Gypsum fiberboard containing a recycled material

Abstract

Gypsum fiberboard comprising a gypsum matrix, wherein, for reinforcement of the gypsum matrix, collected and recycled packaging of insulating materials comprising a kraft paper recyclate and / or a papyroline recyclate is added.

Description

[0001] The invention relates to a gypsum fiberboard which is made from a slurry containing a gypsum matrix.

[0002] Gypsum fiberboards are gypsum boards reinforced with fibers, usually without a paper facing. A slurry containing a gypsum matrix is ​​used to manufacture them. Glass and / or cellulose fibers added to the slurry reinforce the gypsum fiberboard, resulting in higher strength compared to, for example, gypsum plasterboard. For the purposes of this invention, gypsum fiberboards also include panel constructions made of multiple gypsum fiberboards. For example, in dry screed elements, two gypsum fiberboards are bonded together in an offset pattern. Such elements are also considered gypsum fiberboards. High-density gypsum fiberboards with a density of >1500 kg / m³ are also included. 3 are to be understood as relevant gypsum fiberboards.

[0003] German patent DE 42 135 12 A1 discloses a method for controlling the production of high-quality gypsum fiberboards, which proposes adding approximately the same amount of kraft paper as a source of high-quality fibers to a recycled paper component. This can positively influence the wet density of the board blanks.

[0004] The object of the invention is to provide a gypsum fiberboard whose reinforcement is at least partially manufactured from a recycled material in a resource-saving manner. The known positive properties of gypsum fiberboards, such as their significantly increased strength compared to gypsum plasterboard and their good fire resistance, should not be adversely affected.

[0005] This problem is solved with a gypsum fiberboard having the features of claim 1. Advantageous embodiments are specified in the dependent claims.

[0006] A gypsum fiberboard according to the invention has a gypsum matrix, wherein kraft paper recyclate and / or papyroline recyclate is added for reinforcement of the gypsum matrix, each of which comprises packaging waste from collected and recycled packaging of insulating materials.

[0007] Kraft paper and / or papyroline are increasingly used as packaging material made from renewable raw materials, even for large-volume building materials such as insulation rolls or the like. The invention proposes the use of kraft paper and / or papyroline waste from the packaging of insulation materials as a reinforcing additive for the slurry of gypsum fiberboards.

[0008] It was found that neither the strength nor the fire protection properties of a gypsum fiberboard according to the invention decrease compared to known gypsum fiberboards which are made from known slurry compositions.

[0009] A proportion of kraft paper recyclate of at least 10 percent by weight of a slurry consisting of at least the gypsum matrix and the kraft paper recyclate is preferred.

[0010] A proportion of papyroline recycled material of at least 10 percent by weight of a slurry consisting of at least the gypsum matrix and the papyroline recycled material is preferred.

[0011] Such a minimum proportion of recycled kraft paper or papyroline offers advantages in that noticeable improvements in quality regarding strength properties can be achieved based on the addition of fibers from these materials.

[0012] Advantageous proportions of the kraft paper recycled content in the sludge are in a range of 10% by weight up to and including 25% by weight, more preferably in a range of 15% by weight up to and including 20% ​​by weight.

[0013] Advantageous proportions of the papyroline recyclate in the sludge are in a range of 10% by weight up to and including 25% by weight, more preferably in a range of 15% by weight up to and including 20% ​​by weight.

[0014] A maximum limit of 25% by weight seems sensible to avoid unwanted reductions in strength due to an excess of cellulose fibers. A range between 15% and 20% by weight appears optimal.

[0015] One advantage is that the proportion of recycled kraft paper consists at least predominantly of kraft paper from packaging waste. This allows for significant savings in raw materials.

[0016] Particularly high strengths can be achieved if the kraft paper recyclate consists exclusively of cellulose fibers, starch, alum and glue.

[0017] Furthermore, it is advantageous if the gypsum fiberboard contains parts of a textile grid or fabric made from recycled papyroline.

[0018] This eliminates the need for the time-consuming removal of the textile grid or fabric that is usually contained in papyroline.

[0019] Furthermore, the invention offers additional advantages by enabling the relatively simple establishment of a reuse cycle. This is achieved by collecting packaging materials from insulation materials wrapped in kraft paper and / or papyroline, such as insulation rolls, on construction sites. These typically not heavily contaminated packaging waste materials can then be added to existing production facilities as a reinforcing additive for the slurries used in the manufacture of gypsum fiberboards. The advantage is that, due to the low degree of contamination, mechanical processing of the recyclates is usually sufficient.

[0020] It is advisable to recycle the packaging material in the case of paper packaging for insulation products such as glass wool or rock wool rolls, which are delivered to a construction site in a highly compressed state. These highly compressed insulation products place relatively high demands on the packaging's strength, while at the same time there are increasing requirements to avoid fossil-based raw materials. Therefore, plastic films, as used in the past, are increasingly being replaced by packaging materials based on renewable raw materials such as kraft paper or papyrol. Such particularly high-strength papers or paper structures also constitute an ideal raw material for the production of gypsum fiberboards, especially with regard to their fiber components. The kraft papers and...The high-quality cellulose fibers contained in Papyrolin and the absence or near absence of recycled paper enable a strength-enhancing effect for the gypsum fiberboard without having to resort to new / virgin materials with regard to the cellulose fibers.

[0021] This concept allows for the simple establishment and maintenance of a material cycle. On a construction site, for example, where insulation materials are unpacked, the resulting packaging materials are separated and collected. In a further step, the collected packaging materials, which contain valuable long-fiber cellulose fibers, are transported to a gypsum fiberboard manufacturer. This manufacturer can then readily integrate them into an existing gypsum fiberboard production line using standard, and especially existing, processing and / or dosing equipment for fibrous materials.

[0022] With the aforementioned recycling loop for packaging materials, especially packaging materials for insulation materials, and their return to a production plant for gypsum fiberboards, both the CO2 footprint for the product life cycles of the insulation materials and the gypsum fiberboards can be reduced and thus further optimized. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 42 135 12 A1

[0003]

Claims

[1] Gypsum fiberboard comprising a gypsum matrix, wherein, for reinforcement of the gypsum matrix, collected and recycled packaging of insulating materials comprising a kraft paper recyclate and / or a papyroline recyclate is added. [2] Gypsum fiberboard according to claim 1, characterized by that a proportion of the kraft paper recyclate is at least 10 percent by weight of a slurry consisting of at least the gypsum matrix and the kraft paper recyclate. [3] Gypsum fiberboard according to claim 1 or 2, characterized by that a proportion of the papyroline recyclate is at least 10 percent by weight of a slurry consisting of at least the gypsum matrix and the papyroline recyclate. [4] Gypsum fiberboard according to any of the preceding claims, characterized by that the proportion of kraft paper recycled material in the sludge is preferably in a range of 10% by weight to 25% by weight, and more preferably in a range of 15% by weight to 20% by weight. [5] Gypsum fiberboard according to any of the preceding claims, characterized by that the proportion of papyroline recyclate in the sludge is preferably in a range of 10% by weight to 25% by weight, and more preferably in a range of 15% by weight to 20% by weight. [6] Gypsum fiberboard according to any of the preceding claims, characterized by that the proportion of kraft paper recycled material contains at least predominantly kraft paper from collected and recycled packaging of insulating materials. [7] Gypsum fiberboard according to any of the preceding claims, characterized by that the proportion of papyroline recycled material contains at least predominantly papyroline from collected and recycled packaging of insulating materials. [8] Gypsum fiberboard according to any of the preceding claims, characterized by that the kraft paper of the kraft paper recyclate consists exclusively of cellulose fibers, starch, alum and glue. [9] Gypsum fiberboard according to any of the preceding claims, characterized by that the gypsum fiberboard contains parts of a textile grid or fabric of the papyroline of the papyroline recyclate.