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EP-4735705-A1 - PLASTERBOARDS AND METHODS FOR MAKING THE SAME

EP4735705A1EP 4735705 A1EP4735705 A1EP 4735705A1EP-4735705-A1

Abstract

The present disclosure relates generally to a plasterboard having a first surface and an opposed second surface, the plasterboard comprising: a body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard; a first liner having a mass loss of at least 70 g/m 2 at 600 °C disposed at the first surface of the plasterboard; and a second liner having a mass loss of no more than 60 g/m 2 at 600 °C disposed at the second surface of the plasterboard.

Inventors

  • LESPIAT, REMI
  • SALLES, Corinne
  • FISHER, ROBIN
  • LIENHART, FABIEN

Assignees

  • Saint-Gobain Placo

Dates

Publication Date
20260506
Application Date
20240628

Claims (15)

  1. 1. A plasterboard having a first surface and an opposed second surface, the plasterboard comprising: a body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard; a first liner having a surface roughness (Rz) of no more than 40 microns disposed at the first surface of the plasterboard; and a second liner disposed at the second surface of the plasterboard, the second liner having a mass loss of no more than 60 g/m 2 at 600 °C and/or a heat release of no more than 400 kJ/m 2 .
  2. 2. A plasterboard according to claim 1 , wherein the first liner has a mass loss of at least 70 g/m 2 (e.g., at least 100 g/m 2 ) at 600 °C; and the second liner has a mass loss of no more than 60 g/m 2 at 600 °C.
  3. 3. A plasterboard according to claim 1 or claim 2, wherein the first liner has a heat release of at least 500 kJ/m 2; and the second liner has a heat release of no more than 400 kJ/m 2 .
  4. 4. The plasterboard of any of claims 1-3, wherein the first liner has a mass loss of at least 115 g/m 2 at 600 °C.
  5. 5. The plasterboard of any of claims 1-4, wherein the second liner has a mass loss of no more than 50 g/m 2 at 600 °C.
  6. 6. The plasterboard of any of claims 1-5, wherein the first liner has a heat release per area of at least 1150 kJ/m 2 .
  7. 7. The plasterboard of any of claims 1-6, wherein the first liner has a heat release per area of no more than 5000 kJ/m 2 .
  8. 8. The plasterboard of any of claims 1-7, wherein the first liner has a surface roughness (Rz) of no more than 35 microns.
  9. 9. The plasterboard of any of claims 1-8, wherein the second liner has a surface roughness (Rz) of at least 80 microns.
  10. 10. The plasterboard of any of claims 1-9, wherein the first liner is a paper liner.
  11. 11 . The plasterboard of any of claims 1-10, wherein the second liner is a glass mat, e.g., an uncoated glass mat.
  12. 12. The plasterboard of any of claims 1-11 , wherein the plaster material is a gypsum material.
  13. 13. A building comprising an interior space that is bounded by a plasterboard according to any of claims 1-12, wherein the first liner faces toward the interior space and the second liner faces away from the interior space.
  14. 14. A building according to claim 13, wherein the building comprises one or more framing members (e.g., studs, joists, sills, headers, rafters), and wherein the plasterboard is attached to the one or more framing members with the second liner facing toward the framing members and the first liner facing away from the one or more framing members.
  15. 15. A wall cavity comprising a space and one or more framing members, wherein the space is bounded by a plasterboard according to any of claims 1-12, wherein the first liner faces away from the space and the second liner faces towards the space, and wherein the plasterboard is attached to the one or more framing members with the second liner facing towards the framing members and the first liner facing away from one or more framing members.

Description

PLASTERBOARDS AND METHODS FOR MAKING THE SAME CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This applicant claims the benefit of priority of European Patent Application no. 23306045.8, filed June 28, 2023, which is hereby incorporated herein by reference in its entirety. BACKGROUND OF THE DISCLOSURE 1 Field [0002] The present disclosure relates generally to plaster boards and methods of making the same. 2. Technical Background [0003] Plaster building products (e.g., known variously as wallboard, ceiling board, plasterboard and “drywall”) are panels made of a plaster core sandwiched between two layers of liner, often paper, on the outside surfaces of the plaster core. They are widely used as construction materials due to their ease of fabrication, high mechanical strength, low thermal conductivity, resistance to spread of fire, and soundproofing properties. The quality of a plasterboard is strongly dependent on its core, which is fabricated by the hydration of slurry (including calcium sulfate hemihydrate, lime, or cements) into a set body. To control the properties of plasterboards, additives are often added to the slurry during the board making process. For example, foaming agents, inorganic compounds, and other additives may be included in the slurry to modulate the density, strength, and/or fire-resistance properties of the board. [0004] To provide fire-resistant plasterboards, it has been common to incorporate fire- resistant additives, such as polymethylhydrosiloxane, to the plaster slurry during the board making process to ultimately improve the fire-resistance properties of the board. By including fire-resistant additives, the plasterboards have reduced board shrinkage at elevated temperatures, indicative of improved structural integrity. [0005] However, additional improvements in fire resistance are desirable. SUMMARY [0006] In one aspect, the present disclosure provides a plasterboard having a first surface and an opposed second surface, the plasterboard comprising: a body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard; a first liner having a mass loss of at least 70 g/m2 (e.g., at least 100 g/cm2, or at least 115 g/cm2) at 600 °C disposed at the first surface of the plasterboard; and a second liner having a mass loss of no more than of no more than 60 g/m2 at 600 °C disposed at the second surface of the plasterboard. [0007] In another aspect, the present disclosure provides a plasterboard having a first surface and an opposed second surface, the plasterboard comprising: a body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard; a first liner disposed at the first surface of the plasterboard, the first paper liner having a heat release of at least 600 kJ/m2 (e.g., at least 1000 kJ/m2, or at least 1150 kJ/m2) and a second liner disposed at the second surface of the plasterboard, the second liner having a heat release of no more than 500 kJ/m2. [0008] In another aspect, the present disclosure provides a plasterboard having a first surface and an opposed second surface, the plasterboard comprising: a body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard; a first liner that is a paper liner disposed at the first surface of the plasterboard; and a second liner disposed at the second surface of the plasterboard, the second liner being a glass mat (i.e. , optionally coated) comprising glass fibers bound by one or more polymer binders. In various embodiments, the second liner has a heat release of no more than 500 kJ/m2. In various embodiments, the second liner has a mass loss of no more than 60 g/m2 at 600 °C. [0009] In another aspect, the present disclosure provides a plasterboard having a first surface and an opposed second surface, the plasterboard comprising: a body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard; a first liner having a surface roughness (Rz) of no more than 40 microns disposed at the first surface of the plasterboard; and a second liner disposed at the second surface of the plasterboard, the second liner having a mass loss of no more than of no more than 60 g/m2 at 600 °C and/or a heat release of no more than 400 kJ/m2. [0010] In another aspect, the present disclosure provides a plasterboard having a first surface and an opposed second surface, the plasterboard comprising: a body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard; a first liner having a surface roughness (Rz) of no more than 40 microns disposed on the first surface of the plasterboard; and a second liner having a surface roughness (Rz) of at least 80 microns disposed on the second surface of the plasterboard. [0011] In another aspect, the pres