CN109311300A - 包含用非离子型聚合物粘结剂粘结的层压多层纸盖板的石膏墙板和方法 - Google Patents

包含用非离子型聚合物粘结剂粘结的层压多层纸盖板的石膏墙板和方法 Download PDF

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CN109311300A
CN109311300A CN201780038220.5A CN201780038220A CN109311300A CN 109311300 A CN109311300 A CN 109311300A CN 201780038220 A CN201780038220 A CN 201780038220A CN 109311300 A CN109311300 A CN 109311300A
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paper
layer
pvoh
boric acid
wallboard
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A·李
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United States Gypsum Co
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United States Gypsum Co
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    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B05D1/12—Applying particulate materials
    • 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
    • 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
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0038—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving application of liquid to the layers prior to lamination, e.g. wet laminating
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/14—Secondary fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • 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
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2250/00—Layers arrangement
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    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/12—Coating on the layer surface on paper 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/712—Weather resistant
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
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    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)
  • Paper (AREA)
  • Panels For Use In Building Construction (AREA)
  • Finishing Walls (AREA)
  • Producing Shaped Articles From Materials (AREA)

Abstract

提供了包含用非离子型聚合物粘结剂和交联剂粘结的层压多层纸盖板的墙板面板，以及制造墙板面板的方法。

Description

包含用非离子型聚合物粘结剂粘结的层压多层纸盖板的石膏 墙板和方法
技术领域
本发明提供了用层压多层纸盖板(paper cover sheet)制备的石膏墙板，其中纸层用非离子型聚合物粘结剂和交联剂粘结在一起。
背景技术
包括墙板、天花板面板和瓦片的各种石膏产品在建筑行业中普遍使用。这些石膏产品中有许多都是通过用煅烧石膏(α半水合硫酸钙、β半水合硫酸钙和/或无水硫酸钙)制备水性石膏浆料，对浆料进行塑型，然后在煅烧石膏再水合成石膏(二水合硫酸钙)时使浆料硬化。称为墙板的石膏板复合材料可以通过将石膏浆料夹在两张纸盖板之间制成。
如美国专利4,959,272(其全部公开内容以引用的方式并入本文)所详细描述的，用于墙板盖板的纸通常通过用水将各种纤维素纤维材料打浆制成，所述纤维素纤维材料可能包含废纸，包括旧瓦楞纸、牛皮纸粉屑和废报纸。然后，通过在若干个连续移动的钢丝圆筒(wire cylinder)上放水，将这种纸水料(paper-water stock)随后形成为纸层。为了制造多层纸，用承载毡将单独的纸层叠加并接合在一起。薄的纸网然后在压榨部脱水，在压榨部中水被挤压出网。压榨纸在多圆筒干燥部(multi-cylinder drying section)中干燥，其中在每个圆筒中添加蒸汽。干燥的纸经过挤压或压光操作，使得厚度均匀，最后卷成卷。这种纸随后作为纸盖板使用，通过将煅烧石膏浆料沉积在两个板之间并允许石膏凝固并干燥，从而形成石膏墙板。
通常使用两种不同的纸盖板。一种纸盖板是用于墙板背面。这种纸盖板被称为背纸板(backer paper sheet)。另一种纸盖板是用于墙板正面，其在墙板安装后可以被看到和装修。这种纸盖板被称为前纸板(facer paper sheet)。
多层纸盖板可能包含多个层。一些填料层(通常2到5层)被制备得具有硬浆性质，比如牛皮纸和硬纸板粉屑。这组填料层随后可用1到2个顶部衬垫层(也称为衬垫层或外层)覆盖。通常情况下，衬垫层主要由具有较短纤维的柔软研磨木材品质的飞叶刨花和报纸组成。用层压多层纸盖板覆盖墙板。通常，纸层通过在层形成和随后的压榨之后立刻彼此叠加而彼此粘附。
在墙板中，纸盖板有助于拔钉强度、抗弯强度、以及抗水性和抗霉菌性。研究还揭示，纸盖板的抗拉强度会影响石膏防火产品的防火性能。
已作出努力，防止层压多层纸盖板中的纸层彼此分离，以及防止分离与石膏芯直接相邻的纸层。如美国专利2,806,811所提供的，在制造纸层期间可在纸浆中添加树脂添加剂以作为配料。这种方法也被称为内部添加法，因为在纸层形成过程中，极低用量的添加剂与纸浆直接混合，以最大限度地减少白水化学变化。然而，提高纸的抗拉强度仍然是纸业中不断研究的课题。
发明内容
本公开提供了一种制备具有提高的抗拉强度的墙板的方法，其中多层纸盖板的纸层用与硼酸交联的非离子型聚合物粘结剂粘结在一起。该方法包含以下步骤：
-从纸浆形成纸层；
-用PVOH(聚乙烯醇)喷涂纸层；
-用硼酸溶液喷涂纸层；
-叠加纸层以形成用非离子型聚合物粘结剂粘结的多层纸板；
-压榨和干燥多层纸板；
制备石膏浆料；
在两个纸板之间沉积石膏浆料，其中至少一个是多层纸板；以及
形成墙板面板。
在一些实施例中，多层纸板包含至少一个填料层和至少一个衬垫层。PVOH和硼酸可以喷涂在以下层的至少一种之间：两个填料层之间、填料层和衬垫层之间、以及两个衬垫层之间。除了交联之外，硼酸还可作为生物杀灭处理剂。
在其他实施例中，PVOH施加于第一层的表面，而硼酸施加于第二层的表面，然后叠加第一层和第二层，使得用PVOH处理的表面与用硼酸处理的表面接触。PVOH聚合物可以是超低聚合度的聚合物、低聚合度的聚合物、或其组合。纸浆可包含再生纸废物，包括由牛皮纸、硬纸板粉屑、飞叶刨花和/或报纸组成的再生纸废物。
PVOH可作为浓度按重量计在1％到10％范围内的水基溶液施加。硼酸可作为浓度按重量计在1％到10％范围内的水基溶液施加。
本发明还涉及一种用这种方法获得的墙板。
墙板包含配置在两个纸盖板之间的石膏芯，第一纸盖板是前盖板并且第二纸盖板是背盖板，其中这两种纸盖板都是多层纸盖板，并且其中这两种纸盖板中的每种纸盖板中的至少两层用与硼酸交联的非离子型聚合物粘结剂粘结在一起，其中非离子型聚合物粘结剂是PVOH聚合物或共聚物。PVOH可以从平均分子量在12,000到200,000范围内，特别是在12,000到50,000范围内的PVOH聚合物中选择。PVOH水解70-100ml％，特别地PVOH水解95-100ml％。合适的PVOH聚合物包括超低聚合度和低聚合度的聚合物。
墙板中的前纸盖板可以包含由1到2个衬垫层覆盖的2到5个填料层，并且前纸盖板和背纸盖板可以包含所述的废纸。
其他实施例提供了一种制造墙板面板的方法，其中执行以下步骤：
-从纸浆形成纸层；
-在层间施加PVOH和硼酸溶液；
-叠加纸层以形成用非离子型聚合物粘结剂粘结的多层纸板；
-压榨和干燥多层纸板；
-制备石膏浆料；
-在两个纸板之间沉积石膏浆料，其中至少一个是多层纸板；以及
-形成墙板面板。
具体实施方式
本发明提供了具有提高的抗拉强度和防火性能的石膏产品，包括石膏墙板。还提供了获得这类产品的方法。
公开了一种在多层纸板形成过程中，在即将叠加纸层之前，将非离子型强度增强聚合物和交联剂直接施加于纸层表面的方法。
多种非离子型强度增强聚合物都是适宜的，包括聚乙烯醇(PVOH)聚合物和聚乙烯醇衍生物。聚乙烯醇(PVOH)是一种聚合物，包含连接在一起形成聚合物结构的乙烯醇单体和/或其衍生物。PVOH可以是均聚物或共聚物。一些共聚物可以包含从乙烯、丙烯酸甲酯和羧酸中选择的单体。合适的PVOH聚合物可以包括具有超低聚合度(150-300)、低聚合度(350-650)、中等聚合度(1000-1500)和高聚合度(1600-2200)的那些。所提供的一些方法使用了超低聚合度或低聚合度的PVOH，或者两者都使用。
PVOH可以通过将聚醋酸乙烯酯水解成聚乙烯醇得到。适宜的PVOH包括部分或完全水解的制剂。PVOH可水解至少60mol％，水解至少70mol％，水解至少80mol％，水解至少90mol％。在一些实施例中，PVOH水解70-100mol％。在其他实施例中，PVOH水解95-100mol％。
不同级别的具有不同分子量的PVOH是适宜的。在一些实施例中，平均分子量在12,000到200,000范围内的PVOH是适宜的。优选地，PVOH是一种低分子量聚合物，平均分子量在12,000到50,000范围内。合适的非离子型强度增强聚合物包括可以商品名SELVOLTM从松井化工有限公司(Sekisui Chemical Co.Ltd.)购得的多种PVOH聚合物。
非离子型强度增强聚合物与交联剂组合使用，所述交联剂在非离子型强度增强聚合物施加于纸层表面后可促进非离子型强度增强聚合物的固化。合适的交联剂包括化学式为H3BO3的硼酸(boric acid)，也被称为硼酸氢盐、硼酸(boracic acid)和原硼酸。
在一些实施例中，通过从纸浆纤维素纤维获得若干纸层来制备多层纸盖板，所述纸浆纤维素纤维可以构成至多100％的再生纸废物。然后用PVOH溶液处理层的表面。PVOH处理可以包含用PVOH溶液对纸层的至少一个表面进行喷涂。另外，PVOH溶液可以在纸层上滚动。然而，在该方法的其他变体中，纸层可以短暂地浸入PVOH溶液中。PVOH溶液可以在各种浓度下使用，包括以重量计从1％到25％的溶液。用PVOH溶液处理后，纸层表面立即用硼酸溶液处理。处理可以包含喷涂和/或将纸层表面短暂地浸入硼酸溶液中。
硼酸溶液可以在各种浓度下使用，包括以重量计从1％到25％的溶液。用硼酸溶液处理后，纸层立即覆盖上另一纸层。因此，这两个纸层用与硼酸交联的PVOH粘结在一起。
在本方法中，硼酸施加于纸层也为纸层提供了生物杀灭处理。这提高纸盖板对真菌和/或微生物生长的抗性，也可以阻止昆虫。此外，在本方法中使用硼酸可能减少或消除在石膏板制造过程中施加额外的杀生物剂的需要。
在该方法的一些实施例中，一个纸层的表面用PVOH溶液处理，而另一个纸层的表面用硼酸溶液处理。在形成多层纸板时，两个表面立即接触，并且两个纸层用与硼酸交联的PVOH胶粘剂粘结在一起。
在一些实施例中，多层纸盖板中的每个层都用与硼酸交联的PVOH胶粘剂粘结。例如，如果这个多层纸板包含5个填料层和2个衬垫层，则每个填料层和衬垫层都用与硼酸交联的PVOH胶粘剂与覆盖层粘结。在其他实施例中，只有衬垫层用与硼酸交联的PVOH胶粘剂与填料层粘结。在其他实施例中，每个衬垫层与另一个衬垫层用与硼酸交联的PVOH胶粘剂粘结。在其他实施例中，只有填料层用与硼酸交联的PVOH胶粘剂粘结。然而，在其他实施例中，填料层用与硼酸交联的PVOH胶粘剂粘结在一起并粘结到衬垫层上。
该方法的其他实施例包括用PVOH处理第一层和用硼酸处理第二层的方法。通过将第一层与第二层叠加，然后将第二层与也用PVOH处理的第三层叠加，然后组装出纸板。因此，通过交替放置用PVOH或硼酸处理的层来组装纸板。
在其他实施例中，制备了PVOH和硼酸的溶液并在层间施加。
相比通过简单地一起压榨而将各种纸层粘结在一起的其他方法，通过实施在多层纸盖板中粘结纸层的方法已经实现了一些技术优势。
这些技术优势包括提高的抗拉强度、抗微生物性和孔隙度。出乎意料的是，这些技术优势并没有显著增加纸的重量，这是很重要的，因为墙板优选为轻的以便于运输和安装。
本领域技术人员会很容易理解，多层纸盖板的抗拉强度是在层彼此分开之前纸盖板可以暴露的拉伸应力的最大量。
抗拉强度可以通过TAPPI质量标准部(Quality and Standard Department)在其名为“纸和纸板的拉伸特性”的标准T 494om-13中提供的方法在拉伸试验机中测量。
本领域技术人员也会很容易理解，纸卡尺指的是以千分之一英寸表达的纸张厚度。这种测量用的是千分尺。卡尺值越大，纸的重量越大。
用Technidyne孔隙度测试仪(New Albany，IN)测量纸的孔隙度。这个仪器测量100cc空气通过纸所花的时间，以秒为单位。这种方法评估纸对空气通过的阻力。时间越短，材料的孔隙度越大。
如下表1所示，测量了多层纸样品的抗拉强度、孔隙度和卡尺值，其中两个纸层用与硼酸交联的PVOH粘结在一起。参见样品A、B、C和D。将这些值与针对多层对照纸获得的值进行了比较，在多层对照纸中，两个层简单叠加然后压榨成纸板。参见表1中的对照样品
从表1可以看出，对于用与硼酸交联的PVOH粘结的样品，观察到抗拉强度显著提高。与对照样品相比，对于这些样品观察到孔隙度时间的明显缩短。令人惊讶的是，从对照样品的卡尺值与其中用与硼酸交联的PVOH粘结纸层的样品的卡尺值的比较可以看出，这些结果是在不增加纸的重量的情况下获得的。
表1.
其他实施例提供了获得具有改进的抗拉强度和孔隙度的墙板的方法。在这些方法中，通过在纸形成过程中用与硼酸交联的PVOH粘结纸层来制造多层纸。然后将多层纸板用作制造石膏面板的至少一个盖板。在一些实施例中，只有前盖板是通过在纸形成过程中用与硼酸交联的PVOH粘结至少两个纸层而获得的。在其他实施例中，两个纸盖板、即前盖板和背盖板都是用多层纸制备的，其中在纸形成过程中用与硼酸交联的PVOH将至少两个纸层粘结在一起。
这种方法取得了各种技术优势，包括在不增加墙板重量的情况下提高了抗拉强度。
本发明现在将通过下面的非限制性实例更详细地描述。
实例1
如下制备一种多层纸板。从PVOH粉末和水制备3％PVOH溶液。用水制备3％硼酸溶液。
对100％DLK(双层牛皮纸)废纸制浆，并在6"英国手抄片模具上制造1.5克手抄片。然后，依次用PVOH和硼酸溶液喷涂手抄片，以达到表1中所列的吸收率。
使用PVOH和硼酸处理后，立即将另一张1.5克的手抄片放置在处理过的手抄片上。然后压榨这张多层纸板并在220oF下干燥。然后，在保持在70oF温度和50％相对湿度的房间里，对多层纸板调节16小时。如上所述从两张手抄片制备对照多层纸板，但省略了用3％PVOH/3％硼酸处理层。
对所有样品进行抗拉强度、孔隙度和卡尺分析。这些测量的结果报道于表1。从表1可以看出，用与硼酸交联的非离子型粘结剂粘结多层纸盖板中的纸层可以使纸的抗拉强度提高高达近20％。抗拉强度的这种增加是在不显著增加纸重量的情况下实现的，因为卡尺值在样品和对照之间没有明显的变化。此外，用与硼酸交联的非离子型粘结剂粘结纸层不会增加干纸的孔隙值。

Claims (10)

1.一种制造墙板面板的方法，所述方法包含：
从纸浆形成纸层；
用PVOH(聚乙烯醇)喷涂所述纸层的至少一些；
用硼酸溶液喷涂所述纸层的至少一些；
叠加所述纸层以形成多层纸板；
压榨和干燥所述多层纸板；
制备石膏浆料；
在两个纸板之间沉积所述石膏浆料，其中至少一个是所述多层纸板，其中所述多层纸板包含至少一个填料层和至少一个衬垫层；以及
形成所述墙板面板。
2.根据权利要求1所述的方法，其中PVOH和硼酸喷涂在以下层的至少一种之间：在两个填料层之间、填料层和衬垫层之间、以及两个衬垫层之间；并且其中用硼酸喷涂也是生物杀灭处理并提高所述多层纸板针对真菌和细菌生长的抗性。
3.根据权利要求1所述的方法，其中PVOH施加于第一层的表面，而硼酸施加于第二层的表面，然后叠加所述第一层和所述第二层，使得用PVOH处理的表面与用硼酸处理的表面接触。
4.根据权利要求1所述的方法，其中PVOH聚合物包含具有超低聚合度的聚合物、具有低聚合度的聚合物或其组合。
5.根据权利要求1所述的方法，其中所述纸浆包含再生纸废物，其包含牛皮纸、硬纸板粉屑、飞叶刨花和/或报纸。
6.根据权利要求1所述的方法，其中PVOH作为浓度按重量计在1％到10％范围内的水基溶液施加。
7.根据权利要求1所述的方法，其中硼酸作为浓度按重量计在1％到10％范围内的水基溶液施加。
8.一种通过权利要求1的方法获得的墙板。
9.一种包含配置在两个纸盖板之间的石膏芯的墙板，第一纸盖板是前盖板并且第二纸盖板是背盖板，其中这两个纸盖板都是多层纸盖板，并且其中这两个纸盖板中的每个纸盖板中的至少两层用与硼酸交联的非离子型聚合物粘结剂粘结在一起，其中所述非离子型聚合物粘结剂是平均分子量在12,000到200,000范围内的PVOH聚合物或共聚物并且水解为70-100ml％。
10.根据权利要求9所述的墙板，其中前纸盖板包含上面覆盖有1到2个衬垫层的2到7个填料层。
CN201780038220.5A 2016-07-06 2017-07-06 包含用非离子型聚合物粘结剂粘结的层压多层纸盖板的石膏墙板和方法 Pending CN109311300A (zh)

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