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CN102802935A - 用于石膏壁板贴面的晶种涂层 - Google Patents

用于石膏壁板贴面的晶种涂层 Download PDF

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Publication number
CN102802935A
CN102802935A CN2010800281289A CN201080028128A CN102802935A CN 102802935 A CN102802935 A CN 102802935A CN 2010800281289 A CN2010800281289 A CN 2010800281289A CN 201080028128 A CN201080028128 A CN 201080028128A CN 102802935 A CN102802935 A CN 102802935A
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CN
China
Prior art keywords
gypsum wallboard
treated
veneer
facing material
adhesive
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Inventor
W·A·赫恩
A·A·金德勒
J·克劳泽
C·莫根罗特
B·伦纳特
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Hercules LLC
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Hercules LLC
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Publication of CN102802935A publication Critical patent/CN102802935A/zh
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    • 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
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    • 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
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    • 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
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Abstract

对用于石膏壁板制造的贴面材料进行表面处理，使其粘附一定量的晶种，以改善贴面材料对湿石膏的粘附亲合力，从而用很少或不加入淀粉并用减量的水就能制造石膏壁板。描述了用于将晶种粘附至贴面材料的各种手段，还描述了转变贴面材料和含贴面材料的壁板的方法。

Description

用于石膏壁板贴面的晶种涂层
相关专利申请
本申请要求享有2009年6月22日申请的美国临时专利申请第61/219,102号的权益，其公开内容的全部通过引用结合在此。
技术领域
本发明涉及可用作石膏壁板制造中添加剂的晶种涂层，其使得用很少或不用淀粉粘结剂就能实现壁板的制造。本发明还涉及用该添加剂处理过的贴面(facing)材料，并涉及生产石膏壁板的方法，与现有技术的方法相比，本方法可明显降低要求的干燥能量的量。更具体地，本发明涉及制备具有改善的湿石膏粘结亲合力的石膏壁板贴面材料组分的方法。
背景技术
石膏壁板行业通过设计能保证两个贴面材料外层之间的有效胶结来生产壁板，外层包裹内石膏板芯，其典型为重纸厚(caliper)纸张。为了促进与贴面材料的粘合，传统上该行业要向石膏芯中添加大量的淀粉粘接剂。该行业还向石膏中添加大大过量的水，这样，在两个贴面材料层之间的石膏的干燥过程中，过量的水可以带着淀粉粘接剂从湿石膏迁移到贴面材料中，从而建立石膏与贴面材料表面的粘结。然而，鉴于从石膏板芯迁移并蒸发过量的水所要求的干燥能量的量，这类方法能耗很高。
工业上通常要求在壁板生产中降低水的用量，因为石膏壁板生产商的干燥成本已大幅上升。还显而易见的是，利用本发明可以实现降低石膏与水的比例，这反过来又可产生强度更高的壁板。还可以在贴面层上涂敷晶种涂层，以通过改善纸张强度来改善壁板的强度，而这对壁板的总强度有着较大的影响。
意外发现，可以实践在湿石膏芯中代替使用淀粉及高的水比例，却仍可在贴面材料层与石膏芯之间实现强的粘结。
发明内容
本发明涉及制造石膏壁板的方法，通过在使贴面材料层与湿石膏接触前向壁板的贴面材料层涂敷包括晶种涂层的表面处理物，以加强石膏与贴面材料层的结合。此时石膏组分可以使用相对较低量的水，却仍可与基层形成强的结合。
本发明还涉及用作石膏壁板制造中的添加剂的晶种涂层组合物，所述涂层组合物使得可以用很少或不用淀粉粘结剂就实现壁板的制造。本发明还涉及用晶种涂层处理的贴面材料层。
此外，本发明涉及具有内石膏板芯的壁板，以及至少一个粘附至内石膏板芯表面的处理过的贴面材料层，其中所述贴面材料层具有用晶种涂层处理过的表面。内石膏板芯的表面粘附至用晶种涂层处理过的贴面材料层的表面。
用于壁板中的处理过的贴面材料含有贴面材料层，其上粘附有晶种层。该贴面材料通常可能被称作“纸”，但是更具体地，贴面材料可以选自纸张、玻璃纤维片和合成片材。
贴面材料采用粘附剂以适当方式处理，使晶种粘附至贴面材料的表面。处理可以包括首先用一定量的水接触贴面材料的表面以润湿贴面材料的表面，随后将晶种以粉末涂敷至增湿的贴面材料表面。或者，晶种可以溶解或悬浮到液体中，如水，再涂敷至贴面材料的表面，随后使增湿的贴面材料表面干燥。或者，粘附剂可以包括表面处理粘合剂。表面处理粘合剂可以是任何粘合剂，例如诸如溶剂基、水基或无溶剂的粘合剂，所述粘合剂可以使晶种粘附至贴面材料的表面，以形成晶种涂层。优选地，表面处理粘合剂包括水和胶乳粘结剂，其可以涂敷至贴面材料表面，随后在将晶种作为粉末涂敷至增湿的贴面材料表面时形成晶种涂层。表面处理粘合剂还可以含有晶种、流变改性剂，如纤维素醚或生物聚合物或其混合物。
在本发明之前，要求在石膏壁板中使用高含量的淀粉与水，以保证石膏与贴面材料组分能恰当结合。
本发明的优点在于能使水/石膏比例降低，因此通过采用更低的水/石膏比例，可以降低生产壁板所要求的能量。因此本发明提供了可以生产性能得到改善的壁板的方法。
具体实施方式
意外发现，石膏壁板的贴面材料层可以用晶种涂层表面处理，这样可加强壁板的内石膏板芯与贴面材料的结合趋势。这种提升的结合趋势或亲合力反过来又可使石膏芯能够以更低的水和淀粉含量进行配制，由此降低干燥壁板所需要能量的量。降低或省去壁板石膏芯的淀粉内含物的优点还包括，当暴露于高湿或其它有利于促进微生物生长的环境条件时，得到的壁板更不易受微生物的侵扰。
本发明涉及用于生产石膏壁板的贴面材料层的表面处理，其中一定量的晶种被粘附至贴面材料的表面，以产生晶种涂层表面处理过的贴面材料。晶种然后在石膏壁板生产中与湿石膏接触时可用于后续的晶体生长，从而增加壁板的石膏芯与贴面材料层之间的粘合力。
本发明中使用的优选的晶种可以选自以下组中：
Figure BPA00001482068300031
以及其含不同结晶水的衍生物。
本发明中使用的更优选的晶种可以选自以下组中：
无水石膏                        CaSO4[无水石膏]
石膏半水合物                    CaSO4x1/2H2O[半水合物]
石膏二水合物                    CaSO4x2H2O[二水合物]
使用粘附剂作为对壁板贴面材料的表面处理物，使晶种粘附至贴面材料。所述处理可以包括首先用一定量的水接触贴面材料的表面，以润湿贴面材料的表面，随后将晶种以粉末涂敷至增湿过的贴面材料表面。或者晶种可以溶解或悬浮在液体中，如水中，再涂敷至贴面材料表面，随后使增润的贴面材料表面干燥。或者，粘附剂可以包括表面处理粘合剂。表面处理粘合剂可以是任何粘合剂，例如诸如溶剂基、水基或无溶剂的粘合剂，所述粘合剂可以使晶种粘附至贴面材料的表面而形成晶种涂层。优选地，表面处理粘合剂包括水和胶乳粘结剂，所述粘合剂可以涂敷至贴面材料表面，随后在将晶种作为粉末涂敷至增湿的贴面材料表面时形成晶种涂层。表面处理粘合剂还可以含有晶种、流变改性剂，如纤维素醚或生物聚合物或其混合物。
表面处理粘合剂还可以任选含有其它配料，如流变改性剂、稳定剂和防腐剂。
当表面处理粘合剂包括胶乳粘结剂时，表面处理粘合剂的胶乳粘结剂组分优选为表面处理粘合剂的约0.5-55重量％。表面处理粘合剂的胶乳粘结剂组分可以选自通常可得到的胶乳聚合物，并可以选自以下组中：乙烯-醋酸乙烯共聚物、聚(醋酸乙烯)(PVOAc)胶乳、苯乙烯-丁二烯橡胶(SBR)、丙烯酸系聚合物、乙烯基丙烯酸系聚合物。优选地，胶乳粘结剂组分为乙烯-醋酸乙烯共聚物或者聚(醋酸乙烯)(PVOAc)胶乳。胶乳粘合剂在本发明中可使用的一种形式是作为可再分散的粉末。
可以在表面处理粘合剂中使用可溶于水的其它物种作为添加剂，以影响所处理贴面材料及所得壁板的其它性能，所述物种选自以下组中：流变改性剂、盐、加速剂和分散剂。优选的流变改性剂包括纤维素醚。本发明中使用的纤维素醚可以选自以下组中：羧甲基纤维素(CMC)、羟丙基甲基纤维素(HPMC)、甲基羟乙基纤维素(MHEC)、甲基纤维素(MC)、羟丙基纤维素(HPC)、疏水改性的羟丙基纤维素(HMHPC)、羟乙基纤维素(HEC)、乙基羟乙基纤维素(EHEC)、疏水改性的羟乙基纤维素(HMHEC)、阳离子疏水改性的羟乙基纤维素(阳离子HMHEC)，和阴离子疏水改性的羟乙基纤维素(阴离子HMHEC)。
流变改性剂还可以包括生物聚合物。优选的生物聚合物包括黄原胶、沃仑胶或丢特胶。
本发明的一个方面是当表面处理粘合剂含有晶种材料及流变改性剂时，可产生高含量晶种的流体混合物。高的晶种含量为晶种的含量是表面处理粘合剂的约2重量％或更高，优选约10重量％。优选的流变改性剂为黄原胶、沃仑胶或丢特胶。
实际中，可以通过典型地用于纸张加工技术的任何机械方法将粘附剂涂敷至贴面材料的表面，包括但不限于使用刮片，使用辊子，使用蓄液敷料器，使用施胶机，使用幕涂机，使用水箱(water box)，或者使用喷雾敷料器。将粘附剂涂敷至用于壁板制造的贴面材料的一个或两个内表面，产生带表面处理的侧面的贴面材料，所述表面处理的侧面能将晶种粘附至贴面材料，以产生晶种涂层。在粘附剂不含水的情况下，用于处理纸张的粘附剂的量为大于0.1gm/m2的水平，优选大于约0.1gm/m2至20gm/m2，优选约0.5-4gm/m2，更优选约1-3gm/m2，还更优选约1.5-2.5gm/m2[基于干燥后的固体(不含水)]。在石膏完全不含淀粉或含减量的淀粉的情况下，在该范围涂敷粘附剂作为涂层与标准操作相比，粘附剂可促进晶种与贴面材料层的粘合，进而可增加壁板贴面材料层与石膏内芯的粘合。
在本发明中使用的贴面材料可以选自纸、玻璃纤维和合成材料。纸张可以经涂敷、涂蜡或未经涂敷。
贴面材料可以是无纺或纺织材料的形式，或者可以为织物、纱布(scrim)、薄膜、片层或箔片的形式。
贴面材料为合成材料时，可以选自聚乙烯、聚丙烯、聚氯乙烯、聚氨酯和环氧。
贴面材料是玻璃纤维材料时，这些材料可以包括(1)诸如玻璃纤维的矿物类材料。衬垫可以包括连续的或离散的线股或纤维，且形式上可以为织造的或非织造的。贴面材料可以包括诸如由短切线股和连续线股制成的无纺垫，使用所述贴面材料能令人满意，并且没有织物材料贵。这类衬垫的线股典型地通过合适的粘合剂结合在一起，形成一体的结构。非织造纤维垫的厚度为，例如，约10-40密耳。
在贴面材料具有所要求水平的孔隙率的情况下，例如某些纸张和其它非织造材料及一些织造织物等等，在生产具有晶种涂层面的贴面材料时，优选粘附剂和最终的晶种涂层对贴面材料的孔隙率有最小的影响。保持贴面材料的孔隙率在生产壁板中是有用的，因为在湿石膏被敷贴到具有晶种涂层面的贴面材料的处理过的表面上之后，该表面上出现的水可以通过贴面材料层容易地蒸发。可以用Hagerty孔隙率计仪器在“低速”凝固时通过称为“Gurley孔隙率”的标准试验方法对贴面材料的孔隙率性能进行测定。
如果要求一个步骤的连续方法，则粘附剂和晶种可以涂敷至贴面材料的表面，然后将湿石膏敷贴到含晶种涂敷面的贴面材料。
含晶种涂敷面的贴面材料可通过机械方法变为壁板，由此湿石膏的层的一个或两个面与含晶种涂敷面的贴面材料的晶种涂敷表面接触，产生可用于建筑应用的壁板组合物。与现有技术相比，在本发明情况下的湿石膏优选不含淀粉或仅含减量的淀粉。与标准的石膏壁板的制备相比，湿石膏通常还可以含有减低含量的水。因此，通过替代含贴面材料的最终壁板组合物的所有或一定比例的淀粉组分，就可产生一种新型的壁板组合物，所述贴面材料含有本发明的贴面材料的晶种涂敷面。
在生产壁板的方法中，设想两步骤方法，其中使预先制备的含本发明晶种涂敷面的贴面材料随后与湿石膏层结合以生产壁板。或者，还可以设想一个步骤的方法，其中将晶种涂层涂敷至贴面材料的表面，并在完全干燥贴面材料之前，将湿石膏敷贴到含晶种涂敷面的贴面材料上以制备壁板。
通过以下实施例进一步示范本发明。实施例用于说明本发明，其中份数和百分比均为基于重量，除非另外指明。
实施例
实施例1
首先，将包括典型的工业石膏壁板纸的贴面材料切成200x300mm的尺寸。然后通过无气喷雾(airless spraying)，用5重量％的可再分散性粉末在自来水中的胶乳分散体在垂直位置以约1g/m2涂布纸张。紧接喷雾后，将晶种、石膏二水合物撒在湿纸张的表面上。
在环境条件下干燥24小时后，使用含晶种表面处理面的纸张用以下程序来制备试样：
-将Alabaster Model石膏用手与55重量％的水混合；
-将该浆液充填放到在所制备纸张一面上的试验环中，并在充填后用第二张纸覆盖；
-将试样压制在一起，直到石膏开始凝固；以及
-在40℃下干燥24小时后，揭开纸张并判断粘合力。
与不含淀粉的试样比较，该程序可取得一般改善，如表1中所示。
实施例2
首先，将包括典型的工业石膏壁板纸的贴面材料切成200x300mm的尺寸。然后，用手将纸张浸泡在自来水中约5分钟，随后将晶种、石膏半水合物撒在湿纸张的表面上。
在环境条件下干燥24小时后，从纸张表面除去粘附不充分的晶种。然后使用实施例1中所述的程序制备试样并进行测试。
与其它试验相比较，含晶种表面处理面的纸张显示出与石膏芯很好的粘合力，如表1中所示。
实施例3
首先，将包括典型的工业石膏壁板纸的贴面材料切成200x300mm的尺寸。然后用手将纸张浸泡在硫酸钙二水合物的水悬浮体中约5分钟。
在环境条件下干燥24小时后，从纸张表面除去粘附不充分的晶种。然后使用实施例1中所述的程序制备试样并进行测试。
与不含淀粉的试样比较，纸张与石膏芯之间的粘合力一般，如表1中所示。
实施例4
首先，将包括典型的工业石膏壁板纸的贴面材料切成200x300mm的尺寸。然后用AquapasTM N 2090可再分散性醋酸乙烯-乙烯共聚物粉末(可从Ashland Inc.得到)的10％的自来水悬浮体喷雾涂布纸张。以干基计，所述纸张涂布有1.75和5重量％的胶乳。
在环境条件下干燥24小时后，使用实施例1中所述的程序制备试样并进行测试。
与不含淀粉的试样比较，贴面材料与石膏芯之间得到的粘合力良好，如表1中所示。
表1：试验结果一览
Figure BPA00001482068300081
用以下等级评定贴面材料的粘合力：
*＝差
**＝一般
***＝良好
****＝很好
*****＝优秀
实施例5
首先，将包括典型的工业石膏壁板纸的贴面材料切成200x200mm的尺寸，并以0.01g的精度进行称重。将10g干混合物加入90g自来水中，所述干混合物含有82％的硫酸钙二水合物、17.5％的AquapasTM N2090可再分散的醋酸乙烯-乙烯共聚物粉末(可以从Ashland Inc.得到)和0.5％的Supercol
Figure BPA00001482068300082
XG 80黄原胶(可以从Ashland Inc.得到)。将混合物用磁搅拌器搅拌20分钟。然后，以20.0g所制备分散体/m2的量，使用无气喷雾涂布纸张(在垂直位置)。
以0.01g的精度对纸张进行再称重，检查是否涂敷了正确的量(2.0g固体/m2)。在环境条件下干燥24小时后，将具有晶种涂层的贴面材料用来制备石膏板。根据以下程序制备试验板：
-使用手混合器用30g泡沫溶液[0.01％的引气剂(air-entraining agent)(AEA)，月桂基聚醚硫酸铵盐]制备泡沫，混合90秒；
-使用600g石膏以55重量％的水制备浆液，计入泡沫水的量；
-用IKA
Figure BPA00001482068300083
Werke GmbH Co.KG磁力搅拌器混合15秒；
-向石膏浆液加入泡沫；
-用IKA
Figure BPA00001482068300091
Werke GmbH Co.KG磁力搅拌器混合15秒，得到均匀的发泡浆液；
-将含有晶种涂层面的纸张以晶种涂层面向上放入模(form)中，加入石膏浆液(板厚度：～10mm)；
-用具有晶种涂层的第二层贴面材料覆盖装有石膏浆液的模；
-在石膏芯凝固后除去模；
-在环境条件下熟化15-30分钟；以及
-在干燥橱中干燥，将板干燥至恒重。
粘合力试验的试验程序：
为了测试覆盖物与干燥的石膏板之间的粘合力，对板的贴面材料进行交叉切割。然后用手撕开贴面材料，目测评估残留在石膏芯上的贴面材料的面积。
与不含淀粉的石膏板相比，实施例5的石膏板显示出明显的改善。
实施例6
首先，将包括典型的工业石膏壁板纸的贴面材料切成50x145mm的尺寸，并以0.01g的精度进行称重。将10g的干混合物加入到90g的自来水中，所述干混合物含有82重量％的晶种、17.5重量％的AquapasTM N2090可再分散的醋酸乙烯-乙烯共聚物粉末(可以从Ashland Inc.得到)和0.5重量％的Supercol
Figure BPA00001482068300092
XG 80黄原胶(可以从Ashland Inc.得到)。将所述混合物用磁搅拌器搅拌20分钟。然后，以20.0g制备分散体/m2的量，使用无气喷雾涂敷纸张(在垂直位置)。
所用的晶种为：
碳酸钙(Fluka 21060)
硫酸钠(Riedel de Haen 13464)
硫酸铁II(Riedel des Haen 12353)
硫酸铝水合物(Riedel de Haen 11046)
硫酸钡(AppliChem A4911，1000)
硫酸钾铝(AppliChem A4396，1000)
碳酸镁(Sigma 63062)
硫酸钾(Kraft 06170.3600)
白云石(90μm，Dolomitwerk Jettenberg)
以0.01g的精度对纸张进行再称重，检查是否涂敷了正确的量(约2.0g固体/m2)。在环境条件下干燥24小时后，将具有晶种涂层的贴面材料用来制备石膏板。根据以下程序制备试验板：
-使用200g的石膏以55重量％的水制备浆液；
-用Handmixer混合15秒；
-用IKA搅拌器混合15秒，得到均匀的浆液；
-将具有晶种涂层面的纸张以晶种涂层面向上放入模中，加入石膏浆液(板厚度：～10mm)；
-用具有晶种涂层的第二层贴面材料覆盖装有石膏浆液的模；
-在环境条件下熟化15-30分钟；以及
-在干燥橱中干燥，将板干燥至恒重。
实施例7
首先，将贴面材料切成50x145mm的尺寸，并以0.01g的精度进行称重。将10g的干混合物加入到90g的自来水中，所述干混合物含有82重量％的硫酸钙二水合物、17.5重量％的AquapasTM N 2090可再分散的醋酸乙烯-乙烯共聚物粉末(可以从Ashland Inc.得到)和0.5重量％的Supercol
Figure BPA00001482068300101
XG 80黄原胶(可以从Ashland Inc.得到)。所述混合物用磁搅拌器搅拌20分钟。然后，以20.0g所制备的分散体/m2的量，使用无气喷雾涂敷贴面材料(在垂直位置)。
所用的贴面材料为：
玻璃纤维片
铝箔
发泡橡胶
棉纺织物，210g/m2
丝纺织物，Pongé08
聚乙烯箔
以0.01g的精度对贴面材料进行再称重，检查是否涂敷了正确的量(2.0g固体/m2)。在环境条件下干燥24小时后，将具有晶种涂层的贴面材料用来制备石膏板。根据以下程序制备试验板：
-使用200g的石膏以55重量％的水制备浆液；
-用Handmixer混合15秒；
-用IKA搅拌器混合15秒，得到均匀的浆液；
-将具有晶种涂层面的纸张以晶种涂层面向上放入模中，加入石膏浆液(板厚度：～10mm)；
-用具有晶种涂层的第二层贴面材料覆盖装有石膏浆液的模；
-在环境条件下熟化15-30分钟；以及
-在干燥橱中干燥，将板干燥至恒重。
实施例8
首先，将包括典型的工业石膏壁板纸的贴面材料切成50x145mm的尺寸，并以0.01g的精度进行称重。纸张用辊涂的方法涂敷粘合剂。除非是喷雾粘合剂，喷雾粘合剂要用喷雾方法涂敷至纸上。然后将硫酸钙二水合物涂敷至粘合剂的上面。
所用的粘合剂为：
10％的甲基羟丙基纤维素溶液(MHPC)
Aerosol Spray粘合剂，溶剂基粘合剂(可从UHU Alleskleber得到的UHU Sprühkleber)
10％的聚乙烯醇溶液
以0.01g的精度对纸张进行再称重，检查是否涂敷了正确的量(～2.0g固体/m2)。在环境条件下干燥24小时后，将具有晶种涂层的贴面材料用来制备石膏板。根据以下程序制备试验板：
-使用200g的石膏以55重量％的水制备浆液；
-用Handmixer混合15秒；
-用IKA搅拌器混合15秒，得到均匀的浆液；
-将具有晶种涂层面的纸张以晶种涂层面向上放入模(form)中，加入石膏浆液(板厚度：～10mm)；
-用具有晶种涂层的第二层贴面材料覆盖装有石膏浆液的模；
-在环境条件下熟化15-30分钟；以及
-在干燥橱中干燥，将板干燥至恒重。
实施例6～8中的粘合力试验的试验程序：
为了测试干燥的石膏板上的覆盖物的粘合力，将板的贴面材料连接到TA.XTplus纹理分析仪(texture analyzer)的力度自控的机器拉杆上。测量撕拉贴面材料所需要的力。将Texture Analyser放置在垂直的位置。将螺旋夹具固定在仪器的臂中。螺旋夹具移动到TA台附近以调整零位。升降台直接设在TA台上，其上放置有带芯和覆盖层(5x14.5cm)的环。
将上部覆盖物固定在螺旋夹具中。纹理分析仪使用的TA.XTplus软件是“Verklebung von
Figure BPA00001482068300121
”，有以下变化：测试距离从10cm变到20cm，测试速度为10mm/min。所测的粘合力为最初90秒中以牛顿[N]值表示的最大力。
与不含淀粉的石膏板相比，实施例6-8的石膏板表现出显著的改善。显著改善是指与不含淀粉的对比例相比，粘合力增加100％以上。
虽然已对本发明进行描述、公开、举例说明，并以设想用于实际中的各种形式的实施方案或修改进行了显示，但这并非本发明的范围，也不应认为这是对本发明保护范围的限定，尤其应保留通过本说明书中教导的内容而提出的其它改进或实施方案，特别是当其落在此后所附的权利要求的宽度和范围内时。

Claims (19)

1.一种用于石膏壁板的经处理的贴面材料，其包括：
贴面材料，其中贴面材料的表面用粘附至贴面材料表面的一定量的晶种处理，其中晶种选自以下组中：CaCO3、CaSO4、BaSO4、Na2SO4、KAl(SO4)2、CaMg(CO3)2、MgCO3、K2SO4、Fe[SO4]3/FeSO4、Al2[SO4]3，及它们的水合物形式。
2.权利要求1的用于石膏壁板的经处理的贴面材料，其中晶种包括CaSO4及其水合物形式。
3.权利要求2的用于石膏壁板的经处理的贴面材料，其中CaSO4为其无水石膏的形式。
4.权利要求2的用于石膏壁板的经处理的贴面材料，其中CaSO4为其半水合物的形式。
5.权利要求2的用于石膏壁板的经处理的贴面材料，其中CaSO4为其二水合物的形式。
6.权利要求1的用于石膏壁板的经处理的贴面材料，其中贴面材料选自以下组中：纸张、玻璃纤维片及合成片材。
7.权利要求6的用于石膏壁板的经处理的贴面材料，其中合成片材可以选自以下组中：聚乙烯、聚丙烯、聚氯乙烯、聚氨酯和环氧。
8.一种制备用于石膏壁板的经处理的贴面材料的方法，其包括以下步骤：
a)得到贴面材料；
b)得到一定量的晶种；和
c)将晶种粘附至贴面材料的至少一个表面，得到具有晶种涂层的贴面材料的表面，其中晶种选自以下组中：CaCO3、CaSO4、BaSO4、Na2SO4、KAl(SO4)2、CaMg(CO3)2、MgCO3、K2SO4、Fe[SO4]3/FeSO4、Al2[SO4]3，及它们的水合物形式。
9.权利要求8的制备用于石膏壁板的经处理的贴面材料的方法，其中晶种的粘附通过以下步骤进行：
i  得到一定量的粘附剂；
ii  将粘附剂涂敷至贴面材料的至少一个表面；以及
iii  随后将晶种涂敷至贴面材料的至少一个表面，得到具有晶种涂层的贴面材料表面。
10.权利要求9的制备用于石膏壁板的经处理的贴面材料的方法，其中粘附剂为水。
11.权利要求9的制备用于石膏壁板的经处理的贴面材料的方法，其中粘附剂是粘合剂。
12.权利要求11的制备用于石膏壁板的经处理的贴面材料的方法，其中粘合剂选自以下组中：溶剂基粘合剂、水基粘合剂或无溶剂粘合剂。
13.权利要求12的制备用于石膏壁板的经处理的贴面材料的方法，其中粘合剂包括乳胶粘合剂。
14.权利要求13的制备用于石膏壁板的经处理的贴面材料的方法，其中乳胶粘合剂是再分散性粉末的形式。
15.权利要求8的制备用于石膏壁板的经处理的贴面材料的方法，其中粘附剂通过选自以下组中的涂敷装置被涂敷至贴面材料的至少一个表面：刮片、辊子、蓄液敷料器、施胶机、幕涂机、水箱和喷雾敷料器。
16.权利要求8的制备用于石膏壁板的经处理的贴面材料的方法，其中晶种的粘附通过以下步骤进行：
i  得到能够吸收水的贴面材料；
ii  将一定量的水作为粘附剂涂敷至贴面材料的至少一个表面；和
iii  随后将晶种涂敷至贴面材料的至少一个表面，得到具有晶种涂层的贴面材料表面。
17.权利要求8的制备用于石膏壁板的经处理的贴面材料的方法，还包括使用纸张作为用于石膏壁板的贴面材料，其中晶种的粘附在纸张生产过程中进行：在纸张生产过程中将晶种涂敷至纸张的湿表面，得到具有晶种涂层的贴面材料表面。
18.权利要求8的制备用于石膏壁板的经处理的贴面材料的方法，其中晶种的粘附通过以下步骤进行：
i  得到能够吸收水的贴面材料；
ii  制备包括一定量的水和一定量的晶种的浆液或溶液；
iii  将包括水和晶种的浆液涂敷至贴面材料的至少一个表面，得到具有晶种涂层的贴面材料表面。
19.一种壁板，其包括：
内石膏板芯；和
经处理的贴面材料，该经处理的贴面材料包括：
贴面材料，其中贴面材料的表面用结合到贴面材料表面的一定量的晶种处理，其中晶种选自以下组中：CaCO3、CaSO4、BaSO4、Na2SO4、KAl(SO4)2、CaMg(CO3)2、MgCO3、K2SO4、Fe[SO4]3/FeSO4、Al2[SO4]3，及它们的水合物形式。
CN2010800281289A 2009-06-22 2010-06-21 用于石膏壁板贴面的晶种涂层 Pending CN102802935A (zh)

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