• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    METHOD OF DETERMINING STRUCTURAL PARAMETERS OF COMPOSITE CONSTRUCTION PANELS. A method of determining the face paper properties of all types of wall panels including providing a core strength value for the wall panel, determining a required nail tensile value based on the wall panel specifications and calculating a value of face paper stiffness based on the provided core strength value and the determined nail tensile value. The method includes displaying the face paper stiffness value on a display device.
    公开号:BR112013026042B1
    申请号:R112013026042-4
    申请日:2012-04-02
    公开日:2021-01-05
    发明作者:Alfred Li
    申请人:United States Gypsum Company；
    IPC主号:
    专利说明:

    PRIORITY CLAIM
    [001] This application is a request for partial continuation of Patent Application No. US 12 / 544,707 filed on August 20, 2009. FIELD OF THE INVENTION
    [002] This invention refers to composite construction panels. More specifically, it refers to a method for determining plaster wall panel structural parameters. BACKGROUND OF THE INVENTION
    [003] Composite construction panels, such as plaster wall panel, are well known for building ceilings and interior walls. Some of the main advantages of the wall panel over other materials is that the wall panel is less expensive, a fire retardant and easy to work with in construction applications. In construction, the wall panel is typically attached to metal or wooden supports of framed walls and ceilings using fasteners such as nails or screws. Because the wall panel is relatively heavy, it must be strong enough to prevent the fasteners from being pulled through the wall panel causing the wall panel to come loose or fall off the brackets.
    [004] Nail traction is an industrial measure of the amount of force necessary for the wall panel to be removed from the associated support and on the head of such fastener. Preferable nail pull values for the wall panel are in the approximate range of 65-85 pounds of force (289.13-378.1 N). Nail traction is a measure of a combination of the core strength of the wall panel, the strength of the face paper and the bond between the face paper and the core. Nail pull tests are performed according to the American Society for Materials Testing (ASTM) standard C473-00 and use a machine that pushes over the head of a fastener inserted into the wall panel to determine the maximum force required to push the fastener head through the wall panel. Because the nail pull value is an important measure of the strength of the wall panel, minimum required nail pull values have been established for the wall panel. Consequently, manufacturers produce wall panels that perform or exceed the minimum required nail pull values.
    [005] To ensure that the wall panel achieves the required nail pull values, conventional wall panel manufacturers adjust structural parameters of the wall panel. Specifically, manufacturers typically adjust the weight of the wall panel face paper or the weight of the wall panel to achieve the required nail pull value, depending on the process savings. During fabrication, the wall panel is tested to determine whether it achieves the required nail pull value. If the tested nail pull value of the wall panel is less than the required nail pull value, manufacturers increase the weight of face paper on the wall panel and / or the weight of the wall panel. This process is repeated until the required nail pull value is reached.
    [006] Such a process is inaccurate and commonly causes the verified nail pull values to exceed the required nail pull values due to excessive face paper weight and / or the total weight of the board added to the wall panel. Also, the excessive weight of face paper and / or from the core to the wall panel and thereby increases the costs of manufacturing and transporting the wall panel. In addition, there is a likelihood of loss of time and material until the desired nail tensile values are achieved on the wall panel production line.
    [007] Thus, there is a need for improved technology to adjust wall panel fabrication systems to produce wall panel that achieve the specified nail tensile values. SUMMARY OF THE INVENTION
    [008] This and other problems easily identified by those skilled in the art are solved by the present method of determining structural composition properties of construction panels such as wall panels.
    [009] The present method is designed to determine plaster wall panel structural parameters before fabrication to reduce manufacturing and transportation costs as well as significantly reducing fabrication time.
    [0010] More specifically, the present method determines the structural parameters of the wall panel and includes providing a core strength value of the wall panel, determining a required nail tensile value and calculating a face paper stiffness value based on the core strength value of the wall panel and the determined nail tensile value. The calculated face paper stiffness value is displayed on a display device for use by a manufacturer.
    [0011] In another embodiment, a method of fabricating a wall panel includes determining a required nail tensile value, providing a core strength value of the wall panel and determining a face paper stiffness value based on the face value. nail traction required and the core strength value provided. The method includes determining a face paper weight based on the determined face paper stiffness value, selecting a face paper type based on the determined face paper weight and producing the wall panel using the selected face paper type and the core resistance value provided.
    [0012] Determining structural parameters before fabrication allows manufacturers to save significant manufacturing and transportation costs by eliminating excessive face paper weight or wall panel weight that is typically used for the wall panel to achieve the tensile values of nail needed. In addition, a significant amount of fabrication time is saved because less time is needed to check the fabricated wall panel to determine the design and composite weight of the final product needed to achieve the required nail tensile values. In addition, the structural integrity and strength of the wall panel are maintained, even through the added weight and stress added by excessive face paper being reduced. DETAILED DESCRIPTION OF THE FIGURES
    [0013] Figure 1. It is a table illustrating a comparison between measured nail tensile data and predicted nail tensile data for different types of wall panel using different face paper stiffness values from face paper weights and Tension Stiffness Index Area (TSIA), as well as different core strength values at varying plate densities.
    [0014] Figure 2 is a graph illustrating nail traction as a function of paper stiffness in face of different core strength values at a plate density of 37 lb / ft3 (592.68 kg / m3).
    [0015] Figure 3 is a graph illustrating nail traction as a function of core strength at different face paper stiffness values at a plate density of 37 lb / ft3 (592.68 kg / m3).
    [0016] Figure 4 is a graph illustrating the relationship between face paper stiffness and core strength at different required nail tensile values at a board density of 37 lb / ft3 (592.68 kg / m3).
    [0017] Figure 5 is a graph illustrating the relationship between the face paper weight and the Tension Stiffness Index (TSIA) values needed to achieve a required nail pull value of 77 lbf (342.51N) at different core strength values for 37 lb / ft3 (592.68 kg / m3) plate density.
    [0018] Figure 6 is a table identifying certain face paper weight values and Tension Stiffness Index (TSIA) values necessary to achieve a required nail pull value of 77 lbf (342.51N) at values different core strengths for 37 lb / ft3 (592.68 kg / m3) plate density based on the graph in Figure 5. DETAILED DESCRIPTION OF THE INVENTION
    [0019] Nail pull values are critical to the strength and utility of drywall. If a nail pull value for a particular wall panel is too low, the fastener holding the wall panel over a frame or other support can push through the wall panel and cause the wall panel to crack, break or break. fallen from the frame or support. Alternatively, if the nail pull values are too high (ie significantly exceed the required nail pull values), the wall panel production sources are inefficiently applied and money is wasted during manufacture.
    [0020] A problem in drywall manufacturing is how to accurately determine the face paper weight that correlates to a nail tensile value needed for wall paneling and a way to use manufacturing and transportation costs more efficiently, as well as the manufacturing time. As stated above, wall panel manufacturers have performed wall panel checks to determine whether to achieve a required nail pull value. If the required nail pull value is not achieved, manufacturers typically increase both the wall panel face paper weights and / or the plate weight. These steps are repeated until the nail strength of the wall panel is reached. This process is not accurate and often causes the wall panel to overweight face paper or board weight, thereby increasing transportation and manufacturing costs as well as manufacturing time.
    [0021] Previous nail traction model correlates the nail traction of plasterboard to the face paper stiffness value and the core strength value for smaller plasterboard (half-inch plasterboard). In another embodiment, this nail traction model has been expanded to a generalized nail traction model that correlates the nail traction value with the face paper stiffness value and the core strength value of several different types of nails. plasterboard including, but not limited to, half inch plasterboard, three quarter inch plasterboard and light weight plasterboard.
    [0022] Specifically, the generalized nail pull model below refers to the nail pull value to the face paper stiffness value and the core strength value of plasterboard having a density from 28 to 48 lb / ft3 (448, 51 to 768.88 kg / m3).
    [0023] The generalized nail traction model can be used to determine a stiffness value for pre-fabricated wall panel that achieves the required nail traction value. The method uses Equation (1) below to correlate a required nail pull value with the face paper stiffness value and the wall panel core stiffness value. Equation (1) is as follows: Nail pull (lbf) = a + [bx (face paper stiffness (kN / m))] + [cx (core strength (psi))] (1) where b = 0 , 009490606731 and c = 0.073937419 constants are determined from the data that best fit the data shown. The constant “a” is determined based on Equation (2) as follows: a = a1 + a2 / [1 + Exp (- (plate density -3) / a4)] (2) where a1 = 6.7441271, a2 = 20.870959, a3 = 43.718215 and a4 = 2.1337464, and the edge density is determined using: Plate density = plate weight / plate caliper (3)
    [0024] Figure 1 shows the predictions of nail traction from the generalized nail traction model as comparing the nail traction measured using different types of plate samples to a specific plate density with varying face papers and bond strength. core.
    [0025] In some situations, changing the stiffness of face paper is more economically feasible. Prior to production, the required nail pull value for the wall panel at a target weight and caliper is specified (ie, half an inch, light weight, five-octave inch, etc.). These values are introduced in Equation (1) above to determine the stiffness value of the wall panel's face paper. For example, the plate density of 37 pounds per cubic foot (592.68 kg / m3), in Equation (1) becomes: Nail pull (lbf) = 7.602932 (33.82N) + [0.009490606731 x (face paper stiffness (kN / m))] + [0.073937419x (core strength (psi))]
    [0026] The face paper stiffness value for wall panel having a plate density of 37 pounds per cubic foot (592.68 kg / m3) is determined using a value of 450 pounds per square inch (psi) (31 , 03 bar) and a required nail pull value of 77 pound-force (lbf) (342.51N) as follows: 77 lbf (342, 51N) = (7.602932) + [(0.009490606731) x ( face paper stiffness (kN / m))] + [(0.073937419) x (450 psi) (31.03 bar)] where the face paper stiffness value = 3805.37 kilo newton / meter (kN / m).
    [0027] The face paper stiffness value is a product of the face paper weight and the Tensile Stiffness Index (TSIA) value, as shown in the following equation: Face Paper Stiffness (kN / m ) = Side Paper Weight (g / m2) xTSIA (kNm / g) (2)
    [0028] Using the example above, the Face Paper Weight for the wall panel above, having a core strength value of 450 psi (31.03 bar), a required nail pull value of 77 lbf (342, 51N ) and a TSIA of 18 kilo newton-meter / gram (kNm / g), is as follows: Face Paper Weight (g / m2) = Face Paper Stiffness (kN / m) / TSIA (kNm / g) = (3805.37 kN / m) / (18 kNm / g) = 211.41 gram / square meter (g / m2) = 43.3 lb / 1000 ft2 (211.40 g / m2) = 43.3 lb / MSF (211.40 g / m2)
    [0029] In the above equation, the TSIA value is a measure of the stiffness of normalized face paper prior to production. Specifically, an ultrasonic Tension Stiffness Orientation (TSO®) checker measures the Tension Stiffness Index (TSI) in all directions of the face paper to determine the TSIA. The stiffer the face paper, the higher the TSIA values. The approximate range of TSIA values for the wall panel is 12 to 26 kNm / g.
    [0030] The face paper stiffness values and TSIA value are used to determine the face paper weight that is required to achieve the nail pull value required for the wall panel to have a core strength value assigned to specific plate density. The calculation for determining the face paper weight is therefore a two-step process, first determining the face paper stiffness and then determining the face paper weight for the wall panel being manufactured .
    [0031] Equations (1), (2) and (3) are preferably stored in a computer memory, personal data assistant or other suitable device. The required nail tensile values, core strength values and constants are also stored in memory in a database or other searchable data format. The memory can be read-only memory (ROM), random access memory (RAM), compact disc read-only memory (CD ROM) or any other suitable memory or memory device. A user or manufacturer enters the required nail pull value and the core resistance value assigned to the specific wall panel product on the computer using a keyboard or other suitable input device. Alternatively, the required nail pull value and the core resistance value assigned to the wall panel can be downloaded and stored in a file or folder in memory. A processor, such as a microprocessor or central processing unit (CPU), calculates the weight of the face paper for the wall panel using Equations (1), (2) and (3), the entered nail pull value and the core resistance value introduced. The calculated face paper weight, or, alternatively, the face paper stiffness value, is displayed to a user on a display device such as a computer screen, monitor or other suitable output device or printed by a printer. The user uses the calculated face paper weight to select the face paper or the type of face paper that is being adhered to the core during the manufacture of the wall panel. The face paper selected using the present method typically targets the face paper stiffness and weight required to achieve the required nail tensile value compared to conventional wall panel production techniques. In addition, the present method reduces the total weight of the manufactured wall panel, which reduces production and transportation costs. The present method also significantly reduces the manufacturing time associated with the production of the wall panel because the intermediate check of the wall panel to determine whether the wall panel achieves the required nail pull values is no longer necessary.
    [0032] Figure 1 is a table that illustrates a comparison between the measured nail traction data and the predicted nail traction data for different wall panels using Equation (1). As shown in the table, the predicted average of nail traction data using Equation (1) correlates well with the measured or verified average nail traction data from the wall panel. Equations (1), (2) and (3) can also be used to predict different structural parameters or wall panel values to improve the manufacturing process.
    [0033] For a density of 37 lb / ft3 (592.68 kg / m3), from Equation (1), the nail traction data in Equation (1) can be expressed as a linear function of paper stiffness against different core strength values ranging from 200 psi to 800 psi (13.79 to 55.16 bar), as shown in Figure 2. The value of the wall panel core strength varies based on the type of wall panel being manufactured. The typical range of core strength values for the wall panel considered in Figure 1 is 300 to 800 psi (20.68 to 55.16 bar).
    [0034] The nail tensile data can also be represented as a linear function of the core strength with the face paper stiffness values ranging from 2000 kN / m to 5000 kN / m, as shown in Figure 3. Preferably , face paper stiffness values range from 3000-5000 kN / m for wall panel. In Figures 2 and 3, it is apparent that increasing the face paper stiffness value or the wall panel core strength value increases the nail tensile value.
    [0035] Figure 4 shows a graphical representation of the face paper stiffness value as a function of the core strength value at varying different nail tensile values. Specifically, the "A" line illustrates the relationship between the face paper stiffness values and the core strength values at a minimum target nail pull value of 77 lbf (342.51N). In addition, using Equation (2), a higher sided paper stiffness value can be realized by increasing either the sided or TSIA paper weight.
    [0036] Figure 5 illustrates the relationship between the face paper weight and the TSIA that reaches a required nail pull value of 77 lbf (342.51N). The face paper weight requirements for different TSIA values are summarized in the table shown in Figure 6. Note that increasing the TSIA value from 12 to 20 kNm / g tends to reduce the face paper weight required by an average 40% at 450 psi (31.03 bar) core strength, while maintaining the required 77 lbf (342.51N) nail pull value.
    [0037] The generalized nail traction model allows the user to determine the optimum weight of face paper sheet that achieves a nail traction value assigned to a specific core strength value for all of the wall panel, such as panel have the following formulations: EXAMPLE A Stucco: 850-950 pounds per 1,000 ft2 (4150.04-4638.28 g / m2) HRA: 12-16 pounds per 1,000 ft2 (58.58-78.11 g / m2 ) Fiberglass: 0-2 pounds per 1,000 ft2 (0-9.76 g / m2) Dispersant (wet basis): 0-8 pounds per 1,000 ft2 (0-39.05 g / m2) Pre- gel (dry basis): 20-40 pounds per 1000 ft2 (97.64-195.29 g / m2) STMP (MCM) (dry base): 2-3 pounds per 1000 ft2 (9.76-14.64 g / m2) Water-to-plaster ratio: 0.8-1.1 EXAMPLE B Plaster: 1100-1300 pounds per 1,000 ft2 (5370.64-6347.12 g / m2) HRA: 8-11 pounds per 1,000 ft2 (39.05-53.70 g / m2) Dispersant (wet basis): 0-8 pounds per 1,000 ft2 (0-39.05 g / m2) Acid-modified starch (dry base): 0-5 pounds per 1000 ft2 (0-24.41 g / m 2) Pre-gel corn flour (dry basis): 0-10 pounds per 1,000 ft2 (0-48.82 g / m2) STMP (MCM) (dry base): 0.7-1.5 pounds per 1000 ft2 (3.41 - 7.32 g / m2) Water-to-plaster ratio: 0.7-0.88 EXAMPLE C Plaster: 1800 pounds per 1000 ft2 (8788.32 g / m2) HRA: 5-10 pounds per 1,000 ft2 (24.41-48.82 g / m2) Fiberglass: 4.5-5.3 pounds per 1000 ft2 (21.97-25.87 g / m2) Dispersant (wet basis): 0- 12 pounds per 1,000 ft2 (0-58.58 g / m2) Acid-modified starch (dry base): 4-6 pounds per 1000 ft2 (19.52-29.29 g / m2) Pre-gel corn flour (dry basis): 0-2 pounds per 1,000 ft2 (0-9.76 g / m2) STMP (MCM) (dry base): 0-0.7 pounds per 1000 ft2 (0-3.41 g / m2) Water-to-plaster ratio: 0.63-0.75
    [0038] The above modalities of the present method enable wall panel manufacturers to determine the important parameters and properties of the wall panel prior to manufacture such as the weight of face paper required to achieve a required nail pull value. Achieving these parameters before manufacturing helps to significantly reduce manufacturing time, as well as manufacturing costs and transportation costs. The present method also allows manufacturers to maintain the structural integrity and performance of the wall panel without adding face paper weight or the total weight on the wall panel.
    [0039] While several particular embodiments of the present method have been shown and described, it will be appreciated by those skilled in the art that changes and modifications can be made to it without departing from the invention in its broadest aspects and as defined in the following claims.
    权利要求:
    Claims (6)
    [0001]
    1. Wall panel fabrication method comprising: determining a required nail pull value based on the type of wall panel; provide a processor configured to perform the following steps: input a core strength value of the wall panel between 300 and 700 psi (20.68 and 48.26 bar) into the processor; determine a face paper stiffness value; determining a face paper weight based on said calculated face paper stiffness value; select a type of face paper based on the said face paper weight displayed; sending said type of face paper and said core strength value to a wall panel making machine; and producing the wall panel with the wall panel production machine using said type of selected face paper and the provided core strength value provided, FEATURED by the fact that a face paper stiffness value is determined based in the following equation: Nail pull (lbf) = a (lbf) + [b (lbf / (kN / m)) x (face paper stiffness (kN / m))] + [c (lbf / psi) x (core resistance (psi))] where b = 0.009490606731 and c = 0.073937419 and where a = a1 + a2 / [1 + Exp (- (plate density-a3) / a4)] and where a1 = 6.7441271, a2 = 20.870959, a3 = 43.718215 and a4 = 2.1337464.
    [0002]
    2. Method according to claim 1, CHARACTERIZED by the fact that determining said face paper weight includes dividing said face paper stiffness value by a Tension Stiffness Index (TSIA) value.
    [0003]
    3. Method, according to claim 2, CHARACTERIZED by the fact that said TSIA value is measured by an ultrasonic tension stiffness orientation tester.
    [0004]
    4. Method, according to claim 2, CHARACTERIZED by the fact that said TSIA value is in a range close to 12 to 26 kNm / g.
    [0005]
    5. Method according to claim 1, CHARACTERIZED by the fact that it includes storing at least one of said calculated face paper stiffness value and said calculated face paper weight in a memory.
    [0006]
    6. Method, according to claim 5, CHARACTERIZED by the fact that said memory includes at least one of: read-only memory, random access memory and a CD ROM.
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    法律状态:
    2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-11-12| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-07-21| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2020-11-10| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-01-05| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 02/04/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/091,740|2011-04-21|
    US13/091,740|US8566041B2|2009-08-20|2011-04-21|Method for determining structural parameters of composite building panels|
    PCT/US2012/031831|WO2012145153A2|2011-04-21|2012-04-02|A method for determining structural parameters of composite building panels|
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