕРСПЕКТИВНЫХ ИССЛЕДОВАНИЙ Устройство выхода волоконно-оптического датчика из композита
US11136451B2 (en) 2017-10-09 2021-10-05 Owens Corning Intellectual Capital, Llc Aqueous binder compositions
KR102488412B1 (ko) 2017-10-09 2023-01-12 오웬스 코닝 인텔렉츄얼 캐피탈 엘엘씨 수성 결합제 조성물
FR3073774B1 (fr) * 2017-11-22 2019-11-15 Hexcel Reinforcements Materiau de renfort comprenant une couche poreuse en un polymere thermoplastique partiellement reticule et procedes associes
JP7089358B2 (ja) * 2017-11-28 2022-06-22 日東電工株式会社 多孔質繊維シート
MX2020006532A (es) 2017-12-19 2020-09-14 Saint Gobain Adfors Canada Ltd Una capa de refuerzo, una placa cementosa y un metodo para formar la placa cementosa.
JP7097781B2 (ja) * 2018-08-23 2022-07-08 日東電工株式会社 積層シート
CN113840966B (zh) 2019-04-09 2024-07-26 欧文斯科宁知识产权资产有限公司 用含水粘合剂组合物形成的绝缘产品
FI4069900T3 (fi) 2019-12-06 2024-06-11 Owens Corning Intellectual Capital Llc Pinnoitekerroksella varustettu komposiittikuitukangasmatto
US11813833B2 (en) 2019-12-09 2023-11-14 Owens Corning Intellectual Capital, Llc Fiberglass insulation product
WO2021118960A1 (en) 2019-12-09 2021-06-17 Owens Corning Intellectual Capital, Llc Fiberglass insulation product
WO2022072780A2 (en) 2020-10-01 2022-04-07 Owens Corning Intellectual Capital, Llc B-stageable aqueous binder compositions
US20240408840A1 (en) * 2021-10-21 2024-12-12 Hexcel Reinforcements SASU Reinforcing material comprising a porous layer made of a reactive thermoplastic polymer and associated methods

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6254817B1 (en) * 1998-12-07 2001-07-03 Bay Mills, Ltd. Reinforced cementitious boards and methods of making same
US6524679B2 (en) * 2001-06-06 2003-02-25 Bpb, Plc Glass reinforced gypsum board
US6746781B2 (en) * 2002-08-21 2004-06-08 G-P Gypsum Corporation Gypsum board having polyvinyl alcohol binder in interface layer and method for making the same
US20080057318A1 (en) * 2006-08-29 2008-03-06 Adzima Leonard J Low density drywall

Family Cites Families (36)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU84387A1 (ru) * 1949-05-14 1949-11-30 А.В. Шлыков Способ изготовлени армированных с поверхности картоном изделий из гипсоопилочных масс
US2806811A (en) * 1954-12-31 1957-09-17 United States Gypsum Co Paper-covered gypsum board
US3993822A (en) * 1970-02-25 1976-11-23 Gebr. Knauf Westdeutsche Gipswerke Multi-layer plasterboard
US4265979A (en) * 1978-06-05 1981-05-05 United States Gypsum Company Method for the production of glass fiber-reinforced gypsum sheets and gypsum board formed therefrom
AU531527B2 (en) * 1979-05-30 1983-08-25 Bpb Industries Ltd. Cementitious building board
US4255485A (en) * 1979-11-08 1981-03-10 Owens-Corning Fiberglas Corporation Binder for glass fiber mat
JPS5876564A (ja) 1981-10-27 1983-05-09 旭フアイバ−グラス株式会社 固体粒子を含有する流動性組成物用補強体
US4563392A (en) * 1982-03-19 1986-01-07 Allied Corporation Coated extended chain polyolefin fiber
CA1341084C (en) * 1987-11-16 2000-08-15 George W. Green Coated fibrous mat-faced gypsum board resistant to water and humidity
US5102728A (en) * 1990-08-17 1992-04-07 Atlas Roofing Corporation Method and composition for coating mat and articles produced therewith
US5112678A (en) * 1990-08-17 1992-05-12 Atlas Roofing Corporation Method and composition for coating mat and articles produced therewith
CA2070489A1 (en) * 1992-06-04 1993-12-05 Ian Norris Davie Gypsum board coating
US6586066B1 (en) 2000-03-21 2003-07-01 Awi Licensing Company Preglued underlayment composite and associated flooring installation system
JP4746181B2 (ja) 2000-05-22 2011-08-10 株式会社リコー 感熱孔版印刷用原紙の製造方法及び感熱孔版印刷用原紙
US6331028B1 (en) * 2000-10-17 2001-12-18 Advance Usa, Inc. Fiber-reinforced composite structure
CN1243615C (zh) * 2001-03-02 2006-03-01 詹姆士·哈代国际金融公司 涂洒装置
KR100729849B1 (ko) 2001-03-28 2007-06-19 주식회사 케이씨씨 내화 석고보드용 조성물
GB2399778A (en) * 2001-12-20 2004-09-29 Atlas Roofing Corp Method and composition for coating mat and articles produced therewith
US6671485B2 (en) * 2001-12-21 2003-12-30 Kabushiki Kaisha Toshiba Image forming apparatus
US7393799B2 (en) * 2002-12-10 2008-07-01 Saint-Gobain Technical Fabrics Canada, Ltd Breathable, waterproofing, tear-resistant fabric
US7049251B2 (en) 2003-01-21 2006-05-23 Saint-Gobain Technical Fabrics Canada Ltd Facing material with controlled porosity for construction boards
US7354876B2 (en) 2003-07-09 2008-04-08 Saint-Gobain Technical Fabrics Canada Ltd. Fabric reinforcement and cementitious boards faced with same
US20070015424A1 (en) 2005-07-15 2007-01-18 Certainteed Corporation Building material having adaptive vapor retarder
US7235288B2 (en) * 2004-03-10 2007-06-26 Johns Manville Polymeric bonding of glass fiber reinforcements with silane based coatings in gypsum board
US7745357B2 (en) * 2004-03-12 2010-06-29 Georgia-Pacific Gypsum Llc Use of pre-coated mat for preparing gypsum board
JP4396363B2 (ja) 2004-04-07 2010-01-13 日東紡績株式会社 石膏ボード
US7473440B2 (en) * 2005-10-20 2009-01-06 Johns Manville Method of treating a coated fibrous mat
US20070141931A1 (en) * 2005-12-21 2007-06-21 Malay Nandi Faced board material having a smooth aesthetically pleasing outer surface and good adhesion of facer to core
US20070197114A1 (en) * 2006-02-23 2007-08-23 Grove Dale A Wear resistant coating composition for a veil product
EP2035516B2 (en) * 2006-06-02 2017-01-04 Valspar Sourcing, Inc. High performance aqueous coating compositions
US7829488B2 (en) * 2008-01-22 2010-11-09 Johns Manville Non-woven glass fiber mat faced gypsum board and process of manufacture
US20090208714A1 (en) * 2008-02-18 2009-08-20 Georgia-Pacific Gypsum Llc Pre-coated non-woven mat-faced gypsum panel
US9346244B2 (en) 2008-08-29 2016-05-24 Certainteed Gypsum, Inc. Composite building boards with thermoplastic coatings and cementitious precoated fibrous mats
US9186869B2 (en) 2008-08-29 2015-11-17 Certainteed Gypsum, Inc. Composite floor underlayment with thermoplastic coatings
US8486516B2 (en) 2008-08-29 2013-07-16 Certainteed Gypsum, Inc. Plastic coated composite building boards and method of making same
EP2172533A1 (en) * 2008-09-26 2010-04-07 Services Pétroliers Schlumberger Composition for borehole treatment

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6254817B1 (en) * 1998-12-07 2001-07-03 Bay Mills, Ltd. Reinforced cementitious boards and methods of making same
US6524679B2 (en) * 2001-06-06 2003-02-25 Bpb, Plc Glass reinforced gypsum board
US6746781B2 (en) * 2002-08-21 2004-06-08 G-P Gypsum Corporation Gypsum board having polyvinyl alcohol binder in interface layer and method for making the same
US20080057318A1 (en) * 2006-08-29 2008-03-06 Adzima Leonard J Low density drywall

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104487242A (zh) * 2012-06-08 2015-04-01 瑟登帝石膏公司 粘合纤维垫的构建
CN104936772A (zh) * 2012-09-06 2015-09-23 爱克斯莫克斯工业股份有限公司 复合片材料及其形成方法
US9566769B2 (en) 2012-09-06 2017-02-14 Xamax Industries, Inc. Composite sheet material and method for forming the same
CN111779749A (zh) * 2016-06-17 2020-10-16 佐治亚-太平洋石膏有限责任公司 自密封紧固件、建筑面板、系统和方法
CN111779749B (zh) * 2016-06-17 2022-05-03 佐治亚-太平洋石膏有限责任公司 自密封紧固件、建筑面板、系统和方法
US11808294B2 (en) 2016-06-17 2023-11-07 Georgia-Pacific Gypsum Llc Coated fastener
CN112207968A (zh) * 2020-09-08 2021-01-12 故城北新建材有限公司 石膏板的上纸硬面设备和上纸硬面方法、石膏板生产线
CN113442268A (zh) * 2021-06-17 2021-09-28 长春市建林教育咨询有限公司 一种双面纤维网水泥板的生产线及应用

Also Published As

Publication number Publication date
WO2010025207A1 (en) 2010-03-04
RU2511365C2 (ru) 2014-04-10
CN102196903B (zh) 2016-01-06
CA2735409A1 (en) 2010-03-04
EP2323842A4 (en) 2012-03-21
CA2735409C (en) 2016-07-19
US10767368B2 (en) 2020-09-08
US20180187416A1 (en) 2018-07-05
US20160273220A1 (en) 2016-09-22
US20100055431A1 (en) 2010-03-04
RU2011111741A (ru) 2012-10-10
MY160549A (en) 2017-03-15
EP2323842A1 (en) 2011-05-25
US9259888B2 (en) 2016-02-16
US9885179B2 (en) 2018-02-06
MX2011002237A (es) 2011-06-22
MX353351B (es) 2018-01-10
US8486516B2 (en) 2013-07-16
US20130295286A1 (en) 2013-11-07

Similar Documents

Publication Publication Date Title
CN102196903A (zh) 塑性材料涂布的复合建筑板材及其制备方法
US9346244B2 (en) Composite building boards with thermoplastic coatings and cementitious precoated fibrous mats
US6737156B2 (en) Interior wallboard and method of making same
US9186869B2 (en) Composite floor underlayment with thermoplastic coatings
AU2015204510B2 (en) Polyester laminated building boards with improved surface characteristics
CN105682913A (zh) 包括防水材料的预浸料、芯、复合物以及制品
CA2824508C (en) Composite building boards with thermoplastic coatings and cementitious precoated fibrous mats
CZ2004932A3 (cs) Způsob výroby panelu se zvukovou izolací, zejména panelu pro laminátovou podlahu, a panel, zejména panel pro laminátovou podlahu
EP1778487B1 (en) Moisture-barrier coating material, a sheet-like product coated with this and methods of manufacturing these
US20060251864A1 (en) Structural laminate
CA2818143C (en) Composite floor underlayment with thermoplastic coatings
US20060263578A1 (en) Structural laminate
JP2003147899A (ja) 建築用板材
JP4138988B2 (ja) 人造石板
JPH0562561B2 (zh)
KR20190012416A (ko) 더블 레이어드 비대칭 복합재료 시트의 제조 방법 및 상기 방법에 의해 제조되는 더블 레이어드 비대칭 복합재료 시트

Legal Events

Date Code Title Description
C06 Publication
PB01 Publication
C10 Entry into substantive examination
SE01 Entry into force of request for substantive examination
C14 Grant of patent or utility model
GR01 Patent grant
CP02 Change in the address of a patent holder
CP02 Change in the address of a patent holder

Address after: American Pennsylvania

Patentee after: CERTAINTEED GYPSUM, Inc.

Address before: American Florida

Patentee before: CERTAINTEED GYPSUM, Inc.

CF01 Termination of patent right due to non-payment of annual fee
CF01 Termination of patent right due to non-payment of annual fee

Granted publication date: 20160106