FIELD OF THE INVENTION
[0001] The invention relates to a reinforcing web to reinforce a cementitious wallboard
or to reinforce a wallboard joint compound, and a method of making the reinforcing
web, as well as, a reinforcing web in a wallboard or in a wallboard joint.
BACKGROUND
[0002] The terminology, wallboard, refers to one or more panels or panel sections having
major surface areas, which form gypsum wallboard or, alternatively, portland cement
wallboard or alternatively, in situ polymeric foam panels of
US 2007/0099524 A1.
U.S. 5,017,312 discloses chopped glass fiber mats tested for flexure and tensile properties according
to ASTM D 790-84a "Standard Test Methods for Flexural Properties of Unreinforced and
Reinforced Plastics and Electrical Insulating Materials," and ASTM D 638-84 "Standard
Test Method for Tensile Properties of Plastics." The tests are performed on mats having
random oriented chopped fibers and mats having directionally oriented chopped fibers.
[0003] US 7,141,284 B2 discloses a reinforcing web having a rewettable coating to solubilize in a slurry
of a joint compound and form an adhesive bond with the joint compound.
[0004] Open wallboard seams are formed between abutting sections of gypsum wallboard that
meet side-by-side, or that meet at inside corners. To fill and cover an open wallboard
seam, a wallboard joint is constructed, by applying a joint compound reinforced with
an imbedded reinforcing tape. Additional seams can appear as cracks in the wallboard,
which are repaired by constructing wallboard joints.
[0005] The joint compound is in the form of a shapeable slurry that fills the seam. The
reinforcing tape is applied to extend across the filled seam, and to overlap the edge
margins of the wallboard abutting the filled seam. It is desirable that the reinforcing
tape is foldable to form a lengthwise crease. The crease is needed for conformance
at an inside corner of a wall meeting another wall or a wall meeting a ceiling, wherein
wallboard sections of the walls and ceiling meet one another at an angle less than
180 degrees. A wallboard joint is constructed at the inside corner by applying joint
compound to imbed the creased reinforcing tape.
[0006] A joint tape made of paper is capable of forming a crease for installation at inside
corners wherein wallboard sections meet one another at an angle of less than 180 degrees.
Moreover, commercial tooling has been developed to use paper tape for machine construction
of a wallboard joint. The tooling continuously dispenses the paper tape and continuously
dispenses a joint compound slurry to imbed the tape. Further, the tooling shapes and
smoothes the joint compound slurry. A drawback of paper tape is that the paper is
weakened by becoming saturated with water from the slurry, and is incapable of passing
air bubbles that are trapped behind the paper tape during construction of a wallboard
joint.
[0007] Instead of a paper tape, a fabric tape has been used to reinforce a joint compound.
A thin porous fabric has been manufactured with random laid glass fibers adhered to
one another with a urea-formaldehyde binder. The tips of the glass fibers tend to
poke out, which is irritating to the touch when handled by a worker. Moreover, a binder
coated fabric resists being folded, and is not able to form a crease for conformance
to an inside corner. Further, the binder covered fabric is not adaptable as is paper
for handling by machine tooling for fabricating a wallboard joint. Such drawbacks
deter using a binder coated fabric for reinforcing a joint compound.
[0008] US 5 865 003 A is concerned with glass fiber mats, particularly shingles formed from such glass
fiber mats.
GB 2 247 031 A relates to a method of reinforcing a tissue, for example of glass fibre, and a tissue
reinforced by the method.
GB 1 214 154 A relates to the manufacture of impregnated fibre material of the kind in which a layer
of reinforcing fibres is impregnated with a flowable bonding material.
US 2003/186037 A1 is directed to saturating a mat with a binder and passing and compressing the mat
between a pair of squeeze rolls to remove binder from the mat.
SUMMARY OF THE INVENTION
[0009] A reinforcing web as defined in claim 7 for imbedding at least partially in a cementitious
material that hardens from a slurry form includes multiple fibers joined together
by a binder. At least some of the fibers have foldable portions, wherein the foldable
portions have less binder composition thereon to increase flexure while folded without
forming a crease or while folded to form a crease, and the foldable portions extend
over a lengthwise central section of the web.
[0010] According to embodiments of the invention, the reinforcing web reinforces either
a cementitious board or a wallboard joint compound.
[0011] According to an embodiment of the invention, a planar section of the web reinforces
a major surface of a wallboard, and foldable portions of the web are of increased
flexure to be foldable over lateral edges of a wallboard to reinforce the lateral
edges.
[0012] According to another embodiment of the invention, a lengthwise central section of
the web is foldable to form a crease for conformance to an inside corner formed by
a wallboard joint compound.
[0013] A method of making a reinforcing web is defined in claim 1 and comprises, applying
a binder onto multiple fibers, wherein the fibers are oriented lengthwise in multiple
directions, including random directions, predetermined directions, or a combination
thereof to form a non-woven web, removing at least some of the binder from foldable
portions of at least some of the fibers to increase flexure of the foldable portions
at a fold of the foldable portions, and joining the fibers to one another by curing
the binder thereon to resist tensile forces exerted in said multiple directions.
[0014] According to an embodiment of the method includes, removing substantially all of
the binder from foldable portions of at least some of the fibers to increase flexure
of the foldable portions at a fold of the foldable portions and to form a crease in
the fold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Embodiments of the invention will now be described by way of example with reference
to the accompanying drawings.
Fig. 1 is a schematic view of a first embodiment of a reinforcement tape.
Fig. 2 is a schematic view of a roll of tape according to one of the embodiments of
a reinforcement tape.
Fig. 3A is schematic view of a portion of a manufacturing system and apparatus.
Fig. 3B is a schematic view of another portion of a manufacturing system and apparatus.
Fig. 4 is a schematic view of a vacuum table of a manufacturing system and apparatus.
Fig. 4A is a view similar to Fig. 4 of another embodiment of a vacuum table.
Fig. 5 is a schematic view of a slitting apparatus of a manufacturing system and apparatus.
Fig. 6 is a schematic view of a second embodiment of a reinforcement tape.
Fig. 7 is a schematic view of another embodiment of a reinforcement web.
Fig. 8 is a schematic view of the reinforcing web of Fig. 7 providing a facing on
a cementitious material to form a board.
Fig. 9 discloses a boxplot of test data in a test for Gurely Stiffness by Sample.
Fig. 10 discloses a boxplot of test data in a test for Flexural Strength (PSI) by
Sample.
DETAILED DESCRIPTION
[0016] The invention relates to a fiber reinforcement web to at least partially imbed in
a cementitious material, and methods for making the same. The reinforcement web is
at least partially embedded in the cementitious material that is hardened from a slurry
form to form a wallboard. The fiber reinforcement web permeability enables penetration
by the cementitious material in slurry form to at least partially imbed the web in
the cementitious material to reinforce the cementitious material. The imbedded web
reinforces the hardened cementitious material, adding to its flexural strength and
its tensile strength, i.e. resistance to deflection and resistance to cracldng and
fracture due to strain induced by external tensile forces and/or due to internal strain.
[0017] The relative permeability of the web, due to the sizes of pores or spaces between
the fibers, and the relative viscosity of the slurry determine to what extent the
web becomes imbedded in the slurry. A web of lower permeability, smaller pores or
spaces between the fibers, promotes penetration of a lower viscosity slurry and tends
to imbed at the surface of a lower viscosity slurry, particularly for a slurry mixture
of the lower viscosity slurry and a higher viscosity slurry. A web of higher permeability,
larger pores or spaces between the fibers, can promote penetration of a lower viscosity
slurry, and can embed deeper, below the surface of the slurry. Further, a web of higher
permeability is required to promote penetration of a higher viscosity slurry.
[0018] A slurry wetting agent applied to coat the fibers further promotes wetting of the
fibers by the slurry together with penetration of the web by the slurry. A solvent
activated adhesive coating on the fibers further promotes adherence of the fibers
to a hardened cementitious material. For example, water is a solvent of a gypsum cementitious
slurry or of an alkali cementitious slurry, which activates a water activated adhesive
coating on the fibers to and adhesive state for adherence to a hardened wallboard
or hardened joint compound.
[0019] Further, the invention relates to a reinforcement web to reinforce a cementitious
material, wherein the web is constructed with a varied flexibility for foldability
and creasability and for achieving a result including but not limited to, bending
the web and/or folding the web and/or creasing the web to conform the web to the shape
or shapes of the cementitious material being reinforced by the web.
[0020] The fiber reinforcement web is constructed for flexibility or flexure, foldability
and creasability at one or more selected locations on the web. The flexibility or
flexure, foldability and creasability varies across the width of the web or alternatively
in another direction.
[0021] The fiber reinforcement web is constructed with chopped reinforcement fibers bonded
together by a binder composition dispersed among the fibers and cured, i.e., solidified,
to bond the fibers together. The binder composition is dispersed with a lower binder
mass distribution and a higher binder mass distribution in respective continuous lines
or continuous areas that extend lengthwise of the web or alternatively in another
direction.
[0022] The lines or areas extend continuously throughout a dimensional measurement of the
web area to include the web thickness, such that a section of the web within the lines
or areas including the web thickness is constructed with relatively less binder composition
to adjust or induce flexibility, foldability and creasability. Alternatively, the
section of the web is constructed with substantially less binder composition to adjust
or induce foldability and/or creasability. In the section of the web, the binder composition
is dispersed with a relatively lower binder mass distribution than elsewhere in the
web.
[0023] The fiber reinforcement web is made with a selected thickness. According to an embodiment
of the invention, a fiber reinforcement web having a maximum thickness of a paper
drywall tape is adapted for use in fabricating a drywall joint. The dry wall tape
is creased lengthwise for conformance to an inside corner. According to another embodiment
of the invention, a fiber reinforcement web having a thickness of a wallboard facing
sheet is adapted for use in fabricating a cementitious wallboard. The fiber materials,
lengths and thickness, the web permeability and thickness, and the binder composition
viscosity are selective to promote penetration of the intended slurry composition
and adherence of the fibers to the cementitious composition. The fiber materials,
lengths and thickness, and the web thickness are selected to promote flexure strength
and tensile strength of the fiber reinforced cementitious.
[0024] Fig. 1 discloses a thin non-woven reinforcement web 104 of multiple fibers 102 in
which the fibers 102 are laid non-woven to provide a reinforcement tape 100. For purposes
of illustration a small section of the web 104 is disclosed to indicate the fibers
102. The fibers 102 comprise a high tensile strength material, including but not limited
to glass or a polymer, for example, a polyester. Further, the fibers 102 are water
resistant when manufactured of glass, a crystalline polymer or a thermoset polymer.
The fibers 102 are alkali resistant when manufactured of either AR glass or polymer
coated glass.
[0025] According to an embodiment of the invention, the fibers 102 are chopped or severed
to lengths of about 19.05 mm (0.75 inch) to about 38.100 mm (1.5 inch.). The fiber
diameters comprise one of about, 11 µm., 13.5 µm or 16 µm. The distribution of the
fibers 102 in the web 104 provides a web thickness preferably equal to that of a commercially
available, cellulosic paper joint tape, about 0.18 mm, plus or minus allowable dimensional
tolerances. The web 104 has a width of about 50 mm (2 inches) desirably about equal
to or less than that of a commercially available, paper joint tape. Thereby, the web
104 has dimensions capable of substituting for a paper tape that is used in commercial
tooling to fabricate a wallboard joint.
[0026] Further, the distribution of spaces between adjacent fibers 102 provides the web
104 with openings for passage of a commercially available joint compound in slurry
form during a process of imbedding the web 104 in the slurry to make a wallboard joint.
[0027] Further, the web 104 in the form of a joint tape 100 is of continuous length, and
has lengthwise lateral sections 106, 108 adjoining a lengthwise central section 110
that encompasses a lengthwise central axis 112 of the web 104. The fibers 102 in the
lengthwise lateral sections 106, 108 are joined together by a binder composition 114
thereon. The binder composition 114 joins the fibers 102 with one another. The fibers
102 in the web 104 are laid flatly and extend in multiple directions, including random
directions, predetermined directions, or a combination thereof to resist tensile forces
exerted in such multiple directions. Thereby, the fibers 102 resist tensile forces
exerted in said directions when the fibers 102 are imbedded in a joint compound. The
joint compound will be reinforced by the imbedded fibers 102 of the web 104 to resist
cracking under stress when forces are exerted on a wallboard joint formed by the reinforced
joint compound. Spaces among the fibers 102 provide passages through the web 104 for
passage of joint compound slurry. As an advantage compared to paper joint tape, the
passages permit escape of air from being trapped behind the web 104. The fibers 102
provide a web 104 that comprises a non-woven mat or fleece in which the fiber lengths
lie flatly in the thickness plane of the web 104, and extend lengthwise in multiple
directions, including random directions, predetermined directions, or a combination
thereof.
[0028] The lengthwise central section 110 of the web 104 is about 1 mm. to about 3 mm. wide.
The lengths of respective fibers 102 are less than the overall width of the web 104.
The lengths of respective fibers 102 are greater than the width of the central section
110 of the web 104. The web 104 of the present invention must be capable of lengthwise
folding to form a crease. The crease is needed for conformance at an inside corner
where two sections of wallboard meet at an angle less than 180 degrees.
[0029] In an embodiment of the invention, the lengthwise central section 110 is foldable
to form a lengthwise crease, extending preferably along the axis 112. The fibers 102
that have the binder composition 114 thereon tend to resist being creased. Thus, some
of the fibers 102 have foldable portions 116 that extend over the central section
110, and are free of the binder composition 114 so as to crease upon being folded.
In an alternative embodiment of the invention, the foldable portions 116 of at least
some of the fibers 102 in the lengthwise central section 110 have less binder composition
114 thereon than do the fibers 102 in the lengthwise lateral sections 106,108, so
as to crease upon being folded.
[0030] The lengths of the fibers 102 are less than the overall width of the web 104. The
lengths of the fibers 102 are greater than the width of the central section 110, such
that the fiber lengths extend in the central section 110, further project outwardly
from the central section 110, and into at least one lateral section 106, 108, wherein
they are joined with other fibers 102 by having the binder composition 114 thereon.
[0031] Construction of a wallboard joint is performed either by manipulating hand tools,
or by using commercial machine tooling. A paper type joint tape can be manually handled
by a human worker who applies the tape by hand, and uses hand tools to imbed the tape
in a slurry of joint compound, and to spread and smooth the joint compound to make
a wallboard joint.
[0032] Alternatively, commercial machine tooling continuously applies a joint compound slurry
and a paper type joint tape while continuously imbedding the paper type joint tape
in the slurry, and spreading and smoothing the joint compound to make a wallboard
joint.
[0033] An embodiment of the tape 100 according to the invention is intended as a replacement
for paper type joint tape for use in commercial machine tooling or for manual handling,
to make a wallboard joint. Accordingly, an embodiment of the web 104 has about the
same dimensions as the paper type joint tape, or less. Further, the web 104 has a
suppleness about that of paper tape for ease in handling and constructing a wallboard
joint by hand tools or commercial machine tooling. Further, the web 104 of the present
invention is rolled up on itself, Fig. 2, while in the form of a reinforcing tape
100, and undergoes unrolling from a roll 200 of the tape 100, for application onto
a wallboard joint and imbedding in a joint compound slurry.
[0034] The web 104 must be capable of forming a crease for installation and conformance
at an inside corner. Further, the web 104 of the present invention must have smooth
fiber surfaces to avoid irritation to a human skin while being handled by a worker.
[0035] A process of making the reinforcement web 104 or tape 100 will now be described.
The fibers 102 are chopped or severed to lengths of about 0.75 inch (19.05 mm.) to
about 1.5 inch (38.100 mm.). The fibers 102 are commercially purchased as chopped
fibers 102.
[0036] Figs. 3A and 3B disclose a system and apparatus 300 to manufacture the web 104 and/or
reinforcing tape 100. In Fig. 3A, the short length fibers 102 are commercially purchased
and are amassed into a slurry 302 by mixing with a slurry solution comprised of water
enhanced with a surfactant and a viscosity increaser. The slurry 302 comprises 0.1212
% solids of a soluble surfactant and 0.0072% solids of a soluble viscosity enhancer
and water to total 386,112 liters (102,000 gallons) of slurry solution mixed with
fibers 102. The slurry 302 comprises an agglomerate of the fibers 102 and slurry solution,
and is capable of settling or slumping to form a thin and uniform layer. The slurry
302 emerges from a head box dispenser 304 that uniformly distributes the slurry 302
in a uniform layer on a forming wire 306. The forming wire 306 comprises a perforated,
non-woven flat fabric of a non-stick material, such as, polytetrafluoroethylene (PTFE).
The non-woven fibers 102 of the slurry 302 are wet laid flatly on the forming wire
306, and extend lengthwise in multiple directions, including random directions, predetermined
directions, or a combination thereof to form the non-woven web 104. The fibers 102
in the web 104 are held together by the slurry solution, and by support against the
forming wire 306, while the web 104 and forming wire 306 are conveyed by industry
standard conveyers 308 to pass over a first vacuum box 310. The first vacuum box 310
removes excess solution by suction, impelling the water in the web 104 and ambient
air downwardly, as indicated by the arrows, through the perforated forming wire 306.
The removed solution is collected in a collection tank 312 for recycled use in the
system 300. The fibers 102 are drawn against the forming wire 306 by the suction to
form a web thickness about equal to that of a paper joint tape.
[0037] In Fig. 3B, the conveyed web 104 is then transferred from the forming wire 306 onto
a saturator wire 314, of similar construction as the forming wire 306. The web 104
on the saturator wire 314 is conveyed by industry standard conveyors 316 and passes
under a curtain coater 318 of the system and apparatus 300, which applies a falling,
flowing curtain of fluent binder composition 114 onto the web 104. The binder composition
114 distributes among the fibers 102. The fluid binder coats the web 104 and adheres
to the tips of the fibers 102, as well, to smooth the surfaces of the fibers 102 for
non-irritating contact with a person's skin. The web 104 is conveyed continuously
lengthwise while being coated with a solution of the binder composition 114.
[0038] In Fig. 3B, the web 104 while on the saturator wire 314 passes over a second vacuum
box 320, directly aligned vertically under the curtain coater 318. The second vacuum
box 320 draws a vacuum (reduced air pressure) to remove excess fluent binder composition
114 by suction from the fibers 102. The removed binder composition 114 is collected
in a collection tank 322 for recycled use in the system 300. Essential amounts of
the binder composition 322 remain on the fibers 102 for subsequent joining of the
fibers 102 together in the binder coated portions of the web 104.
[0039] Further, in Fig. 3B, the saturator wire 314 and the conveyed, binder coated web 104
pass over a top surface 324 of a vacuum table 326. A motor driven vacuum pump 328
draws air from an interior 330 of the vacuum table 326, which draws a vacuum (reduced
air pressure) in the interior 330 of the vacuum table 326, while one or more water
jet nozzles 332 focus a stream of water 334 from above.
[0040] In Fig. 4, the surface 324 of the vacuum table 326 has a lengthwise, narrow slot
400 over which the lengthwise central section 110 of the web 104 is conveyed. In preferred
embodiment of the invention, the nozzles 332, in Fig. 3, focus the stream of water
334 in a narrow pattern aligned with the lengthwise slot 400 to impinge the lengthwise
central section 110 of the web 104. Water is a solvent for the uncured binder composition
114. A solvent 334 other than water can be dispensed to impinge a binder composition
114 that is soluble in the solvent 334 other than water. Water dispenses from each
water jet nozzle 322 and passes through the foldable portions 116 of the fibers 102
that extend into the narrow central section 110 of the web 104. The water is vacuum
drawn by the reduced air pressure of the vacuum table 326, through the central section
110 of the web 104 and into the slot 400 of the vacuum table 326. Fig. 4A discloses
the narrow slot 400 transverse or crosswise to the lengthwise central section 110.
The stream of water 334 is focused in a narrow pattern by an appropriate number of
the nozzles 332 of Fig. 4, to impinge the lengthwise central section 110 of the web
104. The web 104 is conveyed lengthwise at a speed sufficient to avoid spreading of
the stream of water 334 beyond the narrow central section of the web 104 before the
water is vacuum drawn into the slot 400 of the vacuum table 36. In Figs. 4 and 4A,
the water flows through the central section 110 of the web 104, which dilutes the
water soluble binder composition 114 and removes at least some of the binder composition
114 from at least some of the foldable portions 116 of the fibers 102 to increase
flexure and reduce stiffness thereof by reducing the amount of binder composition
114, and alternatively, removing substantially all of the binder composition 114 from
such foldable portions 116 to permit folding and creasing of the foldable portions
116. Alternatively, the binder composition 114 is completely removed from the foldable
portions 116 of the fibers 102 that are in the central section 110 of the web 104.
The removed binder composition 114 is collected in a collection tarde 336 for recycled
use in the system 300. The binder removing operation is narrowly focused on, and confined
to, the longitudinal central section 110 of the web 104 by the combined, focused water
jet and the width of the narrow slot 400 through the surface 324 of the vacuum table
326. The non-removed binder composition 114 remains adhered to respective fibers 102.
[0041] In Fig. 3B, thereafter the web 104 is conveyed through a curing oven 338 at elevated
temperature, such that the binder composition 114 on the fibers 102 is heated to a
curing temperature, which drives off the solvent and solidifies the binder composition
114 to a thermoset state. The binder 114 is cured and set to a thermoset state, wherein
the binder 114 is solidified and becomes insoluble in water and other solvents, and
joins the fibers 102 together in the web 104. The web 104 is rolled up to form the
roll 200 of reinforcement tape 100.
[0042] The binder composition 114 is cooled to ambient temperature after the web 104 leaves
the curing oven 338. The binder composition renders the fibers 102 more supple to
the touch. However, the binder coated fibers 102 resist flexure when folded and resist
forming a crease when folded. Moreover, the binder composition is applied to the fibers
102 accumulated on a shaped conveyor belt surface, straight or curved, to form a web
104 having a shape formed by and conforming to the shape of the conveyor belt surface.
When hardened, the binder composition render the binder coated fibers 102 sufficiently
stiff to retain the web 104 with a shape as formed. For example, the binder coated
fibers 102 form a flat web 104 to provide a flat major surface of a gypsum board or
cement board. According to embodiments of the invention, the foldable portions 116
of at least some of the fibers 102 have less binder composition thereon to increase
its flexure while folded, and preferably have substantially or essentially all of
the binder composition removed, so as to form a crease while folded and creased. The
foldable portions 116 are in the section 110 of the web 104 that is foldable.
[0043] The web 104 avoids having a rough texture that is irritating to human skin, particularly
where tips of the fibers 102 are exposed, and particularly where the fibers 102 are
exposed at the surface of the web 104 and are prickly to the touch. Accordingly, a
nonirritating binder composition 114 coats the fibers 102. An embodiment of a non-irritating
binder composition 114 comprises 3-10 grams of a matting agent, for example, a polymethyl
urea resin with about 0.6% reactive methyl groups and primary particles of about 0.1
to 0.15 µm. forming agglomerates of about 3.5 to 6.5 µm. diameter, and a 20% solids
solution of GP Resi-Mat, a urea formaldehyde copolymer forming resin soluble in water,
as a binder for wet laid glass fiber mat, a commercial product of Georgia-Pacific
Building Products, Atlanta, Georgia. The preferred solid is marketed as PERGOPAK m5
a trademark of Albemarle Corporation, which refers to a polymethyl urea resin having
a water content of 15 weight % H
2O corresponding to the m5 designation and forming a thermosetting urea-formaldehyde
copolymer, condensation product or reaction product.
[0044] Alternatively, a non-formaldehyde fluid binder composition 114 comprises Acrodur
950L, a water soluble thermosetting acrylic polymer binder cut to a range of 15% -
25% solids from 50%-55% solids, for example, 200g of water as a solvent for 200g of
Acrodur.
[0045] According to an embodiment of the invention, the web 104 for use as a joint tape
100 is preferably about equal to the width of a paper joint tape. Fig. 5 discloses
another embodiment of the invention, wherein the web 104 is conveyed through a slitter
apparatus 500. The web 104 is conveyed by a tow chain or by industry standard conveyors
504. A slitting blade 502 is disclosed, which may be circular or flat. The slitting
blade 502 slits the web 104 lengthwise to a desired width corresponding to the width
of a wallboard joint tape, preferably about equal to the width of a paper joint tape
or less than the width of a paper joint tape, to substitute for paper joint tape in
applicator tooling. Slitting with a sharp blade would leave sharp edges on the severed
fibers 102, which would provide a source of skin irritation. Accordingly, the slitter
apparatus 500 has a blunt edge slitting blade 502 to slit through the web 104, while
the blunt edge makes crushed edges on the fiber ends along the sections 106, 108,
Fig. 1, of the web 104. The crushed edges are less irritating to skinj than are sharp
edges. Depending upon the overall width of the conveyed web 104, the slitter apparatus
has a sufficient number of blades 502 to slit the web 104 lengthwise to form one or
more joint tapes 100, side by side. Further, the vacuum table 326 is provided with
one or more lengthwise slots 400 corresponding to the number of central sections 110
of respective joint tapes 100 to be manufactured, side by side. Further, the vacuum
table 326 is provided with one or more lengthwise slots 400 corresponding to the number
of foldable portions 116 are intended for the same single reinforcement web 104 of
the type disclosed by Fig. 7 below.
The slitter apparatus 500 slits the web 104 to form the lengthwise lateral sections
106, 108 adjoining each lengthwise central section 110. Preferably the central section
110 is equidistant from lateral edges of the web 104. The tape 100 is rolled up on
itself to provide a roll 200 of tape. Thereafter, the tape 100 is dispensed by unrolling
from the roll 200, either by hand operation or by tooling operation.
[0046] Fig. 6 discloses another embodiment of the invention, wherein the tape 100 is provided
with a fold line 600 that provides a guide for folding the tape 100 with ease. The
tape 100 is folded along the central longitudinal axis 112 to provide a crease 600
along the tape axis. The tape 100 is then unfolded for the crease 600 to lie essentially
flat and provide a fold line. Further, the unfolded tape 100 is rolled up on itself
to provide a roll 200 of tape, as in Fig. 2, having a fold line 600 as a guide for
folding and creasing the tape 100 in the future. Thereafter, the tape 100 is dispensed
by unrolling from the roll, either by hand operation or by tooling operation. The
fold line 600 provides a guide for folding the tape 100 with ease along the fold line
600 to conform the tape 100 to an inside corner in preparation for imbedding in a
wall board joint. The tape 100 can be folded, for example, ninety degrees, and return
to its original flat shape without losing tensile strength. By removing the binder
in the anticipated foldable portions 116, the fibers are free of the binder and are
free to flex without fracturing in response to being folded. This feature differs
from tapes in which their fibers are held by a binder, which resists flexure of the
fibers, and which causes the fibers to become weakened or fractured when the fibers
are flexed. The fibers in the foldable portions 116 of the lengthwise central section
110 extend into the binder coated lateral sections 106,108 for the binder to bond
the fibers to other fibers in the tape 100, and to resist pull-out of the fibers from
a hardened joint compound. Further, a hardened joint compound adheres to the fibers
that bridge across the foldable portions 116 to the binder coated lateral sections
106,108 to reinforce the joint compound and provide resistance to cracking.
[0047] Fig. 7 discloses an alternative embodiment of a reinforcement web 104 to imbed at
least partially in a surface of a cementitious material, for example, a cementitious
board formed by hardening a slurry of a gypsum mixture or portland cement mixture
or in situ foamed polymeric material. The reinforcement web 104 provides a facing
or facing layer of the cementitious material. According to an alternative embodiment
of the invention, the fibers of the reinforcement web are fabricated of polymeric
material, AR glass fibers or an alkali resistant polymer coating applied to chopped
glass fibers intended to imbed at least partially in alkaline cementitious material,
for example, portland cement. The reinforcement web 104 has a flat central section
110 of binder coated fibers 102 to form a flat surface of a wallboard. Adjacent to
and contiguous with the central section 110, the reinforcement web 104 has lengthwise
foldable portions 116, wherein at least some of the binder composition 114 is removed
from at least some of the foldable portions 116 of the fibers 102 to increase flexure
and reduce stiffness thereof by reducing the amount of binder composition 114. Alternatively,
removing substantially or essentially all of the binder composition 114 from such
foldable portions 116 permits folding and creasing of the foldable portions 116. The
foldable sections are adjacent to lateral web sections 700 adjacent to respective
lateral edges 702 of the web 104. The web sections 700 are coated with the binder
composition 114, or alternatively, the binder composition 114 is removed partially
or fully removed to adjust the flexure and/or foldability of the web sections 700.
[0048] Fig. 8 discloses a cementitious composite material 802 forming a facing layer of
a cementitious board 800 reinforced by the reinforcement web 104 of Fig. 7. The entire
web 104 is at least partially imbedded in the cementitious material 802 that is hardened
from a slurry form. The foldable portions 116 are of reduced flexure to fold in conformity
with the lateral edges 804 of the board 800. The flexure is increased by removal of
a corresponding amount of at least some of the binder composition 114 from the foldable
portions 116. When sharply defined corner edges of the board 800 are desired, the
foldable portions 116 are capable of mapping around the edges and creasing along each
of the foldable portions 116 by removal of substantially or essentially all of the
binder from the foldable portions 116. The foldable portions 116 are folded by flexure
thereof to wrap by flexure around corresponding edges 804 of the board 800 to reinforce
the edges 804 against damage due to impact or thermal expansion and contraction. Further,
the foldable portions 116 are foldable with creases to form substantially or essentially
sharp edges 804 on the board 800. Alternatively, the foldable portions 116 are foldable
without creases for the edges 804 on the board 800 to have rounded configurations.
A flat central section 110 of the web 104 covers a flat major surface of the board
800. The opposite major surface of the board 800 is covered by another reinforcement
web 104a that is at least partially embedded in the cementitious material 802. The
web sections 700 of the web 104 overlap and cover corresponding edge sections 700a
of the other reinforcement web 104a, and the overlapped sections 700 and 700a are
at least partially imbedded in the cementitious material 802.
[0049] To support the claims of increased foldability/flexibility, three different tests
were conducted; Gurley Stiffness, Strength after bending, and ASTM D790-84a Standard
Test Methods for Flexural Properties of Un-reinforced and Reinforced Plastics and
Electrical Insulating Materials.
[0050] In three tests; Gurley Stiffness, Strength after bending, and ASTM D790-84a (Flexural
Strength) the glass fiber mat with the "folding Point" or seam or reduced binder area
showed results consistent with the mat being more flexible/foldable than a standard
glass mat of equal weight and thickness.
[0051] For the Gurley stiffness test a standard glass mat was tested against a glass mat
with a "folding point" or seam or area with reduced binder. A typical Gurley Stiffness
testing apparatus was used. The glass mat with seam shows a Gurley Stiffness of 106.47
which is lower than the glass mat without seam 257.43. Using Statistical Analysis
a one-way ANOVA shows a statistically significant difference or P value of less than
0.05. With the glass mat with seam being less stiff/more flexible than the glass mat
without the seam.
Table 1 Gurley Stiffness Test
Sample # |
0.9 lb Glass Mat With Seam |
0.9 lb Glass Mat without Seam |
1 |
105.64 |
222.40 |
2 |
113.98 |
227.96 |
3 |
100.08 |
233.52 |
4 |
100.08 |
278.00 |
5 |
105.64 |
333.60 |
6 |
100.08 |
250.20 |
7 |
88.96 |
305.80 |
8 |
166.80 |
183.48 |
9 |
100.08 |
289.12 |
10 |
83.40 |
250.20 |
Average |
106.47 |
257.43 |
[0052] For the Strength After Bending Test a standard glass mat was tested against a glass
mat with a "folding point" or seam or area with reduced binder. Samples were tested
before and after bending 180°. The samples with the binder reduced area showed a 34.53%
loss of strength which was lower by almost half of the standard glass mat at 64.38%.
Table 2 Strength After Bending Test
|
Tensile Strength (lbf) |
Sample |
With Seam |
Without Seam |
0 Deg |
20.23 |
28.18 |
0 Deg |
21.65 |
29.09 |
0 Deg |
19.00 |
20.31 |
0 Deg |
20.06 |
21.50 |
0 Deg |
14.14 |
22.84 |
0 Deg |
15.86 |
22.67 |
0 Deg |
19.60 |
26.35 |
0 Deg |
16.10 |
21.21 |
Average |
18.33 |
24.02 |
180 Deg |
7.98 |
6.28 |
180 Deg |
15.16 |
7.81 |
180 Deg |
12.79 |
9.58 |
180 Deg |
11.83 |
9.71 |
180 Deg |
12.04 |
9.80 |
180 Deg |
14.42 |
9.75 |
180 Deg |
9.24 |
8.17 |
180 Deg |
9.22 |
8.63 |
180 Deg |
10.50 |
8.56 |
180 Deg |
12.58 |
7.27 |
Average |
11.58 |
8.56 |
% loss of Strength |
36.85 |
64.38 |
[0053] The following discussion refers to the ASTM D 790-84a "Standard Test Methods for
Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating
Materials." For this test a standard glass mat was tested against a glass mat with
a "folding point" or seam or area with reduced binder. The test method used was ASTM
D790-84a. And
US Patent 5,017,312 states ASTM D790-84a is used as a method used to quantify the flexural properties
of a glass reinforced composite material. Procedure A was used with a support span
of 30mm. The rate of crosshead motion was 6.8mm/minute. The glass mat with seam showed
a Flexural Strength of 0.428 MPa lower than the standard glass mat at 0.789 MPa. Using
Statistical Analysis a one-way ANOVA shows a statistically significant difference
or P value of less than 0.05. The standard glass mat shows a higher Flexural Strength.
Table 3 ASTM D790-84a Test Method
Sample |
Width |
Thickness |
Peak load |
Flexural Strength |
Flexural Strength |
I. D. |
mm |
mm |
N |
MPa |
PSI |
GlassMatSeam |
12.7 |
0.194 |
0.017 |
0.310 |
45 |
GlassMatSeam |
12.7 |
0.232 |
0.025 |
0.382 |
55 |
GlassMatSeam |
12.7 |
0.224 |
0.033 |
0.522 |
76 |
GlassMatSeam |
12.7 |
0.234 |
0.025 |
0.379 |
55 |
GlassMatSeam |
12.7 |
0.210 |
0.033 |
0.557 |
81 |
GlassMatSeam |
12.7 |
0.236 |
0.028 |
0.420 |
61 |
Average |
|
|
0.027 |
0.428 |
62 |
|
|
|
|
|
|
GlassMatControl |
12.7 |
0.290 |
0.063 |
0.770 |
112 |
GlassMatControl |
12.7 |
0.270 |
0.044 |
0.577 |
84 |
GlassMatControl |
12.7 |
0.275 |
0.056 |
0.722 |
105 |
GlassMatControl |
12.7 |
0.250 |
0.048 |
0.680 |
99 |
GlassMatControl |
12.7 |
0.280 |
0.065 |
0.823 |
119 |
GlassMatControl |
12.7 |
0.295 |
0.097 |
1.165 |
169 |
Average |
|
|
0.062 |
0.789 |
114 |
[0054] This description of the exemplary embodiments is intended to be read in connection
with the accompanying drawings, which are to be considered part of the entire written
description. In the description, relative terms such as "lower," "upper," "horizontal,"
"vertical,", "above," "below," "up," "down," "top" and "bottom" as well as derivative
thereof (e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed
to refer to the orientation as then described or as shown in the drawing under discussion.
These relative terms are for convenience of description and do not require that the
apparatus be constructed or operated in a particular orientation. Terms concerning
attachments, coupling and the like, such as "connected" and "interconnected," refer
to a relationship wherein structures are secured or attached to one another either
directly or indirectly through intervening structures, as well as both movable or
rigid attachments or relationships, unless expressly described otherwise.
1. A method of making a non-woven reinforcement web (104) for reinforcing a cementitious
wallboard or a cementitious wallboard joint compound, comprising:
assembling fibres (102) to form a precursor of the non-woven reinforcement web (104);
dispersing a binder composition (114) among the fibres (102) either before or after
the fibres (102) form the precursor;
varying the amount of the binder composition (114) in respective sections (106, 108,
110) of the precursor, wherein different sections (106, 108, 110) of the precursor
have different amounts of the dispersed binder composition (114); and
curing the binder composition (114) to form the non-woven reinforcement web (104)
having the fibres (102) joined together by a cured binder composition (114), wherein
different sections (106, 108, 110) of the non-woven reinforcement web (104) have different
amounts of the cured binder composition (114) to adjust flexibility of the different
sections (106, 108, 110) of the non-woven reinforcement web (104), wherein at least
some of the fibres (102) have foldable portions (116) extending in a lengthwise central
section (110), wherein the foldable portions (116) have less binder composition (114)
than fibres (102) in lengthwise lateral sections (106, 108) so as to crease upon being
folded, wherein the lengthwise central section (110) of the non-woven reinforcement
web (104) comprises a width of between about 1 mm and about 3 mm, and wherein the
lengths of the fibres (102) are greater than the width of the lengthwise central section
(110) and less than the width of the non-woven reinforcement web (104).
2. The method of claim 1, further comprising:
dispersing the binder composition (114) among the fibres (102) either before or after
assembling the fibres (102) to form the precursor; and
varying the amount of the binder composition (114) in the respective sections (106,
108, 110) of the precursor by removing portions of the binder composition (114) from
the respective sections (106, 108, 110) of the precursor, or by dispersing adjusted
amounts of the binder composition (114) among the fibres (102) forming the respective
sections (106, 108, 110) of the precursor.
3. The method of claim 1, further comprising:
varying the amount of the binder composition (114) in respective sections (106, 108,
110) of the precursor by distributing a decreased binder composition mass per fibre
unit volume among the fibres (102) forming at least a section of the precursor, to
form the non-woven reinforcement web (104) with a section capable of bending with
a radius of curvature inversely proportional to binder composition mass per fibre
unit volume.
4. The method of claim 1, further comprising
varying the amount of the binder composition (114) in respective sections (106, 108,
110) of the precursor to provide at least a section of the precursor substantially
without the binder composition (114) and to form the non-woven reinforcement web (104)
with a foldable and creasable section of the non-woven reinforcement web (104) substantially
without the binder composition (114).
5. The method of claim 1, further comprising:
varying the amount of the binder composition (114) in respective sections (106, 108,
110) of the precursor, by removing substantially all of the binder composition (114)
from a section of the precursor corresponding to the lengthwise central section (110)
of the non-woven reinforcement web (104), or by dispersing the binder composition
(114) among the fibres (102), excluding the foldable portions (116) of the fibres
(102) in the section of the precursor corresponding to the lengthwise central section
(110), of the non-woven reinforcement web (104),
wherein the non-woven reinforcement web (104) has a thickness of about 0.18 mm, and
a width of about 50 mm to substitute for a paper tape to fabricate a wallboard joint,
and the lengthwise central section (110) of the non-woven reinforcement web (104)
is foldable to conform to a wallboard joint at an inside corner.
6. The method of claim 1, further comprising;
varying the amount of the binder composition (114) in respective sections (106, 108,
110) of the precursor, by removing substantially all of the binder composition (114)
from sections (106, 108, 110) of the precursor corresponding to lengthwise sections
(106, 108, 110) of the non-woven reinforcement web (104) that are foldable to cover
corresponding edges of a wallboard, or by dispersing the binder composition (114)
among the fibres (102), excluding the foldable portions (116) of the fibres (102),
in said sections of the precursor corresponding to lengthwise sections (106, 108,
110).
7. A non-woven reinforcement web (104) for reinforcing a cementitious wallboard or a
cementitious wallboard joint compound, comprising:
multiple fibres (102) joined together by a binder composition (114) and forming the
non-woven reinforcement web (104); and the binder composition (114) being dispersed
among the fibres (102), wherein the fibres (102) in different sections (106, 108,
110) of the non-woven reinforcement web (104) have different mass distributions of
the binder composition (114) to adjust the flexibility of the different sections (106,
108, 110) of the non-woven reinforcement web (104), wherein at least some of the fibres
(102) have foldable portions (116) extending in a lengthwise central section (110),
wherein the foldable portions (116) have less binder composition (114) than fibres
(102) in lengthwise lateral sections (106, 108) so as to crease upon being folded,
wherein the lengthwise central section (110) of the non-woven reinforcement web (104)
comprises a width of between about 1 mm and about 3 mm, and wherein the lengths of
the fibres (102) are greater than the width of the lengthwise central section (110),
and less than the width of the non-woven reinforcement web (104).
8. The non-woven reinforcement web (104) of claim 7, wherein the lengthwise central section
(110) of the non-woven reinforcement web (104) is substantially without the binder
composition (114), wherein the non-woven reinforcement web (104) has a thickness of
about 0.18 mm, and a width of about 50 mm to substitute for a paper tape to fabricate
a wallboard joint, and the lengthwise central section (110) of the non-woven reinforcement
web (104) is foldable to conform to a wallboard joint at an inside corner.
9. The non-woven reinforcement web (104) of claim 7, wherein the binder composition (114)
is non-irritating to a person's skin.
10. A reinforcing tape (100) for imbedding in a joint compound, consisting of a thin non-woven
reinforcement web (104) according to claim 7.
11. The reinforcing tape (100) of claim 10, wherein the foldable portions (116) are substantially
free of the binder composition (114).
12. The reinforcing tape (100) of claim 10, wherein the lengthwise central section (110)
is foldable to form the crease for conformance to an inside corner.
13. The reinforcing tape (100) of claim 10, wherein the joined together fibres (102) extend
in multiple directions in the thin non-woven web (104) to resist tensile forces exerted
in the multiple directions.
14. The reinforcing tape (100) of claim 10, wherein the length of the fibres (102) are
greater than the width of the lengthwise central section (110) of the thin non-woven
web (104), and less than the width of the thin non-woven web (104).
1. Verfahren zum Herstellen eines Armierungsvlieses (104)zum Armieren einer zementösen
Wandbauplatte oder einer Fugenverbindung für zementöse Wandbauplatten, umfassend:
Anordnen von Fasern (102), um einen Vorläufer des Armierungsvlieses (104) zu bilden,
Verteilen einer Bindemittelzusammensetzung (114) unter den Fasern (102), entweder
bevor oder nachdem die Fasern (102) den Vorläufer bilden,
Variieren der Menge der Bindemittelzusammensetzung (114) in entsprechenden Abschnitten
(106, 108, 110) des Vorläufers, wobei unterschiedliche Abschnitte (106, 108, 110)
des Vorläufers unterschiedliche Mengen der verteilten Bindemittelzusammensetzung (114)
aufweisen, und
Härten der Bindemittelzusammensetzung (114), um das Armierungsvlies (104) zu bilden,
bei dem die Fasern (102) durch eine gehärtete Bindemittelzusammensetzung (114) miteinander
verbunden sind, wobei unterschiedliche Abschnitte (106, 108, 110) des Armierungsvlieses
(104) unterschiedliche Mengen der gehärteten Bindemittelzusammensetzung (114) aufweisen,
um die Flexibilität der unterschiedlichen Abschnitte (106, 108, 110) des Armierungsvlieses
(104) zu justieren, wobei mindestens ein Teil der Fasern (102) umklappbare Abschnitte
(116) aufweist, die sich in einem längsgerichteten mittleren Abschnitt (110) erstrecken,
wobei die umklappbaren Abschnitte (116) weniger Bindemittelzusammensetzung (114) als
Fasern (102) in längsgerichteten seitlichen Abschnitten (106, 108) aufweisen, so dass
sie beim Umklappen einen Falz bilden, wobei der längsgerichtete mittlere Abschnitt
(110) des Armierungsvlieses (104) eine Breite zwischen etwa 1 mm und etwa 3 mm umfasst
und wobei die Längen der Fasern (102) größer als die Breite des längsgerichteten mittleren
Abschnitts (110) und kleiner als die Breite des Armierungsvlieses (104) sind.
2. Verfahren nach Anspruch 1, ferner umfassend:
Verteilen der Bindemittelzusammensetzung (114) unter den Fasern (102), entweder bevor
oder nachdem die Fasern (102) angeordnet werden, um den Vorläufer zu bilden, und
Variieren der Menge der Bindemittelzusammensetzung (114) in den entsprechenden Abschnitten
(106, 108, 110) des Vorläufers durch Entfernen von Abschnitten der Bindemittelzusammensetzung
(114) von den entsprechenden Abschnitten (106, 108, 110) des Vorläufers oder durch
Verteilen justierter Mengen der Bindemittelzusammensetzung (114) unter den Fasern
(102), die die entsprechenden Abschnitte (106, 108, 110) des Vorläufers bilden.
3. Verfahren nach Anspruch 1, ferner umfassend:
Variieren der Menge der Bindemittelzusammensetzung (114) in entsprechenden Abschnitten
(106, 108, 110) des Vorläufers durch Verteilen einer verringerten Bindemittelzusammensetzungsmasse
pro Fasereinheitenvolumen unter den Fasern (102), die mindestens einen Abschnitt des
Vorläufers bilden, um das Armierungsvlies (104) mit einem Abschnitt zu bilden, der
in der Lage ist, sich mit einem Krümmungsradius zu biegen, der umgekehrt proportional
zur Bindemittelzusammensetzungsmasse pro Fasereinheitenvolumen ist.
4. Verfahren nach Anspruch 1, ferner umfassend:
Variieren der Menge der Bindemittelzusammensetzung (114) in entsprechenden Abschnitten
(106, 108, 110) des Vorläufers, um mindestens einen Abschnitt des Vorläufers im Wesentlichen
ohne die Bindemittelzusammensetzung (114) bereitzustellen und um das Armierungsvlies
(104) mit einem umklappbaren und falzbaren Abschnitt des Armierungsvlieses (104) im
Wesentlichen ohne die Bindemittelzusammensetzung (114) zu bilden.
5. Verfahren nach Anspruch 1, ferner umfassend:
Variieren der Menge der Bindemittelzusammensetzung (114) in entsprechenden Abschnitten
(106, 108, 110) des Vorläufers durch Entfernen von im Wesentlichen der gesamten Bindemittelzusammensetzung
(114) von einem Abschnitt des Vorläufers, der dem längsgerichteten mittleren Abschnitt
(110) des Armierungsvlieses (104) entspricht, oder durch Verteilen der Bindemittelzusammensetzung
(114) unter den Fasern (102) unter Aussparung der umklappbaren Abschnitte (116) der
Fasern (102) in dem Abschnitt des Vorläufers, der dem längsgerichteten mittleren Abschnitt
(110) des Armierungsvlieses (104) entspricht,
wobei das Armierungsvlies (104) eine Dicke von etwa 0,18 mm und eine Breite von etwa
50 mm als Ersatz für ein Papierband aufweist, um eine Wandbauplattenfuge herzustellen,
und der längsgerichtete mittlere Abschnitt (110) des Armierungsvlieses (104) umklappbar
ist, um sich der Form einer Wandbauplattenfuge an einer innenliegenden Ecke anzupassen.
6. Verfahren nach Anspruch 1, ferner umfassend:
Variieren der Menge der Bindemittelzusammensetzung (114) in entsprechenden Abschnitten
(106, 108, 110) des Vorläufers durch Entfernen von im Wesentlichen der gesamten Bindemittelzusammensetzung
(114) von Abschnitten (106, 108, 110) des Vorläufers, die längsgerichteten Abschnitten
(106, 108, 110) des Armierungsvlieses (104) entsprechen, die umklappbar sind, um entsprechende
Ränder einer Wandbauplatte zu bedecken, oder durch Verteilen der Bindemittelzusammensetzung
(114) unter den Fasern (102) unter Aussparung der umklappbaren Abschnitte (116) der
Fasern (102) in den Abschnitten des Vorläufers, die längsgerichteten Abschnitten (106,
108, 110) entsprechen.
7. Armierungsvlies (104) zum Armieren einer zementösen Wandbauplatte oder einer Fugenverbindung
einer zementösen Wandbauplatte, umfassend:
mehrere Fasern (102), die durch eine Bindemittelzusammensetzung (114) miteinander
verbunden sind und das Armierungsvlieses (104) bilden, und wobei die Bindemittelzusammensetzung
(114) unter den Fasern (102) verteilt ist, wobei die Fasern (102) in unterschiedlichen
Abschnitten (106, 108, 110) des Armierungsvlieses (104) unterschiedliche Masseverteilungen
der Bindemittelzusammensetzung (114) aufweisen, um die Flexibilität der unterschiedlichen
Abschnitte (106, 108, 110) des Armierungsvlieses (104) anzupassen, wobei mindestens
einige der Fasern (102) umklappbare Abschnitte (116) aufweisen, die sich in einem
längsgerichteten mittleren Abschnitt (110) erstrecken, wobei die umklappbaren Abschnitte
(116) weniger Bindemittelzusammensetzung (114) als Fasern (102) in längsgerichteten
seitlichen Abschnitten (106, 108) aufweisen, so dass sie beim Umklappen einen Falz
bilden, wobei der längsgerichtete mittlere Abschnitt (110) des Armierungsvlieses (104)
eine Breite zwischen etwa 1 mm und etwa 3 mm umfasst und wobei die Längen der Fasern
(102) größer sind als die Breite des längsgerichteten mittleren Abschnitts (110) und
kleiner als die Breite des Armierungsvlieses (104).
8. Armierungsvlies (104) nach Anspruch 7, wobei der längsgerichtete mittlere Abschnitt
(110) des Armierungsvlieses (104) im Wesentlichen ohne die Bindemittelzusammensetzung
(114) ist, wobei das Armierungsvlies (104) eine Dicke von etwa 0,18 mm und eine Breite
von etwa 50 mm als Ersatz für ein Papierband aufweist, um eine Wandbauplattenfuge
herzustellen, und der längsgerichtete mittlere Abschnitt (110) des Armierungsvlieses
(104) umklappbar ist, um sich der Form einer Wandbauplattenfuge an einer innenliegenden
Ecke anzupassen.
9. Armierungsvlies (104) nach Anspruch 7, wobei die Bindemittelzusammensetzung (114)
die Haut eines Menschen nicht reizt.
10. Armierungsband (100) zum Einbetten in eine Fugenverbindung, bestehend aus einem dünnen
Armierungsvlies (104) nach Anspruch 7.
11. Armierungsband (100) nach Anspruch 10, wobei die umklappbaren Abschnitte (116) im
Wesentlichen frei von der Bindemittelzusammensetzung (114) sind.
12. Armierungsband (100) nach Anspruch 10, wobei der längsgerichtete mittlere Abschnitt
(110) umklappbar ist, um den Falz zum Anpassen an die Form einer innenliegenden Ecke
zu bilden.
13. Armierungsband (100) nach Anspruch 10, wobei sich die miteinander verbundenen Fasern
(102) in dem dünnen Vlies (104) in mehrere Richtungen erstrecken, um Zugkräften zu
widerstehen, die in mehrere Richtungen ausgeübt werden.
14. Armierungsband (100) nach Anspruch 10, wobei die Länge der Fasern (102) größer ist
als die Breite des längsgerichteten mittleren Abschnitts (110) des dünnen Vlieses
(104) und kleiner als die Breite des dünnen Vlieses (104).
1. Procédé pour la fabrication d'une toile de renforcement non-tissée (104) pour le renforcement
d'un panneau mural à base de ciment ou d'un composé à joints de panneau mural à base
de ciment, comprenant :
l'assemblage de fibres (102) pour former un précurseur de la toile de renforcement
non-tissée (104) ;
la dispersion d'une composition de liant (114) parmi les fibres (102), avant ou après
la formation du précurseur à l'aide des fibres (102) ;
la modification de la quantité de composition de liant (114) dans des sections respectives
(106, 108, 110) du précurseur, les différentes sections (106, 108, 110) du précurseur
présentant des quantités différentes de la composition de liant (114) dispersée ;
et
le durcissement de la composition de liant (114) pour former la toile de renforcement
non-tissée (104) comportant les fibres (102) assemblées entre elles par une composition
de liant (114) durcie, différentes sections (106, 108, 110) de la toile de renforcement
non-tissée (104) présentant des quantités différentes de la composition de liant (114)
durcie pour ajuster la souplesse des différentes sections (106, 108, 110) de la toile
de renforcement non-tissée (104), au moins une partie des fibres (102) présentant
des portions pliables (116) s'étendant dans une section centrale longitudinale (110),
les portions pliables (116) comportant une plus petite quantité de composition de
liant (114) que des fibres (102) dans des sections latérales longitudinales (106,
108), de façon à se plisser lors du pliage, la section centrale longitudinale (110)
de la toile de renforcement non-tissée (104) présentant une largeur comprise entre
environ 1 mm et environ 3 mm, et les longueurs des fibres (102) étant supérieures
à la largeur de la section centrale longitudinale (110) et inférieures à la largeur
de la toile de renforcement non-tissée (104).
2. Procédé selon la revendication 1, comprenant en outre :
la dispersion de la composition de liant (114) parmi les fibres (102) avant ou après
l'assemblage des fibres (102) pour former le précurseur ; et
la modification de la quantité de composition de liant (114) dans les sections respectives
(106, 108, 110) du précurseur, en ôtant des portions de la composition de liant (114)
dans les sections respectives (106, 108, 110) du précurseur, ou en dispersant des
quantités ajustées de la composition de liant (114) parmi les fibres (102) formant
les sections respectives (106, 108, 110) du précurseur.
3. Procédé selon la revendication 1, comprenant en outre :
la modifications de la quantité de composition de liant (114) dans des sections respectives
(106, 108, 110) du précurseur en distribuant une masse de composition de liant réduite
par volume unitaire de fibres parmi les fibres (102) formant au moins une section
du précurseur, pour former la toile de renforcement non-tissée (104) avec une section
capable de fléchir avec un rayon de courbure inversement proportionnel à la masse
de composition de liant par volume unitaire de fibres.
4. Procédé selon la revendication 1, comprenant en outre :
la modifications de la quantité de composition de liant (114) dans des sections respectives
(106, 108, 110) du précurseur pour obtenir au moins une section du précurseur substantiellement
exempte de composition de liant (114), et pour former la toile de renforcement non-tissée
(104) avec une section de la toile de renforcement non-tissée (104) apte à se plier
et à se froisser, quasiment sans composition de liant (114).
5. Procédé selon la revendication 1, comprenant en outre :
la modification de la quantité de composition de liant (114) dans des sections respectives
(106, 108, 110) du précurseur, en ôtant quasiment la totalité de la composition de
liant (114) dans une section du précurseur correspondant à la section centrale longitudinale
(110) de la toile de renforcement non-tissée (104), ou en dispersant la composition
de liant (114) parmi les fibres (102) hormis dans les portions pliables (116) des
fibres (102) dans la section du précurseur correspondant à la section centrale longitudinale
(110) de la toile de renforcement non-tissée (104),
dans lequel la toile de renforcement non-tissée (104) présente une épaisseur d'environ
0,18 mm et une largeur d'environ 50 mm pour remplacer une bande de papier pour la
fabrication d'un joint de panneau mural, et la section centrale longitudinale (110)
de la toile de renforcement non-tissée (104) est pliable pour se conformer à un joint
de panneau latéral dans un coin intérieur.
6. Procédé selon la revendication 1, comprenant en outre :
la modification de la quantité de composition de liant (114) dans des sections respectives
(106, 108, 110) du précurseur, en ôtant quasiment la totalité de la composition de
liant (114) dans des sections (106, 108, 110) du précurseur correspondant à des sections
longitudinales (106, 108, 110) de la toile de renforcement non-tissée (104) aptes
à être pliées pour couvrir des bords correspondants d'un panneau mural, ou en dispersant
la composition de liant (114) parmi les fibres (102) hormis dans les portions pliables
(116) des fibres (102), dans lesdites sections du précurseur correspondant aux sections
longitudinales (106, 108, 110).
7. Toile de renforcement non-tissée (104) destinée à renforcer un panneau mural à base
de ciment ou un joint de panneau mural à base de ciment, comprenant :
une multitude de fibres (102) assemblées entre elles par une composition de liant
(114) et formant la toile de renforcement non-tissée (104) ; et la composition de
liant (114) étant dispersée parmi les fibres (102), les fibres (102) dans différentes
sections (106, 108, 110) de la toile de renforcement non-tissée (104) présentant des
distributions de masses différentes de la composition de liant (114) pour ajuster
la souplesse des différentes sections (106, 108, 110) de la toile de renforcement
non-tissée (104), au moins une partie des fibres (102) présentant des portions pliables
(116) s'étendant dans une section centrale longitudinale (110), les portions pliables
(116) présentant une plus petite quantité de composition de liant (114) que des fibres
(102) dans des sections latérales longitudinales (106, 108), de manière à se plisser
lors du pliage, la section centrale longitudinale (110) de la toile de renforcement
non-tissée (104) présentant une largeur comprise entre environ 1 mm et environ 3 mm,
et les longueurs des fibres (102) étant supérieures à la largeur de la section centrale
longitudinale (110) et inférieures à la largeur de la toile de renforcement non-tissée
(104).
8. Toile de renforcement non-tissée (104) selon la revendication 7, dans laquelle la
section centrale longitudinale (110) de la toile de renforcement non-tissée (104)
est quasiment exempte de composition de liant (114) la toile de renforcement non-tissée
(104) présentant une épaisseur d'environ 0,18 mm, et une largeur d'environ 50 mm,
pour remplacer une bande de papier afin de fabriquer un joint de panneau mural, et
la section centrale longitudinale (110) de la toile de renforcement non-tissée (104)
pouvant être pliée pour se conformer à un joint de panneau mural dans un coin intérieur.
9. Toile de renforcement non-tissée (104) selon la revendication 7, dans laquelle la
composition de liant (114) n'est pas irritante pour la peau d'une personne.
10. Bande de renforcement (100) destinée à être enrobée dans un composé de joint, consistant
en une toile de renforcement non-tissée (104) fine selon la revendication 7.
11. Bande de renforcement (100) selon la revendication 10, dans laquelle les portions
pliables (116) sont quasiment exemptes de composition de liant (114).
12. Bande de renforcement (100) selon la revendication 10, dans laquelle la section centrale
longitudinale (110) peut être pliée pour former le pli lui permettant de se conformer
à un coin intérieur.
13. Bande de renforcement (100) selon la revendication 10, dans laquelle les fibres (102)
assemblées entre elles s'étendent dans de multiples directions dans la fine toile
non-tissée (104) pour résister aux forces de traction exercées dans les multiples
directions.
14. Bande de renforcement (100) selon la revendication 10, dans laquelle la longueur des
fibres (102) est supérieure à la largeur de la section centrale longitudinale (110)
de la fine toile non-tissée (104) et inférieure à la largeur de la fine toile non-tissée
(104).