Plaster board panels

• US 4,181,767 A
• Filed: 04/20/1978
• Issued: 01/01/1980
• Est. Priority Date: 04/25/1977
• Status: Expired due to Term

• Current Assignee: Hoechst Aktiengesellschaft (Sanofi )
• Original Assignee: Hoechst Aktiengesellschaft (Sanofi )
• Inventors: Steinau, Peter
• Primary Examiner(s): Lesmes, George F.
• Assistant Examiner(s): Thomas, Alexander S.
• Application Number:
  US05/898,414
• Time in Patent Office: 621 Days
• Field of Search: 428/68, 428/70, 428/71, 428/76, 428/507, 428/537, 428/538, 428/296, 428/511, 428/513, 428/219, 156/39-41, 156/43, 156/44, 156/45, 52/309.15, 52/417
• US Class Current: 428/219
• CPC Class Codes: B32B 13/08 of paper or cardboard
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 29/02 next to a fibrous or filamentary layer
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: Y10T 428/31902 Monoethylenically unsaturated
• CPC Class Codes: Y10T 428/31982 Wood or paper
• CPC Class Codes: Y10T 428/31996 Next to layer of metal salt [e.g., plasterboard, etc.]
• CPC Class Codes: Y10T 442/692 Containing at least two chemically different strand or fiber materials

Abstract

Plaster board panels wherein at least the top layer of one of the two cardboard sheets contains polyolefin fibrides can be easily dehydrated during their manufacture because of the porosity of the cardboard sheets. The finished panels have a substantially sealed surface of low porosity which is resistant to wet treatment and thus suitable for the application of various painting and coating systems.

Claims

1. A plaster board panel consisting essentially of a gypsum core having two sides, faced by a cardboard sheet on each side of the gypsum core, each sheet having a plurality of cardboard sheet layers, and one of said layers being the outermost layer, wherein at least the outermost cardboard sheet layer on one of the two sides contains 90 to 10% by weight of cellulose containing fibers, and from 10 to 90% by weight of polyolefin fibrides, relative to dry matter.

2. The plaster board panel, as claimed in claim 1, wherein the outermost cardboard sheet layer of each of the two sides contains 90 to 10% by weight of cellulose containing fibrides, and from 10 to 90% by weight of polyolefin fibrides, relative to dry matter.

3. The plaster board panel, as claimed in claim 1, wherein the cardboard sheet layers contain 90 to 10% by weight of cellulose containing fibers, and from 10 to 90% by weight of polyolefin fibrides, relative to dry matter.

4. The plaster board panel, as claimed in claim 1, 2 or 3, wherein the cellulose containing fibers are contained in amounts of 60 to 30% by weight and the polyolefin fibrides are contained in amounts of 40 to 70% by weight.

5. The plaster board panel, as claimed in claims 1, 2 or 3, wherein the polyolefin is polypropylene.

6. The plaster board panel, as claimed in claims 1, 2 or 3, wherein the polyolefin is polyethylene.

7. The plaster board panel, as claimed in claim 6, wherein the polyethylene has a viscosity of from 0.3 to 30 dl/g and a density of 0.93 to 0.97 g/cm³.

8. The plaster board panel, as claimed in claim 7, wherein the polyethylene has a viscosity of from 0.7 to 10 dl/g.

9. The panel, as claimed in claims 1, 2 or 3, wherein said each of said cardboard sheets have a weight of about 300 g/m² and the outermost cardboard sheet layer has a weight of 10 to 100 g/m².

10. The panel, as claimed in claim 9, wherein the outermost cardboard sheet layer has a weight of 30 to 70 g/m².

11. The panel as claimed in claims 1, 2 or 3, wherein the layer containing the polyolefin fibrides is applied to the plastic board panel simultaneously with the remaining cardboard sheet layers.

12. A process for the manufacture of a plaster board panel consisting essentially of a gypsum core having two sides and a cardboard sheet bonded to each of the two sides of the gypsum core, the cardboard sheet including a plurality of cardboard sheet layers, comprising the steps of

introducing a gypsum paste between two cellulose containing cardboard sheets to form a panel, the outermost layer of at least one of the cardboard sheets containing from 90% to 10% by weight cellulose containing fibers and from 10 to 90% by weight polyolefin fibrides, relative to dry matter, and

subjecting the panels to a heat treatment for a period of time and at a temperature sufficient to plastify the polyolefin fibrides.

13. The process as claimed in claim 12, comprising the steps of

first, introducing a gypsum paste having a water content between two cardboard sheets containing cellulose to form a panel, the top layer of at least one of the cardboard layers consisting of 90 to 10% by weight cellulose containing fibers and from 10 to 90% by weight polyolefin fibrides, relative to dry matter;

second, subjecting the panel to a heat treatment for a period of time and at a temperature sufficient to evaporate the water;

third, continuing the heat treatment for a period of time and at a temperature sufficient to plastify the polyolefin fibrides.

14. The process as claimed in claim 13, comprising the further step:

fourth, applying a hot gas shower to the panel to further plastify the polyolefin fibrides.

15. The process as claimed in claim 12 or 13, wherein the polyolefin is polyethylene.

16. The process as claimed in claim 12 or 13, wherein the polyolefin is polypropylene.

17. The process as claimed in claim 13, comprising the further step of

fourth, rolling a heated roller having a temperature above the softening point of the polyolefin fibrides, over the cardboard layer containing the polyolefin fibrides.

18. The process, as claimed in claims 12 or 13, wherein the cellulose fibers are contained in amounts of 60 to 30% by weight and the polyolefin fibrides are contained in amounts of 40 to 70% by weight.

19. The process, as claimed in claims 12 or 13, wherein during heat treatment the outermost layer containing the polyolefin fibrides has a temperature of from 130°

to 200°

C.

20. The process, as claimed in claim 13, wherein in said second and third steps, said heat treatment comprises placing the panel into a drying cabinet.

21. The process, as claimed in claim 12 or 13, wherein the temperature of the heat treatment is about 250°

C.

22. The process as claimed in claim 14, wherein said hot gas shower has a gas temperature of 130°

to 300°

C.

23. The process, as claimed in claim 22, wherein said gas shower has a gas temperature of 140°

to 200°

C.