CN1498161A - Coated gypsum board products and method of manufacturing thereof - Google Patents
Coated gypsum board products and method of manufacturing thereof Download PDFInfo
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- CN1498161A CN1498161A CNA028041550A CN02804155A CN1498161A CN 1498161 A CN1498161 A CN 1498161A CN A028041550 A CNA028041550 A CN A028041550A CN 02804155 A CN02804155 A CN 02804155A CN 1498161 A CN1498161 A CN 1498161A
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- 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
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- 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
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- 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
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- 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
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- 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
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- 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
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- 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
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- 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
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Wood Science & Technology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Mechanical Engineering (AREA)
- Crystallography & Structural Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Panels For Use In Building Construction (AREA)
- Laminated Bodies (AREA)
- Finishing Walls (AREA)
- Paints Or Removers (AREA)
Abstract
A gypsum board is coated with a coating during the manufacturing process to form a coated gypsum board. Coatings are applied to wet gypsum boards before being dried in the oven and coating penetrates through at least a portion of the facing sheet and into the gypsum core of the gypsum board. Rapid coating compositions allow faster installation; quick setting compositions provide for more durable finishes. Either coating may be made lightweight by addition of perlite and may have enhanced finish appearance by incorporating pigments. A coated gypsum board can be fastened to a support structure to form a wall and the seams between adjacent coated gypsum boards can be taped and finished using a joint compound having a composition substantially similar to the composition of the coating. Overall, the resulting coated gypsum board and the method used to produce it help to improve final finish appearance and to reduce manufacturing time and costs.
Description
Background of invention
Invention field
Present invention relates in general to be used for the coating of gypsum board products, and preparation.More specifically, the present invention relates to be used for the coating composition of gypsum board products, and the method that in continuous manufacture of gypsum board method, prepares and be coated with this coating.
Correlation technique is discussed
Below in the discussion to correlation technique, with reference to some structure and/or method.Yet following reference should not be interpreted as admitting that these structures and/or method constitute prior art.If suitable, the applicant has kept these structures of proof clearly and/or method can not be come at right of the present invention as prior art.
The product density of conventional gypsum panel products and surface type and fineness is processed into has desired intensity and outward appearance, simultaneously minimum production weight and cost.In general, be that the calcined gypsum slurry is stirred in blender with moisture foaming agent, deposit to then on the conveyer belt that is placed with panel.Base plate is placed on the slurry, and wet gypsum board products has formed expectation thickness between format roll.Wet plasterboard solidifies in transport process, is cut into desired length, and the gypsum board products that will wet passes through drying oven and drying.
The coating of gypsum board products can be used to make the surface evenly, and is used to improve appearance, is under creating conditions and after being coated with decorative coating.Disclose a kind of two step autofrettages that are used to be coated with gypsum board products of previously known in Australian patent application 19322/92, its disclosure is hereby incorporated by.In this plasterboard manufacture process, face coat is applied on the panel and before placing gypsum on the panel and is dried.
The method of another kind of coating coating is used an independent coating process after manufacturing and dried gypsum panel products.
People's such as Zuber United States Patent (USP) 6,105,325 discloses the facing outward appearance and the application that the wadding of the plasterboard paper that is connected is complementary with the tie point coating, also its disclosure is hereby incorporated by.
In said method, coating has produced the aesthetic characteristic of expectation, comprises surface color and polish, reflectivity and water imbibition.Yet these methods are capital-intensive, need independent and the special production equipment that is coated with coating therein, and owing to a part that is not large-scale online production equipment makes inefficiency.
Summary of the invention
The invention provides a kind of coating plasterboard, this plasterboard can be made in continuous plasterboard manufacture method.This plasterboard can be made or its both sides constitute with paper, and the one side constitutes with paper, or either side does not all have paper.And this plasterboard coating can be applied to before the drying on the wet plasterboard.
In an illustrative embodiment, the coating plasterboard comprises the gypsum central layer, and this gypsum central layer has first side and second side, and a panel that is placed on first side.Be coated with at least a portion that is placed on panel, and at least a portion coating penetration is in the gypsum central layer.In another embodiment, plasterboard further comprises the base plate on second side that is positioned at the gypsum central layer.On the one hand, coating can be penetrated in the gypsum central layer, reaches basic uniform depth on the whole area of plasterboard.Nail nipping value (nail holdvalue) with plasterboard of such coating is greater than 80 pounds.
Make in the method that is coated with plasterboard a kind of, gypsum slurry is deposited and forms wet plasterboard, and coating is applied on the wet plasterboard, and the plasterboard that then wets is dried.This coating can be applied directly on the gypsum central layer or be applied on the panel on the gypsum slurry.When coating was applied on the plasterboard before drying, this coating can be penetrated in panel and/or the gypsum central layer, and formed the coating of thickness up to 30 mils.
In an illustrative embodiment, be sealant with the coating that is applied on the plasterboard, or the sealant of dilution.
In another illustrative embodiment, this coating contains a kind of composition, and it comprises 25-75vo1.% water, 30-70wt.% calcium carbonate, 0-30wt.% filler, other additive of 2-10wt.% latex emulsion and 0-10wt.%.Filler can comprise one or more micas, talcum, clay and lime stone.Also the 2-8wt.% perlite can be added in the coating,, also can add the pigment of effective dose so that the color of expectation is provided for coating to form light-end products.
In another embodiment, the coating that is applied on the plasterboard is contained a kind of composition, it comprises 10-60vol.% water, the 50-90vol.% calcined gypsum; The 0.1-10vol.% adhesive; The 0-50vol.% lime stone; The 0-10vol.% clay; Other filler of 0-30vol.%; With the 0-10vol.% additive.Filler can comprise one or more micas and talcum.Also the 2-15vol.% perlite can be added in the coating,, also can add the pigment of effective dose so that the color of expectation is provided for coating to form light-end products.
Utilize a kind of exemplary process deposit gypsum slurry of making wall to have the wet plasterboard of gypsum central layer, coating be applied on this wet plasterboard with formation, and dry should wet plasterboard.The step of coating coating was carried out before the step of dry wet plasterboard.Thereby this coating plasterboard is fixed to and forms wall on the supporting construction then, and the seam between the adjacent coating plasterboard is sealed and repaired with sealant, and described sealant contains a kind of and the substantially similar composition of this coating composition.
Accompanying drawing is simply described
From following detailed description of preferred embodiments of the invention, and in conjunction with the accompanying drawings, aspects and advantages of the present invention will become apparent, the similar numeral analogous components in the accompanying drawing, wherein:
Fig. 1 is the viewgraph of cross-section that has been coated with the coating plasterboard of coating on panel.
Fig. 2 is the viewgraph of cross-section that has been coated with the coating plasterboard of coating on the gypsum central layer.
Fig. 3 is the schematic diagram of an embodiment of the production line of introducing application step before drying plaster boards.
Fig. 4 is the schematic plan view that shows the application step of coating machine.
Detailed description of the preferred embodiments
Although description herein refers to when having or wallboard, the patch block of interior top, ceiling perhaps is generically and collectively referred to as plasterboard, and under each situation, notion of the present invention is normally used for wallboard, ceiling or the patch block of interior top.
In general, plasterboard is installed in such as wall in the mode that the edge adjoins joint in architectural process, on the surface of ceiling and analog thereof.After fixing plasterboard from the teeth outwards with suitable attachment (as nail, screw, epoxy resin or the like), cover the seam of attachment and/or artificial vestige (as the recess of nail, ailhead, screwed hole with coating, or the like), to present even and smooth surface layer.For seam, described coating and adhesive tape can be used in combination.Coating material refers to sealant sometimes.
Used coating can be a kind of in two types in the plasterboard industry.In the first kind, form hard coating after coating is applied and As time goes on moisture content is evaporated.In second type, coating is applied and allow it to place one section reasonable time, and the component of this coating is frozen into hard gypsum base coating during this period.
In manufacture process, the coating of the first kind or second type can be applied on the side of plasterboard (for example be applied on the panel or be coated directly onto on the gypsum central layer) to form the coating plasterboard.Can select coating, so as the coating of coating plasterboard basically with the coating or the sealant coupling of seam that will be used for covering attachment and/or artificial vestige, described attachment be fixed on the supporting construction relevant with being coated with plasterboard.
Figure 1 shows that an embodiment of coating plasterboard 100.Gypsum central layer 105 is between base plate 110 and panel 115.Coating 120 is positioned on the panel 115.Figure 2 shows that another embodiment of coating plasterboard 200, its floating coat 205 directly places on the plasterboard 210.Should know and to use any combination of panel and base plate to put into practice the present invention.In the removed situation of one or more layers plate, coating can be coated directly onto on the gypsum central layer, is accompanied by coating penetration in the gypsum central layer.
Coating is uniformly applied to (for example, if use panel, to be applied on the panel, or to be coated directly onto on the gypsum central layer) on the surface of plasterboard and reaches homogeneous thickness t, and this one-tenth-value thickness 1/10 preferably is not subjected to the influence of surface irregularity.The typical thickness t of coating can reach 30 Mills, is preferably the 3-20 Mill, more preferably the 5-15 Mill.Preferred thickness depends on final application.For example, for wallboard, this thickness t is preferably 10 Mills; For the patch block of interior top 20 Mills.And the thickness outside these scopes also can be among consideration of the present invention.But about 30 Mills or higher coating may cause the crack or the scouring of finishing when it is dry.Therefore, thicker coating should carefully be used.
Have in the embodiment of panel at plasterboard, coating can be penetrated at least a portion panel, and in some cases, coating can be passed panel always and is penetrated into the gypsum core plate portion, covers at least a portion plasterboard.In one embodiment, coating can be penetrated into plasterboard cover whole basically it with the area of coating, just whole plasterboard, or predetermined portions are if selected plasterboard zone is applied.
Although preferably coating is penetrated in the plasterboard with homogeneous thickness basically, the infiltration thickness of coating can be subjected to the influence of relative humidity level and/or plasterboard coagulation grade.In viewgraph of cross-section shown in Figure 1, coating 120 has been penetrated in the panel 115, and the thickness that is penetrated in the gypsum central layer 110 is d.In other situation, promptly lower or gypsum is in the situation of coagulation grade higher state in water content, and coating only is penetrated into thickness certain in the panel.In an embodiment of the plasterboard with panel, the thickness that is penetrated into the gypsum central layer is approximately between the 5-20 Mill, preferably between the 10-15 Mill.In the embodiment of the plasterboard that does not have panel, infiltration thickness is approximately between the 5-30 Mill, preferably between the 10-20 Mill.
Figure 3 shows for preparing a method that is coated with plasterboard, wherein described the flow chart of coating gypsum board production line.Total preparation process 300 comprises mixes 305 gypsum slurries, is intended shape with gypsum moulding 310, is desired size with gypsum cutting 315, is coated with 320 subsequently to form gypsum board products, then drying 325.Gypsum mainly solidifies between forming step 310 and cutting step 315.Manufacturing step from moulding 310 to cutting is described as moulding and solidifies production line herein, wherein comprise cutting; The step that herein will cut after 315 is described as coating and drying production line.
The manufacturing of the coating plasterboard of moulding is from moulding and solidify production line.In first embodiment, when also wetting, the gypsum central layer on the first surface of gypsum central layer, is coated with coating.In other embodiments, plasterboard has panel and/or base plate, when the gypsum central layer is also wetting, is being coated with on as panel surface on the first surface with coating.For the application's purpose, in manufacture process, before plasterboard passes drying oven, think that the gypsum central layer wets at any time.
In order to control the setting time of gypsum central layer, the component that can regulate plasterboard is for example by the promoter used in the control gypsum slurry composition and the use amount of set retarder.Promoter comprises the wisp of lenticular, and they are by starch or the coating of other soluble substance.Along with the dissolving of the coating of starch or other soluble substance, the promoter crystal forms the starting point or the seed of gypsum crystal growth.Set retarder preferably is added in the plasterboard component, so that postpone the setting time of gypsum central layer.Set retarder does not have The Long-term Effect for intensity or other characteristic of final plate product.
Expected delay setting time in some cases is not so that gypsum slurry can solidify before the setting time of expectation.For example,, can cause inefficiency in blender, for example stop up and/or block instrument, be accompanied by the downtime of safeguarding and/or repairing if gypsum slurry just begins to solidify.In addition, if slurry outside the blender but before moulding, solidify, sizing material forming may cause that crystal structure is destroyed in process of setting, this can cause not too firm final plate product.Therefore, in manufacture process, can be used singly or in combination promoter and set retarder setting time, thereby obtain solidifying or hardness of expectation in the time of expectation with the adjusting gypsum.
After moulding, plasterboard is along moulding and solidify production line and be transmitted system and be sent to cutting position.Select transfer rate and distance in conjunction with the setting time of gypsum, have expectation with formation and solidify or the gypsum of hardness, be convenient to subsequently cutting and processing.Cutting is finished with cutting machine, as known traditionally in this area.After cutting, plasterboard is reversed, and is placed into then to transmit the surface, then is sent to coating and drying production line.Have in the situation of panel and/or base plate at the gypsum central layer, the processing of plasterboard causes base plate to contact with transmitting the surface, and panel is exposed.
On coating and drying production line, there is or do not have the plasterboard of panel and/or base plate all to be transmitted device and be conveyed through coating machine, this coating machine is placed on before the dry instrument.Fig. 4 has schematically described flowing water coating process 400.Coating machine 405 is positioned at transmission approach 410 tops of plasterboard 415.The transmission approach typically comprises conveyer belt 420, has placed applied plasterboard on it, although can use other suitable transmission approach, as transmission or non-live-roller.Uncoated and wet plasterboard 425 passes through under coating machine 405, by coating spreader 430 coating coatings.Coating plasterboard 435 is sent to following production stage then, if any, then for example carries out drying in baking oven.
Can be coated with coating with traditional coating machine such as curtain formula coating machine.An example of curtain formula coating machine is provided by Hymmen International, and it can be by custom-designed to be fit to concrete production line or manufacturing equipment.Curtain formula coating machine provides the continuous coating curtain, and wet plasterboard passes therethrough.Other coating apparatus can comprise sprayer, as nozzle or spray sprayer, dropper and atomization technique.An example of spraying technology is by Graco, and Inc. provides, and has used the spary tip that is suspended on the wallboard circuit.Another optional method is a technique, and this technology scrapes the coating compound on the surface of plasterboard, promptly scrapes on the surface of gypsum central layer or panel.
Coating can be applied on the plasterboard under any condition of gypsum sets.For example, coating can be applied before oven drying, thereby coating is penetrated into during transmitting in wetted surface plate and/or the wet gypsum central layer.After coating, the coating plasterboard is dried, and prepares then to store and transport.Optionally, coating can be coated with after drying, is maybe needing and will being penetrated into the depth minimization of panel of temperature-sensitive in this coating for example.
Coating can be applied on the whole surface area of plasterboard, or is applied on the predetermined portions of plasterboard.Under latter event, predetermined portions can be specified like this, for example by hiding plasterboard to stop specified portions applied, perhaps by coating apparatus only is adjusted to coating is applied on the predetermined portions.
Can predict the several optional embodiment of coating composition, each all can influence final products.An embodiment of coating is known as " coating fast " herein, and this coating is hardened by evaporation moisture content.Coating comprises water fast; Calcium carbonate; Filler such as lime stone, mica, talcum and/or clay; Adhesive; Latex emulsion; With other additive such as anticorrisive agent and thickener.The water content of coating is 35-45wt.% fast, by adding entry it is diluted to dilution factor between 10%-60% in mixture, for example between 25-70wt.%, preferably between 39-56wt.%.Table 1 has provided the illustrative prescription of an embodiment of quick coating.
Table 1
| Component | Content (wt.%) |
| Water | ????25-75 |
| Calcium carbonate | ????30-70 |
| Mica | ????0-10 |
| Talcum | ????0-10 |
| Clay | ????0-10 |
| Latex emulsion | ????2-10 |
| Other additive | ????0-10 |
In a lightweight embodiment of quick coating, filler can comprise the perlite of 2-8wt.%.Added pigment in another embodiment of coating fast, this pigment is added into effective dose so that be that coating provides the expectation color.In addition, can make quick coating in case basically with the performance such as the water imbibition of sealant, couplings such as reflectivity.After being coated with decorative coating, mate the aesthetic appearance that can improve plasterboard basically at the finished product condition next one or a plurality of characteristics.
Therefore, according to an aspect of the present invention, can assemble wall with the sealant of sealant or dilution coating plasterboard by the preparation plasterboard and before drying steps.And, when plasterboard is fixed on the supporting construction when forming wall, can seal and repair seam between the adjacent plate with sealant, described sealant contains the composition substantially similar with coating.
Another embodiment of the invention has been used a kind of coating, and this coating is known as " gel coating " at this.The process of setting of gypsum sets forms firm gypsum base coating to gel coating in the plasterboard by being similar to.Gel coating comprises a kind of dry products, and this product contains calcined gypsum; Adhesive; Filler such as lime stone, mica, talcum and/or clay; With other additive such as anticorrisive agent, promoter and thickener.Calcined gypsum can be α type or β type or this blend of two types.Before the use, gel coating is mixed the formation mixture with the water of 30-60vol.%.Table 2 has provided an illustrative prescription of gel coating.
Table 2
| Component | Content (vol.%) |
| Water | ????10-60 |
| Calcined gypsum | ????50-90 |
| Adhesive | ????0.1-10 |
| Lime stone | ????0-50 |
| Clay | ????0-10 |
| Other filler | ????0-30 |
| Other additive | ????0-10 |
In a lightweight embodiment of gel coating, filler can comprise the perlite of 2-15vol.%.Added pigment in another embodiment of gel coating, this pigment is added into effective dose so that be that coating provides the expectation color.
Gel coating more has elastic force for collision than quick coating usually, and is promptly more tough and tensile, and can be used to provide anti-mechanical damage surface on plasterboard, for example in the heavy traffic area or public situation use.In addition, can make quick coating in case with the performance such as the water imbibition of sealant, reflectivity etc. mate basically.After being coated with decorative coating, mate the aesthetic appearance that can improve plasterboard basically at the finished product condition next one or a plurality of performances.
The adhesive that is suitable for above-mentioned quick coating and gel coating comprises starch, and it helps bond properties.The example of such adhesive is a wheaten starch, and its amount can be between 0.01-5%.
The amount that is suitable for the anticorrisive agent of above-mentioned quick coating and gel coating can be between 0.01-5%.This additive can prevent that product from degenerating too early before using.It is because may have water and/or a large amount of organic material in prescription that coating can degenerate.Anticorrisive agent also is known as antimicrobial usually.
Promoter can be used to regulate the setting time in the above-mentioned gel coating.An example of promoter is a potassium sulfate.Promoter can exist with suitable amount, to obtain the setting time of expectation.Typically, the amount of promoter with solid weight meter between 0.01-15%.
Thickener as the plain basic thickener of general fibre, can be used to regulate the rheological property of coating, and can exist with suitable amount.Typically be worth with solid weight meter between 0.01-35%.
The coating penetration that is produced by the coating of coating adheres on the gypsum central layer as panel better to the improved coating plasterboard of wet plasterboard performance.In one embodiment, coating can improve the intensity of plate, as measured by the nail nipping value.Table 3 comprises the nail nipping value of coating plasterboard and uncoated plasterboard.As can be seen from Table 3, with respect to traditional uncoated gypsum board products, coating has improved the nail nipping value up to 25%.
Table 3
| Sample | The nail nipping value |
| Coating | 80 pounds |
| Uncoated | 63 pounds |
In addition, with respect to uncoated plasterboard, the coating plasterboard demonstrates machinery or strength advantage, and this makes can use lighter panel, is accompanied by to reduce cost.Typically, panel can be any weight between the 40-60 pound.In some applications, the cardboard of panel mineral that have been fusion or synthetic fibers.If panel is applied, the improved plate intensity of being given by coating makes the weight of cardboard reduce.Advantage of the present invention is accomplished, has still obtained required processing characteristics simultaneously, so that can not rupture when handling in manufacture process.
According to an embodiment preferred, plasterboard is to deposit on the panel that places on the ring-like conveyer belt by the formation gypsum slurry and with slurry to be prepared.Then base plate is placed gypsum slurry above.By gypsum and optional panel and base plate are passed one or more format rolls to form expectation thickness, panel, gypsum slurry and base plate are formed wet plasterboard then.Wet plasterboard transmits on conveyer belt, finishes up to setting time, with the blade cuts machine plasterboard is cut into desired length subsequently, makes it pass mechanical coating machine then.Add the excessive water of heat abstraction subsequently, as in drier or baking oven.In any stage of this method, panel or base plate or both can be removed.
In another embodiment of the invention, gypsum board products can form on production line, as being known as top patch block in the preparation usually.In the method, can expect component with high speed shear blender batch mixed.Each batch is forced on the ring-like conveyer belt by the outlet of extruder then.After predetermined setting time, mixture is cut into desired length then.Cutting Length passes mechanical coating machine then, evaporates unnecessary moisture content by drier subsequently.
According to one embodiment of the invention, can make light gypsum board.The density of such plate can from be low to moderate 1000 pounds per 1000 square feet to 1700 pounds per 1000 square feet or bigger change.In gypsum cutting back and gypsum when still not having drying, wet plasterboard is transported to coating and drying production line.Coating thickness is up to the coating of 30 Mills, and is dry in dry run subsequently, for example dry in baking oven.
According to another embodiment of the invention, the gypsum board products with expectation thickness can be made according to conventionally known method.For example, can make the plasterboard of 1/2 inch or 1/4 inch.In gypsum cutting back and gypsum when still not having drying, wet plasterboard is transported to coating and drying production line.Coating thickness is up to the coating of 30 Mills, and is dry in dry run subsequently, for example dry in baking oven.
Although invention has been described in conjunction with its preferred embodiment, but will be understood by those skilled in the art that, under the situation that does not deviate from the spirit and scope of the present invention defined in the appended claims, can carry out not having special interpolation, deletion, modification and the replacement of describing herein to the present invention.
Claims (26)
1. plasterboard that has been coated with coating on it, described plasterboard comprises:
Have first side and second side and and be placed on the gypsum central layer of the panel on first side; With
Be positioned at the coating at least a portion panel,
Wherein at least a portion coating penetration passes at least a portion of panel and arrives in the gypsum central layer.
2. plasterboard as claimed in claim 1, wherein said coating penetration reach uniform depth basically on the whole area of plasterboard in the gypsum central layer.
3. plasterboard as claimed in claim 1, the thickness of wherein said coating is up to 30 Mills.
4. plasterboard as claimed in claim 3, the thickness of wherein said coating is preferably the 3-20 Mill.
5. plasterboard as claimed in claim 1, wherein said coating is a sealant.
6. plasterboard as claimed in claim 1, wherein said coating comprises:
25-75wt.% water;
30-70wt.% calcium carbonate;
The 0-30wt.% filler;
The 2-10wt.% latex emulsion; With
The 0-10wt.% additive.
7. plasterboard as claimed in claim 6, wherein filler comprises one or more in mica, talcum, clay and the lime stone.
8. plasterboard as claimed in claim 6, wherein said composition further comprises the 2-8wt.% perlite.
9. plasterboard as claimed in claim 6, wherein said composition comprise that further the pigment of effective dose is so that provide the color of expectation for coating.
10. plasterboard as claimed in claim 1, wherein said coating comprises:
10-60vol.% water;
The 50-90vol.% calcined gypsum;
The 0.1-10vol.% adhesive;
The 0-50vol.% lime stone;
The 0-10vol.% clay;
Other filler of 0-30vol.%; With
The 0-10vol.% additive.
11. plasterboard as claimed in claim 10, wherein said other filler comprises one or more in mica and the talcum.
12. plasterboard as claimed in claim 10, wherein said composition further comprises the 2-15vol.% perlite.
13. plasterboard as claimed in claim 10, wherein said composition comprise that further the pigment of effective dose is so that provide the color of expectation for coating.
14. plasterboard as claimed in claim 1, the nail nipping value of wherein said plasterboard is greater than 80 pounds.
15. plasterboard as claimed in claim 1, wherein said plasterboard comprise that further one is placed on the base plate on second side of gypsum core plate.
16. plasterboard as claimed in claim 1, wherein said plasterboard comprise that further one is placed on the base plate on first side, and wherein the gypsum central layer deposits thereon as gypsum slurry.
17. one kind prepares the method that is coated with plasterboard, described method comprises:
The deposit gypsum slurry forms the wet plasterboard with gypsum central layer;
Coating is applied on this wet plasterboard; With
The dry plasterboard that should wet,
The step of wherein said coating coating was carried out before drying steps.
18. method as claimed in claim 17, wherein said coating is applied directly on the gypsum central layer.
19. method as claimed in claim 17, wherein said gypsum slurry is deposited on the panel, and wherein said coating is applied on the panel.
20. method as claimed in claim 19, it further comprises the step that base plate is placed the position relative with panel, and the gypsum central layer is between them.
21. method as claimed in claim 17, wherein said coating is applied at the plasterboard solidificating period.
22. method as claimed in claim 19, it further comprises the cutting plasterboard, wherein cuts before the coating coating and carries out.
23. method as claimed in claim 17, wherein said coating curtain formula coating machine, spray coating machine, dropper or atomization technique coating.
24. method as claimed in claim 19, wherein said coating penetration are passed at least a portion of panel and are arrived at least a portion of gypsum central layer.
25. method as claimed in claim 19, wherein said coating are the sealants of dilution.
26. a method of making wall, described method comprises:
The deposit gypsum slurry forms the wet plasterboard with gypsum central layer;
Coating is applied on this wet plasterboard;
The dry plasterboard that should wet, the step of wherein said coating coating was carried out before drying steps;
Should be coated with plasterboard is fixed to and forms wall on the supporting construction; With
Seal and repair in abutting connection with the seam between the coating plasterboard with sealant, described sealant contains the composition substantially similar with coating composition.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US26406801P | 2001-01-26 | 2001-01-26 | |
| US60/264,068 | 2001-01-26 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1498161A true CN1498161A (en) | 2004-05-19 |
| CN1317123C CN1317123C (en) | 2007-05-23 |
Family
ID=23004422
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB028041550A Expired - Fee Related CN1317123C (en) | 2001-01-26 | 2002-01-25 | Coated gypsum board products and method of manufacturing thereof |
Country Status (16)
| Country | Link |
|---|---|
| EP (1) | EP1358052A4 (en) |
| JP (1) | JP2004520966A (en) |
| KR (1) | KR100842847B1 (en) |
| CN (1) | CN1317123C (en) |
| AU (1) | AU2002245308B2 (en) |
| BR (1) | BR0206941A (en) |
| CA (1) | CA2435574A1 (en) |
| IL (1) | IL156937A0 (en) |
| MX (1) | MXPA03006599A (en) |
| NO (1) | NO20033319L (en) |
| NZ (1) | NZ527112A (en) |
| PL (1) | PL363475A1 (en) |
| RU (1) | RU2280560C2 (en) |
| UA (1) | UA76975C2 (en) |
| WO (1) | WO2002058902A2 (en) |
| ZA (1) | ZA200305485B (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107285724A (en) * | 2017-08-09 | 2017-10-24 | 苏州雪原风知识产权服务有限公司 | A kind of preparation method of wall decoration plasterboard |
| CN109476548A (en) * | 2016-07-28 | 2019-03-15 | 美国石膏公司 | The plasterboard for being used to prepare the method for the plasterboard with polymer coating and being prepared by the method |
| CN109928706A (en) * | 2019-03-29 | 2019-06-25 | 河北科技大学 | A kind of method and apparatus that three-D pattern being made using gypsum slurries |
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| US7208225B2 (en) | 1995-06-30 | 2007-04-24 | Lafarge Platres | Prefabricated plaster board |
| US20040048110A1 (en) | 2002-09-09 | 2004-03-11 | Steven Butler | Wallboard comprising an improved multi-layer facing material and a method for making the same |
| GB0223875D0 (en) * | 2002-10-15 | 2002-11-20 | Bpb Plc | Method and apparatus for producing a multilayer cementitious product |
| US7989370B2 (en) * | 2003-10-17 | 2011-08-02 | Georgia-Pacific Gypsum Llc | Interior wallboard and method of making same |
| WO2005100279A1 (en) * | 2004-04-13 | 2005-10-27 | Lafarge Platres | A system using a drywall board and a jointing compound, coating for wall construction |
| US7214411B2 (en) | 2004-04-13 | 2007-05-08 | Lafarge Platres | Coating spray apparatus and method of using same |
| EP2010711A2 (en) * | 2006-03-23 | 2009-01-07 | Hercules Incorporated | Improved paper for gypsum wallboard |
| US7897660B2 (en) | 2007-10-29 | 2011-03-01 | Eastman Chemical Company | Incorporation of a resin dispersion to improve the moisture resistance of gypsum products |
| CN102776995A (en) * | 2012-07-27 | 2012-11-14 | 嘉兴博隆铝装饰板有限公司 | Suspended ceiling blank automatic production line |
| CA2920895C (en) | 2013-08-27 | 2018-09-18 | Valspar Sourcing, Inc. | Coating and binder compositions for gypsum boards |
| WO2017184945A1 (en) * | 2016-04-22 | 2017-10-26 | Sproule Iii Charles G | Reinforced rigid insulation |
| US20180080226A1 (en) | 2016-09-22 | 2018-03-22 | United States Gypsum Company | Gypsum boards with polymer coating and methods for making same |
| 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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| CH179377A (en) * | 1934-08-28 | 1935-09-15 | Gips Union A G | Process for impregnating plasterboards, plasterboards and similar plaster bodies. |
| DE1009387B (en) * | 1953-05-30 | 1957-05-29 | Frisalit Werke G M B H | Process to increase the adhesion of mortar on water-absorbing sub-surface, e.g. made of plaster or the like. |
| US4205041A (en) * | 1977-09-19 | 1980-05-27 | Hymes Richard H | Tapeless joint compound |
| DD142872A1 (en) * | 1979-04-16 | 1980-07-16 | Georg Kraemer | METHOD AND PRIMER FOR AUTOMATIC FOUNDATION OF PLASTER PANELS |
| JPS58135186A (en) * | 1982-01-29 | 1983-08-11 | 松下電工株式会社 | Method of dressing hydraulic inorganic board |
| US5207830A (en) * | 1990-03-21 | 1993-05-04 | Venture Innovations, Inc. | Lightweight particulate cementitious materials and process for producing same |
| CN2147095Y (en) * | 1992-12-31 | 1993-11-24 | 刘彬华 | Polyvinyl board imitated shaped-material |
| CA2139373C (en) * | 1994-05-12 | 2002-06-25 | Therese A. Espinoza | Ready-mixed, setting type joint compound |
| CN2215405Y (en) * | 1994-08-19 | 1995-12-20 | 郑根莲 | Plaster plate for decoration |
| US6105325A (en) | 1995-06-30 | 2000-08-22 | Lafarge Platres | Method, assembly and additional coat for the construction of interior works |
-
2002
- 2002-01-25 JP JP2002559220A patent/JP2004520966A/en not_active Withdrawn
- 2002-01-25 AU AU2002245308A patent/AU2002245308B2/en not_active Ceased
- 2002-01-25 NZ NZ527112A patent/NZ527112A/en unknown
- 2002-01-25 BR BR0206941-5A patent/BR0206941A/en not_active Application Discontinuation
- 2002-01-25 PL PL02363475A patent/PL363475A1/en not_active Application Discontinuation
- 2002-01-25 KR KR1020037009895A patent/KR100842847B1/en not_active IP Right Cessation
- 2002-01-25 CN CNB028041550A patent/CN1317123C/en not_active Expired - Fee Related
- 2002-01-25 EP EP02713458A patent/EP1358052A4/en not_active Withdrawn
- 2002-01-25 MX MXPA03006599A patent/MXPA03006599A/en active IP Right Grant
- 2002-01-25 CA CA002435574A patent/CA2435574A1/en not_active Abandoned
- 2002-01-25 IL IL15693702A patent/IL156937A0/en unknown
- 2002-01-25 RU RU2003125961/03A patent/RU2280560C2/en not_active IP Right Cessation
- 2002-01-25 WO PCT/US2002/002106 patent/WO2002058902A2/en active Application Filing
- 2002-01-25 UA UA2003087997A patent/UA76975C2/en unknown
-
2003
- 2003-07-16 ZA ZA200305485A patent/ZA200305485B/en unknown
- 2003-07-23 NO NO20033319A patent/NO20033319L/en not_active Application Discontinuation
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109476548A (en) * | 2016-07-28 | 2019-03-15 | 美国石膏公司 | The plasterboard for being used to prepare the method for the plasterboard with polymer coating and being prepared by the method |
| CN107285724A (en) * | 2017-08-09 | 2017-10-24 | 苏州雪原风知识产权服务有限公司 | A kind of preparation method of wall decoration plasterboard |
| CN109928706A (en) * | 2019-03-29 | 2019-06-25 | 河北科技大学 | A kind of method and apparatus that three-D pattern being made using gypsum slurries |
| CN109928706B (en) * | 2019-03-29 | 2023-11-03 | 河北科技大学 | Method and equipment for preparing three-dimensional pattern by using gypsum slurry |
Also Published As
| Publication number | Publication date |
|---|---|
| PL363475A1 (en) | 2004-11-15 |
| KR100842847B1 (en) | 2008-07-02 |
| BR0206941A (en) | 2004-02-25 |
| NO20033319D0 (en) | 2003-07-23 |
| WO2002058902A2 (en) | 2002-08-01 |
| EP1358052A4 (en) | 2007-10-24 |
| NO20033319L (en) | 2003-09-26 |
| AU2002245308B2 (en) | 2006-04-06 |
| NZ527112A (en) | 2004-03-26 |
| RU2003125961A (en) | 2005-02-20 |
| UA76975C2 (en) | 2006-10-16 |
| RU2280560C2 (en) | 2006-07-27 |
| EP1358052A2 (en) | 2003-11-05 |
| CA2435574A1 (en) | 2002-08-01 |
| MXPA03006599A (en) | 2004-10-15 |
| ZA200305485B (en) | 2004-06-23 |
| JP2004520966A (en) | 2004-07-15 |
| WO2002058902A3 (en) | 2002-09-19 |
| CN1317123C (en) | 2007-05-23 |
| IL156937A0 (en) | 2004-02-08 |
| KR20030082575A (en) | 2003-10-22 |
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