EP4263464A1 - Plaque de plâtre, suspension de stuc, utilisation d'une suspension de stuc et d'une cloison - Google Patents

Plaque de plâtre, suspension de stuc, utilisation d'une suspension de stuc et d'une cloison

Info

Publication number
EP4263464A1
EP4263464A1 EP21847456.7A EP21847456A EP4263464A1 EP 4263464 A1 EP4263464 A1 EP 4263464A1 EP 21847456 A EP21847456 A EP 21847456A EP 4263464 A1 EP4263464 A1 EP 4263464A1
Authority
EP
European Patent Office
Prior art keywords
plasterboard
relative
stucco
amount
gypsum
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.)
Pending
Application number
EP21847456.7A
Other languages
German (de)
English (en)
Inventor
Richard Wakefield
Nicholas Jones
Jan Rideout
Laura BROOKS
Maike PARMAR
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.)
Saint Gobain Construction Products UK Ltd
Original Assignee
Saint Gobain Construction Products UK 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 Saint Gobain Construction Products UK Ltd filed Critical Saint Gobain Construction Products UK Ltd
Publication of EP4263464A1 publication Critical patent/EP4263464A1/fr
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/16—Sulfur-containing compounds
    • C04B24/20—Sulfonated aromatic compounds
    • C04B24/22—Condensation or polymerisation products thereof
    • C04B24/226—Sulfonated naphtalene-formaldehyde condensation products
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B11/00—Calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/003—Phosphorus-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form

Definitions

  • the present invention relates to a plasterboard, more specifically a plasterboard comprising sodium trimetaphosphate (STMP) and a fluidiser.
  • STMP sodium trimetaphosphate
  • the invention also relates to a stucco slurry, the use of a stucco slurry and a partition.
  • Gypsum construction panels often referred to as plasterboards, are commonly used in the provision of internal walls and ceilings within buildings.
  • the major component of these plasterboards is typically gypsum, also known as calcium sulphate dihydrate CaSO 4 2(H 2 O).
  • Plasterboards are typically formed by mixing stucco, also known as calcium sulphate hemihydrate CaSO 4 0.5(H 2 O), with water.
  • stucco also known as calcium sulphate hemihydrate CaSO 4 0.5(H 2 O)
  • the stucco is hydrated by the water and crystals of gypsum grow and interlink to form the plasterboard.
  • excess water is driven off by drying the setting plasterboard in an energy intensive process.
  • plasterboards comprises significant amounts of gypsum
  • other components can be incorporated into the plasterboard.
  • these component are added to the stucco slurry such that they become evenly distributed through the plasterboard during the manufacturing and drying process.
  • One additive that is sometimes added to a stucco slurry is sodium tri metaphosphate (STMP).
  • STMP sodium tri metaphosphate
  • the addition of sodium trimetaphosphate may be advantageous as it can reduce the deflection seen in the final plasterboard. As low levels of deflection are required in most applications, STMP is usually added to plasterboards in relatively large amounts.
  • plasterboards In view of the above, it is common for plasterboards to include relatively high levels of both STMP and fluidiser. Such boards have many desirable features, especially when used as part of internal partitions in markets where the boards themselves form the face of the partition.
  • Objects and aspects of the present invention seek to address at least this problem.
  • a plasterboard comprising gypsum, sodium trimetaphosphate in an amount from 0.04 wt.% to below 0.17 wt.% relative to the gypsum and fluidiser in an amount of 0.42 wt.% to 0.76 wt.% inclusive relative to the gypsum.
  • the applicant has surprisingly found that reducing the level of sodium trimetaphosphate to these relatively low levels dramatically decreases the surface water absorption of the plasterboard, without increasing the deflection seen in the final plasterboard. As such, the applicant has found that far less cracking is observed in a plaster skim layer over these plasterboards that with previously available plasterboards.
  • the fluidiser is present in an amount of at least 0.46 wt.% relative to the gypsum. Preferably, the fluidiser is present in an amount of at most 0.74 wt.% relative to the gypsum. More preferably, the fluidiser is present in an amount of 0.51 wt.% relative to the gypsum.
  • the sodium trimetaphosphate is present in an amount of at least 0.042 wt.% relative to the gypsum.
  • the sodium trimetaphosphate is present in an amount of at most 0.13 wt.% relative to the gypsum. More preferably, sodium trimetaphosphate is present in an amount of at most 0.084 wt.% relative to the gypsum.
  • the fluidiser comprises a polyanion naphthalene sulfonate. More preferably, the fluidiser is Retanal NH35 made by Chromogenia.
  • the plasterboard comprises a gypsum matrix.
  • the majority component of the plasterboard is gypsum.
  • a stucco slurry comprising stucco, water, sodium trimetaphosphate in an amount from 0.047wt.% to below 0.2 wt.% relative to the stucco and fluidiser in an amount of 0.5 wt.% to 0.9 wt.% inclusive relative to the stucco.
  • Such a stucco slurry may be used to provide a plasterboard with the advantages already described.
  • the relative amounts of the sodium tri metaphosphate and the fluidiser between the first and second aspects of the invention are equivalent, with the variance due to the difference in molecular weight between gypsum (calcium sulphate dihydrate) and stucco (calcium sulphate hemihydrate).
  • the fluidiser is present in an amount of at least 0.55 wt.% relative to the stucco.
  • the fluidiser is present in an amount of at most 0.88 wt.% relative to the stucco. More preferably, the fluidiser is present in an amount of 0.6 wt.% relative to the stucco.
  • Such levels of fluidiser may be preferable as they ensure the slurry is fluid enough for processing without negatively influencing the chemistry of the production process.
  • the sodium trimetaphosphate is present in an amount of at least 0.05 wt.% relative to the stucco.
  • the sodium trimetaphosphate is present in an amount of at most 0.15 wt.% relative to the stucco. More preferably, the sodium trimetaphosphate is present in an amount of at most 0.1 wt.% relative to the stucco.
  • the fluidiser comprises a polyanion naphthalene sulfonate.
  • Polyanion naphthalene sulfonate may also be known as polynaphthalene sulfonate.
  • the fluidiser is Retanal NH35.
  • the water is present in an amount of 75 wt.% or less relative to the stucco. More preferably, the water is present in an amount of 70 wt.% or less relative to the stucco. Reducing the water content of the slurry may be preferable as it may reduce the time needed for any plasterboard produced from the stucco slurry to dry.
  • the slurry is a plasterboard precursor slurry.
  • a plasterboard precursor slurry is a slurry that is used in the manufacture of a plasterboard.
  • the slurry as hereinbefore described in the formation of a gypsum product.
  • the gypsum product is a plasterboard.
  • a partition comprising at least one plasterboard as previously described, wherein the at least one plasterboard is fixed to at least one frame member.
  • the partition comprises a plaster skim layer across at least a portion of the surface of said at least one plasterboard. More preferably, the partition comprises a plaster skim layer substantially across at least one face of the partition.
  • Figure 1 is a graph depicting the measured deflection in a variety of plasterboards both within and outside the scope of the present invention:
  • Figure 2 is a graph illustrating the water adsorption of a variety of plasterboards both within and outside the scope of the present invention
  • FIG. 3 is a partition according to the present invention.
  • Figure 4 is a comparison of cracking seen in a partition including a plasterboard according to the present invention and a comparative example.
  • Figure 5 is a further graph illustrating the water adsorption of a variety of plasterboards both within and outside the scope of the present invention.
  • Figure 1 is a graph illustrating the measured deflection of a number of plasterboards.
  • plasterboards comprising 0.51 wt.% relative to the gypsum Retanal NH35 fluidiser were manufactured using standard manufacturing techniques, each plasterboard also containing STMP between 0.0 wt.% and 0.84 wt.% relative to the gypsum.
  • Each plasterboard had a width of 2.4 m, a thickness of 12.5 mm and paper facings extending across both major faces (12.5 mm Gyproc Wallboard).
  • each plasterboard was measured by incorporating the plasterboard sheet into a partition, placing a straight edge across the width of the plasterboard and measuring the maximum distance between the straight edge and the face of the plasterboard.
  • the measured deflection of the plasterboard was far higher where no STMP was present in the board, whereas even small amounts of STMP were sufficient to significantly improve the plasterboard’s deflection performance. Deflection of the plasterboard is undesirable, as it can lead to a partition formed by the plasterboards appearing to undulate along its length. Additionally, the measured defection where STMP is not present can lead to cracks appearing in the locations of the joints between plasterboards, these cracks usually extending along the length of the joints where the plasterboards abut one another.
  • Figure 2 is a graph illustrating the surface water adsorption of a number of plasterboards.
  • plasterboards comprising 0.51 wt.% relative to the gypsum Retanal NH35 fluidiser were manufactured as outlined in relation to Figure 1 , each plasterboard also containing STMP between 0.0 wt.% and 0.84 wt.% relative to the gypsum.
  • the surface water absorption of the plasterboards increased significantly when STMP was present in an amount of 0.17 wt.% relative to the gypsum and above.
  • Figure 3(a) illustrates the framework within the partition 300.
  • the partition 300 comprises metal studs 310 running vertically with centres at 600mm, the metal studs 310 mounted in channels 320 running perpendicular to the studs 310, the channels 320 located at the top and bottom of the studs 310.
  • plasterboards 330 of 12.5mm thickness and 2.4 m width are mounted to the metal studs 310 and channels 320 using standard drywall screws 340 at 300 mm vertical centres.
  • Each plasterboard comprises gypsum, with STMP at 0.084 wt.% relative to the gypsum and fluidiser in the form of Retanal NH35 at 0.51 wt.% relative to the gypsum.
  • the joints between plasterboards 330 could be staggered to improve the performance of the partition 300. Additionally, it is envisaged that the joints between the plasterboards 330 may be covered by scrim tape before the partition 300 is substantially covered with a plaster layer, for example with Thistle multifinish.
  • FIG 4 two partitions are depicted, the first partition as illustrated in Figure 4(a) not according to the present invention, and the second partition as illustrated in Figure 4(b) according to the present invention.
  • the illustrated partition has been skimmed with an approximately 2mm layer of Thistle multifinish plaster and allowed to dry to provide a plaster skim layer.
  • Figure 4(a) depicts a section of a partition constructed as outlined in Figure 3, where the plasterboards used within the partition have the composition of Comparative Example 1.
  • Figure 4(a) focuses on an area where two plasterboards within the partition abut, with the line of abutment between the plasterboards extending substantially vertically though the centre of the figure.
  • a crack is present in the plaster layer used to skim the partition, this crack found in the region where the plasterboards abut.
  • the region of abutment is highlighted by a rectangle drawn on to the surface of the partition. Such cracks are undesirable, as they reduce the aesthetic appeal of the partition.
  • Figure 4(b) again depicts a section of a partition constructed as outlined in Figure 3, in this case where the plasterboards used within the partition have the composition of Example 2.
  • Figure 4(b) again focuses on an area where two plasterboards within the partition abut, with the line of abutment between the plasterboards extending substantially vertically though the centre of the figure.
  • no cracking is seen in the region where the plasterboards abut when plasterboards according to the present invention are used in the partition.
  • the region of abutment is highlighted by a rectangle drawn on to the surface of the partition.
  • Figure 5 is a graph illustrating the surface water adsorption of a number of plasterboards.
  • Plasterboards comprising Retanal NH35 fluidiser in amounts of 0.3 wt.%, 0.55 wt.% and 1.0 wt.% relative to the gypsum were manufactured using standard manufacturing techniques.
  • Each plasterboard also contained STMP between 0.02 wt.% and 0.20 wt.% relative to the gypsum.
  • the surface water adsorption of each plasterboard was measured using Cobb rings according to EN520:2009 5.9.1.
  • plasterboards comprising Retanal NH35 fluidiser in an amount of 0.55 wt.% relative to the gypsum were manufactured using standard manufacturing techniques, each plasterboard also containing STMP between 0 wt.% and 0.13 wt.% relative to the gypsum.
  • the percentage expansion of the plasterboard samples was measured by cutting samples 200mm by 50mm of each plasterboard perpendicular to the machine direction, and subsequently fixing a small brass knob to each end of the sample. The samples were then immersed in water. A reference Perspex sample was also tested in the same manner and the percentage dimensional expansion of each sample relative to the Perspex reference sample expansion was calculated. Dimensional measurements of each sample were taken at intervals of 1 , 2, 6 and 24 hours to determine the percentage expansion at each of these time points.
  • plasterboards of the invention exhibit both reduced surface water absorption and good expansion characteristics.
  • an advantageous range of STMP relative to the gypsum is from 0.04 wt.% to below 0.17 wt.% relative to the gypsum.
  • the selected range of fluidiser is preferred for improved ease of manufacture. It is challenging to provide an adequately fluid slurry using fluidiser in an amount of less than 0.42 wt.% relative to the gypsum. In addition, it is desirable to reduce resource cost and so it is advantageous to minimise the quantity of fluidiser added to the slurry, while maintaining the fluidising properties. As such, it is preferable to incorporate fluidiser in an amount of less than 0.76 wt.% inclusive relative to the gypsum.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

La présente demande décrit une plaque de plâtre comprenant du gypse, du trimétaphosphate de sodium en une quantité de 0,04 % en poids à moins de 0,17 % en poids par rapport au gypse, et un fluidificateur en une quantité de 0,42 % en poids à 0,76 % en poids inclus par rapport au gypse. La présente demande décrit en outre une suspension de stuc, l'utilisation de la suspension de stuc et d'une cloison.
EP21847456.7A 2020-12-21 2021-12-20 Plaque de plâtre, suspension de stuc, utilisation d'une suspension de stuc et d'une cloison Pending EP4263464A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB2020269.3A GB2602152B (en) 2020-12-21 2020-12-21 A plasterboard, a stucco slurry, use of a stucco slurry and a partition
PCT/EP2021/086891 WO2022136321A1 (fr) 2020-12-21 2021-12-20 Plaque de plâtre, suspension de stuc, utilisation d'une suspension de stuc et d'une cloison

Publications (1)

Publication Number Publication Date
EP4263464A1 true EP4263464A1 (fr) 2023-10-25

Family

ID=74221494

Family Applications (1)

Application Number Title Priority Date Filing Date
EP21847456.7A Pending EP4263464A1 (fr) 2020-12-21 2021-12-20 Plaque de plâtre, suspension de stuc, utilisation d'une suspension de stuc et d'une cloison

Country Status (3)

Country Link
EP (1) EP4263464A1 (fr)
GB (1) GB2602152B (fr)
WO (1) WO2022136321A1 (fr)

Family Cites Families (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6342284B1 (en) * 1997-08-21 2002-01-29 United States Gysum Company Gypsum-containing product having increased resistance to permanent deformation and method and composition for producing it
US6406537B1 (en) * 2000-11-22 2002-06-18 United States Gypsum Company High-strength joint compound
AU2004221854B2 (en) * 2003-03-19 2009-06-11 United States Gypsum Company Acoustical panel comprising interlocking matrix of set gypsum and method for making same
US20060278132A1 (en) * 2005-06-09 2006-12-14 United States Gypsum Company Method of improving dispersant efficacy in making gypsum products
US7731794B2 (en) * 2005-06-09 2010-06-08 United States Gypsum Company High starch light weight gypsum wallboard
US9802866B2 (en) * 2005-06-09 2017-10-31 United States Gypsum Company Light weight gypsum board
US20080070026A1 (en) * 2005-06-09 2008-03-20 United States Gypsum Company High hydroxyethylated starch and high dispersant levels in gypsum wallboard
US7736720B2 (en) * 2005-06-09 2010-06-15 United States Gypsum Company Composite light weight gypsum wallboard
US7771851B2 (en) * 2005-08-26 2010-08-10 United States Gypsum Company Gypsum-containing products containing alpha hemihydrate
EP2658824A1 (fr) * 2010-12-29 2013-11-06 United States Gypsum Company Procédé d'amélioration de la résistance d'une plaque de plâtre
US8323785B2 (en) * 2011-02-25 2012-12-04 United States Gypsum Company Lightweight, reduced density fire rated gypsum panels
US20150104629A1 (en) * 2013-10-15 2015-04-16 United States Gypsum Company Gypsum wallboard produced using a high water-to-stucco ratio
US11414352B2 (en) * 2018-04-11 2022-08-16 United States Gypsum Company Method for making a lightweight gypsum composition with internally generated foam and products made from same
US20200024191A1 (en) * 2018-07-20 2020-01-23 United States Gypsum Company Siloxane polymerization in gypsum wallboard
US11186066B2 (en) * 2018-08-14 2021-11-30 United States Gypsum Company Gypsum board from gypsum having high level of chloride salt and a perforated sheet and methods associated therewith
CN111196709A (zh) * 2018-11-19 2020-05-26 北新集团建材股份有限公司 一种防水、防火、防霉、高强玻纤毡石膏板及其制备方法

Also Published As

Publication number Publication date
GB2602152A (en) 2022-06-22
GB202020269D0 (en) 2021-02-03
GB2602152B (en) 2023-12-20
WO2022136321A1 (fr) 2022-06-30

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