TW201623751A - 具有增進固定強度之建築面板 - Google Patents

具有增進固定強度之建築面板 Download PDF

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TW201623751A
TW201623751A TW104138444A TW104138444A TW201623751A TW 201623751 A TW201623751 A TW 201623751A TW 104138444 A TW104138444 A TW 104138444A TW 104138444 A TW104138444 A TW 104138444A TW 201623751 A TW201623751 A TW 201623751A
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gypsum
gypsum board
particles
weight percent
percent relative
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TW104138444A
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Laura Brooks
Nicola Jupp
Joanna Sparkes
Adam Richardson
Nicholas Jones
Jan Rideout
Keith Humphrey
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Bpb Ltd
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    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

一種石膏板，其包含有石膏基質，石膏基質具有嵌於其中的複數結塊纖維顆粒，而結塊纖維顆粒的含量相對於石膏為至少1重量百分比，且石膏基質更包含聚合添加物，聚合添加物的含量相對於石膏為至少1重量百分比。

Description

具有增進固定強度之建築面板
本發明係有關一種用於建築結構之面板，特別是關於一種能提供分隔區之面板，以供水槽、電視或散熱器固定之。
輕重量之面板，例如石膏板（如石膏材料之石膏板）、聚苯乙烯板與纖維板，一般在建築物中提供分隔區，在應用上的優點包含重量輕，且安裝迅速。
然而，在某些狀況中，如此輕重量之面板有一缺點，即強度不夠支撐設備（例如水槽、電視、散熱器、滅火器、架子及其他任何需與面板貼附之物）。在如此狀況裡，設備的重量會造成固定裝置（例如螺絲釘）從面板上脫落，使設備從此分隔區上掉離。
為了克服此問題，先前的作法是利用聚合物基底的支撐薄層膠黏於石膏板的一面，此支撐薄層譬如為聚氯乙烯、高密度聚乙烯（HDPE）、尼龍、聚碳酸酯、膠木、聚丙烯、乙縮醛或玻璃纖維。
目前發現藉由在石膏板中包含木製品和聚合添加物，石膏板可以具有足夠的能力來保持固定裝置，且不需要支撐薄層。
因此，本發明的第一方面在於提供一種石膏板，其包含石膏基質，石膏基質具有嵌於其中的複數結塊纖維顆粒，而結塊纖維顆粒的含量相對於石膏為至少1重量百分比，且石膏基質更包含聚合添加物，聚合添加物的含量相對於石膏為至少1重量百分比； 其中， 石膏板的任一面並沒有附加支撐薄層。
透過省略掉支撐薄層，則有可能提供一面板，由於較佳的易製造性與被減少的未加工之材料成本，此面板以較低成本以具有適當之固定強度。此外，此面板較容易地再利用，因為可以避免分開薄層與石膏板之需求。
術語「薄層」意指在涵蓋具有厚度至少為1公釐（例如2公釐）的聚合物基底之片材，實質上包含有聚氯乙烯、高密度聚乙烯（HDPE）、尼龍、聚碳酸酯、膠木、聚丙烯、乙縮醛或玻璃纖維。在此所用之術語「薄層」意指貼附於石膏板之一面的片材，例如利用膠合方法，使得在石膏板和片材之間產生明確的界面。因此，術語「薄層」並非意指部分或全部嵌入在石膏板內的對象。
雖然沒有薄層貼附於石膏板的任一面，但是石膏板可具有表層紙於石膏板的一面或兩面上。在其他例子中，石膏板可具有墊子，例如玻璃纖維墊，其部分或全部嵌入石膏板的表面。
一般來說，顆粒的含量相對於石膏為至少2重量百分比。又一般來說，顆粒的含量相對於石膏為低於10重量百分比，較佳者為低於8重量百分比。
顆粒可以譬如為木材顆粒（如木屑或細木屑顆粒）或紙屑。較佳地，顆粒為木材顆粒。在一般情況下，顆粒是不規則形狀。
為避免造成疑問，術語「木材顆粒」並非意旨木材衍生材料（如紙粒子）的顆粒，因為這已經處理到單根纖維的地步，不再由木材中所存在的天然黏合劑所結合。
一般來說，這些顆粒的長度大於0.5公釐的長度。在一般情況下，這些顆粒的長度是小於25釐米，較佳者為小於20釐米。
一般來說，這些顆粒的厚度小於4公釐，較佳者為小於3公釐。在顆粒為紙粒子的情況下，其厚度通常小於0.5公釐。
在一些實施例中，顆粒可以是木材顆粒，且石膏板可以進一步包括玻璃纖維。在這種情況下，玻璃纖維的較佳含量為至少1重量百分比。
一般來說，聚合添加物的含量相對於石膏為至少2重量百分比，較佳者為至少4重量百分比。
一般來說，聚合添加物是選自下列群組：聚乙酸乙烯(polyvinyl acetate)、聚乙烯-醋酸乙烯共聚物(poly vinyl acetate-ethylene co-polymer)、聚乙烯氫吡咯酮交叉結合聚苯乙烯磺酸(polyvinyl pyrrolidone crosslinked with polystyrene sulfonate)、聚乙烯醇、甲基纖維素(methyl cellulose)、羥乙基甲纖維素（hydroxyethyl methyl cellulose）、苯乙烯-丁二烯共聚物膠乳（styrene-butadiene copolymer latex）、丙烯酸酯乳膠（acrylic ester latex）、丙烯酸酯共聚物乳液（acrylic copolymer latex）、聚酯樹脂、環氧樹脂、聚甲基丙烯酸甲酯（polymethyl methacrylate）、聚丙烯酸、陽離子澱粉、乙基化澱粉、葡聚糖及其混合物。
較佳地，聚合添加物為聚乙酸乙烯和澱粉其中之一。
在一些例子中，澱粉可為天然澱粉（即，未改質澱粉）。在其他例子中，澱粉可以是改質性澱粉，例如，酸解澱粉。
最佳地，聚合添加物為聚乙酸乙烯。
本發明的第二方面在於提供一種石膏板，其包含石膏基質，石膏基質具有嵌於其中的複數木材顆粒，而木材顆粒的含量相對於石膏為至少2重量百分比，且石膏基質更包含複數玻璃纖維，玻璃纖維的含量相對於石膏為至少1重量百分比。
較佳地，石膏板的任一面並沒有附加支撐薄層。
術語「薄層」意指在涵蓋具有厚度至少為1公釐（例如2公釐）的聚合物基底之片材，實質上包含有聚氯乙烯、高密度聚乙烯（HDPE）、尼龍、聚碳酸酯、膠木、聚丙烯、乙縮醛或玻璃纖維。在此所用之術語「薄層」意指貼附於石膏板之一面的片材，例如利用膠合方法，使得在石膏板和片材之間產生明確的界面。因此，術語「薄層」並非意指部分或全部嵌入在石膏板內的對象。
雖然沒有薄層貼附於石膏板的任一面，但是石膏板可具有表層紙於石膏板的一面或兩面上。在其他例子中，石膏板可具有墊子，例如玻璃纖維墊，其部分或全部嵌入石膏板的表面。
在一般情況下，木材顆粒是不規則形狀。
一般來說，木材顆粒的長度大於0.5公釐的長度。在一般情況下，這些顆粒的長度是小於25釐米，較佳者為小於20釐米。
一般來說，木材顆粒的厚度小於4公釐，較佳者為小於3公釐。
在本發明的第一或第二方面的一些實施例中，石膏板具有表層紙。這些表層紙可同時包含纖維素纖維和玻璃纖維，因為這被認為會提高石膏板的耐火性。在其他例子中，石膏板可以具有墊子，例如玻璃纖維墊，其部分或完全嵌入石膏板的表面。
在本發明的第一或第二方面的一些實施例中，石膏基質包含疏水性添加物，如矽油或蠟。
在本發明的第一或第二方面的一些實施例中，石膏基質可包含殺菌劑。
在本發明的第一或第二方面的一些實施例中，石膏基質可包含有抗收縮劑，例如非發泡蛭石、矽微粉、和/或黏土，以提高產品的耐火性。
在本發明的第一或第二方面的一些實施例中可包括泡沫或輕質骨料，如珍珠岩。這樣的添加物於本領域中已知用來製造具有可接受厚度的低密度板。
本發明將僅透過範例方式進行描述。
石膏材質之石膏板是使用下列所述方法來製備： 將灰泥和其它乾添加物（包含木屑）稱重後，放到一個袋子中搖晃混合。將水和濕添加物稱重後，放到碗中，並使用電動攪拌器混合60秒。 將乾粉狀的添加物加入放到碗中的濕添加物，並使用電動攪拌機混合30秒。 將所得漿料夾入兩片紙襯墊之間，並使其水合，由混合時間測起進行25分鐘。然後，在烘箱中於160℃下乾燥1小時。 如此產生的石膏板為12.5公釐厚。
範例 1 石膏材質之石膏板是由包含下列所述成分之漿料所準備而成。 ·          木屑，其含量相對於灰泥為3重量百分比（木屑的最大直徑是介於1-20公釐的範圍內，且厚度為0.5-3公釐）; ·          玉米澱粉（取自Tate & Lyle），其含量相對於灰泥為6重量百分比。 ·          玻璃纖維的含量相對於灰泥為3重量百分比。
範例 2 石膏材質之石膏板是由包含下列所述成分之漿料所準備而成。 ·          灰泥； ·          木屑，其含量相對於灰泥為3重量百分比（木屑的最大直徑是介於1-20公釐的範圍內，且厚度為0.5-3公釐）; ·          聚乙酸乙烯（Vinamul 4841），其含量相對於灰泥為6重量百分比。
範例 3 石膏材質之石膏板是由包含下列所述成分之漿料所準備而成。 ·          灰泥； ·          木屑，其含量相對於灰泥為3重量百分比（木屑的最大直徑是介於1-20公釐的範圍內，且厚度為0.5-3公釐）; ·          玉米澱粉（取自Tate & Lyle），其含量相對於灰泥為12重量百分比； ·          玻璃纖維，其含量相對於灰泥為2重量百分比。
範例 4 石膏材質之石膏板是由包含下列所述成分之漿料所準備而成。 ·          灰泥； ·          木屑，其含量相對於灰泥為3重量百分比（木屑的最大直徑是介於1-20公釐的範圍內，且厚度為0.5-3公釐）; ·          聚乙酸乙烯（Vinamul 4841），其含量相對於灰泥為12重量百分比； ·          玻璃纖維，其含量相對於灰泥為2重量百分比。
比較範例1 石膏材質之石膏板是由包含下列所述成分之漿料所準備而成。 ·          灰泥； ·          木屑，其含量相對於灰泥為3重量百分比（木屑的最大直徑是介於1-20公釐的範圍內，且厚度為0.5-3公釐）; ·          玻璃纖維，其含量相對於灰泥為2重量百分比。
比較範例 2 石膏材質之石膏板是由包含下列所述成分之漿料所準備而成。 ·          灰泥； ·          木屑，其含量相對於灰泥為3重量百分比（木屑的最大直徑是介於1-20公釐的範圍內，且厚度為0.5-3公釐）。
螺釘拔出強度 螺釘拔出試驗的進行，是對於樣品測定100公釐，這100公釐是控制於23℃的溫度及50％的相對濕度下。將50公釐的單個螺紋木製螺釘***到樣品中，並穿過定位在樣品表面上的金屬負載傳遞元件。負載傳遞元件的第一部分被配置在螺桿頭和樣品表面上，其第二部份被配置成與試驗機卡合，使得負載得以沿著螺釘的軸線施加到螺釘上。以1牛頓-公尺（Nm）的轉矩來扭緊螺釘。 再將樣品安裝在茲維克（Zwick）萬能試驗機，並使用10牛頓（N）的預負載沿著螺釘的軸線來施加到螺釘。隨後，藉由固定的十字頭速度設定為10公釐/分鐘，將負載增加，直到拔出螺釘後完成。 結果列示於表1。這些平均值，皆取自8個樣品。表 1
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Claims (14)

  1. 一種石膏板，包含一石膏基質，該石膏基質具有嵌於其中的複數結塊纖維顆粒，該些結塊纖維顆粒的含量相對於該石膏為至少1重量百分比，該石膏基質更包含一聚合添加物，該聚合添加物的含量相對於該石膏為至少1重量百分比； 其中， 該石膏板的任一面並沒有附加支撐薄層。
  2. 如請求項第1項所述之石膏板，其中該聚合添加物的含量相對於該石膏為至少4重量百分比。
  3. 如請求項第1或2項所述之石膏板，其中該些顆粒的含量相對於該石膏為至少2重量百分比。
  4. 如請求項第1-3項中任一項所述之石膏板，其中該些顆粒為木材顆粒。
  5. 如請求項第4項所述之石膏板，其中該些木材顆粒的長度係介於0.5-25公釐的範圍。
  6. 如請求項第4或5項所述之石膏板，其中該些木材顆粒的厚度係小於4公釐。
  7. 如請求項第4-6項中任一項所述之石膏板，其中該石膏板更包含複數玻璃纖維。
  8. 如請求項第7項所述之石膏板，其中該些玻璃纖維的含量為至少1重量百分比。
  9. 如請求項第1-8項中任一項所述之石膏板，其中該聚合添加物係選自下列群組：聚乙酸乙烯(polyvinyl acetate)、聚乙烯-醋酸乙烯共聚物(poly vinyl acetate-ethylene co-polymer)、聚乙烯氫吡咯酮交叉結合聚苯乙烯磺酸(polyvinyl pyrrolidone crosslinked with polystyrene sulfonate)、聚乙烯醇、甲基纖維素(methyl cellulose)、羥乙基甲纖維素（hydroxyethyl methyl cellulose）、苯乙烯-丁二烯共聚物膠乳（styrene-butadiene copolymer latex）、丙烯酸酯乳膠（acrylic ester latex）、丙烯酸酯共聚物乳液（acrylic copolymer latex）、聚酯樹脂、環氧樹脂、聚甲基丙烯酸甲酯（polymethyl methacrylate）、聚丙烯酸、陽離子澱粉、乙基化澱粉、葡聚糖及其混合物。
  10. 如請求項第1-8項中任一項所述之石膏板，其中該聚合添加物為澱粉或聚乙酸乙烯。
  11. 如請求項第10項所述之石膏板，其中該聚合添加物為聚乙酸乙烯。
  12. 一種石膏板，包含一石膏基質，該石膏基質具有嵌於其中的複數木材顆粒，該些木材顆粒的含量相對於該石膏為至少2重量百分比，該石膏基質更包含複數玻璃纖維，該些玻璃纖維的含量相對於該石膏為至少1重量百分比。
  13. 如請求項第12項所述之石膏板，其中該石膏板的任一面並沒有附加支撐薄層。
  14. 如請求項第12或13項所述之石膏板，其中該些顆粒的最大尺寸係介於0.5-25公釐的範圍。
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