A method for determining structural parameters of composite building panels.

(54) Title: METHOD FOR DETERMINING THE STRUCTURAL PARAMETERS OF COMPOSITE CONSTRUCTION PANELS.

(54) Title: A METHOD FOR DETERMINING STRUCTURAL PARAMETERS OF COMPOSITE BUILDING PANELS.

(57) Summary

A method of determining the coating paper properties of all types of wall plate is described, including providing a wall plate core strength value, determining a required nail removal value based on the specifications of the wall plate and calculate a stiffness value of the covering paper based on the provided core strength value and the determined nail removal value. The method includes displaying the calculated stiffness value of the backing paper on a display device.

(57) Abstract

A method of determining face paper properties of all types of wallboard including providing a core strength valué of the wallboard, determining a required nail pulí valué based the wallboard specifications and calculating a face paper stiffness valué based on the provided core strength valué and the determined nail polished valued. The method ineludes displaying the calculated face paper stiffness valué on a display device.

fetus

Sjm

AND

<img file="MX337746B_D0001.tif" />

Institute

Mexican Property

Industrial

<img file="MX337746B_D0002.tif" />

PATENT TITLE NO. 337746

Owner (s): UNITED STATES GYPSUM COMPANY

Address: 550 West Adams Street, Chicago, Illinois, 60661-3676, USA

Denomination: METHOD FOR DETERMINING THE STRUCTURAL PARAMETERS OF COMPOSITE CONSTRUCTION PANELS.

Classification: lnt.CI.8: B32B37 / 02; B32B37 / 14; B32B41 / 00; E04C2 / 04; G06F19 / 00 Inventor (s): ALFRED Ll

Number:

MX / a / 2013/011901 í w 8 '

Country:

US

REQUEST

International filing date:

from Apr, il 2012:

PRIORITY

Date:

April 2011

Number:

13/091,740

Validity: Twenty years

Expiration Date: April 2, 2032 é

The reference patent is granted based on articles 1 / * section V, 6th section III and 59 of 'to the Industrial Property Law.

Pursuant to article 23 of the Industrial Property Law, this patent has a validity of twenty non-valid years, counted from the date of filing of the international application and will be subject to the fee fee to keep the .rights. ;? (B

Who subscribes to the present title if it is justified. ") The provisions. By. sections 6 fractions III and 7 ° bis 2 of the Industrial Property Law (Official Gazette of the Federation (DOF) Z7 / 06/1991, amended as' 02706/1994, 2571071996. 26/12/1997, 1 * 5/1999, 01/26/2004, 05/16/2005, 01/25/2005, «/ 05 / 2009,06 / 01/2010, 06/18/2010. 06/26/2010. 2 ^ 01/2012 and 09.ni/2012), articles 1st, 3rd faction V subsection a), 4 'and 12th fractions I and III read Regulation of the Institute M&gt; *' lcano of the Piupndec Indistrial (DOF 14 / 12/1999, refined on * 1/07 / 2002,15 / 07/2004, 28707/2004 yifr / 09/2007); articles 1, 3, 4, 5 traction V subsection a), 16 fractions I and III and 30 of the Christian Statute ¿»4i» «tutpMe! (ie« to.tett'Prop¡edaclkrtMiaMMM (i¡MMMMtolrilinMltaiaNMttMM! NMMMMMMMtaMM! ); 1st. 3rd and 5th subsection a) of the Agreement that delegates powers to the Deputy Directors General, Coordinator, Divisional Directors, Holders of Regional Offices, Divisional Deputy Directors, Departmental Coordinators and other subordinates of the Mexican Institute of Industrial Property. (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004, 08/04/2004 and 09/13/2007).

<img file="MX337746B_D0003.tif" />

Issue date: March 16, 2016 · · · *

DIVISIONAL DIRECTOR OF PATENTS

NAHANNY CANAL REYES

Sands No. 5o0. 1st floor.

Pueblo Santa Maris Tepspan, Xochmilco, CP 16020.

Mexico City

Tei. (56? 53 34 07 00 www.impi qcb.mx

<img file="MX337746B_D0004.tif" />

<img file="MX337746B_D0005.tif" />

<img file="MX337746B_D0006.tif" />

MX / 2016/22082

33W6

- '' 'vi' i | 4

METHOD FOR DETERMINING THE STRUCTURAL PARAMETERS OF »aacesasairaM5-eT.íTpL-i

COMPOSITE CONSTRUCTION PANELS

FIELD OF THE INVENTION

This invention relates to composite building panels. More specifically, it relates to a method of determining the structural parameters of a plasterboard wall.

BACKGROUND OF THE INVENTION

Composite building panels, such as drywall, are well known for the construction of ceilings and interior walls. Some of the main advantages of the wall plate over other materials is that the wall plate is more economical, flame retardant, and easier to work with in construction applications. In construction, the wall plate is

<td>generally assured</td><td>to supports</td><td>of wood</td><td>or</td><td>metal</td><td>of</td>

<td>half-timbered walls and</td><td>ceilings</td><td>through</td><td>the</td><td>use</td><td>of</td>

<td>bras like nails</td><td>or screws</td><td>. Given the</td><td>the</td><td>license plate</td><td>of</td>

<td>wall is relatively</td><td colspan="5">heavy it must be enough</td>

sturdy to prevent fasteners from pulling on the wall plate and causing the wall plate to loosen or come loose from the fasteners.

Nail removal is an industrial measurement of the amount of force required to move the plate away from

Ref.:244249

<img file="MX337746B_D0007.tif" />

ins'iíTu re mexsaw; OF THE PROPERTY

INDUSTRIAL

<img file="MX337746B_D0008.tif" />

wall of the associated support and on the head of the fastener.

............................................

The preferable nail removal values ​​for the wall plate range from approximately 65 to 85 pounds of force. Nail removal is a measurement of a combination of the strength of the wallplate core, the strength of the liner paper, and the bond between the liner paper and the core. Tests of resistance to nail extraction are carried out in accordance with the Society's standard C473-00

American Standards for Materials Testing (ASTM) and they use a machine that pulls the head of a fastener inserted into the wall plate to determine the maximum force required to pull the fastener head out of the wall plate. Since the nail removal value is an important measure of the strength of the wall plate, minimum nail removal values ​​required for wall plates have been established. Therefore, manufacturers produce wall plates that meet or exceed the minimum required nail removal values.

To ensure that the wall plate meets the required nail removal values, conventional wall plate manufacturers adjust the structural parameters of the wall plate. Specifically, manufacturers generally adjust the weight of the wall plate liner paper or the weight of

I '

X. £ 'ν.λί X ^;ϊ; / '&lt;&gt;_;ΙΝϋϊ'ϊυ ΤΟ: Ο

L · '· ί.Λ? Γ! Ο; - · / ί) Λθ λ ..

the wall plate to achieve the required nail removal value, according to the economy of the process. During fabrication, the wall plate is tested to see if it meets the required nail removal value. If the evaluated nail removal value of the wall plate is less than the required nail extraction value, the manufacturers increase the weight of the liner paper on the wall plate and / or the weight of the wall plate. The process is repeated until the required nail removal value is reached.

The process is inaccurate and often causes the evaluated nail removal values ​​to exceed the required nail removal values ​​due to the excess weight of the liner paper and / or the total weight of the plate added to the wall plate. Also, the excess weight of the liner paper and / or the core on the wall plate increases the manufacturing and shipping costs of the wall plate. On the other hand, there is a possibility of a waste of time and material until the desired nail removal values ​​are achieved in the wall plate production line.

Therefore, a better technique is needed to fine tune the wall plate fabrication systems to produce wall plates that meet the specified nail removal values.

BRIEF DESCRIPTION OF 1Α INVENTION

These and other problems readily identified by those skilled in the art are solved by the present method of determining the structural properties of composite building panels such as wall plates.

The present method has been designed to determine the structural parameters of a gypsum wall plate prior to manufacturing to reduce manufacturing and shipping costs, as well as significantly reducing production time.

More specifically, this method determines the structural parameters of the wall plates and includes providing a wall plate core strength value, determining a required nail removal value, and calculating a stiffness value of the liner paper on the basis of the supplied core strength value and the determined nail removal value. The calculated stiffness value of the backing paper is displayed on a display device that can be used by a manufacturer.

In another embodiment, a method of making wall plates includes determining a required nail removal value, providing a wall plate core strength value, and determining a stiffness value of the backing paper based on the removal value. of nails required and the resistance value of the core provided T ~ E ~ method includes determining a weight of the coating paper based on the stiffness value of the determined coating paper, select a type of liner paper based on the weight of the given liner paper and produce the wall plate using the type of liner paper selected and the core strength value provided.

Determining structural parameters prior to fabrication allows manufacturers to save significant manufacturing and shipping costs by eliminating excess weight of the liner paper or wallplate that is generally used for wallplate to achieve the values ​​of nail removal required. Also, a significant amount of fabrication time is saved because less time is needed to evaluate the fabricated wall plate to determine the composite design and weight of the finished product required to achieve the required nail removal values. On the other hand, the structural integrity and strength of the wall plate are maintained even though the additional weight and stress incorporated by the overlay paper is reduced.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 is a table illustrating a comparison between nail removal information

<img file="MX337746B_D0009.tif" />

' TO ^F ¿: 'V: C MlXICAÍaG L'c LA PROi'JED / W ll'. 'D'JS'i a; aj.

Measurement and predicted nail removal information for different types of wall plates using different stiffness values ​​of the backing paper from various weights of the backing paper and the Tensile Stiffness Index Area (TSIA) English), as well as different core resistance values ​​at various plate densities.

Figure 2 is a graph illustrating nail removal as a function of the stiffness of the backing paper at different core resistance values ​​at a plate density of 37 lb / cubic feet.

Figure 3 is a graph illustrating nail removal as a function of core strength at different stiffness values ​​of the backing paper at a plate density of 37 lb / cubic feet.

Figure 4 is a graph illustrating the relationship between liner paper stiffness and core strength at various required nail removal values ​​at a plate density of 37 lb / cubic feet.

Figure 5 is a graph illustrating the relationship between the value of the coating paper weight and the value of the Tensile Stiffness Index Area (TSIA) necessary to achieve a required nail removal value of 77 lbf at different values ​​of core strength for a plate density of 37 lb / cubic feet.

<img file="MX337746B_D0010.tif" />

Figure 6 is a table identifying some coating paper weight values ​​and the Tensile Stiffness Index Area (TSIA) values ​​needed to achieve the required nail removal value of 77 lbf at different λ / strength values of the core for the plate density of 37 lb / cubic feet based on the graph in Fig. 5.

DETAILED DESCRIPTION OF THE INVENTION

Nail removal values ​​are critical to the strength and usefulness of the gypsum wall plate. If a nail removal value for a particular wallplate is too low, the fastener holding the wallplate in a frame or other bracket may pull the wallplate off and cause the wallplate to crack, crack, or release from frame or bracket. Alternatively, if nail removal values ​​are very high (i.e. significantly exceed the required nail removal values), wall plate production resources are inefficiently applied and money is wasted during fabrication .

One problem in making gypsum wall boards is how to accurately determine the weight of the backing paper that correlates to a required nail removal value for the wall board and a way that uses costs more efficiently. manufacturing and shipping, as well as manufacturing time. As described, wallplate manufacturers have performed the wallplate to determine if it meets the required nail removal value. If the required nail removal value is not reached, manufacturers typically increase the weight of the wall plate liner paper and / or the plate weight. These steps are repeated until the required nail removal value is reached from the wall plate. This process is not exact and usually causes the wall plate to be overweight to the liner paper or to the weight of the plate and therefore increases manufacturing and shipping costs as well as manufacturing time.

The previous model of nail removal correlates nail removal from drywall with the stiffness value of the liner and the core strength value for smaller drywall (half-inch drywall). In another embodiment, this nail extraction model has been expanded to a generalized nail extraction model that correlates the nail extraction value with the stiffness value of the liner paper and the core strength value of different types of boards. gypsum boards, including but not limited to half-inch drywall, three-quarter inch drywall, and lightweight drywall.

Specifically, the generalized nail extraction model below relates the value of

<img file="MX337746B_D0011.tif" />

Nail removal with the stiffness value of the covering paper and the core strength value of gypsum board with a density between 28 and 48 lb / cubic feet.

The generalized nail removal model can be used to determine a pre-fabrication stiffness value for wall plate backing paper that reaches the required nail removal value. The method uses Equation (1) below to correlate a required nail removal value with the stiffness value of the backing paper and the core strength value of the wall plate. Equation (1) is as follows:

Nail removal (lbf) = a + [bx (liner paper stiffness (kN / m))] + [cx (core strength (psi))] (1) where b = 0.009490606731 and c = 0.073937419 are constants determined a from the experimental data that best adapt to the reflected data.

The constant a is determined on the basis of Equation (2) as follows:

a = al + 32 / [1 + Exp (- (plate density - a3) / a4)] (2) where al = 6.7441271, a2 = 20.870959, a3 = 43.718215 and a4 = 2.1337464, and the plate density It is determined using:

Plate Density = Plate Weight / Plate Gauge (3)

Figure 1 shows the nail extraction predictions of the generalized nail extraction model in relation to nail extraction measured by using different types of plate samples at a specific plate density with various strengths of the coating paper and core.

In some situations, changing the stiffness of the backing paper is more economically feasible. Prior to fabrication, the required nail removal value for the wallplate is specified at a target weight and gauge (i.e., half inch, light weight, five eighths of an inch, etc.). Values ​​are entered into Equation (1) above to determine the stiffness value of the wall plate backing paper. For example, for the plate density of 37 inches per cubic foot, Equation (1) becomes:

Nail removal (lbf) = 7.602932 + [0.009490606731 x (stiffness of liner paper (kN / m))] + [0.073937419 x (core strength (psi))]

The stiffness value of the wall paper for wall plates with a plate density of 37 pounds per cubic foot is determined using a core strength value of 450 pounds per square inch (psi) and a required nail removal value of 77 pounds

<img file="MX337746B_D0012.tif" />

+ [(0.073937419) of the force oaDel (lbf) as follows:

lbf = (7.602932) + [(0.009490606731) x (coating paper stiffness (kN / m))] x (450 psi)] where the coating stiffness value = 3805.37 kiloNewton / meter (kN / m).

The stiffness value of the liner paper is the result of the weight value of the liner paper and the value of the Tensile Stiffness Index Area (TSIA) 10 as shown in the following equation:

Coating paper stiffness (kN / m) = Coating paper weight (g / m2) x TSIA (kNm / g) (2)

Using the example above, for the above wallplate having a core resistance value 15 of 450 psi, a required nail removal value of 77lbf and a TSIA of 18 kiloNewton-meter / gram (kNm / g), the Coating paper weight is as follows:

Coating paper weight (g / m²) = Stiffness of the coating paper (kN / m) / TSIA (kNm / g) = (3805.37 kN / m) / (18 kNm / g) = 211.41 gram / square meter (g / m²) = 43.3 lb / 1000 square feet = 43.3 lb / MSF

In the equation above, the TSIA value is a measurement of the normalized stiffness of the backing paper ^Λ· ' ,·&gt;;:

prior to production. Specifically, a Tensile Stiffness Orientation (TSO®) ultrasonic testing machine measures the Tensile Stiffness Index (TSI) in all directions of the coating paper to determine the TSIA. The stiffer the overlay paper, the higher the TSIA values. The approximate oscillation of the TSIA values ​​for wall plates is 12 to 26 kNm / g.

The stiffness value of the backing paper and the TSIA value are used to determine the weight of the backing paper that is needed to achieve the required nail removal value for wall plates with a designated core strength value at a density of specific plate. The calculation for determining the weight of the covering paper is therefore a two-step process which first consists of determining the stiffness of the covering paper and then determining the weight of the covering paper for the wall plate being manufactured. .

Equations (1), (2) and (3) are preferably stored in the memory of a computer, a personal data assistant, or other suitable device. The required nail removal values, core strength values, and constants are also stored in the memory of a database or other search engine data format. Memory can be a memory of

Vk

'....... ί.

¡Μϊτπί ;;:.: Λ ·: τ .: c ε&gt; ς

<img file="MX337746B_D0013.tif" />

read-only (ROM), random access memory (RAM), compact disk read-only memory (CD ROM), or any other memory or suitable memory device. The user or manufacturer enters the required nail removal value and the designated core resistance value for the specific wall plate product into the computer using a keyboard or other input device. Alternatively, the required nail removal value and core strength value designated for the wall plate 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 backing paper for the wall plate using Equations (1), (2) and (3), the entered nail removal value and entered core resistance value. The calculated coating paper weight, or alternatively the stiffness value of the coating paper, is displayed to a user on a display device such as a computer screen, monitor, or other output device, or printed through a printer. The user uses the calculated liner paper weight to select the liner paper or the type of liner paper to adhere to the core during wall plate fabrication. The

<img file="MX337746B_D0014.tif" />

the use of ¹ · .I coating paper selected by this method is generally directed at the stiffness and weight of the coating paper required to achieve the required nail removal value relative to conventional wall plate production techniques. Also, the present method reduces the total weight of the manufactured wall plate, which reduces manufacturing and shipping costs. The present method also significantly reduces the manufacturing time associated with wall plate production because the intermediate wall plate test to determine if the wall plate reaches the required nail removal values ​​is no longer necessary.

Figure 1 is a table illustrating a comparison between the measured nail removal information and the expected nail removal information for different wall plates using Equation (1). As shown in the table, the predicted mean nail removal information using Equation (1) correctly correlates with the measured or evaluated mean nail removal information from the wall plate. Equations (1), (2) and (3) can also be used to predict various parameters or structural values ​​of wall plate to improve the manufacturing process.

For a plate density of 37 lb / cubic feet, from Equation (1), the nail removal information in Equation (1) can be expressed as a linear function of the stiffness of the backing paper at different strength values ​​of the core ranging from 200psi to 800psi, as shown in Fig. 2. The core strength value of the wallplate varies depending on the type of wallplate being manufactured. The typical oscillation of core resistance values ​​for the wall plate considered in Fig. 1 is 300 to 800 psi.

Nail removal information can be graphically represented as a linear function of core strength with the stiffness values ​​of the liner paper ranging from 2000 kN / m to 5000 kN / m, as shown in Figure 3. Preferably, the stiffness values ​​of the covering paper range between 3000 and 5000 kN / m for wall plates. In Figures 2 and 3, it is apparent that increasing the stiffness value of the backing paper or the core strength value of the wall plate increases the nail removal value.

Figure 4 shows a graph of the stiffness value of the coating paper as a function of the core resistance value at different nail removal values. Specifically, line A illustrates the relationship between the stiffness values ​​of the liner paper and the core strength values ​​at an extraction value of

<img file="MX337746B_D0015.tif" />

nails minimum target 77 lbf. Also, using the

Equation (2), a higher stiffness value of the backing paper can be achieved by increasing the weight of the backing paper or the TSIA.

Figure 5 illustrates the relationship between liner paper weight and TSIA reaching a required nail removal value of 77 lbf. The coating paper weight requirements for the various TSIA values ​​are summarized in the table shown in Fig. 6. Please note that increasing the TSIA value from 12 to 20 kNm / g tends to reduce the required weight of the overlay paper an average of 40% at a core strength of 450 psi, while maintaining the required nail removal value. 77 lbf.

The generalized nail removal model allows the user to determine the optimal liner paper weight that achieves a designated nail removal value at a specific core strength value for all types of wall plate, such as plate wall with the following formulations:

EXAMPLE A

Stucco: 850-950 lbs per 1000 square feet HRA: 12-16 lbs per 1000 square feet Fiberglass: 0-2 lbs per 1000 square feet Dispersants (wet base): 0-8 lbs per 1000 square feet Pre-gelled cornmeal (dry basis): 20-40 lbs per 1000

<img file="MX337746B_D0016.tif" />

square feet

STMP (MCM) (dry basis): 2-3 lbs per 1000 square feet Water-to-stucco ratio: 0.8-1.1

EXAMPLE B

Stucco: 1100-1300 lbs per 1000 square feet HRA: 8-11 lbs per 1000 square feet Dispersant (wet base): 0-8 lbs per 1000 square feet Acid Modified Starch (dry base): 0-5 lbs per 1000 feet squares

Pregelled cornmeal (dry basis): 0-10 lbs per 1000 square feet

<td>STMP (MCM) (dry basis):</td><td>0.7-1.5 lbs</td><td>by 1</td><td>.000 square feet</td>

<td>Relationship</td><td>water-stucco:</td><td> 0.7-</td><td> 0.88</td>

<td></td><td>EXAMPLE C</td><td></td><td></td>

<td>Stucco: 1,800</td><td>lbs per 1000</td><td>feet</td><td>squares</td>

HRA: 5-10 lbs per 1000 square feet Fiberglass: 4.5-5.3 lbs per 1000 square feet Dispersant (wet base): 0-12 lbs per 1,000 square feet Acid Modified Starch (dry base): 4-6 lbs per 1000 square feet

Pregelled cornmeal (dry basis): 0-2 lbs per 1000 square feet

STMP (MCM) (dry basis): 0-0.7 lbs per 1000 square feet Water-to-stucco ratio: 0.63-0.75

<img file="MX337746B_D0017.tif" />

The previous modalities of the present method yjrjiacr.T.TftjtMJMTJÍl · »» '~ ί Jtx.

They allow wall plate manufacturers to determine important parameters and properties of the wall plate prior to fabrication, such as the weight of liner paper required to achieve a required nail removal value. Obtaining these parameters prior to manufacturing helps to significantly reduce manufacturing time as well as manufacturing and shipping costs. The present method also allows manufacturers to maintain the structural integrity and performance of the wall plate without incorporating liner weight or total weight on the wall plate.

While various special embodiments of the present method have been demonstrated and described, those skilled in the art will appreciate that changes and modifications can be made to the method without departing from the invention in its broader aspects and as set forth in the following claims.

It is noted that in relation to this date, the best method known by the applicant to put the aforementioned invention into practice, is the one that is clear from the present description of the invention.