CN105584190A - 具有优化的断裂特性的声学隔音材料的改进的制造方法 - Google Patents

具有优化的断裂特性的声学隔音材料的改进的制造方法 Download PDF

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CN105584190A
CN105584190A CN201510909443.7A CN201510909443A CN105584190A CN 105584190 A CN105584190 A CN 105584190A CN 201510909443 A CN201510909443 A CN 201510909443A CN 105584190 A CN105584190 A CN 105584190A
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layer
viscoplasticity
adhesive
methods
gas
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布兰登.蒂尼亚诺夫
凯文.苏拉斯
艾伯特.亚尼兹
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Pacific Coast Building Products Ltd Co
Pacific Coast Building Products Inc
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Abstract

用于建筑构造的层压结构由一种制造工艺而制成，使得层压步骤不需要升高的干燥温度或者长期的驻留时间。该工艺采用库存材料，从而同时降低成本和改善性能。此工艺使用专门配方的粘弹性胶合剂和环境温度干燥装置而完成。从而，制造设施的生产能力、产品的成本和交付的性能都比现有方法大大地改善了。

Description

具有优化的断裂特性的声学隔音材料的改进的制造方法
本申请是申请号为200980115534.6、申请日为2009年5月8日、发明名称为“具有优化的断裂特性的声学隔音材料的改进的制造方法”的发明专利申请的分案申请。
相关申请的交叉引用
本申请要求2008年5月8日由BrandonD.Tinianov,KevinJ.Surace,andAlbertC.Yanez提交的标题为“IMPROVEDMETHODSOFMANUFACTURINGACOUSTICALSOUNDPROOFINGMATERIALSWITHOPTIMIZEDFRACTURECHARACTERISTICS”的美国专利申请号12/117,687的优先权。本申请涉及共同转让的于2003年9月8日由K.Surace和M.Porat提交的标题为“ACOUSTICALSOUNDPROOFINGMATERIALANDMETHODSFORMANUFACTURINGSAME”的美国专利申请No.10/658,814(该申请于2007年2月27日被发布，现在为美国专利7,181,891)，于2007年4月9日由B.Tinianov提交的标题为“ACOUSTICALSOUNDPROOFINGMATERIALWITHIMPROVEDFRACTURECHARACTERISTICSANDMETHODSFORMANUFACTURINGSAME”的美国专利申请号11/697,691，和于2007年6月12日由B.Tinianov和K.Surace提交的标题为“METHODSOFMANUFACTURINGACOUSTICALSOUNDPROOFINGMATERIAL”的美国专利申请号11/770,476，上述申请的全部内容通过引用被结合于此。
背景技术
目前，制造用于建筑行业的庞大的和/或者重的层压板需要较大的制造用空间(area)。除了与处理中的材料相关联的大体积外，任何要求材料被搁置较长时间的工艺步骤都会增加制造所需的空间。对给定的材料生产量，所需要的空间随工艺步骤的增加和任何步骤中工艺时间的延长而增加。
例如，在上述的美国专利7,181,891中所公开的层压结构包括通过粘弹性胶合剂的粘结剂层相互连接的两个非金属材料的外层(其在一个实施例中为纸饰面的石膏墙板)和一个内约束层。在一些实施例中，其它材料被结合在外石膏层之间。在一个制造层压结构的过程的实施例中，例如在'891专利中所公开的结构，包括干燥一个完成的结构同时将压力施加到该结构。依据构成层压结构的材料，对于粘结剂需要几小时至几天的驻留时间(定义为单个工艺步骤所需的时间)来适合地干燥，在这段时间中可以建造其它类似的单独结构，这可能也需要几小时至几天的驻留时间来干燥。长的干燥时间是由于粘结剂中的液体渗透进石膏片中，石膏片然后通过蒸发将液体运送到周围环境。大量材料在所述的构造序列中被搁置在干燥步骤，这个量取决于生产速度。结果，需要对应于单个结构件的体积乘以期望的成品生产量和当前步骤(instantstep)的驻留时间的大干燥室。此外，制造工艺的一些步骤可能需要干燥室维持在指定的升高温度和相对低的湿度，这是一项能量消耗大的要求。
例如，对于每天一千个四英尺×八英尺×一英寸的结构件的生产要求，其中某一步骤的驻留时间需要在120至140华氏度的恒定温度、大约百分之三十的相对湿度以及恒定空气流下进行四十八小时干燥，在任意给定时间需要为两千个结构件提供所需环境条件的搁置空间，在近似25英尺×45英尺占地上提供最小25英尺的垂直净空距离(clearance)的这种搁置空间，总计达28,125立方英尺的受限制的空间(conditionedspace)。当制造要求超过每天一千件成品板时，需要更大的干燥容积。任何其它的也需要显著的驻留时间的工艺步骤类似地增加了为给定的制造产量所需的设施。长的周期时间，定义为构造一个成品结构件从开始到结束所需的时间，也延长了制造操作对被制造的产品的需求的增加做出反应的时间。
现有的制造工艺的另一个关键方面是，层压板(在一个实施例中，为纸饰面石膏墙板)的外层由传统建筑材料的最终成品的形式构成。美国专利申请号11/697,691已展示，对于使用石膏墙板的实施例，优选在与粘弹性胶合剂相接触的内表面上没有饰纸。在美国专利申请号11/697,691中，提出了要结合成层压隔音板的板应该制造或者选购以使它们在一个面上没有耐用纸。实践中这比较困难，因为饰纸(石膏墙板的任何一侧)用作耐用、防磨损的表面并且还显著地改善石膏墙板的弯曲刚度。一个表面上没有了纸，改造后的石膏墙板在运输和处理的过程中特别易受损坏和/或损毁。
对于这些改造后的无纸的石膏墙板原材料的第二个顾虑是，它们的制造困难，这使得它们的价格高于传统板的价格。并且，只有少数几家制造商能够生产这种改造的材料，因此，供层压板使用的材料会受到限制。
需要一种用于易于划线和折断的分层结构的制造方法，其中制造过程中产品的中间工艺搁置被最小化并且原材料成本也大大减少。
发明内容
一种包括多种材料的夹心结构的层压结构使用工艺方法构造而成，所述工艺方法中，某些步骤的驻留时间从几小时或者几天被缩短至几分钟。在一个实施例中，在增加任何附加的层到层压构造件之前，粘结剂被干燥，以消除成品层压结构的漫长的干燥工艺步骤。通过在施加粘结剂后立即向专门配方的粘结剂表面吹气，对粘结剂进行干燥，从而形成压力敏感粘结剂(“PSA”)。这样，夹心结构中的相邻的一层可在无需进一步干燥的时间的情况下施加。在一个实施例中，个体的工艺驻留时间和总的周期时间被缩减到足以容许使用传送带(conveyorbelt)类型的组装线装置来完成成品层压结构的构造，其中处理中的材料不被搁置或者堆积。
此外，所述工艺采用了新颖的制造步骤，在该步骤中库存石膏墙板沿厚度被对分从而产生内表面没有纸的适配的两半。此步骤减少了原材料库存，并且对于根据本发明的层压板而言，维持或者改善了层压板的断裂特性(划线和折断板的能力)。
附图说明
通过以下附图和书面说明可以更加充分地理解本发明。
图1是根据本发明的工艺顺序的一个示例。
图2示出一个被对分的库存(stock)石膏墙板板。
图3a和3b示出对分石膏墙板库存板的方法。
图4和图5示出一种由根据本发明的方法制作的层压的声音衰减结构的侧视图。
图6示出一个带有多个侧向开口(其中示出开口602至608)的扩散器板，这些侧向开口用于使所用的干燥气体通过以将带有水分的粘弹性胶合剂转换成粘弹性压力敏感粘结剂(“PSA”)。
具体实施方式
定义
干式墙的分层替代件包括由选定厚度的石膏板或者其它材料的两个外层构成的夹心结构(sandwich)，两个外层利用声音耗散粘结剂而彼此胶合，其中，声音耗散粘结剂应用到两个外层的全部的或者少于全部的内表面上。在一个实施例中，粘结剂层是具有特定厚度的专门配方的QuietGlueQuietGlue是一种粘弹性材料。QuietGlue可以从加利福尼亚州Sunnyvale市的SeriousMaterials公司获得。通常，QuietGlue由表1中陈述的材料制得。
表1QuietGlue320
优选配方只是粘弹性胶合剂的一个例子。其它配方可用于实现类似的结果，给出的范围是研究过的成功配方的例子。形成在两个石膏板的内表面上，粘结剂层大约1/16英寸厚。在各种实施例中，不同层数的、具有不同成份的材料被夹在外石膏板之间，每一层都通过PSA胶合到相邻的层。在以下的讨论中，“粘结剂”、“胶合剂”和“PSA”可互换地使用来指称在分层结构夹心情形中的材料层。在此书面说明中，PSA始终指称已干燥而形成粘弹性压力敏感粘结剂的粘弹性胶合剂层。
参考图1，示出根据本发明的工艺流程100的一个示例。任何对顶层和底层的引用应当被理解为仅参照在图2至5的情形中所描述的这些层，而不在本结构的任意使用方向或者可选的组装方向的情形下。步骤102指明一种石膏墙板形式的库存材料(stockmaterial)。此材料常见于建筑行业，并且由石膏或者石膏和纤维增强复合芯构成，所述复合芯由一层粘接到芯的纸所包围。通常，短边留有暴露的石膏芯。石膏墙板通常4英尺宽、8英尺长，不过9、10和12英尺的长度也是常见的。石膏板片的厚度范围从大约1/4英寸厚至超过一英寸厚。这种产品在建筑材料领域普遍可得，由伊利诺斯州芝加哥市的USGCorporation公司、北卡罗来纳州夏洛特市的NationalGypsum公司以及法国库贝瓦市的Saint-Gobain公司制造。
制造工艺步骤104指明在厚度上对石膏墙板进行对分。产生的切割板在图2中以透视图示出。在图2中，物件200表示被对分的板。第一半件202通过图3所示的装置而与第二半件204分离。依据最终的层压组件的要求，两个半件202和204可具有相等的厚度或者不等的厚度212a和212b。由图可见，纸206绕板200的外部延展，但不延伸至通过分离工艺暴露的内表面208和210。
新颖的石膏芯的对分(bisection)提供两个重要的优于现有方法的优点。第一，相比同类的两个一半厚度的板片的叠层，单个对分板片明显地更便宜。例如，一个4英尺宽×8英尺长类型的x石膏的5/8英寸厚的板片的批发价格近似$150每千平方英尺(msf)。一个同样4英尺宽×8英尺长的5/16英寸厚的板的批发价格近似$125至$150每千平方英尺。然而，没有对分，就需要两个5/16英寸厚的板片来替代每个对分的5/8英寸厚的板。因此，在这个示例中，由于对分的板，层压的石膏墙板的成本是$150msf，而堆叠的一对5/16英寸厚的板大约$250至$300msf。对分创新节省了板材成本的近似40％至50％。第二个优点是，对分技术容许最佳的断裂特性(如美国专利申请11/697，691中所描述)而无需非标准的外层材料。这容许了在采购(sourcing)原材料板方面更大的灵活性。因此，新颖制造方法具有更好的材料供应和价格。
图3a和3b示出用于对分库存石膏墙板的两种示例方法。图3a描绘了置于平台上的库存石膏墙板板302、辊、传送带或者其它适合的支承件304。在图3a的右侧，306描绘一种用于切割板而无需直接接触的高强度激光。适合的商业板切割设备可获得，例如基于由得克萨斯州休斯敦市的Han'sLaserTechnology公司制造的CS0405陶瓷切割激光器的高强度CO2激光器。在有限的生产试验中，该方法作为板对分的方法已证实是可行的。
图3b再次描绘置于平台上的库存石膏墙板板302、辊、传送带或者其它适合的支承件304。横跨板的面的是锯片308和诸如带锯(bandsaw)工具310的机动支承结构的形式的机械切割设备。适合的商业可获得的板切割设备包括由德国Rimsting市SERRAMaschinenbauGmbH公司制造的BavariaSL130i移动锯机(mobilesawmill)。这种锯具有连接到刚性板支承结构的直线横动头部(lineartraversinghead)。采用SL130i的试验能够以近似十三英尺每分钟的速度对分石膏板。此速度与在此公开的改进的制造速度相一致。
在板对分之后，板在工艺步骤106中被分离，以使下板半件204可通过从上述工艺步骤108所指定的适合的方法来部分地或者全部地涂敷胶合剂。对分板204的上部分最好使用分布的真空吸杯系统(distributedvacuumsuctioncup)而提起。商业可获得的真空辅助系统有由德国Glatten市的J.SchmalzGmbH公司制造的Saugerspinne和VacuMaster轻真空辅助提升设备(lightvacuumassistedliftingdevice)。
图4示出放置在工作面408上的具有选定厚度的底部石膏板406。如前所述，在一些实施例中，工作面408为用于在全部工艺步骤中移动材料的传送带，例如可从伊利诺斯州埃尔克格罗夫市的ConveyorSystems&Engineering公司获得的一百英尺的OALACSIModel190RB辊道皮带传送机。石膏板206可使用带真空杯的架空提升设备(overheadliftingequipment)而放置在工作面408上，或者由工人简单地抬起板406并将它放在适合的位置。升降装置可将石膏板移动到工作面的高度。粘结剂404，例如QuietGlue以完全的或者部分的覆盖范围而施加到底部石膏板406的上表面。如果部分地涂敷胶合剂，那么可使用许多种选定的胶合剂图案中的任何一种，包括条纹形、任意图案和任何其它适合的几何形状。粘结剂404可通过辊(类似于油漆辊)、刷子、板刀(broadknife)施加，或者用分配喷嘴(dispensingnozzle)进行喷洒。粘结剂404可覆盖石膏406的整个上表面，或者，在一些实施例中，粘结剂404可施加在少于整个表面，例如在上述的美国专利申请号11/734,770中所公开的。施加有粘结剂404的底部石膏层406形成中间夹心结构410。
接着，粘结剂404如在制造工艺步骤110中所描述的进行干燥，以使粘结剂中的水分含量以重量计不大于百分之五。
在一个实施例中，四(4)英尺×八(8)英尺的材料板上的厚度在三十二分一英寸(1/32”)与八分之一英寸(1/8”)之间的粘弹性胶合剂层易受环境空气流(flowofambientair)(通常在十九摄氏度(19℃)与二十四摄氏度(24℃)之间大约为五万立方英尺每分钟(50,000ft3/min))的影响。粘弹性胶合剂的初始水分含量以重量计为大约百分之三十(30％)，而在大约五分钟的气流后，湿度含量以重量计已减小至大约百分之五(5％)。
有各种方法可用来干燥粘结剂404。在一个实施例中，带有暴露的粘结剂410的夹心结构在气体扩散器下通过，其中，一定体积的空气，例如五十立方英尺每分钟，被提供穿过位于胶合剂上方大约一(1)英寸与一(1)英尺之间的扩散器中的开口。在一些实施例中，提供的气体是环境空气。在其它的实施例中，提供的气体是预热的和/或已除湿的空气。吹气(gas-blowing)系统包括用于接收来自吹风机(blower)的增压气体(pressurizedgas)的充气室(plenumchamber)(未示出)，增压气体随后穿过扩散器中的开口流出到暴露的粘结剂的表面上。图6图示了扩散器板600的一个示例。当夹心结构410在扩散器底下通过(假定为传送带方法)时，扩散器板600面向夹心结构410。在所示的示例中，开口602、604、606和608为近似十八英寸长(在板600的短方向)、八分之一英寸宽、在二分之一英寸的中心上、以五至六英寸交错，并且胶合剂层在扩散器下方一(1)英寸至一(1)英尺处通过。扩散器板600的开口可采用其它的设计，例如均匀分布的小孔。
在一个实施例中，中间板夹心结构410在传送带408上以十英尺每分钟在气体扩散器板600下方大约六(6)至八(8)英寸处移动，其中扩散器600为四英尺宽、二十四英尺长(在皮带运行的方向)。因此，粘结剂暴露于环境温度空气的流动气体，近似70华氏度和30％相对湿度，持续近似2.4分钟。扩散器400和开口的确切的排气面积和形状不是至关紧要的，只要扩散器600的排气面积能够实现期望的气流，并且只要扩散器板600的排气面积足够低，以使充气室具有充分的背压以提供近似均匀的气流流出扩散器。在一个实施例中，气流为近似50,000立方英尺每分钟。
在一个未使用传送带的实施例中，中间板夹心结构410被放置在工作面408上，该工作面408可以是与放置板210以施加粘结剂404的工作面相同的工作面，或者也可以不是该相同工作面，并且其中与板夹心结构410的尺寸和形状近似并且近似地对齐在板夹心结构上方的扩散器600在暴露的粘结剂上方吹气，例如速度近似十七英尺每秒容量大约50,000立方英尺每分钟的空气。工艺中的一个重要参数是在将粘结剂404转变成PSA时达到的粘结剂的干燥程度。对于根据本发明的方法一个具体实施方式，干燥时间、气流速度、扩散器板600开口面积、通过扩散器600提供的气体的温度和湿度、以及粘结剂404的厚度的组合被调节以在将粘结剂404转变成PSA时提供适合的液体含量，例如使用诸如由德国汉堡市的TewsElectronik公司制造的MW3260微波湿度传感器之类的湿度传感器测得的以重量计百分之五的液体。假定这些因素适度地恒定，则干燥时间被作为干燥步骤110的预定时间。如果粘结剂被完全干燥，那么夹心结构中的下一材料不能粘附于其上。近似百分之五的液体含量提供发粘的、具有良好的粘附特性但是在夹心结构于制造工艺步骤112中被组装后不需要进一步干燥的粘结剂。
参考图5，在一些将使用本发明的方法构造的结构中，在两个外板之间有附加的材料层504，例如石膏板402、406。例子包括乙烯基塑料(vinyl)、金属薄板、胶合板(plywood)和石膏，这在上述的美国专利7,181,891中更加扩展地讨论了。如果该选项被选取，则附加的材料504在步骤112中被放置在夹心结构410之上(即，在暴露的PSA204上)，然后粘结剂502在步骤104中被施加到新放置的材料504的暴露表面上，如前述。在步骤106，粘结剂502被干燥来形成PSA，而另外的对附加层的选择在步骤110中考虑。如果没有更多的材料层504要增加，则继续步骤112，其中顶部石膏板402被放置在PSA502之上来完成夹心结构从而创建组件400。
在步骤114，完全组装的层压结构400被压在一起。在一个实施例中，层压结构400在一个直径六英寸、近似五十磅重的辊下近似十英尺每分钟地通过(或者，辊在层压结构400之上通过)。在步骤114的压力施加之后，层压结构400就完成了并且为货运做好准备；不需要进一步的干燥或者其它的制造工艺步骤。
尽管工艺被描述为干燥粘弹性胶合剂以实质地创建粘弹性压力敏感粘结剂，该工艺也可被用来部分地干燥粘弹性胶合剂由此来缩短堆叠结构在完全地组装好时必须放置在干燥室中以从用于将多个材料层结合在一起的粘弹性胶合剂中去除另外的水分的时间。
以上已经为图示和说明的目的而给出对本发明的一些实施例的描述。本说明并不意图穷举或者将本发明严格限制在所公开的形式。许多修改和变型对于在相关领域的技术人员是显而易见的。
如果任何公开通过引用被结合于此而该结合的公开部分地或者全部地与本公开矛盾，那么对于矛盾的范围、和/或更广泛的公开、和/或更广泛的术语的定义，由本公开控制。如果这种被结合的公开部分地或者整体地相互矛盾，那么对于矛盾的范围，由日期较后的公开控制。
以上给出了对总体概念和具体实施例的公开，所寻求的保护范围由所附的权利要求限定。所发布的权利要求不作为对申请人要求保护已公开但还没有通过一个或多个进一步的申请(包括依照35U.S.C.§120和/或35U.S.C.§251提交的申请)而书面要求保护的主题的权利的限制。
除非在此特别申明，普通术语具有它们在所表示的各自情形中对应的普通含义，并且领域的普通术语具有它们的相应的固定含义。

Claims (27)

1.一种形成适合用于构造墙、地板、天花板或门的层压结构的方法，所述层压结构包括具有选定厚度和面积的平板，所述方法包括:
将石膏墙板跨过其厚度对分并分离，以提供包括第一表面和第二表面的第一外部层；
将含有水分的粘弹性胶合剂层施加到所述第一表面；
使气体在所述胶合剂之上流过并持续一段预定的时间，以从所述胶合剂移除选定量的水分；和
将第二材料层放置到所述胶合剂层上，其中所述胶合剂在所述第一层与第二层之间，由此将所述第一外部层结合到所述第二层。
2.如权利要求1所述的方法，其中，所述第二材料层为所述层压结构的一个外部层。
3.如权利要求2所述的方法，其中，包括在将所述第二层放置在所述胶合剂上之后向层压结构施加压力。
4.如权利要求1所述的方法，其中，包括在气体流过所述粘结剂之上以前干燥所述气体。
5.如权利要求1所述的方法，其中，所述第一和第二外部材料层由单个被对分的层制得。
6.如权利要求1所述的方法，包括：
将第二粘弹性胶合剂层施加到所述第二层的暴露表面；和
使气体在所述第二粘弹性胶合剂层之上流过并持续一段预定的时间，以从所述胶合剂中移除选定量的水分。
7.如权利要求6所述的方法，其中，包括在所述气体流过所述第二粘弹性胶合剂层之上以前干燥所述气体。
8.如权利要求6所述的方法，其中，包括在所述气体被迫经过所述第二粘弹性胶合剂层上方并持续所述一段预定的时间之后，将第三材料层放置在所述第二粘弹性胶合剂层上，由此来得到所述层压结构。
9.如权利要求8所述的方法，其中，包括在将第三材料层放置在所述第二粘弹性胶合剂层上之后向所述层压结构施加选定的压力。
10.一种形成层压板的方法，所述层压板至少包括第一材料层和第二材料层，其中，每个材料层通过粘弹性胶合剂被接合到相邻的材料层，所述方法包括：
将粘弹性胶合剂以选定的图案放置在一个材料层的暴露表面上，第二层材料将要接合于所述暴露表面；并且其中所述第一材料层和所述第二材料层通过将石膏墙板跨过其厚度被对分和分离而被提供；
使气体流过所述粘弹性胶合剂之上，以从所述胶合剂中移除水分；和
在气体流过所述粘弹性胶合剂之上以后，将所述第二材料层放置在所述粘弹性胶合剂之上。
11.如权利要求10所述的方法，其中，所述粘弹性胶合剂以选定的图案被放置在所述暴露表面上，以覆盖少于全部的所述暴露表面。
12.如权利要求10所述的方法，其中，所述粘弹性胶合剂作为一个连续的层被放置在所述暴露表面。
13.如权利要求11所述的方法，其中，所述粘弹性胶合剂具有介于三十二分之一英寸与八分之一英寸之间的厚度。
14.如权利要求9所述的方法，其中，所述气体被迫经过所述粘弹性胶合剂之上并持续充足的时间，以使所述粘弹性胶合剂的水分含量低于粘弹性胶合剂的以重量计的百分之五。
15.如权利要求9所述的方法，其中，所述气体被迫经过所述粘弹性胶合剂之上并持续充足的时间，以使所述粘弹性胶合剂的水分含量达到粘弹性胶合剂的以重量计的百分之三十与百分之五之间。
16.如权利要求9所述的方法，其中，所述气体为空气。
17.如权利要求16所述的方法，其中，所述空气处在近似环境温度下。
18.如权利要求17所述的方法，其中，所述空气被迫以介于大约一万立方英尺每秒与大约五万立方英尺每秒的流动速度横越所述粘弹性胶合剂。
19.一种由权利要求9所述的方法制得的结构。
20.一种由权利要求1所述的方法制得的结构。
21.如权利要求11所述的方法，其中，所述选定的图案包括从由圆形、正方形、长方形、三角形、条形、多边形、随机形状和半圆形构成的一组图案中选定的一个或多个图案。
22.如权利要求10所述的方法，其中，所述第一材料层是第一石膏墙板层，该第一石膏墙板层在所述第一层成为所述层压板的一部分时会成为所述第一层的内表面的表面上没有纸或者其它的涂层。
23.如权利要求22所述的方法，其中，所述第二材料层是第二石膏墙板层，该第二石膏墙板层在所述第二层成为所述层压板的一部分时会成为所述第二层的内表面的表面上没有纸或者其它的涂层。
24.一种形成适合用于构造墙、地板、天花板或门的层压结构的方法，所述方法包括:
将石膏墙板跨过其厚度对分并分离，以提供包括第一表面和第二表面的第一外部层；
将含有水分的粘弹性胶合剂层施加到所述第一表面的至少部分上；
使气体流过所述胶合剂之上并持续一段预定的时间，以从所述胶合剂移除选定量的水分；和
将第二材料层放置在所述胶合剂层上，其中胶合剂在所述第一层与第二层之间，从而将所述第一外部层结合到所述第二层。
25.如权利要求24所述的方法，其中，所述第一外部材料层包括饰面的石膏墙板的一部分，所述部分沿平行于墙板的前后表面的平面被切割，以使所述部分具有的厚度小于所述墙板的厚度，并且在将成为所述层压结构的外表面的表面上保持通常的墙板饰面材料，并且使内部墙板材料暴露于将成为平行于所述外表面且处于所述层压结构的内部的所述部分的表面上。
26.如权利要求25所述的方法，其中，所述石膏墙板用纸或者纤维玻璃毡饰面。
27.如权利要求24所述的方法，其中，所述粘弹性胶合剂被施加到所述第一表面的全部上。
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AU2009244050B2 (en) 2012-06-28
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EP2283191A4 (en) 2011-11-30
AU2009244050A1 (en) 2009-11-12
US20090280356A1 (en) 2009-11-12
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CN102016196A (zh) 2011-04-13
CA2723606C (en) 2016-07-12

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