Hydraulic binder-based, tapered-edge boards, production method and production line therefor, and light work construction method

Abstract

The subject of the invention is a novel plasterboard and its manufacturing processes. The novel board comprises, on one side, two first parallel feathered edges and, on the other side, two other, second, parallel feathered edges that are perpendicular to the first ones; or, on one side, two first parallel feathered edges and, either on the same side or on the other side, two second parallel feathered edges that are perpendicular to the first ones, the said other parallel feathered edges having a width of between 100 and 200 mm; or, on one side, two first parallel feathered edges and, either on the same side or on the other side, two second parallel feathered edges that are perpendicular to the first ones, the said second parallel feathered edges having a width such that the ratio of the width of the said second parallel feathered edges to the width of the said first parallel feathered edges is between 1.5 and 5.

1 . Board made of a hydraulic binder with a facing on each of its sides, having, on one side, two first parallel feathered edges and, on the other side, two second other parallel feathered edges that are perpendicular to the first ones.  
   
   
       2 . Board according to  claim 1 , in which the said second parallel feathered edges are transverse.  
   
   
       3 . Board according to  claim 1 , which furthermore includes two third feathered edges that are parallel to the second feathered edges, on the other side of the board from that having the said second feathered edges.  
   
   
       4 . Board according to  claim 3 , in which the ratio of the depth of the said second feathered edges to the depth of the said third feathered edges is between 1 and 10, preferably between 2 and 5.  
   
   
       5 . Board according to  claim 3 , in which the said second other parallel feathered edges have a width of between 100 and 200 mm.  
   
   
       6 . Board according to  claim 5 , in which the width of the said second parallel feathered edges is between 120 and 180 mm or between 150 and 200 mm or between 100 and 150 mm.  
   
   
       7 . Board according to  claim 3 , in which the said first and second parallel feathered edges have approximately the same width.  
   
   
       8 . Board according to  claim 3 , in which the said other parallel feathered edges have a width such that the ratio of the width of the said second parallel feathered edges to the width of the said first parallel feathered edges is between 1.5 and 5, preferably between 2 and 4.  
   
   
       9 . Board made of a hydraulic binder with a facing on each of its sides, having, on one face, two first parallel feathered edges and, either on the same side or on the other side, two second parallel feathered edges that are perpendicular to the first ones, the said other parallel feathered edges having a width of between 100 and 200 mm.  
   
   
       10 . Board according to  claim 9 , in which the width of the said second parallel feathered edges is between 120 and 180 mm or between 150 and 200 mm or between 100 and 150 mm.  
   
   
       11 . Board according to  claim 9 , in which the said first and second parallel feathered edges have approximately the same width.  
   
   
       12 . Board according to  claim 9 , in which the said other parallel feathered edges have a width such that the ratio of the width of the said second parallel feathered edges to the width of the said first parallel feathered edges is between 1.5 and 5, preferably between 2 and 4.  
   
   
       13 . Board made of a hydraulic binder with a facing on each of its sides, having, on one side, two first parallel feathered edges and, either on the same side or on the other side, two second parallel feathered edges that are perpendicular to the first ones, the said second parallel feathered edges having a width such that the ratio of the width of the said second parallel feathered edges to the width of the said first parallel feathered edges is between 1.5 and 5.  
   
   
       14 . Board according to  claim 13 , in which the ratio is between 2 and 4.  
   
   
       15 . Board according to  claim 13 , in which the width of the said second parallel feathered edges is between 100 and 200 mm, preferably between 120 and 180 mm or between 150 and 200 mm.  
   
   
       16 . Board according to  claim 9 , in which the said second parallel feathered edges are transverse.  
   
   
       17 . Board according to one of  claim 9 , which furthermore includes two third feathered edges that are parallel to the second feathered edges, on the other side of the board from the side having the said second feathered edges.  
   
   
       18 . Board according to  claim 17 , in which the ratio of the depth of the said second feathered edges to the depth of the said third feathered edges is between 1 and 10, preferably between 2 and 5.  
   
   
       19 . Board according to  claim 9 , in which the said second parallel feathered edges are on the same side as the said first parallel feathered edges.  
   
   
       20 . Board according to  claim 9 , in which the said second parallel feathered edges are on the other side from the side having the said first parallel feathered edges.  
   
   
       21 . Board according to  claim 13 , in which the said second parallel feathered edges are transverse.  
   
   
       22 . Board according to one of  claim 13 , which furthermore includes two third feathered edges that are parallel to the second feathered edges, on the other side of the board from the side having the said second feathered edges.  
   
   
       23 . Board according to  claim 22 , in which the ratio of the depth of the said second feathered edges to the depth of the said third feathered edges is between 1 and 10, preferably between 2 and 5.  
   
   
       24 . Board according to  claim 13 , in which the said second parallel feathered edges are on the same side as the said first parallel feathered edges.  
   
   
       25 . Board according to  claim 13 , in which the said second parallel feathered edges are on the other side from the side having the said first parallel feathered edges.  
   
   
       26 . Board according to  claim 1 , this board having marking on the side having the two first parallel feathered edges, which marking identifies the presence of the two other parallel feathered edges that are perpendicular to the first ones, the said board being intended to be used in cooperation with an identical second board, a parallel feathered edge of a first board being butted against a parallel feathered edge of a second board, these feathered edges of the said boards being identified by the marking present on that side having the two first parallel feathered edges of the said boards.  
   
   
       27 . Board according to  claim 20 , this board having marking on the side having the two first parallel feathered edges, which marking identifies the presence of the two other parallel feathered edges that are perpendicular to the first ones, the said board being intended to be used in cooperation with an identical second board, a parallel feathered edge of a first board being butted against a parallel feathered edge of a second board, these feathered edges of the said boards being identified by the marking present on that side having the two first parallel feathered edges of the said boards.  
   
   
       28 . Board according to  claim 25 , this board having marking on the side having the two first parallel feathered edges, which marking identifies the presence of the two other parallel feathered edges that are perpendicular to the first ones, the said board being intended to be used in cooperation with an identical second board, a parallel feathered edge of a first board being butted against a parallel feathered edge of a second board, these feathered edges of the said boards being identified by the marking present on that side having the two first parallel feathered edges of the said boards.  
   
   
       29 . Board according to  claim 26 , in which the marking comprises more than three, especially more than five, repeated marks, preferably from six to ten, advantageously seven, repeated marks.  
   
   
       30 . Board according to  claim 1 , in which the hydraulic binder is plaster.  
   
   
       31 . Board according to  claim 9 , in which the hydraulic binder is plaster.  
   
   
       32 . Board according to  claim 13 , in which the hydraulic binder is plaster.  
   
   
       33 . Method of constructing an interior structure, comprising the following steps: 
 a) the boards according to  claim 1  are placed on a support, the boards being butted together along the feathered edges;    b) the boards are fixed to the support along the feathered edges;    c) the boards are joined together with at least one joint cement; and, optionally,    d) the joints are finished with a complementary finish plaster.    
   
   
       34 . Method of constructing an interior structure, comprising the following steps: 
 a) the boards according to  claim 9  are placed on a support, the boards being butted together along the feathered edges;    b) the boards are fixed to the support along the feathered edges;    c) the boards are joined together with at least one joint cement; and, optionally,    d) the joints are finished with a complementary finish plaster.    
   
   
       35 . Method of constructing an interior structure, comprising the following steps: 
 a) the boards according to  claim 13  are placed on a support, the boards being butted together along the feathered edges;    b) the boards are fixed to the support along the feathered edges;    c) the boards are joined together with at least one joint cement; and, optionally,    d) the joints are finished with a complementary finish plaster.    
   
   
       36 . Method according to  claim 35 , in which the joint cement is applied along the joints between boards with a tool, the characteristic size of which is greater than twice the width of the said first parallel feathered edges and less than or equal to twice the width of the said other parallel feathered edges.  
   
   
       37 . Method of constructing an interior structure, comprising the following steps: 
 a) the boards according to  claim 26  are placed on a support, the boards being butted together along the feathered edges, one parallel feathered edge of a first board being butted against a parallel feathered edge of a second board, these feathered edges of the said boards being identified by the marking present on that side having the two first parallel feathered edges of the said boards;    b) the boards are fixed to the support along the feathered edges;    c) the boards are joined together with at least one joint cement; and, optionally,    d) the joints are finished with a complementary finish plaster.    
   
   
       38 . Method of constructing an interior structure, comprising the following steps: 
 a) the boards according to  claim 27  are placed on a support, the boards being butted together along the feathered edges, one parallel feathered edge of a first board being butted against a parallel feathered edge of a second board, these feathered edges of the said boards being identified by the marking present on that side having the two first parallel feathered edges of the said boards;    b) the boards are fixed to the support along the feathered edges;    c) the boards are joined together with at least one joint cement; and, optionally,    d) the joints are finished with a complementary finish plaster.    
   
   
       39 . Method of constructing an interior structure, comprising the following steps: 
 a) the boards according to  claim 28  are placed on a support, the boards being butted together along the feathered edges, one parallel feathered edge of a first board being butted against a parallel feathered edge of a second board, these feathered edges of the said boards being identified by the marking present on that side having the two first parallel feathered edges of the said boards;    b) the boards are fixed to the support along the feathered edges;    c) the boards are joined together with at least one joint cement; and, optionally,    d) the joints are finished with a complementary finish plaster.    
   
   
       40 . Method of construction according to  claim 37 , in which the joint cement and/or the finish plaster are/is placed along the boundary defined by the marking of the board.  
   
   
       41 . Construction method according to  claim 33 , in which, during step c), a tape, especially a paper tape, or a tape made of glass-fibre fabric, which may or may not be self-adhesive, is used.  
   
   
       42 . Process for manufacturing a board according to  claim 1 , comprising one of the following steps: 
 1) a hydraulic binder composition is poured onto a facing material supported by a conveyor belt comprising at least two forming tapes fitted with longitudinal tapes, and this is covered with a second facing material so as to obtain a preform and then an impression is made in the upper part of the preform before the first forming tape;    2) the hydraulic binder composition is left to set; and    3) the preform is cut at the feathering created by the impression into a board made of hydraulic binder with a facing on each of its sides, comprising, on one side, two first parallel feathered edges and, on the other side, two other parallel feathered edges that are perpendicular to the first ones.    
   
   
       43 . Process for manufacturing a board according to  claim 20 , comprising one of the following steps: 
 1) a hydraulic binder composition is poured onto a facing material supported by a conveyor belt comprising at least two forming tapes fitted with longitudinal tapes, and this is covered with a second facing material so as to obtain a preform and then an impression is made in the upper part of the preform before the first forming tape;    2) the hydraulic binder composition is left to set; and    3) the preform is cut at the feathering created by the impression into a board made of hydraulic binder with a facing on each of its sides, comprising, on one side, two first parallel feathered edges and, on the other side, two other parallel feathered edges that are perpendicular to the first ones.    
   
   
       44 . Process for manufacturing a board according to  claim 25 , comprising one of the following steps: 
 1) a hydraulic binder composition is poured onto a facing material supported by a conveyor belt comprising at least two forming tapes fitted with longitudinal tapes, and this is covered with a second facing material so as to obtain a preform and then an impression is made in the upper part of the preform before the first forming tape;    2) the hydraulic binder composition is left to set; and    3) the preform is cut at the feathering created by the impression into a board made of hydraulic binder with a facing on each of its sides, comprising, on one side, two first parallel feathered edges and, on the other side, two other parallel feathered edges that are perpendicular to the first ones.    
   
   
       45 . Process for manufacturing a board according to  claim 26 , comprising the following steps: 
 1) a hydraulic binder composition is poured onto a facing material supported by a conveyor belt comprising at least two forming tapes fitted with longitudinal tapes, and this is covered with a second facing material so as to obtain a preform and then an impression is made in the upper part of the preform before the first forming tape;    2) the hydraulic binder composition is left to set; and    3) the preform is cut at the feathering created by the impression into a board made of hydraulic binder with a facing on each of its sides, comprising, on one side, two first parallel feathered edges and, on the other side, two other parallel feathered edges that are perpendicular to the first ones;    in which an impression is made in the facing material with the marking.    
   
   
       46 . Process for manufacturing a board according to  claim 27 , comprising the following steps: 
 1) a hydraulic binder composition is poured onto a facing material supported by a conveyor belt comprising at least two forming tapes fitted with longitudinal tapes, and this is covered with a second facing material so as to obtain a preform and then an impression is made in the upper part of the preform before the first forming tape;    2) the hydraulic binder composition is left to set; and    3) the preform is cut at the feathering created by the impression into a board made of hydraulic binder with a facing on each of its sides, comprising, on one side, two first parallel feathered edges and, on the other side, two other parallel feathered edges that are perpendicular to the first ones;    in which an impression is made in the facing material with the marking.    
   
   
       47 . Process for manufacturing a board according to  claim 28 , comprising the following steps: 
 1) a hydraulic binder composition is poured onto a facing material supported by a conveyor belt comprising at least two forming tapes fitted with longitudinal tapes, and this is covered with a second facing material so as to obtain a preform and then an impression is made in the upper part of the preform before the first forming tape;    2) the hydraulic binder composition is left to set; and    3) the preform is cut at the feathering created by the impression into a board made of hydraulic binder with a facing on each of its sides, comprising, on one side, two first parallel feathered edges and, on the other side, two other parallel feathered edges that are perpendicular to the first ones;    in which an impression is made in the facing material with the marking.    
   
   
       48 . Manufacturing process according to  claim 42 , wherein the hydraulic binder comprises plaster.  
   
   
       49 . Line for producing hydraulic-binder-based boards from a preform comprising a facing material covered with a hydraulic binder composition and supported by a conveyor belt, comprising at least two forming tapes fitted with longitudinal tapes, this line furthermore including a device that produces an impression in the preform before the first forming tape, this impression being produced in the upper part of the preform.  
   
   
       50 . Production line according to  claim 49 , in which the device for forming the impression in a hydraulic-binder-based preform comprises at least: 
 a frame;    two first pulleys supported at a first end of the frame and two second pulleys at a second end of the frame; the first pulleys and second pulleys being in parallel planes; the pulleys facing each other being identical;    two transmission belts wrapped respectively around the first pulleys and the second pulleys;    at least one wire fixed removably to the belts and extending between these belts so that its longitudinal axis is parallel to the axis of rotation of the pulleys;    the distance between the transmission belts of this apparatus being at least equal to the width of the preform and this apparatus being appropriately placed so that when its transmission belts turn, its wire(s) creates(create) an impression in the preform.    
   
   
       51 . Production line according to  claim 49 , wherein the hydraulic binder comprises gypsum plaster.  
   
   
       52 . Process for manufacturing a hydraulic-binder-based board from a preform intended to be cut, comprising the following steps: 
 1) a hydraulic binder composition is poured onto a facing material supported by a conveyor belt, which comprises at least two forming tapes fitted with longitudinal tapes, the said composition being covered with a second facing material so as to obtain a preform, and then an impression is made in this preform before the first forming tape;    2) the hydraulic binder composition is left to partly set on at least one forming tape;    3) a lath is introduced under the partially-set preform opposite the point or at the point where the impression has been made; and    4) the preform is cut at the feathering created by the lath.    
   
   
       53 . Process according to  claim 52 , in which the setting in step 2, corresponds to between 5 and 30% hydration.  
   
   
       54 . Process according to  claim 52 , in which the lath is introduced after the first forming belt.  
   
   
       55 . Process according to  claim 52 , in which the impression is made in the upper part of the preform and the lath is introduced opposite the point where the impression has been made, so as to form transverse feathered edges on the same side as the longitudinal feathered edges formed by the longitudinal tapes.  
   
   
       56 . Process according to  claim 52 , in which the lath is removed after complete hydraulic setting.  
   
   
       57 . Process according to  claim 52 , in which the lath is removed before complete hydraulic setting.  
   
   
       58 . Process according to  claim 57 , in which the lath is introduced during a period corresponding to 0.5 to 5% hydration.  
   
   
       59 . Manufacturing process according to  claim 52 , wherein the hydraulic binder comprises gypsum plaster.  
   
   
       60 . Line for producing hydraulic-binder-based boards from a preform comprising a facing material covered with a hydraulic binder composition and supported by a conveyor belt, comprising at least two forming belts fitted with longitudinal tapes, this line furthermore including a device for making an impression in the preform before the first forming belt, and a device for introducing, under the preform between two forming belts, a lath opposite the point or at the point where the impression has been made.  
   
   
       61 . Production line according to  claim 60 , in which the device for forming the impression in a hydraulic-binder-based preform comprises at least: 
 a frame;    two first pulleys supported at a first end of the frame and two second pulleys at a second end of the frame; the first pulleys and second pulleys being in parallel planes; the pulleys facing each other being identical;    two transmission belts wrapped respectively around the first pulleys and the second pulleys;    at least one wire fixed removably to the belts and extending between these belts so that its longitudinal axis is parallel to the axis of rotation of the pulleys;    the distance between the transmission belts of this apparatus being at least equal to the width of the preform and this apparatus being appropriately placed so that when its transmission belts turn, its wire(s) creates an impression in the preform.    
   
   
       62 . Production line according to  claim 60 , in which the device for introducing a lath under the preform between two forming belts opposite the point or at the point where the impression has been made comprises at least: 
 a laths magazine;    at least one lath;    means for extracting, one at a time, a lath from the laths magazine;    means for receiving the extracted lath;    means for moving the extracted lath in a direction parallel to its length;    means for supporting the moved lath; and    means for sliding the lath under the facing material.    
   
   
       63 . Production line according to  claim 60 , in which the device for introducing a lath under the preform between two forming belts, opposite the point or at the point where the impression has been made, comprises at least: 
 a secondary forming device, the said device comprising: a belt supporting a forming lath, this belt being mounted on rollers, this belt sliding over a plate, preferably made of marble, and facing the other side of the preform;    a backing device, the said backing device comprising: a belt mounted on rollers, this belt sliding over a plate, preferably made of marble;    the belts having a linear speed approximately equal to that of the forming belts.    
   
   
       64 . Production line according to  claim 63 , which furthermore includes, downstream of the secondary forming device and also facing the backing device: 
 a calibration device, the said device comprising: a belt mounted on rollers, this belt sliding over a plate, preferably made of marble;    the belt having a linear speed approximately equal to that of the forming belts.    
   
   
       65 . Production line according to  claim 60 , wherein the hydraulic binder comprises gypsum plaster.