FGD Gypsum Coating for Plasterboard Jointing and Finishing
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Solution Overview
Problem
There is a need for a jointing coating for construction elements, particularly paper-faced plasterboards, that offers excellent workability, including low application energy and good glide, while also performing both filling and finishing functions effectively.
Innovation Solution
A drying coating comprising 50-85% FGD gypsum with specific particle size characteristics and a minimal particle size distribution, combined with an organic binder and other components like calcium carbonate, talc, and cellulose derivatives, which can be mixed in any order, providing a '2-in-1' ready-mix coating for plasterboards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional filling coatings are used, then good bonding and adhesion are achieved, but additional finishing coating is required
Solution Approach 1:
The patent combines filling and finishing functions into a single coating composition. The coating includes filler particles (5-35 μm) for filling capability and fine particles (1-5 μm) for finishing capability, allowing one coating to perform both functions that traditionally required separate filling and finishing coatings.
Solution Approach 2:
The coating composition is designed to be universal, serving both as a filling coating and a finishing coating. By incorporating a broad particle size distribution with both coarse and fine particles, the single coating can fill joints and provide a finished surface, eliminating the need for separate coating applications.
2Manufacturing precision
If drying coatings with broad particle size distribution are used, then filling capability is improved, but glide and workability deteriorate
Solution Approach 1:
The coating employs local quality by having different particle sizes perform different functions. Coarse particles (5-35 μm) provide filling capability in critical areas, while fine particles (1-5 μm) provide glide and workability. This spatial and functional differentiation of particle roles resolves the contradiction between filling performance and application ease.
Solution Approach 2:
The coating is a composite material containing multiple particle size fractions with complementary properties. The combination of coarse filler particles for filling and fine particles for flow characteristics creates a composite system that achieves both good filling capability and excellent glide, preventing the trade-off that would occur with a single particle size distribution.
3Reliability
If multiple separate coatings are used for filling and finishing, then functional performance is improved, but application time and complexity increase
Solution Approach 1:
The patent merges filling and finishing operations into a single coating application. The dual-function coating eliminates the need for separate filling and finishing coats, reducing application time while maintaining the functional performance of both operations through its multi-component particle system.
Data Source
AI summary
The invention concerns a drying coating material comprising, in weight percentages based on the total weight of coating material, 50 to 85 % of FGD gypsum and/or natural or synthetic gypsum having the following particle size properties: (i) a d50 ranging between 35 and 70 ?m and (ii) a span (d90 - d10/d50) less than 2. The invention also concerns a method for preparing said coating material. The invention further concerns a method for constructing a structure using said coating material.