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CN1668458A - 对预处理纤维增强水泥产品的包装 - Google Patents

对预处理纤维增强水泥产品的包装 Download PDF

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CN1668458A
CN1668458A CNA038167360A CN03816736A CN1668458A CN 1668458 A CN1668458 A CN 1668458A CN A038167360 A CNA038167360 A CN A038167360A CN 03816736 A CN03816736 A CN 03816736A CN 1668458 A CN1668458 A CN 1668458A
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topping
fiber cement
interlayer
cement product
processing layer
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W·彭
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James Hardie International Finance BV
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Abstract

通过将保护层施加到纤维增强水泥产品的处理过的表面上，制成受保护的预处理纤维增强水泥产品。所述保护层在使用、储存、和运输期间保护所述预处理纤维增强水泥产品的处理层免受损坏。除去所述保护层不会在所述处理层上留下粘附的残留物，不会损坏所述处理层，并且基本上不会撕裂所述保护层。通常将受保护的预处理纤维增强水泥产品叠放在托盘上以便于储存和运输。可选地，可以在叠放的、受保护的预处理纤维增强水泥产品之间放置隔层。

Description

对预处理纤维增强水泥产品的包装
技术领域
本申请通常涉及建筑材料，更具体地涉及对预处理纤维增强水泥产品的包装。
背景技术
在建筑行业，销售和安装之前，常常用涂覆法或层压法对建筑材料进行预处理。例如，预先处理过的护墙板(siding plank)和镶板(panel)因为在安装期间节省人工和时间而受到欢迎；护墙板承包商只需要在建筑物的外墙上安装材料，而不需要后续的处理。制造预处理产品也使制造商受益匪浅。在建筑材料离开工厂之前对其进行处理，通过这种方式，制造商可以完全控制处理过的产品的质量和一致性，从而确保施涂了足够的涂层厚度，以及确保涂层具有可预知的使用年限。与材料的最终用户相比，节约措施使得制造商能以较低的成本对材料进行涂覆和层压。因此，预处理的护墙板受到建筑商的欢迎，因为他们可以收取处理过的护墙板所额外增加的费用，而不用承受自己处理护墙板的费用。
传统地，在木制托盘上将未处理过的护墙板和镶板一张叠放在另一张的上面，用金属带或塑料带将未处理过的护墙板和镶板固定到托盘上，并用塑料将这些护墙板和镶板包起来或放在袋子里以保护这些护墙板在运输、使用和储存期间免受损坏和自然环境的影响。预处理过的护墙板需要额外的包装和保护以保持由工厂施涂的涂层的完整和外观。在包装预处理过的护墙复合物(siding composite)例如硬质纤维板或OSB护墙板时，在两张护墙板或镶板之间常用塑料薄膜、泡沫、或纸构成的保护层来保护经过预处理的表面。通常在缺乏粘合剂的条件下使用这些保护层。如果不用粘合剂将这些保护层固定到产品上，自动化应用就不太精确。因此，这些保护层通常是用人工施加的，这种做法价格昂贵并限制了生产量。包装由纤维增强水泥制成的预处理护墙板和镶板还产生了一个特别的问题，因为纤维增强水泥的磨损性可能在储存、运输、和使用纤维增强水泥产品期间损害保护层。
在典型的制造纤维增强水泥护墙板的操作中，从单张板材上切割出几块护墙板。然后，分别处理和包装这些护墙板，使各张护墙板背对背和面对面地放置，保护层夹在每张护墙板之间或有时候夹在由面对面所叠成的护墙板之间，从而保护预先理表面。这种形式的叠放可以防止护墙板或镶板具有磨损性的背面不会接触到预处理过的前面。面对面和背对背地叠放这些护墙板需要一种装置，用该装置在叠放操作中以人工方式或机械方式翻转这些护墙板，因此需要额外的人工或为此目而建造的装置，该装置会增加额外的装置资金、操作和维护费用。
除了保护纤维增强水泥物品的预处理表面之外，这些保护层，也被称为托盘纸(slip sheet)，有助于使处理过的表面保持干净。保护层也可以保护处理过的表面不受潮湿环境的影响并抑制风化。
在一些情况下，保护层本身会破坏处理过的表面，例如，改变处理过的表面的光泽度(例如，抛光)，改变处理过的表面的颜色，或者当从处理过的表面除去保护层的时候会带走部分处理过的表面。保护层也可以将不希望出现的湿气截留在处理过的表面上。
发明概述
在一个实施例中，本发明公开了一种受保护的预处理纤维增强水泥产品，该产品具有在储存、运输和使用期间保护处理层免受损坏的保护层。当除去保护层时，保护层不会在处理层留下粘附的残留物，而且还抗撕裂。受保护的预处理纤维增强水泥产品方便地叠放在托盘上以便于储存和运输。本发明还公开了一种制造受保护的预处理纤维增强水泥产品的方法。本发明公开了一种其上粘合有隔层的保护层和该保护层的制造方法。
本发明公开的一个实施例提供了一种受保护的预处理纤维增强水泥产品，该产品包括纤维增强水泥产品、施加在纤维增强水泥产品上的处理层(finish layer)，以及粘附在处理层的保护层。保护层在储存、运输和使用期间保护处理层免受损坏。除去保护层不会在处理层上留下残留物并且不会损坏处理层，保护层还抵抗由除去保护层所引起的撕裂。
另一个实施例提供了受保护的预处理纤维增强水泥产品的一种组件，该组件包括多张叠放起来的受保护的预处理纤维增强水泥物品。受保护的预处理纤维增强水泥产品包括纤维增强水泥产品、施加在纤维增强水泥产品上的处理层，以及粘附于处理层的保护层。保护层在储存、运输和使用期间保护处理层免受损坏。除去保护层不会在处理层上留下残留物并且不会损坏处理层，保护层还抵抗由除去保护层所引起的撕裂。
另一个实施例提供了一种使用受保护的预处理纤维增强水泥产品建造建筑物的方法。受保护的预处理纤维增强水泥产品包括纤维增强水泥产品、施加在纤维增强水泥产品上的处理层，以及粘附于处理层的保护层。保护层在储存、运输和使用期间保护处理层免受损坏。除去保护层不会在处理层上留下残留物并且不会损坏处理层，保护层还抵抗由除去保护层所引起的撕裂。除去保护层并将纤维增强水泥产品固定到建筑物框架上。
另一个实施例提供了一种制造受保护的预处理纤维增强水泥产品的方法。受保护的预处理纤维增强水泥产品包括纤维增强水泥产品、施加在纤维增强水泥产品上的处理层，以及粘附于处理层的保护层。保护层在储存、运输和使用期间保护处理层免受损坏。除去保护层不会在处理层上留下残留物并且不会损坏处理层，保护层还抵抗由除去保护层所引起的撕裂。该方法包括将保护层粘附到预处理纤维增强产品的处理层上。
另一个实施例提供了一种用于制造受保护的预处理纤维增强水泥产品保护层的，其上粘合有隔层的保护层。受保护的预处理纤维增强水泥产品包括纤维增强水泥产品、施加在纤维增强水泥产品上的处理层，以及粘附在处理层的保护层。保护层在储存、运输和使用期间保护处理层免受损坏。除去保护层不会在处理层上留下残留物并且不会损坏处理层，保护层还抵抗由除去保护层所引起的撕裂。其上粘合有隔层的保护层包括保护层和粘合到保护层一面上的隔层。
另一个实施例提供了一种用于制造受保护的预处理纤维增强水泥产品的，其上粘合有隔层的保护层的制造方法。受保护的预处理纤维增强水泥产品包括纤维增强水泥产品、施加在纤维增强水泥产品上的处理层，以及粘附在处理层的保护层。保护层在储存、运输和使用期间保护处理层免受损坏。除去保护层不会在处理层上留下残留物并且不会损坏处理层，保护层还抵抗由除去保护层所引起的撕裂。该方法包括将隔层粘合到保护层的一面上。
附图简述
图1A和图1B以横截面图展示了所公开的，受保护的预处理纤维增强水泥产品的一个实施例，该产品具有粘附的保护层和隔层。
图2以横截面图展示了所公开的，受保护的预处理纤维增强水泥产品的一个实施例，该产品具有粘附的保护层和折叠的隔层。
图3以横截面图展示了所公开的，受保护的预处理纤维增强水泥产品的一个实施例，该产品具有以静电形式附着的保护层和折叠的隔层。
图4所示为所公开的，用于制造受保护的预处理纤维增强水泥产品的方法的一个实施例。
图5所示为公开的，用于制造受保护的预处理纤维增强水泥产品的方法的一个实施例。
图6以横截面图展示了所公开的，其上粘合有隔层的保护层的一个实施例。
图7所示为公开的，用于制造其上粘合有隔层的保护层的方法的一个实施例。
优选实施方式详述
在一个实施例中，本发明描述了一种包装系统，该系统用于在使用、运输和储存期间保护预处理纤维增强水泥物品或产品的处理层免受损坏。本发明还描述了一种制备该包装系统并将该包装系统用于处理过的纤维增强水泥物品的方法。本发明中所用的术语“损坏”具有普通的含义，也有处理层上不希望出现的改变这一特殊的含义，包括如光泽度的改变(例如抛光)；颜色的改变；带走一部分处理层(例如碎屑、凹痕、刮痕等)；风化；以及来自该包装系统的残留物(例如粘附的残留物)。
所公开的系统和方法可以用来包装预处理产品，该产品可由任何合适的一种材料或多种材料制成，例如木材、木质复合物、水泥、混凝土、金属、橡胶、橡胶复合物、聚合物树脂，和聚合物复合物。在一个实施例中，该材料或基底是纤维增强水泥。本发明所用的术语“纤维增强水泥”具有普通的含义，也包括由纤维、硅石和水泥制成的材料。在一个实施例中，该纤维是纤维素纤维，例如由木浆制得。典型的水泥是硅酸盐水泥(Portland cement)。纤维增强水泥还可以包括其他的成分，例如密度调节剂、添加剂、骨料，和防水剂。典型的纤维增强水泥物品是建筑产品并包括如镶板、厚板、屋顶板、拱腹、横木、镶边、饰线、门、柱、壁柱，等等。纤维增强水泥产品可以是平滑的、有纹理的、或带孔的。
选择保护层或保护板以在使用、运输和储存期间保护纤维增强水泥产品的处理表面。保护层可以由任何能够提供足够保护的材料制成，这些材料包括纸、聚合物树脂、聚合泡沫、以及它们的复合材料。用于保护层的优选材料是聚合物薄膜。
可以用任何合适的处理剂处理纤维增强水泥产品。合适的处理剂在本技术领域是熟知的，例如水基涂料、溶剂基涂料、油基涂料、或无溶剂或低溶剂涂料；基于乳液、醇酸树脂、环氧、聚氨脂、瓷漆、或丙烯酸的处理剂；或者粉末涂料。处理剂可以在环境温度下固化也可以在高温下固化。在其他实施例中，处理剂是紫外线固化的或光固化的。在另一个实施例中，采用本技术领域已知的方法，例如通过加热方式或粘合剂将处理层层压到纤维增强水泥基底。
处理层可以单层或单涂层，或者多涂层加以使用。在多涂层的处理层中，可选择每一涂层以提供特定的性能特征。在一个实施例中，在纤维增强水泥物品上涂上底料层，在底料层上涂上一个或多个装饰层。通常底料层使后来涂上的处理层的附着力增强，底料层也可以具有其它的特性，例如防水性或杀菌活性。
在一个实施例中，顶涂层带有颜料，并具有所选的表面光泽度。还可以选择具有其它所需性质的特定顶涂层，例如耐久性、防褪色、易清洁或用水管理(water management)。
在另一个实施例中，顶涂层为透明涂层或半透明涂层，该涂层可以是保护性的涂层，并且/或者提供其它的优点，例如防紫外线、耐久性、防水性、或所需的表面光泽度。
在另一个实施例中，处理层就是按照实地所需而处理的底涂层。
将受保护的纤维增强水泥产品方便地叠放起来以便储存和运输。在一个实施例中，在托盘上叠放这些受保护的纤维增强水泥产品。可以面对背地叠放这些受保护的纤维增强水泥产品而不会损坏到处理过的表面。在另一个实施例中，受保护的纤维增强水泥产品是面对面和/或背对背叠放的。
保护层也在使用过程中，例如在建筑工地保护处理层不受损坏。在建筑物的建造过程中，将受保护的纤维增强水泥产品固定到建筑物框架上。在一个实施例中，在将受保护的纤维增强水泥产品固定到建筑物框架上之前先除去保护层。在另一实施例中，在将受保护的纤维增强水泥产品固定到建筑物框架上之后，才除去保护层。例如，可以用部分钉进板内的两个钉子将受保护的纤维增强水泥板部分固定到框架上。然后除去保护层，再将钉子钉牢到它们的最终位置。之后可以采用另外的钉子将板完全固定。
图1A所示为根据本发明公开的一个实施例中受保护的纤维增强水泥产品100，该产品包括纤维增强水泥产品110、处理层120、可选的粘合层130和保护层140。
通过在纤维增强水泥产品110的顶面上涂上或层压处理层120，制成处理过的纤维增强水泥产品，处理层120包括一个或多个涂层或叠层。如上文所述，施加涂层和叠层所用的材料和方法都是本技术领域熟知的。
可选地将粘合层130施加到位于纤维增强水泥产品110之上的处理层120上。在另一个实施例中，粘合层130可以可选地施加到保护层140的一个表面上。在上述两种情况的任何一种情况下，粘合层130都将保护层140粘附固定到处理层120上。可选的粘合层130的粘附性优选地提供了对处理层120的弱粘合力，从而可以轻松地除去聚合物薄膜140，而不在处理层120上留下粘附的残留物并且不带走或损坏处理层120。而且，在一个实施例中，粘合层的分离性和保护层的抗拉强度结合起来，使得可以从受保护的纤维增强水泥产品上除去保护层，而不会出现撕裂现象或只有很小的撕裂。
适用于保护层140的材料包括聚合物薄膜；至少一面上可选覆有聚合物薄膜的纸板；或至少一面可选覆有聚合物薄膜的聚合物泡沫板。在某些实施例中，保护层是聚合物织物或聚合物无纺布。在一个实施例中，保护层的厚度为约0.0001英寸到约0.08英寸(约0.003到2mm)。在另一个实施例中，保护层的厚度为约0.0003英寸到约0.03英寸(约0.008到0.8mm)。在另一个实施例中，保护层的厚度为约0.001英寸到约0.01英寸(约0.03到0.3mm)。在一个实施例中，保护层的最终抗拉强度为约500到约约60,000psi。在另一个实施例中，保护层的最终抗拉强度为约1000到约约5000psi。如上所述，在一个实施例中，从受保护的预处理纤维增强水泥产品上除去保护层时，保护层表现出抗撕裂性。
在某些实施例中，保护层140是单层薄膜或多层薄膜。单层薄膜是其中聚合物树脂与粘合剂混合在一起的保护层140。在使用单层薄膜的实施例中，粘合层130被集成到保护层140中。可以制成聚合物薄膜的合适聚合物树脂是本技术领域已知的，例如有聚乙烯、聚丙烯、聚氯乙烯、聚偏二氯乙烯、聚酯、聚酰胺、硅酮及其混合物或共聚物。聚乙烯可以是诸如低密度的、线性低密度的、高密度的、或茂金属类的任何一种合适类型。合适的粘合剂包括乙烯-丙烯酸、乙烯-乙酸乙烯酯，或两者的混合物。使用例如高剪切混合器、或单螺杆挤出机或双螺杆挤出机的装置混合聚合物树脂和粘合剂的方法在本技术领域是熟知的。然后用例如挤出、吹塑、和浇铸等本技术领域已知的方法将混合的聚合物树脂和粘合剂制成薄膜。
多层薄膜是至少一个面上施加有粘合层130的保护层140。粘合剂可以涂到聚合物薄膜上；涂覆粘合剂的面上可选包括聚合物薄膜的纸板上；或者涂覆粘合剂的面上可选包括聚合物薄膜的泡沫板上。在一个优选的实施例中，保护层是聚合物薄膜。用来制造聚合物薄膜的任何已知的合适聚合物树脂都可以用来制造聚合物薄膜，这样的聚合物树脂包括如聚乙烯、聚丙烯、聚氯乙烯、聚偏二氯乙烯、聚酯、聚酰胺、硅酮、或其混合物或共聚物。聚乙烯可以是例如低密度的、线性低密度的、高密度的、或茂金属类的任何一种合适类型。在一个实施例中，聚合物薄膜可以由两种或两种以上聚合物树脂的混合物制成。在另一个实施例中，聚合物薄膜包括多层聚合物树脂。
可以使用本技术领域所熟知的装置和方法，例如通过溶剂涂布、挤出、热熔性涂布、压延、幕式涂布、凹版式或模型涂布(gravure orpattern coating)、喷涂、层压、压力进给的模头涂布(pressure-feed diecoating)、刮涂、辊涂、或任何其他合适的技术将粘合层130施加到保护层140上。
用于单层薄膜和多层薄膜中粘性成分的优选粘合材料是压敏粘合剂和热熔性粘合剂，这些粘合剂可以将处理层120微弱地粘合到纤维增强产品110上。因此可以轻易地从处理层120上除去保护层140，而不会留下任何粘附的残留物，也不会对处理层120造成负面影响，如改变光泽度(例如，抛光污点)、改变颜色、或者带走一部分处理层120。这些粘合材料的实例包括基于下列物质的组合物：聚丙烯酸酯、聚乙烯基醚、橡胶(例如，天然橡胶)、聚异戊二烯、聚氯丁烯、丁基橡胶、氯丁橡胶、乙烯丙烯二烯烃橡胶(EPDM)、聚异丁烯、丁二烯-丙烯腈聚合物、热塑性弹性体、苯乙烯-丁二烯橡胶、聚-α-烯烃、无定形聚烯烃、硅酮、含乙烯的共聚物(例如乙烯-丙烯酸、乙烯-乙酸乙烯酯、乙烯-丙烯酸乙酯、乙烯-n-丙烯酸丁酯，和乙烯-丙烯酸甲酯)、聚氨酯、聚酰胺、环氧树脂、聚乙烯吡咯烷酮和聚乙烯吡咯烷酮共聚物、聚酯和其混合物或共聚物。粘性成分还可以包括调节剂，例如增粘剂、增塑剂、填料、抗氧化剂、稳定剂、颜料、固化剂、交联剂，溶剂等。
单层薄膜和多层薄膜都可以分别制造，并用诸如压力辊或层压压机等制成适于连续施加到处理过的纤维增强产品的合适形式(例如卷材)。压力辊可以加热或不加热使用。单层聚合物薄膜也可以混合并挤出成为薄膜，然后马上将该薄膜施加到处理过的纤维增强水泥产品上。相类似地，可以共挤出多层薄膜并同时施加到处理过的纤维增强水泥产品上。
在另一个实施例中，粘合层130施加到纤维增强水泥产品110的处理层120上，保护层施加到粘合层130上。用于粘合层130的合适粘合剂和合适的保护层140与上述用于单层薄膜中的那些物质类似。通过上述的方式将粘合层施加到纤维增强水泥产品上。
当在运输托盘上将纤维增强水泥产品一张叠放在另一张的上面时，以及使用时，保护层140优选地抵抗来自相邻物体如纤维增强水泥产品、托盘和金属或塑料带的磨损。因此，在公开的包装系统的一个实施例中，面对背地叠放纤维增强水泥产品，从而避免了叠放时翻转交替的产品的需要。在其他的实施例中，纤维增强水泥产品是面对面和背对背叠放的。因此，应选择具有预定厚度、抗拉强度和冲击强度的保护层，以提供所需的耐久度。所选择的保护层140和粘合剂不会对处理层120造成负面影响，例如改变光泽度(例如，抛光或磨光没有光泽的处理层)、改变处理层的颜色、或带走一部分处理层。
图1B所示的另一个实施例类似于图1A所示的实施例，但还包括一个或多个可选的隔层150。可选地，采用一个或多个隔层150而在纤维增强水泥产品之间提供额外的减震作用。隔层150优选是减震的，并可以使力不会集中到损坏纤维增强水泥产品110或处理层120的程度。
隔层150优选地由不会损坏或擦伤处理层120表面的材料制成。隔层150的厚度、尺寸、和形状所取决于的因素包括隔层材料的可压缩性和弹性，以及纤维增强水泥产品110的尺寸、形状、和重量；处理层120的特性；保护层140的特性；以及受保护的纤维增强水泥产品预期的储存、运输、和使用条件。合适的隔层材料包括固态聚合材料，例如弹性体、橡胶、或固态塑料；聚合泡沫，例如聚乙烯、聚苯乙烯、或聚氨酯泡沫；织物材料，例如毡或织物网；或者任何其他较软的材料，例如纸或木纤维垫。
隔层150的厚度优选为约0.005到约0.1英寸，更优选为约0.01到约0.05英寸。隔层150的宽度优选为约0.1到约2英寸，更优选为约0.3到约0.7英寸。隔层150可以是连续的窄带、不连续的窄带、或一组以预定方式在保护层表面延伸的预定形状。例如，因为要将产品通过施加隔层的机器，可以平行于进给方向的方式将隔层施加到产品上。在另一个实施例中，以垂直于进给方向的方式将隔层施加到产品上。在另一个实施例中，以与进给方向成一定角度的方式将隔层施加到产品上。而在另一个实施例中，用一种不同的方式将隔层施加到产品上。每张纤维增强水泥产品采用的隔层150的数目将取决于隔层150的性质，也取决于纤维增强水泥产品的尺寸、形状和重量。在一个实施例中，每张纤维增强水泥产品采用至少两个隔层150。在其他的实施例中，每张纤维增强水泥产品采用的隔层150的数目多达约10个、约20个、约30个、约40个、约50个或更多。隔层可以是预制的，或者在包装的过程中例如采用塑料挤出机制造。
在叠放一组纤维增强水泥产品的过程中，可以用人工方式或机械方式将隔层150放到保护层140的顶上。隔层150也可以预先粘附到保护层140上、或者粘附到纤维增强水泥产品110的后侧。隔层150也可以和保护层140共挤出。
图2以横截面的形式展示了本发明公开的受保护的纤维增强水泥产品200的第二个实施例。如以上所描述的那样，通过在纤维增强水泥产品110上施加处理层120而制备出处理过的纤维增强水泥产品。保护层140和可选的粘合层130也和上述的那些类似。
在图2所示的实施例中，将保护层140施加到纤维增强水泥产品1 10的处理层120上，以使保护层140的一部分折回自身，从而形成了能够提供额外减震作用的折叠隔层150’。图2中的细部A展示了使用中隔层150’被压平的状态。隔层150’减轻了保护层140上的磨损。在将保护层140施加到纤维增强水泥产品110表面的过程中，形成折叠的隔层150’。在另一个实施例中，在将保护层施加到处理层120之前，先形成折叠的隔层150’。
保护层140和可选的粘合层130也和上述的那些类似。保护层140的性质取决于制成保护层的特定材料。预定保护层140的厚度、弹性和可压缩性以形成具有所需性质的折叠隔层150’。
可以沿与纤维增强水泥产品通过包装机的轴向平行的方向形成隔层150’。在另一个实施例中，隔层150’沿垂直于进给方向的方向形成。在再一个实施例中，隔层150’沿与进给方向成一定角度的方向形成。在又一个实施例中，隔层150’沿多个与进给方向成一定角度的方向形成。
每张纤维增强水泥产品采用的隔层150’的优选数目将取决于隔层150’的性质，也取决于纤维增强水泥产品的尺寸、形状和重量。在一个实施例中，每张纤维增强水泥产品采用至少两个隔层150’。在其他的实施例中，每张纤维增强水泥产品采用的隔层150’的数目多达约10个、约20个、约30个、约40个、约50个或更多。
图3所示为根据本发明公开的受保护的纤维增强水泥产品300的第三个实施例。通过在保护层140的底面上分布静电荷而将保护层140施加到纤维增强水泥产品110的处理层120上。所示实施例包括可选的折叠隔层150’，该隔层150’如上述一样通过折叠保护层140而整体式地形成。图3中的细部A展示了使用中隔层150’被压平的状态。在在将保护层140施加到纤维增强水泥产品110表面上的过程中，形成折叠的隔层150’。在另一个实施例中，在将保护层施加到处理层120之前，先形成折叠的隔层150’。
保护层140和上述的保护层类似。保护层140的特性取决于制成保护层的特定材料。预定保护层140的厚度、弹性和可压缩性以形成具有所需特性的折叠隔层150’。
可以沿纤维增强产品通过包装机的轴向平行的方向形成隔层150’。在另一个实施例中，隔层150’沿垂直于进给方向的方向形成。在再一个实施例中，隔层150’沿与进给方向成一定角度的方向形成。在又一个实施例中，隔层150’沿多个与进给方向成一定角度的方向形成。
每张纤维增强水泥产品采用的隔层150’的优选数目将取决于隔层150’的特性，也取决于纤维增强水泥产品的尺寸、形状和重量。在一个实施例中，每张纤维增强水泥产品采用至少两个隔层。在其他的实施例中，每张纤维增强水泥产品采用的隔层150’的数目多达约10个、约20个、约30个、约40个、约50个或更多。
另一个实施例(未示出)包括与上述图1所示的实施例中那些隔层类似的隔层150，具有折叠的隔层或者没有折叠的隔层。
图4所示为本发明公开的，用于包装预处理纤维增强水泥产品的方法的一个实施例400。在步骤410中，使用者获得预处理的纤维增强水泥产品。在步骤420中，使用者获得具有预定厚度、抗拉强度和冲击强度的保护层。在步骤430中，使用者获得具有预定粘合特性的粘合剂。如上述的那样，可以将粘合剂整合到单层薄膜形式的保护层中，可以将粘合剂事先涂到多层膜形式的保护层上，或者可以将粘合剂与保护层分开。在可选步骤440中，使用者获得具有预定厚度、可压缩性和弹性的隔层。在步骤450中，保护层通过粘附力施加到纤维增强水泥产品的处理层上，从而形成了受保护的纤维增强水泥产品。在一个实施例中，在处理剂(例如，涂料)完全固化后，再施加上保护层。在另一个实施例中，在处理剂部分固化时就施加保护层，但不粘手。在将保护层施加到纤维增强水泥产品的过程中，可选形成隔层。在可选步骤460中，将隔层施加到受保护的纤维增强水泥产品上。在步骤470中，将多张受保护的纤维增强水泥产品成堆叠放在一起。优选地，该产品堆包括预定数目的受保护的纤维增强水泥产品。
图5所示为用于包装预处理纤维增强水泥产品的本发明公开方法的另一个实施例500。在步骤510中，使用者获得预处理的纤维增强水泥产品。在步骤520中，使用者获得具有预定的厚度、抗拉强度和冲击强度的保护层。在本实施例中没有用到粘合剂。在可选步骤540中，使用者获得具有预定的厚度、可压缩性和弹性的隔层。在步骤550中，保护层以静电方式施加到纤维增强水泥产品的处理层上，从而形成了受保护的纤维增强水泥产品。当将保护层施加到纤维增强水泥产品上的过程中，可选地形成折叠的隔层。在可选步骤560中，将隔层施加到受保护的纤维增强水泥产品上。在步骤570中，将多张受保护的纤维增强水泥产品成堆叠放在一起。优选地，该产品堆包括预定数目的受保护的纤维增强水泥产品。
图6所示为本发明公开的，其上粘合有隔层的保护层的一个实施例600，其包括保护层140和一个或多个隔层150。可以用本技术领域已知的任何方式将隔层粘合到保护层上。在一个实施例中，用具有预定粘合特性的粘合剂将隔层粘合到保护层上。在另一个实施例中，通过加热的方式将隔层粘合到保护层上。可选地，将受保护的处理层包装成适于应用预处理纤维增强水泥产品的形式，例如包装成卷。
图7所示为本发明公开的，用于制造其上粘合有隔层150的保护层的方法中的一个实施例700。在步骤710中获得了具有预定的厚度、抗拉强度和冲击强度的保护层。在步骤720中获得了具有预定的形状、厚度、可压缩性和弹性的隔层。在可选步骤730中，获得了具有预定粘合强度的粘合剂。在步骤740中，将隔层粘合到保护层的一面上。在使用粘合剂的实施例中，用粘合剂将隔层粘合到保护层上。在其他的实施例中，用诸如加热等其他方式将隔层粘合到保护层上。在可选步骤750中，将受保护的处理层包装成适于应用预处理纤维增强水泥产品的形式，例如包装成卷。
实施例1
塑料“托盘纸”
用两层涂料(褐棕色，15个光泽度单位，James Hardie BuildingProducts，Fontana，CA)处理5/16”×4”×6”的纤维增强水泥板(选的是Cedarmill结构，James Hardie Building Products，Fontana，CA)的一面。第一层涂料在60摄氏度的炉子中用4分钟烘干。烘干后的厚度为0.002到0.004英寸。第二层涂料在105摄氏度的炉子中用2分钟烘干。烘干后的厚度为0.001到0.003英寸。对0.0025”厚的透明聚乙烯薄膜(LDF 318，Dow Chemical)(作为保护涂料面的托盘纸)进行测试。当板表面为大约90-140华氏度时，从烘干涂层的炉子中取出纤维增强水泥板，此后，将聚乙烯薄膜施加到纤维增强水泥板的涂料面上。将1/16”厚的硅橡胶板(30硬度计硬度，邵氏硬度A)置于聚乙烯薄膜的顶上，以接纳纤维增强水泥板的粗糙表面。这种组件在印压机中以25psi的压强被压制，随后立即释放压力。聚乙烯薄膜粘附到涂料面上的程度并不让人满意，震动或倒置的情况下就发生层离。薄膜在除去的时候不会撕裂。除去薄膜后，板的处理表面具有不均匀的光泽度和抛光痕迹。
实施例2
混合单层薄膜
按照实施例1所述的方法在纤维增强水泥板上涂覆涂料。按照实施例1所述的方法将由聚乙烯和乙烯-丙烯酸混合制成的、厚0.002”的单层薄膜(整体式709薄膜，Dow Chemical)层压到纤维增强水泥板处理过的表面上。薄膜粘附到处理过的表面，震动或倒置的情况下不会发生层离，但可以轻易剥落。除去薄膜后，板的处理表面具有均匀的外观，没有抛光、光泽度的改变、或者颜色的改变。薄膜在除去的时候不会撕裂。在处理过的表面没有留下粘附的残留物，而且没有处理层被带走。
实施例3
多层薄膜保护的板的储存测试
按照实施例1所述的方法涂覆多张纤维增强水泥板，5/16”×8.25”×3’(选的是Cedarmill结构，James Hardie Building Products，Fontana，CA)。当板表面的温度为大约90-140华氏度时，从烘干涂层的地方取出板，随后就将涂有乙烯-丙烯酸粘合剂的聚乙烯透明多层薄膜(DAF708，0.0009”厚，Dow Chemical)施加到每张板的处理表面上。在薄膜的顶上放置1/8”厚的硅橡胶板(30硬度计硬度，邵氏硬度A)。将这种组件置于滚压机中，在180磅/线性英寸的压强下以50英尺/分钟的速度移动。薄膜粘附到处理过的表面上，而且在震动或倒置的情况下并不会发生层离，然而可以轻易剥落。除去薄膜后，板的处理表面具有均匀的外观，没有抛光、光泽度的改变、或者颜色的改变。薄膜在除去的时候不会撕裂。在处理过的表面没有留下粘附的残留物，而且没有处理层被带走。
在42”×13”×12”的托盘上叠放受保护的纤维增强水泥板。托盘上还有未受保护的板(总共840张板，长宽高比例为4∶5∶42)。一些板是面对面和背对背叠放的，而其他的则是面对背地叠放的。托盘重约2000磅。通过在测试托盘的顶上堆放重约2000磅的模拟托盘，构成测试组件。将测试组件储存3天。当拆开组件后，薄膜被撕裂并损坏。除去薄膜后，板的处理表面有严重的磨损，包括损坏和擦伤。
实施例4
储存和运输薄膜和隔层保护的板
按照实施例3所述的方式进行涂覆，并将多层薄膜层压到每张板的处理表面上。将两个0.08”×0.5”的橡皮条纵向放置于薄膜的顶上，与每张板的每个长边距离大约1英寸。按照实施例3所述的方式组建叠放了水泥板的测试托盘。按照实施例3所述的方式构成由测试托盘和模拟托盘组成的测试组件。将测试组件储存3天。然后，将测试组件放在卡车车板的前端上(测试托盘在底部)。两个叠放在一起的模拟托盘放在测试组件的后面并紧靠测试组件；将单个模拟托盘放置在叠放的模拟托盘的后面并紧靠叠放的模拟托盘。卡车运行3000英里。返回后检查水泥板，没有出现损坏的现象。可以轻易除去塑料膜。除去薄膜后，板的处理表面具有均匀的外观，没有抛光、光泽度的改变、或者颜色的改变。薄膜在除去的时候不会撕裂。在处理过的表面没有留下粘附的残留物，而且没有处理层被带走。
表I总结了实施例1-实施例4的测试结果。“剥离后的外观”这一结果是在将保护层层压到处理过的水泥板上后马上确定的。在任何一种情况下，保护层都不会在处理层上留下粘附的残留物或带走处理层的任何部分。“储存和运输”这一结果是在实施例3中储存3天后，以及实施例4中储存3天和运输3000英里后确定的。
                                    表I
实施例     保护层     隔层 剥离后的外观   储存和运输
1 2.5密耳厚的聚乙烯薄膜 无 不均匀的光泽度，有抛光现象 不适用
2  2.0密耳厚的单层薄膜，由聚乙烯和乙烯-丙烯酸混合制成 无 均匀的光泽度，没有抛光现象 不适用
3  0.9密耳厚的单层薄膜，由涂有乙烯-丙烯酸的聚乙烯薄膜制成 无 均匀的光泽度，没有抛光现象 多层薄膜受到损坏，处理过的表面被擦伤和损坏
4  0.9密耳厚的多层薄膜，由涂有乙烯-丙烯酸的聚乙烯薄膜制成 两个80密耳×1/2”的橡皮条 均匀的光泽度，没有抛光现象 多层薄膜完好无损，处理过的表面完好无损
在加利福尼亚州的丰塔纳，将根据实施例1到实施例4所制备的受保护的纤维增强水泥产品的样品露天储存在托盘上。在一年的时间内，周期性地从样品上除去保护层。在任何一种情况下，除去保护层时薄膜都不会撕裂。在样品处理表面的任何部分都没有留下粘附的残留物，而且任何样品的处理层都没有被带走。
上述的实施例用来说明优选的实施例，并没有限制的意义。显而易见的是，在不偏离本发明的构思的前提下，本技术领域的普通技术人员可以对优选实施例进行修饰和变化。本发明的范围是由所附的权利要求限定的。

Claims (70)

1.一种受保护的预处理纤维增强水泥产品，包括：
纤维增强水泥产品、施加在所述纤维增强水泥产品上的处理层，以及粘附在所述处理层的保护层，其中
所述保护层在储存、运输和使用期间保护所述处理层免受损坏，
除去所述保护层不会在所述处理层上留下残留物并且不会损坏所述处理层，并且
所述保护层还抵抗由除去所述保护层所引起的撕裂。
2.根据权利要求1所述的受保护的预处理纤维增强水泥产品，其中用粘合剂将所述保护层粘附到所述处理层上。
3.根据权利要求2所述的受保护的预处理纤维增强水泥产品，其中所述粘合剂包括选自下列组中的粘合材料：聚丙烯酸酯、乙烯-丙烯酸、聚乙烯醚、橡胶、聚异戊二烯、聚氯丁烯、丁基橡胶、氯丁橡胶、乙烯丙烯二烯烃橡胶、聚异丁烯、丁二烯-丙烯腈聚合物、热塑性弹性体、苯乙烯-丁二烯橡胶、聚-α-烯烃、无定形聚烯烃、硅酮、含乙烯的共聚物、聚氨酯、聚酰胺、环氧树脂、聚乙烯吡咯烷酮和聚乙烯吡咯烷酮共聚物、聚酯、这些物质的混合物，以及这些物质的共聚物。
4.根据权利要求3所述的受保护的预处理纤维增强水泥产品，其中所述粘合剂包括乙烯-丙烯酸。
5.根据权利要求2所述的受保护的预处理纤维增强水泥产品，其中所述粘合剂涂在所述处理层和所述保护层之间。
6.根据权利要求1所述的受保护的预处理纤维增强水泥产品，其中所述保护层包括聚合物薄膜。
7.根据权利要求6所述的受保护的预处理纤维增强水泥产品，其中所述聚合物薄膜包括选自下列组中的聚合物树脂：聚乙烯、聚丙烯、聚氯乙烯、聚偏二氯乙烯、聚酯、聚酰胺、硅酮、这些物质的混合物，以及这些物质的共聚物。
8.根据权利要求7所述的受保护的预处理纤维增强水泥产品，其中所述聚合物树脂是聚乙烯。
9.根据权利要求1所述的受保护的预处理纤维增强水泥产品，还包括一个所施加的隔层。
10.根据权利要求9所述的受保护的预处理纤维增强水泥产品，其中所述隔层是固态聚合物。
11.根据权利要求10所述的受保护的预处理纤维增强水泥产品，其中所述隔层是橡胶。
12.根据权利要求9所述的受保护的预处理纤维增强水泥产品，其中所述隔层的厚度为约0.005到约0.1英寸。
13.根据权利要求9所述的受保护的预处理纤维增强水泥产品，其中所述隔层的宽度为约0.01英寸到约2英寸。
14.根据权利要求1所述的受保护的预处理纤维增强水泥产品，还包括折叠隔层，该折叠隔层包括在所述保护层上形成的折叠。
15.根据权利要求1所述的受保护的预处理纤维增强水泥产品，其中所述保护层的厚度是约0.0001英寸到约0.08英寸。
16.根据权利要求15所述的受保护的预处理纤维增强水泥产品，其中所述保护层的厚度是约0.0003英寸到约0.03英寸。
17.根据权利要求16所述的受保护的预处理纤维增强水泥产品，其中所述保护层的厚度是约0.001英寸到约0.01英寸。
18.一种受保护的预处理纤维增强水泥产品的组件，包括多个叠放起来的受保护的预处理纤维增强水泥物品，其中受保护的预处理纤维增强水泥产品包括：
纤维增强水泥产品、施加在所述纤维增强水泥产品上的处理层，以及粘附在所述处理层的保护层，其中
所述保护层在储存、运输和使用期间保护所述处理层免受损坏，
除去所述保护层不会在所述处理层上留下残留物并且不会损坏所述处理层，并且
所述保护层还抵抗由除去所述保护层所引起的撕裂。
19.根据权利要求18所述的组件，其中在托盘上叠放所述受保护的预处理纤维增强水泥产品。
20.根据权利要求18所述的组件，其中面对背地叠放所述受保护的预处理纤维增强水泥产品。
21.根据权利要求18所述的组件，其中面对面和/或背对背地叠放所述受保护的预处理纤维增强水泥产品。
22.根据权利要求18所述的组件，其中所述受保护的预处理纤维增强水泥产品被捆扎在一起。
23.一种建造建筑物的方法，包括：
获得受保护的预处理纤维增强水泥产品，其中所述受保护的预处理纤维增强水泥产品包括
纤维增强水泥产品、施加在所述纤维增强水泥产品上的处理层，以及粘附在所述处理层的保护层，其中
所述保护层在储存、运输和使用期间保护所述处理层免受损坏，
除去所述保护层不会在所述处理层上留下残留物并且不会损坏所述处理层，并且
所述保护层还抵抗由除去所述保护层所引起的撕裂；
除去所述保护层；和
将所述纤维增强水泥产品固定到建筑物框架上。
24.根据权利要求23所述的方法，其中在将所述纤维增强水泥产品固定到所述建筑物框架上之前，先除去所述保护层。
25.根据权利要求23所述的方法，其中在将所述纤维增强水泥产品固定到建筑物框架上之后，才除去所述保护层。
26.一种制造受保护的预处理纤维增强水泥产品的方法，其中受保护的预处理纤维增强水泥产品包括纤维增强水泥产品和施加在所述纤维增强水泥产品上的处理层，该方法包括：
将保护层粘附到所述处理层上，其中
所述保护层在储存、运输和使用期间保护所述处理层免受损坏，
除去所述保护层不会在所述处理层上留下残留物并且不会损坏所述处理层，并且
所述保护层还抵抗由除去所述保护层所引起的撕裂。
27.根据权利要求26所述的方法，其中用粘合剂将所述保护层粘附到所述处理层上。
28.根据权利要求27所述的方法，其中所述粘合剂包括选自下列组中的粘合材料：聚丙烯酸酯、乙烯-丙烯酸、聚乙烯醚、橡胶、聚异戊二烯、聚氯丁烯、丁基橡胶、氯丁橡胶、乙烯丙烯二烯烃橡胶、聚异丁烯、丁二烯-丙烯腈聚合物、热塑性弹性体、苯乙烯-丁二烯橡胶、聚-α-烯烃、无定形聚烯烃、硅酮、含乙烯的共聚物、聚氨酯、聚酰胺、环氧树脂、聚乙烯吡咯烷酮和聚乙烯吡咯烷酮共聚物、聚酯、这些物质的混合物，以及这些物质的共聚物。
29.根据权利要求28所述的方法，其中所述粘合剂包括乙烯-丙烯酸。
30.根据权利要求27所述的方法，其中所述粘合剂涂在所述处理层和所述保护层之间。
31.根据权利要求26所述的方法，其中所述保护层包括聚合物薄膜。
32.根据权利要求31所述的方法，其中所述聚合物薄膜包括选自下列组中的聚合物树脂：聚乙烯、聚丙烯、聚氯乙烯、聚偏二氯乙烯、聚酯、聚酰胺、硅酮、这些物质的混合物，以及这些物质的共聚物。
33.根据权利要求32所述的方法，其中所述聚合物树脂是聚乙烯。
34.根据权利要求26所述的方法，还包括一个所施加的隔层。
35.根据权利要求34所述的方法，其中所述隔层是固态聚合物。
36.根据权利要求35所述的方法，其中所述隔层是橡胶。
37.根据权利要求34所述的方法，其中所述隔层的厚度为约0.005到约0.1英寸。
38.根据权利要求34所述的方法，其中所述隔层的宽度为约0.01英寸到大约2英寸。
39.根据权利要求26所述的方法，还包括折叠隔层，该折叠隔层包括在所述保护层上形成的折叠。
40.根据权利要求26所述的方法，其中所述保护层的厚度是约0.0001英寸到约0.08英寸。
41.根据权利要求40所述的方法，其中所述保护层的厚度是约0.0003英寸到约0.03英寸。
42.根据权利要求41所述的方法，其中所述保护层的厚度是约0.001英寸到约0.01英寸。
43.一种其上粘合有隔层的保护层，该保护层用于制造受保护的预处理纤维增强水泥产品，其中所述受保护的预处理纤维增强水泥产品包括：
纤维增强水泥产品、施加在所述纤维增强水泥产品上的处理层，以及粘附在所述处理层的保护层，其中
所述保护层在储存、运输和使用期间保护所述处理层免受损坏，除去所述保护层不会在所述处理层上留下残留物并且不会损坏所述处理层，并且
所述保护层还抵抗由除去所述保护层所引起的撕裂；
其上粘合有隔层的保护层包括保护层和粘合到所述保护层一面上的隔层。
44.根据权利要求43所述的其上粘合有隔层的保护层，所述保护层被包装成卷。
45.根据权利要求43所述的其上粘合有隔层的保护层，其中所述隔层是固态聚合物。
46.根据权利要求45所述的其上粘合有隔层的保护层，其中所述隔层是橡胶。
47.根据权利要求43所述的其上粘合有隔层的保护层，其中所述隔层的厚度为约0.005到约0.1英寸。
48.根据权利要求43所述的其上粘合有隔层的保护层，其中所述隔层的宽度为约0.01英寸到约2英寸。
49.根据权利要求43所述的其上粘合有隔层的保护层，还包括涂到所述保护层上与隔层粘合面相反的另一面上的粘合剂。
50.根据权利要求49所述的其上粘合有隔层的保护层，其中所述粘合剂包括选自下列组中的粘合材料：聚丙烯酸酯、乙烯-丙烯酸、聚乙烯醚、橡胶、聚异戊二烯、聚氯丁烯、丁基橡胶、氯丁橡胶、乙烯丙烯二烯烃橡胶、聚异丁烯、丁二烯-丙烯腈聚合物、热塑性弹性体、苯乙烯-丁二烯橡胶、聚-α-烯烃、无定形聚烯烃、硅酮、含乙烯的共聚物、聚氨酸酯、聚酰胺、环氧树脂、聚乙烯吡咯烷酮和聚乙烯吡咯烷酮共聚物、聚酯、这些物质的混合物，以及这些物质的共聚物。
51.根据权利要求50所述的其上粘合有隔层的保护层，其中所述粘合剂包括乙烯-丙烯酸。
52.根据权利要求43所述的其上粘合有隔层的保护层，其中所述保护层包括聚合物薄膜。
53.根据权利要求52所述的其上粘合有隔层的保护层，其中所述聚合物薄膜包括选自下列组中的聚合物树脂：聚乙烯、聚丙烯、聚氯乙烯、聚偏二氯乙烯、聚酯、聚酰胺、硅酮、这些物质的混合物，以及这些物质的共聚物。
54.根据权利要求53所述的其上粘合有隔层的保护层，其中所述聚合物树脂是聚乙烯。
55.根据权利要求43所述的其上粘合有隔层的保护层，其中所述保护层的厚度是约0.0001英寸到约0.08英寸。
56.一种制造其上粘合有隔层的保护层的方法，该保护层用于制造受保护的预处理纤维增强水泥产品，其中所述受保护的预处理纤维增强水泥产品包括：
纤维增强水泥产品、施加在所述纤维增强水泥产品上的处理层，以及粘附在所述处理层的保护层，其中
所述保护层在储存、运输和使用期间保护所述处理层免受损坏，
除去所述保护层不会在所述处理层上留下残留物并且不会损坏所述处理层，并且
所述保护层还抵抗由除去所述保护层所引起的撕裂；
所述方法包括将隔层粘合到保护层的一面上。
57.根据权利要求56所述的方法，还包括将所述具有隔层的保护层包装成卷。
58.根据权利要求56所述的方法，其中所述隔层是固态聚合物。
59.根据权利要求58所述的方法，其中所述隔层是橡胶。
60.根据权利要求56所述的方法，其中所述隔层的厚度为约0.005到约0.1英寸。
61.根据权利要求56所述的方法，其中所述隔层的宽度为约0.01英寸到约2英寸。
62.根据权利要求56所述的方法，其中以加热的方式将所述隔层粘合到所述保护层上。
63.根据权利要求56所述的方法，其中用粘合剂将所述隔层粘合到所述保护层上。
64.根据权利要求56所述的方法，其中所述保护层还包括涂到所述保护层上与隔层粘合面相对的另一面上的粘合剂。
65.根据权利要求64所述的方法，其中所述粘合剂包括选自下列组中的粘合材料：聚丙烯酸酯、乙烯-丙烯酸、聚乙烯醚、橡胶、聚异戊二烯、聚氯丁烯、丁基橡胶、氯丁橡胶、乙烯丙烯二烯烃橡胶、聚异丁烯、丁二烯-丙烯腈聚合物、热塑性弹性体、苯乙烯-丁二烯橡胶、聚-α-烯烃、无定形聚烯烃、硅酮、含乙烯的共聚物、聚氨酯、聚酰胺、环氧树脂、聚乙烯吡咯烷酮和聚乙烯吡咯烷酮共聚物、聚酯、这些物质的混合物，以及这些物质的共聚物。
66.根据权利要求65所述的方法，其中所述粘合剂包括乙烯-丙烯酸。
67.根据权利要求56所述的方法，其中所述保护层包括聚合物薄膜。
68.根据权利要求67所述的方法，其中所述聚合物薄膜包括选自下列组中的聚合物树脂：聚乙烯、聚丙烯、聚氯乙烯、聚偏二氯乙烯、聚酯、聚酰胺、硅酮、这些物质的混合物，以及这些物质的共聚物。
69.根据权利要求68所述的方法，其中所述聚合物树脂是聚乙烯。
70.根据权利要求56所述的方法，其中所述保护层的厚度是约0.0001英寸到约0.08英寸。
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US8297018B2 (en) 2012-10-30
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CA2496972A1 (en) 2004-01-22
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JP2005532932A (ja) 2005-11-04
NZ538092A (en) 2007-01-26
DK1534511T3 (da) 2012-07-09
TW200402498A (en) 2004-02-16
AR040590A1 (es) 2005-04-13
WO2004007193A3 (en) 2004-04-08
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US20040086676A1 (en) 2004-05-06
JP4406360B2 (ja) 2010-01-27

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