AU2010202894B2 - Reinforced plasterboard - Google Patents

Reinforced plasterboard Download PDF

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Publication number
AU2010202894B2
AU2010202894B2 AU2010202894A AU2010202894A AU2010202894B2 AU 2010202894 B2 AU2010202894 B2 AU 2010202894B2 AU 2010202894 A AU2010202894 A AU 2010202894A AU 2010202894 A AU2010202894 A AU 2010202894A AU 2010202894 B2 AU2010202894 B2 AU 2010202894B2
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AU
Australia
Prior art keywords
reinforced
paper
paper liner
plasterboard
liner
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
AU2010202894A
Other versions
AU2010202894A1 (en
Inventor
Thanh K. Huynh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Knauf Gypsum Pty Ltd
Original Assignee
USG Boral Building Products Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2009904926A external-priority patent/AU2009904926A0/en
Application filed by USG Boral Building Products Pty Ltd filed Critical USG Boral Building Products Pty Ltd
Priority to AU2010202894A priority Critical patent/AU2010202894B2/en
Publication of AU2010202894A1 publication Critical patent/AU2010202894A1/en
Assigned to USG BORAL BUILDING PRODUCTS PTY LIMITED reassignment USG BORAL BUILDING PRODUCTS PTY LIMITED Alteration of Name(s) of Applicant(s) under S113 Assignors: BORAL AUSTRALIAN GYPSUM LIMITED
Application granted granted Critical
Publication of AU2010202894B2 publication Critical patent/AU2010202894B2/en
Ceased legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

C:\NRcnorlDCC\EJLk 19 343 1_-.DO-C-74)7/20 10 A reinforced plasterboard including a core of cementitious material, and a reinforced paper liner on at least one side of the core, wherein the reinforced paper liner 5 includes two layers of paper with a reinforcement layer interposed between said two layers of paper.

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (ORIGINAL) Name of Applicant: Boral Australian Gypsum Limited Actual Inventor: Thanh K. Huynh Address for Service: DAVIES COLLISON CAVE, Patent Attorneys, 1 Nicholson, Melbourne, Victoria 3000 Invention Title: "Reinforced plasterboard" Details of Associated Provisional Application: No: 2009904926 The following statement is a full description of this invention, including the best method of performing it known to us: C:\NRPorb\DCC\EJL\3051874_.DOC. 8/7/10 C :\RPorbADCC\EIL813431|I.DOC-7A)7/2010 REINFORCED PLASTERBOARD Field of the Invention 5 This invention relates to a reinforced plasterboard and, more particularly but not exclusively, to a reinforced plasterboard having a gypsum core and a reinforced paper liner to improve impact resistance and flexural strength. Background of the Invention 10 It is known to provide a reinforced plasterboard having external layers of paper on either side of a core of cementitious gypsum based material. One previously proposed reinforced plasterboard has an internal layer of mesh reinforcement embedded within one side of the core of cementitious material, with a layer of paper immediately adjacent to the 15 mesh reinforcement. Although plasterboard reinforced in this way with a layer of mesh reinforcement embedded within a side of the core of cementitious material may result in improved resistance to impacts from soft bodies, such as human impact with plasterboard wall panels 20 in buildings, the applicant has determined that it would be beneficial for there to be provided plasterboard panels with further improved impact resistance and flexural strength. More specifically, in testing existing reinforced plasterboard according to a standard hard body impact testing regime, it was found that the plasterboard exhibited significant damage on both the side of the plasterboard subjected to the impact, and also the rear of the board 25 where the paper liner is prone to tearing/perforation. The applicant has identified that it would be advantageous for there to be provided an improved reinforced plasterboard product which performs better in hard body impact tests, preferably with minimal deformation of the side of the plasterboard subjected to the impact and without tearing/perforation of the paper liner on the reverse side. 30 H:\txb\Interwoven\NRPortbl\DCC\TXB\88432461 .doc - 11/11/15 -2 Examples of the invention seek to solve, or at least ameliorate, one or more disadvantages of previous reinforced plasterboard panels. Summary of the Invention In accordance with one aspect of the present invention, there is provided a 5 reinforced plasterboard including a core of cementitious material, and a reinforced paper liner on at least one side of the core, wherein the reinforced paper liner includes a reinforcement element, the reinforcement element being incorporated within the paper liner during forming of the paper liner by being within one or more layers of paper of the paper liner. 10 Preferably, the reinforced paper liner includes two layers of paper with the reinforcement element in the form of a reinforcement layer interposed between said two layers of paper. Alternatively, the reinforced paper liner includes a layer of paper with the reinforcement element integrally formed within said layer of paper. 15 Preferably, the reinforced plasterboard comprises the reinforced paper liner on one side of the core, and a like reinforced paper liner on an opposite side of the core. In a preferred example, the reinforced plasterboard comprises the reinforced paper liner on one side of the core, and a paper liner on an opposite side of the core. The reinforcement element may be in the form of a mesh. More preferably, the 20 reinforcement element is in the form of an open weave fibre mesh layer. Preferably, the cementitious material includes gypsum plaster. In accordance with another aspect of the present invention, there is provided a method of continuously forming a reinforced plasterboard as described above, including the steps of: C.NRPortbhDCC\EJlI5 131431_1DOC-717/212110 -3 providing a continuous feed of the two layers of paper, providing a continuous feed of the reinforcement layer between the layers of paper; adhering together the two layers of paper and the reinforcement layer to 5 form the reinforced paper liner; providing a continuous feed of cementitious material slurry adjacent one of said layers of paper; and setting the cementitious material slurry to adhere to the reinforced paper liner to form the core of cementitious material. 10 In accordance with yet another aspect of the present invention, there is provided a method of continuously forming a reinforced plasterboard as described above, including the steps of: providing a continuous feed of the reinforced paper liner, wherein the 15 reinforced paper liner is pre-formed with the reinforcement element within said one or more layers of paper; providing a continuous feed of cementitious material slurry adjacent one side of the reinforced paper liner; and setting the cementitious material slurry to adhere to the reinforced paper 20 liner to form the core of cementitious material. Preferably, the method of continuously forming a reinforced plasterboard includes the steps of: providing a continuous feed of a further paper liner to be located at a side of 25 the cementitious material slurry opposite to the reinforced paper liner; and setting the cementitious material slurry between the reinforced paper liner and the further paper liner. Preferably, the further paper liner is a like reinforced paper liner. More preferably, 30 the further paper liner is a pre-formed like reinforced paper liner.
C:NRPonblDCC\EJLI 81343 fLDOC.7AJ?/20 10 -4 Alternatively, the further paper liner is formed continuously on-line during the forming of the reinforced plasterboard. Brief Description of the Drawings 5 The invention is described, by way of non-limiting example only, with reference to the accompanying drawings in which: Figure 1 shows a cross-sectional perspective view of a reinforced plasterboard in 10 accordance with a first example of the present invention; Figure 2 shows a cross-sectional perspective view of a reinforced plasterboard in accordance with a second example of the present invention; 15 Figure 3 shows components of a reinforced paper liner used in the examples shown in Figures 1 and 2; Figure 4a shows a front view of a prior art reinforced plasterboard damaged in a hard body impact test; 20 Figure 4b shows a rear side of the prior art reinforced plasterboard of Figure 4a; Figure 5a shows a front side of a reinforced plasterboard in accordance with an example of the invention, damaged in a hard body impact test; and 25 Figure 5b shows a rear side of the reinforced plasterboard of Figure 5a. Detailed Description 30 With reference to Figures 1 to 3, there are illustrated reinforced plasterboards 10, in accordance with examples of the present invention. Each of the reinforced plasterboards C \NRPonbl\DCC\EJL\813431I.DOC-7/)7f2l)O -5 10 has a reinforced paper liner 12 on one or both sides of a core 14 of cementitious material, so as to improve impact resistance and flexural strength. The reinforced plasterboard 10 may be suitable for use as panelling to cover a wall, ceiling or floor of a building. 5 In both cases shown in Figures 1 and 2, the reinforced plasterboard 10 includes the core 14 of cementitious material, and the reinforced paper liner 12 on at least one side of the core 14. The reinforced paper liner 12 includes two layers of paper 16, 18 with a reinforcement in the form of a reinforcement layer 20 interposed between the two layers of 10 paper 16, 18. Although the examples shown in the drawings have the reinforced paper liner including two layers of paper with the reinforcement element in the form of a reinforcement layer interposed between the layers of paper, in other examples the 15 reinforced paper liner may include a layer of paper with the reinforcement element integrally formed within the layer of paper. In such a case, the reinforcement element may comprise an impregnated reinforcement mesh which is integrated within the paper during manufacture of the paper. 20 With reference to Figure 1, there is shown a cross-sectional perspective view of a reinforced plasterboard 10 in accordance with a first example of the present invention. The reinforced plasterboard includes the core 14 of cementitious material covered on one side with a reinforced paper liner 12, and on the opposite side with a further paper liner 22 which comprises a single sheet of paper 24. The reinforced paper liner 12 includes one 25 layer of paper 16 adjacent the core 14, an external layer of paper 18, and a reinforcement layer 20 interposed between the two layers of paper 16, 18. Turning to Figure 2, there is shown a reinforced plasterboard 10 in accordance with a second example of the present invention, including a reinforced paper liner 12, 12a on 30 each side of the core 14. In particular, the reinforced plasterboard 10 includes the central core 14 formed of gypsum based cementitious material, with a reinforced paper liner 12 on C:\NRPonbDCCEiL"f 13431_ .DOC-7A7/2011) -6 one side of the core 14, and a like reinforced paper liner 12a on an opposite side of the core 14. The reinforced paper liner 12 includes a layer of paper 16 adjacent the core 14, an external layer of paper 18, and a reinforcement layer 20 interposed between the two layers of paper 16, 18. Similarly, the reinforced paper liner 12a includes a layer of paper 16a 5 adjacent the core 14, an external layer of paper 18a, and a reinforcement layer 20a interposed between the two layers of paper 16a, 18a. Because of the reinforced paper liners 12, 12a incorporating the reinforcement layer 20, 20a sandwiched between two layers of paper 16, 18 (16a, 18a), the reinforced plasterboard 10 has greater resistance to hard body impact and greater flexural strength when compared to either non-reinforced 10 plasterboard or prior art reinforced plasterboard having a layer of reinforcement mesh embedded within the core of cementitious material. The reinforcement layer 20 may be in the form of a mesh, as shown in Figure 3. Specifically, the reinforcement layer 20 may be in the form of an open weave fibre mesh 15 layer 26. Figure 3 shows the reinforcement layer 20 in the form of an open weave fibre mesh layer 26, and depicts the reinforcement layer 20 resting flat on one layer of paper 16, with the other layer of paper 18 folded away from the reinforcement layer 20 so as to clearly demonstrate the manner in which the reinforcement layer 20 is interposed between the two layers of paper 16, 18. In practice, the two layers of paper 16, 18 and the 20 reinforcement layer 20 are adhered together to form the reinforced paper liner 12. The reinforced plasterboard 10 may be formed "on-line" by providing a continuous feed of the two layers of paper 16, 18, providing a continuous feed of the reinforcement layer 20 between the layers of paper 16, 18, and by adhering together the two layers of 25 paper 16, 18 and the reinforcement layer 20 to form the reinforced paper liner 12. A slurry of cementitious material is continuously fed adjacent to one of the layers of paper 16, 18, and the cementitious material is then set to adhere to the reinforced paper liner 12. The reinforced paper liner 12 may be pre-formed such that it is provided in a single roll from which it is fed in forming the reinforced plasterboard continuously. Alternatively, the two 30 layers of paper 16, 18 may be fed from separate rolls, and the reinforcement layer 20 may be fed from another roll, such that the three layers 16, 18, 20 are brought together to form C\NRPonbWlDCC\FJL%1813431_1 DOC-7A7/2010 -7 the reinforced paper liner 12 on-line during the continuous formation of the reinforced plasterboard 10. With reference to Figures 4a, 4b, 5a and 5b, there are shown results of a hard body 5 impact test conducted on a sample of previous reinforced plasterboard 28 (Figures 4a and 4b) and a sample of reinforced plasterboard 10 in accordance with an example of the present invention (Figures 5a and 5b). In the hard body impact text, a 4.0 kilogram steel ball was swung at a right angle to each of the wall specimens at a predetermined swing arc and drop height, equating to an imposed impact energy. The results shown in Figures 4a, 10 4b, 5a, 5b and below are for 1,000 millimetre drop height and 30 Nm. With reference to Figure 4a, it can be seen that the steel ball has produced a relatively large dent, approximately 36 millimetres in diameter in the previous reinforced plasterboard 28. Furthermore, as shown in Figure 4b, the reverse side of the previous 15 reinforced plasterboard 28 has been damaged considerably by perforation of the paper liner. In contrast, the reinforced plasterboard 10 in accordance with an example of the present invention has fared much better in the hard body impact test. Figure 5a shows that 20 the dent in the front surface of the reinforced plasterboard 10 is smaller than the dent in Figure 4a (bearing in mind the different magnification of the photographs evidenced by the measurement tape 30), and Figure 5b shows that there is no perforation in the external paper liner on the rear side of the reinforced plasterboard 10. 25 The reinforced plasterboard 10 in accordance with the example of the present invention is able to maintain integrity of the paper liner, and displays an improvement in flexural strength in both directions of the plasterboard (across and parallel directions), as shown in the table below: Board Type Average Flexural Strength (N) Across direction Parallel direction Example of present invention 773 644 C:RPotnblDCC\EJL%1S8D431_ DOC-7M17/2010 -8 Previous reinforced plasterboard 720 576 While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various 5 changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above described exemplary embodiments. The reference in this specification to any prior publication (or information derived 10 from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. 15 Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. 20

Claims (14)

1. A reinforced plasterboard including a core of cementitious material, and a reinforced paper liner on at least one side of the core, wherein the reinforced paper liner includes a reinforcement element, the reinforcement element being incorporated within the paper liner during forming of the paper liner by being within one or more layers of paper of the paper liner.
2. A reinforced plasterboard as claimed in claim 1, wherein the reinforced paper liner includes two layers of paper with the reinforcement element in the form of a reinforcement layer interposed between said two layers of paper.
3. A reinforced plasterboard as claimed in claim 1, wherein the reinforced paper liner includes a layer of paper with the reinforcement element integrally formed within said layer of paper.
4. A reinforced plasterboard as claimed in any one of claims 1 to 3, wherein the reinforced plasterboard comprises the reinforced paper liner on one side of the core, and a like reinforced paper liner on an opposite side of the core.
5. A reinforced plasterboard as claimed in any one of claims 1 to 3, wherein the reinforced plasterboard comprises the reinforced paper liner on one side of the core, and a paper liner on an opposite side of the core.
6. A reinforced plasterboard as claimed in any one of claims 1 to 5, wherein the reinforcement element is in the form of a mesh.
7. A reinforced plasterboard as claimed in claim 6, wherein the reinforcement element is in the form of an open weave fibre mesh layer.
8. A reinforced plasterboard as claimed in any one of claims 1 to 7, wherein the cementitious material includes gypsum plaster. C :RPotnbDCC\EJLUisi3431_ DOC-7A7/2010 - 10
9. A method of continuously forming a reinforced plasterboard as claimed in claim 2, or any one of claims 4 to 8 when dependent on claim 2, including the steps of: providing a continuous feed of the two layers of paper, providing a continuous feed of the reinforcement layer between the layers 5 of paper; adhering together the two layers of paper and the reinforcement layer to form the reinforced paper liner; providing a continuous feed of cementitious material slurry adjacent one of said layers of paper; and 10 setting the cementitious material slurry to adhere to the reinforced paper liner to form the core of cementitious material.
10. A method of continuously forming a reinforced plasterboard as claimed in any one of claims 1 to 8, including the steps of: 15 providing a continuous feed of the reinforced paper liner, wherein the reinforced paper liner is pre-formed with the reinforcement element within said one or more layers of paper; providing a continuous feed of cementitious material slurry adjacent one side of the reinforced paper liner; and 20 setting the cementitious material slurry to adhere to the reinforced paper liner to form the core of cementitious material.
11. A method of continuously forming a reinforced plasterboard as claimed in claim 9 or claim 10, including the steps of: 25 providing a continuous feed of a further paper liner to be located at a side of the cementitious material slurry opposite to the reinforced paper liner; and setting the cementitious material slurry between the reinforced paper liner and the further paper liner. 30
12. A method of continuously forming a reinforced plasterboard as claimed in claim 11, wherein the further paper liner is a like reinforced paper liner. H:\txb\Interwoven\NRPortbl\DCC\TXB\88432461 .doc - 11/11/15 - 11
13. A method of continuously forming a reinforced plasterboard as claimed in claim 12, wherein the further paper liner is a pre-formed like reinforced paper liner.
14. A method of continuously forming a reinforced plasterboard as claimed in claim 12, wherein the further paper liner is formed continuously on-line during the forming of the reinforced plasterboard.
AU2010202894A 2009-10-09 2010-07-08 Reinforced plasterboard Ceased AU2010202894B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2010202894A AU2010202894B2 (en) 2009-10-09 2010-07-08 Reinforced plasterboard

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AU2009904926 2009-10-09
AU2009904926A AU2009904926A0 (en) 2009-10-09 Reinforced plasterboard
AU2010202894A AU2010202894B2 (en) 2009-10-09 2010-07-08 Reinforced plasterboard

Publications (2)

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AU2010202894A1 AU2010202894A1 (en) 2011-04-28
AU2010202894B2 true AU2010202894B2 (en) 2015-12-03

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AU2010202894A Ceased AU2010202894B2 (en) 2009-10-09 2010-07-08 Reinforced plasterboard

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Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113482233A (en) * 2021-07-23 2021-10-08 夏德斌 Composite gypsum board and manufacturing method thereof
CN114671663B (en) * 2022-04-11 2023-03-10 泰山石膏（铜陵）有限公司 Fire-resistant gypsum board for building and preparation method thereof

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999004112A1 (en) * 1997-07-16 1999-01-28 Fletcher Challenge Limited Reinforced plasterboard
WO2004069532A1 (en) * 2003-01-30 2004-08-19 Milliken & Company Textile reinforced wallboard

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999004112A1 (en) * 1997-07-16 1999-01-28 Fletcher Challenge Limited Reinforced plasterboard
WO2004069532A1 (en) * 2003-01-30 2004-08-19 Milliken & Company Textile reinforced wallboard

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