EP1076137B1 - Plaque de plâtre - Google Patents

Plaque de plâtre Download PDF

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Publication number
EP1076137B1
EP1076137B1 EP00306833A EP00306833A EP1076137B1 EP 1076137 B1 EP1076137 B1 EP 1076137B1 EP 00306833 A EP00306833 A EP 00306833A EP 00306833 A EP00306833 A EP 00306833A EP 1076137 B1 EP1076137 B1 EP 1076137B1
Authority
EP
European Patent Office
Prior art keywords
plasterboard
printing
lining paper
colour
print
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.)
Expired - Lifetime
Application number
EP00306833A
Other languages
German (de)
English (en)
Other versions
EP1076137A3 (fr
EP1076137A2 (fr
EP1076137B9 (fr
Inventor
Frederick K. BPB Gypsum Head Office Lunn
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.)
BPB Ltd
Original Assignee
BPB 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
Application filed by BPB Ltd filed Critical BPB Ltd
Publication of EP1076137A2 publication Critical patent/EP1076137A2/fr
Publication of EP1076137A3 publication Critical patent/EP1076137A3/fr
Publication of EP1076137B1 publication Critical patent/EP1076137B1/fr
Application granted granted Critical
Publication of EP1076137B9 publication Critical patent/EP1076137B9/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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

Definitions

  • This invention relates to the manufacture of plasterboard (also known in USA as gypsum wallboard).
  • plasterboard also known in USA as gypsum wallboard.
  • Plasterboard is well known for use in forming ceilings and interior wall surfaces in buildings.
  • the front face and side edge surface of the plasterboard have been provided by a multi-ply paper referred to as plasterboard liner, while the reverse face is surfaced with a second liner paper. Both of these liners are multi-ply papers.
  • plasterboard One method for utilising plasterboard has been to fasten the plasterboard into position and then cover its exposed face and the joints between plasterboard sheets with a thin "skim coat" of wet plaster. After this has set, it requires decoration with paint or wallpaper.
  • plasterboard is manufactured using a plasterboard liner paper which has a light colour. This is used to form the front surface and the side edge surfaces.
  • the side edges of the boards are shaped to form a recess at their abutting edges. After the boards are fastened into position, their abutting edges are joined with tape and a jointing compound which is worked into the recess on top of the joining tape to create a continuous flat wall surface, with joints visible at regular intervals.
  • the wall is then decorated, either with wallpaper or with multiple coats of paint, which serves among other things to conceal the joints. If paint is used, the normal requirement is a first "mist coat” or primer, followed by two full further coats. This requires painters to come to the wall three times.
  • US patent 4579610 proposed a process in which the surface of a plasterboard liner paper is gravure printed with a clear or tinted latex base coat.
  • the gravure process applies this material as a pattern of dots, so that the applied material does not seal the paper.
  • the base paper is then overprinted with a decorative design.
  • Dimensions for the gravure pattern are not exemplified, but it is feasible that the dots of a gravure pattern might cover 50% or less of the total area to which the pattern is applied.
  • EP-A-521804 has described plasterboard manufactured using a liner paper with a coating applied to the liner paper before the boards are manufactured.
  • the document recognises that this can avoid contrast between the colour of the board and the colour of material used to form joints between the boards.
  • the proprietors of this document are marketing pre-decorated boards and a jointing compound of matching colour.
  • the application of a decorative layer to the plasterboard liner could cause an unwanted reduction in the permeability of the liner paper and in this way impede the escape of steam during drying of the plaster.
  • pre-decorated liner paper and plasterboard can be made by printing the liner paper before it is used in board manufacture, moreover it is not necessary to use a printing process which applies a pattern of spaced dots with gaps between them.
  • a pre-decorated plasterboard having lining paper at its surfaces with material printed thereon over the whole of one face of the board, with a density of print on the lining paper sufficient that under optical examination at least 80% of the surface of the lining paper is covered by the applied print.
  • the applied print may extend onto adjoining edges of the board.
  • the material which is applied by printing will generally include colour to match the colour of the board to the colour of a jointing compound to be used for joining board edges.
  • the applied material may also include colourless or tinted lacquer, for example to increase the durability of the printed surface.
  • the printed material may be a continuous layer of applied print. Alternatively it could be provided as gravure dots overlapping one another and between them covering 80% or more of the total surface area.
  • Determination of the extent of surface coverage is carried out by visual examination using a magnifying lens or microscope with magnification not greater than 100 times. We have discovered that areas of print which appear to be continuous at this magnification are not completely continuous when observed under an electron microscope operated to give something approaching the highest magnification achievable with such an instrument. These discontinuities which are observable only at such a high resolution of detail are believed to be pores through the ink (rather than unprinted areas) and are ignored when determining whether the printed material covers 80% or more of the surface area.
  • the lining paper web which receives the print will generally have a width slightly greater than the width of the plasterboards which will be made, so that it can cover one face and two edges of the boards and also wrap around onto the margins of the reverse face where it will be overlapped by the second web.
  • the print is applied to the entire width of one surface of a web of lining paper and in consequence the resulting plasterboard has the printed colour completely covering the face of the board, two opposite edges of the board and the margins of the reverse face.
  • edge portions of the web which form the edges of the board and wrap around onto the reverse face may be left unprinted.
  • the printed colour extends from the exposed face onto at least part of each edge.
  • pre-decorated boards can be used to form ceilings, interior partitions or the interior faces of wall by securing them to a supporting structure, e.g. by nailing or screwing them to studwork in conventional manner, or by using concealed fastenings.
  • the boards may be of conventional size. Boards for use in making walls and ceilings may have length exceeding 2 metres and width exceeding 70 cm, often exceeding 1 metre. Smaller boards may be utilised as ceiling tiles, supported by a grid structure which is itself suspended from above.
  • the joints between the boards may then be filled with a jointing compound and this will also be used to cover the heads of screws, nails or other exposed fixings.
  • the printed material on the boards should give them a colour which matches the colour of the jointing compound.
  • the joints in the wall or ceiling are much less apparent.
  • the invention includes a combination of
  • the material which is printed on will be a uniform colour which matches the colour of the jointing compound.
  • the invention can be used to provide boards which will match the colour of the jointing compound, so that the finished wall will have a single colour (or conceivably a pattern) in which the joints blend into the wall and further decoration is not required.
  • Another possibility is to provide a wall which is painted after the plasterboards have been fastened in place and joined, but which requires fewer coats of paint.
  • the invention includes a method of making a room surface by fixing plasterboards as specified above, filling joints between them with a mobile composition which is then allowed to set, and applying no more than two coats of paint as the only decorative treatment prior to occupation of the room.
  • the invention also includes use of such plasterboards and a settable, mobile jointing composition in making such a room surface.
  • the printing of material can be done directly onto the paper liner before the liner is used in plasterboard manufacture. It is preferably applied by a printing process which applies a continuous layer of ink to the substrate which is being printed.
  • a process which is particularly envisaged is by flexographic printing.
  • the flexographic process is widely used for printing onto fibreboard for boxes, paper for paper sacks, and other packaging materials. In that application the print is applied to the paper or board from, for example, a "stereo" or a moulded printing roller which is formed using a polymeric material and is a mirror image of the design or wording which is being printed.
  • Continuous printing along a web is a technique which is already available in the printing industry.
  • a normal flexographic printing machine can be used, but the roller which would normally carry a stereo is instead provided with a continuous surface of the polymer material or a printing roller with a smooth surface can be used.
  • the continuous surface is provided by a flexible sheet of polymeric material wrapped around a roller, edges of the sheet which extend along a circumference of the roller are butted against each other.
  • Printing could be carried out by another printing process, so long as the result is to apply print to over 80% of the surface to which print is applied.
  • coverage is even higher, such as at least 90% or at least 95% of the area.
  • Printing by a gravure process at more than one printing station would be a way to cover a high proportion of the total area: gravure dots applied at one printing station could largely fill the gaps between dots applied at another, although overlap of dots would also occur.
  • weight of solids applied including binder resin, will lie in a range from 7 to 30 gram/m 2 .
  • Flexographic or other printing can be carried out using inks with an aqueous base or using inks with an organic solvent base in which pigment is dispersed. It is generally preferred to use an aqueous base and so avoid the use of flammable organic solvent.
  • aqueous-based inks can be used for the present invention.
  • a water-based ink suitable for use in the present invention is likely to contain pigment, water and binder materials.
  • the binder materials are likely to be synthetic polymers such as acrylic resins.
  • the first print is desirably carried out using a coloured ink.
  • a coloured ink may well contain more than 40% by weight of pigment, as well as binder, water and minor ingredients.
  • the pigment is likely to constitute more than 50% of the total solids in the ink.
  • a top layer of print may contain a much lower proportion of pigment or even none at all, e.g. 0 to 25% of the solids content, with a higher proportion of binder resin.
  • Such a layer can serve as a lacquer, giving an improved resistance to marking during handling and to abrasion after wetting. The latter is valuable for giving a "wipe-clean" or washable surface.
  • ink it is normal practice for the manufacture of ink to be carried out by a specialist ink manufacturer who may well be working in close co-operation with a company having facility to manufacture and print paper.
  • the formulation of ink to provide a required colour is part of the normal skill of the ink manufacturer.
  • the lining paper onto which the printed colour is applied may be made in conventional manner using the normal machinery employed for making multi-ply paper and board by a wet-laid process.
  • the fibres used in the manufacture of the plies of the lining paper may be new or recycled or a mixture of the two.
  • the top ply it may be desirable to use fibres which have been bleached or incompletely bleached (so-called semi-bleached fibres) so that the top ply is a light colour before print is applied to it.
  • the fibres of the top ply are predominantly chemical fibres and therefore lignin-free so as to avoid yellowing.
  • the invention can be put into effect using a top ply formed with a predominance of semi-chemical and/or mechanical fibres which retain some or all of the natural lignin content of the original timber.
  • the top ply could be made from pulp - i.e. new fibres. However, for the sake of economy it will normally be made from recycled fibres, supplemented if necessary with new fibres.
  • Waste paper to provide the recycled fibres will generally be selected to give a light off-white, shade. Suitable sources include unprinted newspaper, lightly printed paper and so-called woody trimmings - i.e. offcuts from paper made using mechanical pulp.
  • the remaining plies form the interior and the reverse face of the lining paper. It is normal for these to contain a high proportion of unbleached fibres which may be chemical fibres, because of their strength is greater than that of mechanical fibres
  • a suitable source of recycled fibre for these interior plies is recycled corrugated board from boxes and cartons.
  • Unsorted mixed waste paper - which is the residue after removing higher value light-coloured material - will generally contain a substantial proportion of unbleached chemical fibres from boxes and cartons. It may well be used as the source of recycled fibre for these interior plies.
  • a plasterboard lining paper conventionally has a weight in a range from 150 to 300 grams per square metre (gsm) and usually lies in a narrower range from 180 to 250 gsm. Paper within this range is suitable for use in this invention.
  • the porosity of plasterboard lining paper can be determined by the Gurley test of porosity laid down in the British Standard BS 6538: Part 3: 1987 entitled "Air Permeance of Paper and Board”. This corresponds to ISO 5635/5 - 1986.
  • This test measures porosity as the time for a known volume (100 ml) of air to pass through a sample of predetermined area. The result is therefore expressed in seconds.
  • each board In a cross-section through two plasterboards fixed in place with edges abutting, each board has a front face and a rear face. In this example, at each edge the board is tapered so that the edge consists of a bevel as well as a narrow side edge.
  • the lining paper on each front face covers each bevel and side edge, before turning onto the margin of the rear face where it is overlapped by the paper on the rear face.
  • Printing in accordance with this invention extends over the whole of the front face and at least part of the bevel. If convenient it covers the paper around the side edge to the extremity of this paper.
  • Samples of a conventional plasterboard liner were printed in accordance with this invention before being used to make plasterboard.
  • the properties of several samples of the lining paper, before printing, were measured and found to be : Weight of single top ply 30 - 40 gsm Total weight 220 gsm Weight of three main plies combined weight 180-190 gsm Air resistance (Gurley) 90 - 102 seconds CIE "L” value 78 to 80 CIE "a" value 0.3 to 0.8 CIE "b” value 4.4 to 5.1
  • the paper was printed on the top ply which becomes the outer surface of plasterboard, at three stations of a multi-colour flexographic printing machine.
  • the flexographic inks and lacquers used were all water-based. At the first station the ink gave a "magnolia” colour. It contained 53% pigment, 15% aqueous acrylic resin, 27% water and a small balance made up of minor ingredients. This high content of pigment was intended to give high colour coverage.
  • the pigment was about 99% titanium dioxide and about 1% coloured pigment
  • the aqueous acrylic resin contained approximately one third resin solids. These were styrene/acrylic copolymers of molecular weight 11,000 to 13,000. Thus the solids content of the ink was 53% pigment and 6.5% binder resin. This ink is referred to below as "ink 1".
  • the next printing station applied a less pigmented ink ("ink 2") containing 20% titanium dioxide pigment dispersed in an aqueous phase which also contained approximately 30% styrene/acrylic binder resin solids as above, partially in solution and partially as a dispersed liquid phase.
  • ink 2 a less pigmented ink
  • titanium dioxide pigment dispersed in an aqueous phase which also contained approximately 30% styrene/acrylic binder resin solids as above, partially in solution and partially as a dispersed liquid phase.
  • lacquer 1 a clear lacquer with no pigment, consisting almost entirely of an aqueous continuous phase containing approximately 46% dispersed styrene/acrylic binder resin of molecular weight over 200,000.
  • the porosity and ultra-violet resistance of several samples of the printed lining paper were measured. Air resistance (Gurley) was found to be approximately 240 seconds. The ultra-violet resistance of the paper was found to be very good.
  • the colour of the print on several samples was determined on the CIE Lab scale, and compared with the colour of the samples before printing.
  • the L, a, b values for the printed liner were approximately 89, 0.1 and 5.2. It was thus somewhat lighter in colour than the unprinted liner with L value of about 80.
  • the printed surface of the paper was examined under a scanning electron microscope. At 250x magnification it was observed that the coating provided continuous colour but had a number of cracks. At high magnification individual particles of the printed pigment could be discerned and a pore structure could be seen.
  • the printing lining paper was used for making plasterboard on a conventional board-making line.
  • the speed of the line, the time in the drying kiln and the temperatures in that kiln were conventional and indeed were the same as used for manufacture using unprinted liner.
  • Example 1 The procedure of Example 1 was repeated using the same and additional inks and lacquers in various compositions.
  • Ink 3 was an opaque white ink, similar in composition to Ink 1 except for the absence of any coloured pigment.
  • Lacquer 2 was a matt lacquer containing 5.8% of titanium dioxide pigment and 36% of styrene/acrylic binder resin solids.
  • Example No Printing stations Gurley value (sec) First Second Third 1 Ink 1 Ink 2 Lacquer 1 240 2 Ink 1 Ink 2 Lacquer 2 240 3 Ink 3 Ink 2 Lacquer 2 260 4 Ink 3 Ink 2 Lacquer 1 290 5 Ink 2 Ink 2 Lacquer 1 225 6 Ink 2 Ink 2 Lacquer 2 230 7 Ink 1 Ink 1 Lacquer 2 315

Claims (14)

  1. Plaque de plâtre pré-décorée ayant un papier de revêtement à ses surfaces avec un matériau de surface imprimé sur celui-ci sur l'ensemble d'une face de la plaque, caractérisée par une densité d'impression suffisante pour que, lors d'un examen optique, au moins 80% de la surface du papier de revêtement soient couverts par l'impression appliquée.
  2. Plaque de plâtre selon la revendication 1, où le matériau imprimé s'étend sur des bords adjacents de la plaque.
  3. Plaque de plâtre selon la revendication 1 ou la revendication 2, où le matériau imprimé a un poids par surface unitaire dans une plage de 7 à 30 g/m2 de poids sec.
  4. Plaque de plâtre selon l'une des revendications précédentes, où la densité d'impression est suffisante pour que, lors d'un examen optique, au moins 90% de la surface du papier de revêtement sur ladite face de la plaque de plâtre soient couverts par l'impression appliquée.
  5. Plaque de plâtre selon l'une des revendications précédentes, où le matériau imprimé comprend une couleur imprimée.
  6. Plaque de plâtre selon la revendication 4, où l'impression appliquée est une couleur uniforme sur l'ensemble de ladite face de la plaque de plâtre.
  7. Plaque de plâtre selon l'une des revendications précédentes, où le matériau imprimé comprend une couche pigmentée sur laquelle est imprimée une autre couche qui contient moins de pigment ou pas de pigment.
  8. Plaque de plâtre selon la revendication 7, où la couche supplémentaire est une laque sans couleur ou teintée.
  9. Combinaison de:
    i) de plaques de plâtre pré-décorées telles que définies dans l'une des revendications précédentes; et
    ii) un composé de jonction mobile, durcissable, pour remplir les joints entre les plaques après la fixation,
    où le matériau imprimé sur les plaques est accordé à la couleur du composé de jonction durci.
  10. Procédé de fabrication d'une plaque de plâtre pré-décorée selon l'une des revendications 1 à 8, comprenant les étapes consistant à:
    imprimer une surface d'une bande de papier de revêtement, introduire du plâtre humide entre la surface opposée de ladite bande de papier de revêtement et une deuxième bande de papier de revêtement, configurer les portions de bord de ladite première bande autour du plâtre pour former des bords de plaque, couper en longueurs et chauffer pour sécher le plâtre en formant ainsi la plaque de plâtre avec une impression sur une face exposée,
    caractérisé en ce que l'impression sur la première bande de papier de revêtement s'étend sur une largeur telle que toute la face de la plaque de plâtre présente l'impression sur celle-ci, la densité de l'impression étant suffisante pour que, lors d'un examen optique, au moins 80% de la surface du papier de revêtement soient couverts par l'impression appliquée.
  11. Procédé selon la revendication 10, où l'étape d'impression est exécutée par impression flexographique.
  12. Procédé selon la revendication 10 ou la revendication 11, où l'étape d'impression sur une surface d'une bande de papier de revêtement comprend l'impression avec une couche pigmentée, et l'impression appliquée réalise une couleur uniforme sur l'ensemble de ladite face exposée de la plaque de plâtre.
  13. Procédé selon la revendication 10, la revendication 11 ou la revendication 12, où l'étape d'impression sur une surface d'une bande de papier de revêtement comprend l'impression du papier de revêtement avec une couche pigmentée suivie d'une surimpression avec une couche contenant moins ou pas de pigment.
  14. Combinaison de:
    i) des plaques de plâtre pré-décorées fabriquées selon le procédé de la revendication 12; et
    ii) un composé de jonction mobile durcissable pour remplir les joints entre les plaques après la fixation,
    où la couleur uniforme du matériau imprimé sur lesdites faces exposées des plaques est accordée à la couleur du composé de jonction durci.
EP00306833A 1999-08-11 2000-08-10 Plaque de plâtre Expired - Lifetime EP1076137B9 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB9918983.9A GB9918983D0 (en) 1999-08-11 1999-08-11 Plasterboard
GB9918983 1999-08-11

Publications (4)

Publication Number Publication Date
EP1076137A2 EP1076137A2 (fr) 2001-02-14
EP1076137A3 EP1076137A3 (fr) 2003-01-02
EP1076137B1 true EP1076137B1 (fr) 2007-04-04
EP1076137B9 EP1076137B9 (fr) 2007-10-17

Family

ID=10858994

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00306833A Expired - Lifetime EP1076137B9 (fr) 1999-08-11 2000-08-10 Plaque de plâtre

Country Status (7)

Country Link
EP (1) EP1076137B9 (fr)
AT (1) ATE358756T1 (fr)
DE (1) DE60034188T2 (fr)
DK (1) DK1076137T3 (fr)
ES (1) ES2284454T3 (fr)
GB (1) GB9918983D0 (fr)
PT (1) PT1076137E (fr)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB0130697D0 (en) 2001-12-21 2002-02-06 Placoplatre S A Plasterboard
DE102007049784A1 (de) 2007-10-17 2009-04-23 Bauer, Jörg R. Mittels eines Tintenstrahldruckverfahrens bedruckbare Bauplatte mit einem Grundkörper mit poröser Oberfläche sowie Verfahren zum Herstellen einer Bauplatte
DE102009017661A1 (de) 2009-04-16 2010-10-21 Interglarion Ltd., Engomi Bedruckbare Bauplatte sowie Verfahren zum Herstellen einer Bauplatte
CA3058058A1 (fr) 2018-10-19 2020-04-19 National Gypsum Properties, Llc Revetement antimicrobien pour panneau de construction

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4579610A (en) * 1984-12-13 1986-04-01 National Gypsum Company Method of making predecorated gypsum board
WO1999057371A1 (fr) * 1998-05-04 1999-11-11 Visy R & D Pty Ltd. Revetement pour plaque de platre

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3507684A (en) 1968-02-20 1970-04-21 United States Gypsum Co Method of making decorated wallboard
US3694298A (en) 1970-05-08 1972-09-26 United States Gypsum Co Decorated gypsum board and method of making same
US3984596A (en) 1971-04-01 1976-10-05 United States Gypsum Company Decorated gypsum board with expanded inorganic particle coating
FR2678652B1 (fr) 1991-07-02 1993-09-24 Platres Lafarge Sa Papier utile comme papier de revetement pour les plaques de platre et ses procedes de preparation.

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4579610A (en) * 1984-12-13 1986-04-01 National Gypsum Company Method of making predecorated gypsum board
WO1999057371A1 (fr) * 1998-05-04 1999-11-11 Visy R & D Pty Ltd. Revetement pour plaque de platre

Also Published As

Publication number Publication date
DE60034188T2 (de) 2007-12-20
EP1076137A3 (fr) 2003-01-02
PT1076137E (pt) 2007-07-06
GB9918983D0 (en) 1999-10-13
DE60034188D1 (de) 2007-05-16
ES2284454T3 (es) 2007-11-16
EP1076137A2 (fr) 2001-02-14
EP1076137B9 (fr) 2007-10-17
DK1076137T3 (da) 2007-08-06
ATE358756T1 (de) 2007-04-15

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