Plasterboard and method for manufacturing the same

Abstract

This disclosure generally relates to a plasterboard having a first surface and a second surface on the opposite side, comprising a body of cured plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, and a plaster disposed on the first surface of the plasterboard, with a curing rate of at least 70 g / m² at 600°C. 2 A first liner having a mass loss of 60 g / m² is placed on the second surface of the plasterboard and is heated at 600°C. 2 It comprises a second liner having the following mass loss.

Description

[Technical Field]

[0001] (Cross-reference of related applications) This application claims priority to European Patent Application No. 23306045.8, filed on 28 June 2023, which is incorporated herein by reference in its entirety. [Background technology]

[0002] 1. Field This disclosure relates, in general terms, to plasterboard and methods for manufacturing the same.

[0003] 2.Background technology Plaster building products (e.g., wall panels, ceiling panels, plasterboards, and various other names such as "drywalls") are panels made of a plaster core sandwiched between two liner layers, often paper, on the outer surface of the plaster core. They are widely used as building materials due to their ease of manufacture, high mechanical strength, low thermal conductivity, fire resistance, and soundproofing properties. The quality of plasterboards depends heavily on their core, which is manufactured by hydrating and hardening a slurry (containing calcium sulfate hemihydrate, lime, or cement). Additives are often added to the slurry during the board manufacturing process to control the properties of the plasterboard. For example, foaming agents, inorganic compounds, and other additives can be included in the slurry to adjust the density, strength, and / or fire resistance properties of the board.

[0004] To provide fire-resistant plasterboard, it was common practice to incorporate fire-resistant additives such as polymethylhydrosiloxane into the plaster slurry during the board manufacturing process to ultimately improve the fire resistance properties of the board. The inclusion of fire-resistant additives reduces board shrinkage at high temperatures, resulting in improved structural integrity.

[0005] However, further improvements in fire resistance are desired. [Overview of the Initiative]

[0006] In one aspect, the present disclosure relates to a plasterboard having a first surface and a second surface on the opposite side, A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, It is placed on the first surface of the plasterboard and at least 70 g / m² at 600°C. 2 (For example, at least 100 g / cm³) 2 , or at least 115 g / cm³ 2 A first liner having a mass loss of, It is placed on the second surface of the plasterboard and is applied at 600°C at a rate of 60 g / m². 2 A plasterboard is provided, comprising a second liner having the following mass loss.

[0007] In another aspect, the present disclosure relates to a plasterboard having a first surface and a second surface on the opposite side, A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, It is placed on the first surface of the plasterboard and contains at least 600 kJ / m 2 (For example, at least 1000 kJ / m³) 2 , or at least 1150 kJ / m³ 2 A first liner having a heat dissipation capacity of ) It is placed on the second surface of the plasterboard and has a concentration of 500 kJ / m 2 A plasterboard is provided, comprising a second liner having the following heat dissipation capacity.

[0008] In another aspect, the present disclosure relates to a plasterboard having a first surface and a second surface on the opposite side, A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, The first liner, which is a paper liner, is placed on the first surface of the plasterboard. Provided is a plasterboard comprising a second liner which is disposed on a second surface of the plasterboard and comprises a glass mat containing glass fibers bonded by one or more polymer binders (i.e., optionally coated). In various embodiments, the second liner has a heat dissipation amount of 500 kJ / m 2 or less. In various embodiments, the second liner has a mass loss of 60 g / m 2 or less at 600 °C.

[0009] In another aspect, the present disclosure provides a plasterboard having a first surface and an opposite second surface, comprising a body of cured plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, a first liner disposed on the first surface of the plasterboard and having a surface roughness (Rz) of 40 microns or less, a second liner disposed on the second surface of the plasterboard and having a mass loss of 60 g / m 2 or less and / or a heat dissipation amount of 400 kJ / m 2 or less at 600 °C.

[0010] In another aspect, the present disclosure provides a plasterboard having a first surface and an opposite second surface, comprising a body of cured plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, a first liner disposed on the first surface of the plasterboard and having a surface roughness (Rz) of 40 microns or less, a first liner disposed on the first surface of the plasterboard and having a surface roughness (Rz) of at least 80 microns or less.

[0011] In another aspect, the present disclosure provides a method of forming a plasterboard as described herein having a first surface and an opposite second surface, comprising providing a slurry comprising a plaster material and water The slurry is placed between the first liner and the second liner, The slurry is cured to form a wet plaster core, This includes drying a wet plaster core at a temperature in the range of 50 to 350°C to provide a cured plaster material. The present invention provides a method in which a hardened plaster material is placed between a first liner on a first surface of a building board and a second liner on a second surface of a building board.

[0012] In another embodiment, the present disclosure provides a building having an interior space bounded by plasterboard as described herein, wherein a first liner faces toward the interior space and a second liner faces toward away from the interior space.

[0013] In another embodiment, the Disclosure provides a wall cavity comprising a cavity space and one or more frame members, wherein the cavity space is bounded by plasterboard as described herein, and the first liner faces away from the cavity space and the second liner faces toward the cavity space, and the plasterboard is attached to one or more frame members such that the second liner faces toward the frame members and the first liner faces away from one or more frame members. [Brief explanation of the drawing]

[0014] The accompanying drawings are included to provide a further understanding of the methods of this disclosure, are incorporated herein, and constitute part of this specification. The drawings are not necessarily to scale, and the sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiments of this disclosure and, together with the description, serve to illustrate the principles and operation of this disclosure.

[0015] [Figure 1] This is a diagram of the fire-resistant board described in this specification. [Figure 2A]This is a graph showing the free shrinkage test results of the liners described in this specification. [Figure 2B] This is a graph showing the free shrinkage test results of the liners described in this specification. [Figure 3] This is a schematic diagram of the small-scale partition test described herein. [Figure 4A] This is a graph of the thermogravimetric analysis results of the liner described herein. [Figure 4B] This is a graph of the thermogravimetric analysis results of the liner described herein. [Figure 4C] This graph shows the mass loss versus partition test results for the liners described herein. [Figure 5A] This is a graph of the differential scanning calorimetry results for the liner described herein. [Figure 5B] This graph shows the heat dissipation and mass loss of the liner compared to the partition test results as described in this specification. [Figure 6] This graph compares partition tests of boards made with various liner combinations. [Figure 7] This graph shows the single-layer material thickness (square markers on the left y-axis) and thermal conductivity data (X markers on the right y-axis) for several liners, illustrating various normalized TCF values ​​(x axis) when used as an inner liner (facing the cavity) along with an outer liner (applied to the opposite side of the gypsum core facing the environment) in a board sample as described herein. [Figure 8] This graph plots the thermal conductivity (y-axis), obtained by dividing the thermal conductivity by the thickness of the single-layer material from the graph in Figure 7, against the normalized TCF value (x-axis) from the graph in Figure 7. [Figure 9] This graph shows the heat dissipation per unit area (square markers on the left y-axis) and mass loss at 600°C (X markers on the right y-axis) for several liners, when used as an inner liner (facing the cavity) along with an outer liner (applied to the opposite side of the gypsum core facing the environment) in a board sample as described herein, with the values ​​being normalized TCF (x-axis). [Modes for carrying out the invention]

[0016] This disclosure relates to providing a plasterboard with good fire resistance. The inventors have noticed that while core materials such as gypsum used in the manufacture of plasterboard can provide fire resistance to the core, the liner placed on the outer surface of the core often does not exhibit good fire resistance. The inventors have noted that while the liner is the primary defense of the board against fire, they are generally made from highly flammable materials.

[0017] In particular, conventional fire-resistant boards include two liners positioned on the outer surface of the board. The inventors note that paper liners can be very desirable in terms of providing a relatively smooth surface for, for example, painting or other modifications, and thus can provide good aesthetics to surfaces facing a room.

[0018] As mentioned above, conventional plasterboard is made from a plaster core sandwiched between two liners on the outer surface of the plaster core. When used to construct walls, the plasterboard liner facing (and closing) the wall cavity is often called the back liner (e.g., backing paper), while the opposite side is often called the front liner (e.g., cover). These liners are the primary defense against fire for the board, but are often made from paper or other highly flammable materials.

[0019] The inventors noted that it is the backing liner that closes the wall cavity that more substantially affects the fire resistance of plasterboard in order to slow the spread of flames. For example, during a fire, the temperature of the wall cavity of a burning structure rises and can exceed the backing paper burning temperature. At this temperature, the backing paper releases heat, adversely affecting the durability performance of the plasterboard. Furthermore, the rapid burning of the backing paper reduces the time it takes for the board to break down, and therefore leads to a more rapid spread of fire. In contrast, the inventors found that the cover has a much less impact on fire resistance. Although it can burn rapidly, it is not significant in contributing to the spread of fire.

[0020] Accordingly, one aspect of the present disclosure provides a plasterboard having a first surface and a second surface opposite to it, a first liner disposed on the first surface, and a second liner disposed on the second surface. The plasterboard according to this aspect comprises a body of cured plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, and a liner disposed on the first surface of the plasterboard with a curing rate of at least 70 g / m² at 600°C. 2 A first liner having a mass loss of 60 g / m² is placed on the second surface of the plasterboard and is heated at 600°C. 2 It comprises a second liner having the following mass loss.

[0021] g / m³ used in this specification 2 The mass loss per unit is measured by thermogravimetric analysis (TGA) at a rate of 5°C / min in contact with air and ambient pressure. The mass loss at 600°C is the total mass loss over the range of 25–600°C. Those skilled in the art will determine the appropriate equipment for performing this measurement. As will be understood by those skilled in the art, the mass loss provides insight into the thermal decomposition of the material. As described above, in various aspects of this disclosure, the first liner has a mass loss of at least 70 g / m² at 600°C. 2 It has a mass loss of . For example, in various embodiments, the first liner has a mass loss of at least 80 g / m² at 600°C. 2 For example, at least 90 g / m2 It has a mass loss of . In various embodiments, the first liner has at least 100 g / m 2 For example, at least 105 g / m² at 600°C. 2 , or at least 110 g / m² at 600°C 2 It has a mass loss of . In some embodiments described herein, the first liner has a mass loss of at least 115 g / m² at 600°C. 2 , at least 120 g / m² at 600°C 2 , or at least 140 g / m² at 600°C 2 , or at least 160 g / m² at 600°C 2 It has a mass loss of . In the various embodiments described herein, the first liner has a mass loss of 90% or less of the mass of the first liner, for example, 80% or less. Those skilled in the art will understand that this value depends on various factors, for example, the amount of inorganic filler or pigment in the first liner. The inventors have determined that using a liner with a higher mass loss as the first liner (for example, positioned so as to face away from the wall cavity and toward the room) does not cause significant problems with respect to overall fire resistance, and importantly, it may allow a variety of paper and polymer materials to be used as the first liner, which may provide a variety of desired overall properties, including a smooth surface for wall finishing.

[0022] In contrast, in this embodiment of the present disclosure, the second liner has lower mass loss at 600°C than the first liner. Advantageously, the inventors have found that such a second liner can provide improved fire resistance to the plasterboard on which they are placed, for example, when the second liner faces a wall cavity. As described above, in this embodiment of the present disclosure, the second liner has a mass loss of 60 g / m² at 600°C. 2 The following mass loss is observed. For example, in some embodiments described herein, the second liner has a mass loss of 50 g / m² at 600°C. 2 For example, 45 g / m² at 600°C. 2 The following, or 40g / m² at 600℃. 2The following mass loss occurs. For example, in some embodiments, the second liner has a mass loss of 35 g / m² at 600°C. 2 For example, 30 g / m² at 600°C. 2 The following mass loss is observed. In some embodiments described herein, the second liner has a mass loss of at least 15 g / m² at 600°C. 2 At least 18 g / m² at 600°C 2 , or at least 20 g / m² at 600°C 2 It has a mass loss of . In some embodiments described herein, the second liner has a mass loss of 15 to 60 g / m² at 600°C. 2 It has a mass loss in the range of 15-50 g / m². For example, in the various embodiments described herein, the second liner has a mass loss of 15-50 g / m². 2 , or 15-45 g / m 2 , or 15-40g / m 2 , or 15-35 g / m 2 , or 15-30 g / m 2 , or 18-60g / m 2 , or 18-50g / m 2 , or 18-45g / m 2 , or 18-40g / m 2 , or 18-35 g / m 2 , or 18-30g / m 2 , or 20-60g / m 2 , or 20-50g / m 2 , or 20-45 g / m 2 , or 20-40 g / m 2 , or 20-35 g / m 2 , or 20-30 g / m 2 It has a mass loss in the range of 600°C.

[0023] As described throughout this disclosure, the inventors have found that using a second liner with low mass loss (e.g., positioning it toward the wall cavity) significantly improves the fire resistance and fire durability of plasterboard. This is true even when the first liner exhibits high mass loss. In certain embodiments described herein, the inventors have found that by using the second liner as a “back liner” (i.e., facing the wall cavity), a sufficient improvement in fire resistance is observed compared to using a conventional front liner (e.g., paper). The front liner is the consumer-facing side of the board and is expected to have a particular aesthetic appearance. By simply using a second liner on the back of the board, the board has improved fire resistance while still meeting the aesthetic requirements of the consumer-facing side of the board.

[0024] Another aspect of the present disclosure is a plasterboard (for example, having the above-mentioned mass loss value) having a first surface and a second surface on the opposite side, comprising a body of cured plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, and a plasterboard disposed on the first surface of the plasterboard with a capacity of at least 600 kJ / m 2 A first paper liner having a heat dissipation capacity of 500 kJ / m² is placed on the second surface of a plasterboard. 2A plasterboard comprising a second liner having the following heat dissipation. In relation to the mass loss described above, the liner can also be characterized by the heat dissipation by the liner at high temperatures. To determine the heat dissipation, differential scanning calorimetry (DSC) can be used to measure the heat dissipation by the liner during heating. The heat dissipation can be determined by DSC at a heating rate of 5°C / min up to 700°C, and the heat dissipation can be determined over a range of 150 to 600°C. Here again, the measurement is performed in the presence of air and under ambient pressure. Those skilled in the art can determine the appropriate equipment to use and can perform this measurement in conjunction with the TGA measurement described above. As with the mass loss described above, in this aspect of the disclosure, the first liner exhibits a relatively high heat dissipation, and the second liner exhibits a relatively low heat dissipation.

[0025] In various embodiments described herein, the first liner has a capacity of at least 650 kJ / m 2 For example, at least 800 kJ / m³ 2 , or at least 900 kJ / m³ 2 It has a heat dissipation capacity per unit area. In various embodiments, the first liner has a heat dissipation capacity of at least 1000 kJ / m 2 For example, at least 1050 kJ / m³ 2 , or at least 1100 kJ / m³ 2 It has a heat dissipation capacity per unit area. In various embodiments, the first liner has a heat dissipation capacity of at least 1150 kJ / m². 2 For example, at least 1250 kJ / m³ 2 , or at least 1500 kJ / m³ 2 It has a heat dissipation capacity per unit area. In the various embodiments described herein, the first liner has a heat dissipation capacity of 5000 kJ / m 2 For example, 4000 kJ / m³ 2 The following, or 3000 kJ / m³ 2 It has the following heat dissipation capacity per unit area.

[0026] In the various embodiments described herein, the second liner has a capacity of 450 kJ / m 2Hereinafter, for example, 400 kJ / m 2 Hereinafter, or 350 kJ / m 2 Hereinafter, or 300 kJ / m 2 Has a heat dissipation amount per area of hereinafter. For example, in some embodiments described herein, the second liner has 250 kJ / m 2 Hereinafter, 200 kJ / m 2 Hereinafter, or 100 kJ / m 2 Has a heat dissipation amount per area of hereinafter. In some embodiments described herein, the second liner has at least 50 kJ / m 2 At least 60 kJ / m 2 Or at least 75 kJ / m 2 Has a heat dissipation amount per area of. In some embodiments described herein, the second liner has a heat dissipation amount per area in the range of 50 - 500 kJ / m 2 For example, in various embodiments, the second liner has a heat dissipation amount per area in the range of 50 - 450 kJ / m 2 Or 50 - 400 kJ / m 2 Or 50 - 350 kJ / m 2 Or 50 - 300 kJ / m 2 Or 50 - 250 kJ / m 2 Or 50 - 200 kJ / m 2 Or 75 - 500 kJ / m 2 Or 75 - 450 kJ / m 2 Or 75 - 400 kJ / m 2 Or 75 - 350 kJ / m 2 Or 75 - 300 kJ / m 2 Or 75 - 250 kJ / m 2 Or 75 - 200 kJ / m 2 Has a heat dissipation amount per area in the range of.

[0027] The first and second liners described herein may be characterized by their surface roughness. Thus, in one aspect of this disclosure, the plasterboard comprises a body of cured plaster material having a first surface and an opposite second surface, extending from the first surface to the second surface of the plasterboard; a first liner disposed on the first surface of the plasterboard and having a surface roughness (Rz) of 40 microns or less; and a second liner disposed on the second surface of the plasterboard and having a surface roughness (Rz) of at least 80 microns. The inventors noted that the surface roughness of the first liner of the plasterboard may be important in terms of providing a smooth surface facing the room. However, the inventors found that the surface roughness of the second liner is less important since the second liner may be positioned to face the wall cavity. Therefore, a much rougher second liner can be used. When used herein, surface roughness is the average R of the material, measured by contact shape measurement using a Surftest SJ-210 instrument. z It refers to.

[0028] In various embodiments described elsewhere in this specification, the first liner has a surface roughness (Rz) of 35 microns or less, for example, 30 microns or less. For example, in various embodiments, the first liner has a surface roughness (Rz) in the range of 10 to 40 microns, for example, 10 to 35 microns, or 10 to 30 microns, or 15 to 40 microns, or 15 to 35 microns, or 15 to 30 microns. In various embodiments described elsewhere in this specification, the second liner has a surface roughness (Rz) of at least 85 microns, for example, at least 90 microns. For example, in various embodiments described separately herein, the second liner has a surface roughness (Rz) in the range of 80 to 1000 microns, for example, 80 to 750 microns, or 80 to 500 microns, or 85 to 1000 microns, or 85 to 750 microns, or 85 to 500 microns, or 90 to 1000 microns, or 90 to 750 microns, or 90 to 500 microns.

[0029] The inventors have focused in particular on the different desirable properties for two different surfaces of a plasterboard. As described above, the surface of the plasterboard facing a room is preferably a smoother surface, and fire resistance is less important for this surface. In contrast, the surface of the plasterboard facing a wall cavity provides desirable fire resistance, but the requirement for smoothness is lower. Accordingly, another aspect of the present disclosure is a plasterboard having a first surface and a second surface on the opposite side (for example, as described in any aspect or embodiment of this specification), comprising a body of cured plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, a first liner disposed on the first surface of the plasterboard having a surface roughness (Rz) of 40 microns or less, and a plasterboard disposed on the second surface of the plasterboard with a curing rate of 60 g / m² at 600°C. 2 The following mass losses and / or 400 kJ / m 2 This is a plasterboard comprising a second liner having the following heat dissipation capacity.

[0030] Based on the disclosure herein, a person skilled in the art can select suitable materials for the first and second liners.

[0031] The first liner can be selected to provide, for example, one or more of the following: relatively high mass loss, relatively high heat dissipation, and relatively high smoothness, as described above. In various embodiments described separately herein, the first liner is a paper liner. The type of paper liner is not particularly limited, and those skilled in the art can select a suitable paper for use as a plasterboard liner. As those skilled in the art will understand, the paper used as a liner can include recycled contents or unused paper and can include fillers and / or reinforcing materials such as fibers and inorganic particles. The paper liner can be treated in various ways, for example, by bleaching, or by surface treatment or coating (such as polymer coating). In various embodiments described herein, the paper liner can appear relatively light in color to the observer. For example, in various embodiments, the paper liner has an L* value of at least 70, an a* value of 5 or less, and a b* value of 5 or less, as measured in the CIELAB color space. In various embodiments, the paper liner may be a so-called "ivory paper" liner. As those skilled in the art will understand, paper liners can provide a desirable degree of smoothness to the room-facing surface of the plasterboard.

[0032] Naturally, in various embodiments, other materials can be used as the first liner. In various embodiments, a polymer film can be used as the first liner. In various embodiments, a glass mat can be used as the first liner. Such a glass mat can provide the relatively smooth surface described above, for example, by comprising a coating of particulate inorganic material (e.g., calcium carbonate) bonded to a polymer. Those skilled in the art can select a polymer or glass mat-based liner to provide the first liner with desired properties, as described herein. For example, a polymer or coating on a glass mat can provide the desired smoothness to the surface facing the room of the plasterboard.

[0033] The second liner can be selected to provide, for example, one or more of the following: relatively low mass loss, relatively low heat dissipation, and relatively low smoothness, as described above.

[0034] In various embodiments described herein, the second liner is a glass mat. In some embodiments, the second glass mat liner is an uncoated glass mat. In other embodiments, the second glass mat liner is a coated glass mat with a coating of particulate inorganic material (e.g., calcium carbonate) bonded to a polymer, providing a relatively smooth surface as described above. Those skilled in the art can select a glass mat liner to provide the first liner with desired properties, as described herein. For example, a glass mat liner with a low organic content can provide low mass loss and / or low heat dissipation.

[0035] Accordingly, in another embodiment, the present disclosure provides a plasterboard having a first surface and a second surface on the opposite side, comprising a body of cured plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, a first liner which is a paper liner disposed on the first surface of the plasterboard, and a second liner which is a glass mat containing glass fibers bound together by one or more polymer binders, disposed on the second surface of the plasterboard.

[0036] As described above, in some embodiments described separately in this specification, one or more of the first liner and the second liner are glass mats. As will be understood by those skilled in the art, a glass mat is a mat containing glass fibers bonded by one or more binders. In various embodiments, particularly when used as the second liner, the glass mat may not be coated. Also, in various embodiments, the glass mat can be coated. The coated glass mat can have a coating on one or more of its surfaces, desirably on one surface and not on the other, such that the uncoated surface faces the body of the cured plaster. Various coatings can be used. For example, in various embodiments, the coating includes particulate inorganic materials (such as calcium carbonate) bonded by a polymer binder. The polymer binder (i.e., the one that binds the glass fibers of the mat and / or the particles of the coating) is not particularly limited. In some embodiments, each of the one or more polymer binders is a urea-based resin, acrylic, or modified phenolic resin. Other coating materials, such as polymer coatings, can be used on the glass mat. Those skilled in the art can select the content of the organic materials (binder(s) and / or polymer coating) to provide a glass mat having desirable properties such as a desirable low mass loss and / or low heat release at 600 °C.

[0037] The areal mass of the liners described in this specification can vary depending on the materials of the liners described in this specification. As will be understood by those skilled in the art, the areal mass refers to the mass per unit area. In some embodiments described in this specification, the first liner has an areal mass in the range of 125 - 350 g / m 2 For example, in various embodiments, the first liner is 125 - 300 g / m 2 , or 125 - 250 g / m 2 , or 175 - 350 g / m 2 , or 175 - 300 g / m 2 , or 175 - 2500 g / m 2 , or 200 - 350 g / m2 , or 200-300g / m 2 , or 200-250g / m 2 It has an area mass in the range of . In various embodiments, for example, if the second liner is an uncoated glass mat, the second liner has an area mass of 150 g / m². 2 For example, 125g / m² 2 The following, or 100g / m² 2 The area mass is as follows: In some embodiments, the second liner has a mass of 50-150 g / m². 2 It has an area mass in the range of 50-125 g / m². For example, in some embodiments, the second liner has an area mass in the range of 50-125 g / m². 2 , or 50-100g / m 2 , or 65-150g / m 2 , or 65-125 g / m 2 , or 65-100g / m 2 , or 80-150g / m 2 , or 80-125 g / m 2 , or 80-100g / m 2 It has an area mass within the range of [range]. Naturally, in various embodiments, for example, when a coated glass mat is used as the second liner, the second liner can have a higher area mass.

[0038] As will be described in more detail in the following embodiments, the fire resistance of the plasterboards described herein can be evaluated using a small partition test. The small partition test evaluates the thermal insulation of a small partition, taking into account thermal conductivity, cavity radiation, board endothermic and exothermic reactions. For the test, a 145 × 195 mm partition is constructed with metal studs and placed as the door of an electric kiln. The furnace temperature follows a quasi-ISO 834 curve. Four thermocouples are placed on each board surface. The criterion "time to reach 140°C plus room temperature on the low-temperature surface" (i.e., TC4) is recorded for each test. A schematic diagram of this test is shown in Figure 3. In the various embodiments described herein, the plasterboards have a substantially longer TC4 than boards otherwise identical, which are made using a paper backing liner.

[0039] It may be desirable that the first and second liners have substantially similar water permeability so that the board dries from both sides at substantially the same rate. Therefore, in various embodiments, the second liner has an ASTM E-96 water permeability at 75% rh and 23°C of no more than 50% of that of the first liner, for example, no more than 20%. Naturally, in other embodiments, there may be greater differences between the water permeability of the liners. In such cases, those skilled in the art can adapt the board manufacturing process accordingly.

[0040] The plasterboard described herein includes a body of hardened plaster material. Those skilled in the art will understand that the liner described herein can be used with various different types of plaster material. In some embodiments described herein, the plaster material is a gypsum material. For example, in some embodiments, the plaster material includes at least 75% by weight of gypsum, or at least 80% by weight of gypsum, or at least 85% by weight of gypsum. In some embodiments described herein, the plaster material includes a base material which is lime or cement. For example, in various embodiments, the plaster material includes at least 75% by weight of lime, or at least 80% by weight of lime, or at least 85% by weight of lime. In other embodiments, the plaster material includes at least 75% by weight of cement, at least 80% by weight of cement, or at least 85% by weight of cement.

[0041] In some embodiments described herein, the plaster material further comprises one or more of the following: accelerators, fluidizers, retarders, dispersants, foaming agents, and glass fibers. In some embodiments described herein, the plaster material further comprises silicone oil.

[0042] In some embodiments described herein, the plasterboard has a thickness substantially equal to 0.375 inches between the first and second surfaces. In some embodiments, the plasterboard has a thickness substantially equal to 0.5 inches between the first and second surfaces. In some embodiments, the plasterboard has a thickness substantially equal to 0.625 inches between the first and second surfaces. In some embodiments as described herein, the plasterboard has a thickness greater than 0.25 inches and less than or equal to 2 inches (e.g., in the range of 0.25 to 0.75 inches, 0.25 to 0.625 inches) between the first and second surfaces.

[0043] In some embodiments described herein, the plasterboard has fire resistance exceeding the 1-hour target specified in the ANSI / UL263 test standard.

[0044] In some embodiments described herein, the plasterboard has a density ranging from 1700 to 2500 lbs / MSF (i.e., 1 MSF = 1000 square feet).

[0045] Another aspect of the present disclosure provides a method for forming a plasterboard according to this specification, having a first surface and a second surface on the opposite side. The method comprises providing a slurry containing a plaster precursor and water; placing the slurry between a first liner and a second liner; curing the slurry to form a wet plaster core; and drying the wet plaster core at a temperature in the range of 50 to 350°C to provide a cured plaster material, wherein the cured plaster material is placed between a first liner on the first surface of a building board and a second liner on the second surface of a building board.

[0046] As described above, the method of the present disclosure comprises providing a slurry comprising a plaster precursor and water. In some embodiments, the plaster precursor comprises a base material selected from stucco, lime, or cement. In some embodiments described herein, the plaster precursor comprises a base material which is a stucco material. As is known in the art, stucco can have a variety of compositions depending on readily available sources and applications. As used herein, “stucco” is a material having at least 75% by weight of calcium sulfate hemihydrate. It is typically provided by calcining a gypsum material to convert gypsum (i.e., calcium sulfate dihydrate) into the corresponding hemihydrate. Real-world samples of stucco typically contain one or more of calcium sulfate dihydrate, calcium sulfate anhydrous, and inert calcium sulfate, along with the hemihydrate (e.g., existing as α-calcium sulfate hemihydrate, β-calcium sulfate hemihydrate, or a combination thereof). In some embodiments, stucco is present in the slurry to provide a hardened plaster material for a core having preferably at least 75% by weight of gypsum, for example, at least 80% by weight of gypsum, or at least 85% by weight of gypsum. In alternative embodiments described herein, the plaster precursor comprises a base material which is lime or cement. For example, in some embodiments, lime is present in the slurry to provide a hardened plaster material for a core having preferably at least 75% by weight of lime, for example, at least 80% by weight of lime, or at least 85% by weight of lime. For example, in some embodiments, cement is present in the slurry to provide a hardened plaster material for a core having preferably at least 75% by weight of cement, for example, at least 80% by weight of cement, or at least 85% by weight of cement.

[0047] As those skilled in the art will understand, water provides fluidity to the slurry to facilitate handling and, at the same time, provides the water necessary for hydrating the base material. Those skilled in the art will select a desirable ratio of plaster precursor to water. In various embodiments of this disclosure, the weight ratio of plaster precursor to water in the slurry is 3:1 or less, or 5:2 or less, or 2:1 or less, or 7:4 or less, or 3:2 or less. For example, in various embodiments, the weight ratio of plaster precursor to water is in the range of 3:1 to 1:2, or 2:1 to 4:7, or 3:1 to 2:3, or 3:1 to 1:1, or 5:2 to 1:2, or 5:2 to 4:7, or 5:2 to 2:3, or 5:2 to 1:1, or 2:1 to 1:2, or 2:1 to 4:7, or 2:1 to 2:3, or 2:1 to 1:1, or 7:4 to 1:2, or 7:4 to 4:7, or 7:4 to 2:3, or 7:1 to 1:1, or 3:2 to 1:2, or 3:2 to 4:7, or 3:2 to 2:3, or 3:2 to 1:1.

[0048] Although not described in detail here, other additives may be present in the slurry. For example, one or more accelerators, fluidizers, retarders, dispersants, foaming agents, glass fibers, and / or silicone oil may be present in the slurry.

[0049] Those skilled in the art can form a slurry onto a board using conventional methods. For example, the slurry may be distributed between opposing liners, cured, and then dried. In some embodiments, drying is carried out at a temperature in the range of 50–350°C to provide a cured plaster material. In some embodiments of the present disclosure, drying is carried out at a temperature in the range of 50–325°C or 50–300°C (i.e., measured in the environment on the board during drying, for example, in a drying oven). For example, in various embodiments, drying is carried out at a temperature in the range of 100–350°C, or 100–325°C, or 100–300°C, or 150–350°C, or 150–325°C, or 150–300°C, or 200–350°C, or 200–325°C, or 200–300°C. Drying may be achieved using an oven, the oven temperature being in the range of 50-350°C, or 50-325°C, or 50-300°C, or 100-350°C, or 100-325°C, or 100-300°C, or 150-350°C, or 150-325°C, or 150-300°C, or 200-350°C, or 200-325°C, or 200-300°C. In various embodiments, during the drying step, the temperature of the plaster core does not exceed 125°C, for example, not exceeding 120°C, 115°C, 110°C, or 105°C.

[0050] Even if the boards produced by the methods described herein do not meet all of the board limitations described below, the methods described herein may be useful for many of the specific parameters mentioned above.

[0051] Another aspect of the present disclosure provides a building comprising an interior space bounded by plasterboard as described herein, wherein a first liner faces toward the interior space and a second liner faces toward the interior space. For example, in some embodiments, the building comprises one or more frame members, and the plasterboard is attached to one or more frame members such that the second liner faces toward the frame members and the first liner faces toward the one or more frame members. The frame members are not particularly limited. For example, one or more frame members may be selected from studs, joists, sills, headers, rafters, or a combination thereof.

[0052] Another aspect of the present disclosure provides a wall cavity comprising a space and one or more frame members, wherein the space is bounded by plasterboard as described herein, and the plasterboard is attached to one or more frame members such that a first liner faces away from the space and a second liner faces toward the space, and the second liner faces toward the frame members and the first liner faces away from the one or more frame members. For example, one or more frame members may be selected from studs, joists, sills, headers, rafters, or a combination thereof. The frame members may consist of one or more materials. For example, one or more frame members may be made from wood, metal, steel, aluminum, plastic, or a combination thereof. In some embodiments described herein, the space of the wall cavity contains air. In some embodiments described herein, the space of the wall cavity contains insulation. In some embodiments, the insulation may be a fibrous material such as glass wool insulation, stone wool insulation, mineral wool insulation, or polyester insulation. In some embodiments, the insulating material may be a plant-based material such as cellulose, flax, or hemp. In some embodiments, the insulating material may be an organic material such as cotton or wool. In some embodiments, the insulating material may be a foamed material such as polyurethane foam, isocyanurate foam, rubber, or expanded polystyrene foam. In some embodiments, the insulating material comprises two or more insulating materials or a combination of forms. In some embodiments, the insulating material may have a surface material or air or moisture barrier material applied to one or more surfaces of the insulating portion. In some embodiments, the surface material or air or moisture barrier material may include paper, foil, polymer, reinforcing material, scrim, or a combination of such materials.

[0053] Those skilled in the art will provide the materials and carry out the processes described herein based on the above general disclosure and with reference to the following examples. [Examples]

[0054] The following examples illustrate specific embodiments of the products of this disclosure and various uses thereof. They are provided for illustrative purposes only and should not be construed as limiting the scope of this disclosure.

[0055] Example 1. Description of the mat

[0056] Different mats were selected for use as backing liners (i.e., facing the cavity) for gypsum board. Table 1 lists these mats. The diameter and length are the average fiber lengths of the glass mats.

[0057] [Table 1]

[0058] Example 2. Shrinkage Test

[0059] Gypsum board was manufactured using the liner of Example 1, and the identified liner is present on the back (i.e., "second") side of the gypsum board. A conventional paper liner was used on the front (i.e., "first") side of the gypsum board. The board was subjected to a free shrinkage test. The free shrinkage test helps to assess the decrease in board width as a function of temperature and to assess the possibility of joint opening during a fire. A linear variable differential transformer (LVDT) is placed over the substrate to measure the dimensions of the substrate.

[0060] Figure 2A reports the results of this shrinkage test for boards with liners A and 1-3, and Figure 2B reports the results of the shrinkage test for boards with liners A and 3-5. No difference in shrinkage was observed between the paper and the uncoated mats, but the coated mats showed slightly better performance, corresponding to an increase of about 1 minute in burning performance under this measurement.

[0061] Example 3. Small-scale partition test

[0062] A gypsum board was manufactured using the mat from Example 1, with the test liner located on the back of the gypsum board. A conventional paper liner was used on the front of the gypsum board. The board was then subjected to a small partition test. The small partition test evaluates the thermal insulation of a small partition, taking into account thermal conductivity, cavity radiation, board endothermic reaction, and exothermic reaction. For the test, a 145 × 195 mm partition was constructed with metal studs (48 mm, U-shaped) sandwiched between plasterboards (the "first" / "front" paper liner faced away from the studs, and the "second" / "back" test liner faced towards the studs). This partition was positioned relative to the opening of an electric kiln (i.e., as a "door"). The furnace temperature followed a quasi-ISO 834 curve. Four thermocouples were placed on the partition, one on each board surface. The criterion of "time to reach 140°C above room temperature on the lower temperature side (i.e., the side away from the kiln)" is the TC4 value. A schematic diagram of this test is shown in Figure 3.

[0063] The test results for each sample are summarized in Table 2 below.

[0064] [Table 2]

[0065] "Norm TCF" is the TC4 value normalized by the density and thickness of the board to compensate for the fact that the mass of gypsum differs somewhat depending on the board. From Table 2, it can be seen that the reduction in the area mass of the paper (US vs. EU) results in an improvement of approximately 4 mins in the TC4 of the board. For board 3, which has a coated mat, it shows a 5 min improvement compared to board A, similar to the TC4 of board B. Boards 4 and 5, which also have coated mats, also show an improvement of approximately 5-6 mins compared to board A. The best results are seen for boards 1 and 2, both of which have uncoated glass mats, with an improvement of 10-11 mins. The uncoated glass mat has the lowest area mass of all the liners tested.

[0066] Example 4. Thermogravimetric Analysis

[0067] To further evaluate the liner of Example 1, thermogravimetric analysis (TGA) was performed with a temperature gradient of 10°C / min. The results are plotted in Figures 4A and 4B. Figure 4A shows the mass losses for mats numbered 1-5, and Figure 4B shows the mass losses for mats numbered A, B, and 1-5.

[0068] To further understand the TGA results, the mass loss and partition test results were plotted relative to each other over the range of 25–600°C under a gradient of 10°C / min in air. This plot is shown in Figure 4C. From Figure 4C, it can be seen that better partition test results are observed when the liner facing the cavity (i.e., the "second" liner) has a lower mass loss at 600°C.

[0069] Example 5. Combination of differential scanning calorimetry and thermogravimetric analysis

[0070] To further evaluate the liner of Example 1, a combination of TGA and differential scanning calorimetry (DSC) was performed with air flushing at a gradient of 5°C / min up to 700°C. The heat dissipation per unit area and the mass loss per unit area at 600°C in the range of 150 to 600°C are shown in Table 3 and Figure 5A.

[0071] [Table 3]

[0072] Table 3 and Figure 5A show that paper has a much higher heat dissipation rate than the tested mats. Interestingly, mats 4 and 5, both of which are coated, have similar heat dissipation rates despite a large difference in area mass. This is because mat 5 has a much higher heat dissipation rate per unit mass than mat 4.

[0073] To further understand the DSC results, the heat dissipation and partition test results are plotted relative to each other in Figure 5B. The mass loss results at 600°C and the partition test results plotted in Figure 4C are also plotted in Figure 5B. From Figure 5B, it can be seen that the partition test results improve as both the heat dissipation per unit area and the mass loss decrease.

[0074] Example 6. Comparison

[0075] Small-scale partition tests were performed on similar board samples as described above. One sample had uncoated glass mat on both sides, some had paper on both sides, and some had uncoated glass mat on the side facing the cavity and paper on the side away from the cavity. The partition test data are plotted against thickness in mm and board density in lbs / MSF in Figure 6.

[0076] Surprisingly, the data demonstrates that having paper on the board surface facing the cavity has a far greater effect than having paper on the board surface facing away from the cavity. From this data, the inventors noticed that, for example, by using a glass mat on the board surface facing towards the cavity, fire resistance can be significantly improved even if a paper liner is used on the board surface facing away from the cavity. This makes it possible to provide a board with improved fire resistance while maintaining a desirable smooth surface by using a paper liner on the board surface facing the cavity.

[0077] Example 7. Thermal conductivity vs. combustion performance

[0078] To determine the thermal conductivity of the liner material, a transient surface source test was performed using a Hot Disk® TPS 1000 instrument. A square liner sample material measuring at least 20 mm × 20 mm was cut. The given square sample material was stacked to provide two stacks with a thickness of at least 5.5 mm, and a Hot Disk® probe was placed between the two stacks. The probe acted as both a heat source (by resistance heating) and a dynamic temperature sensor (by resistance measurement). The probe's temperature was increased from room temperature by a fraction of a degree to several degrees, and the temperature rise as a function of time was recorded. The instrument calculates the thermal conductivity of the material based on these values.

[0079] The data is provided in Table 4 below.

[0080] [Table 4]

[0081] Figure 7 provides graphs of single-layer material thickness (square markers on the left y-axis) and thermal conductivity data (X markers on the right y-axis) for several liners, showing various normalized TCF values ​​(x axis) when used as an inner liner (facing the cavity) along with an outer paper liner (applied to the opposite side of the gypsum core facing the environment) in board samples as described herein. Figure 8 is a graph plotting the thermal conductivity (y axis) divided by the single-layer material thickness from the graphs in Figure 7 against the normalized TCF values ​​(x axis) from the graphs in Figure 7. This graph provides a comparison of the thermal conductivity of the liner under test with the normalized TCF values ​​of boards made from the liners under test. In particular, these data demonstrate that there is no strong correlation between thermal conductivity or thermal conductance measured near room temperature and combustion performance.

[0082] Figure 9 provides graphs of heat dissipation per unit area (square markers on the left y-axis) and mass loss at 600°C (X markers on the right y-axis) for several liners, showing various normalized TCF values ​​(x-axis) when used as an inner liner (facing the cavity) along with an outer liner (applied to the opposite side of the gypsum core facing the environment) in board samples as described herein. In particular, the data show a very strong correlation between fire performance and each of the heat dissipation and mass loss, each measured at a temperature far more relevant to fire conditions than thermal conductivity measured near room temperature.

[0083] Various embodiments and aspects of this disclosure are provided by the following numbered embodiments, which can be combined in any number and any combination that is not technically or logically inconsistent. Embodiment 1. A plasterboard having a first surface and a second surface on the opposite side, A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, It is placed on the first surface of the plasterboard and at least 70 g / m² at 600°C. 2 A first liner having a mass loss of, It is placed on the second surface of the plasterboard and is applied at 600°C at a rate of 60 g / m². 2 A plasterboard comprising a second liner having the following mass loss. Embodiment 2. A plasterboard having a first surface and a second surface on the opposite side (for example, as described in Embodiment 1), A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, It is placed on the first surface of the plasterboard and contains at least 600 kJ / m 2 A first liner having a heat dissipation capacity, It is placed on the second surface of the plasterboard and has a concentration of 500 kJ / m 2 A plasterboard is provided, comprising a second liner having the following heat dissipation capacity. Embodiment 3. A plasterboard having a first surface and a second surface on the opposite side, A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, A first liner is placed on the first surface of the plasterboard and has a surface roughness (Rz) of 40 microns or less, The present invention provides a plasterboard comprising a first liner disposed on the first surface of the plasterboard and having a surface roughness (Rz) of at least 80 microns or less. Embodiment 4. A plasterboard having a first surface and a second surface on the opposite side (for example, as described in any one of Embodiments 1 to 3), A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, A first liner is placed on the first surface of the plasterboard and has a surface roughness (Rz) of 40 microns or less, It is placed on the second surface of the plasterboard and is applied at 600°C at a rate of 60 g / m². 2 The following mass losses and / or 400 kJ / m 2 A plasterboard comprising a second liner having the following heat dissipation capacity. Embodiment 5. A plasterboard having a first surface and a second surface on the opposite side (for example, as described in any one of Embodiments 1 to 4), A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, The first liner, which is a paper liner, is placed on the first surface of the plasterboard. A plasterboard comprising a second liner, which is a glass mat (optionally coated glass mat) containing glass fibers bonded together by one or more polymer binders, disposed on the second surface of the plasterboard. Embodiment 6. The second liner has a capacity of 500 kJ / m 2 A plasterboard according to Embodiment 5, having the following heat dissipation capacity. Embodiment 7. The second liner is 60 g / m² at 600°C. 2 A plasterboard according to embodiment 5 or 6, having the following mass loss. Embodiment 8. The first liner has a density of at least 80 g / m² at 600°C. 2 (For example, at least 90 g / m 2 A plasterboard according to any one of embodiments 1 to 7, having a mass loss of ). Embodiment 9. The first liner has a density of at least 105 g / m² at 600°C. 2 (For example, at least 110 g / m²) 2 A plasterboard according to any one of embodiments 1 to 7, having a mass loss of ). Embodiment 10. The first liner has a density of at least 115 g / m² at 600°C. 2 (For example, at least 120 g / m²) 2 , or at least 140 g / m² 2 , or at least 160 140g / m 2 A plasterboard according to any one of embodiments 1 to 7, having a mass loss of ). Embodiment 11. A plasterboard according to any one of Embodiments 1 to 10, wherein the first liner has a mass loss of 90% or less of the mass of the first liner, for example, 80% or less. Embodiment 12. The second liner is 50 g / m² at 600°C. 2 (For example, 45g / m²) 2 The following, or 40g / m² 2 A plasterboard according to any one of embodiments 1 to 11, having the mass loss described below. Embodiment 13. The second liner is 35 g / m² at 600°C. 2 (For example, 30g / m²) 2 A plasterboard according to any one of embodiments 1 to 11, having the mass loss described below. Embodiment 14. The second liner has a density of at least 15 g / m² at 600°C. 2 (For example, at least 18 g / m 2 , or at least 20 g / m 2 A plasterboard according to any one of embodiments 1 to 13, having a mass loss of ). Embodiment 15. The first liner has a capacity of at least 650 kJ / m³ at 600°C. 2 For example, at least 800 kJ / m³ 2 , or at least 900 kJ / m³ 2 A plasterboard according to any one of embodiments 1 to 14, having a heat dissipation amount per unit area. Embodiment 16. The first liner is at least 1000 kJ / m³ at 600°C. 2 For example, at least 1050 kJ / m³ 2 , or at least 1100 kJ / m³ 2 A plasterboard according to any one of embodiments 1 to 14, having the heat dissipation capacity. Embodiment 17. 1150 kJ / m³ at 600°C 2 (For example, at least 1250 kJ / m³) 2 , or at least 1500 kJ / m³ 2 A plasterboard as described in any one of Embodiments 1 to 14. Embodiment 18. The first liner has a capacity of 5000 kJ / m 2 For example, 4000 kJ / m³ 2 The following, or 3000 kJ / m³ 2 A plasterboard according to any one of Embodiments 1 to 17, having the following heat dissipation amount per unit area. Embodiment 19. The second liner has a capacity of 450 kJ / m 2 (For example, 400 kJ / m³) 2 The following, or 350 kJ / m³ 2 The following, or 300 kJ / m³ 2 A plasterboard according to any one of Embodiments 1 to 18, having the heat dissipation amount per unit area as follows. Embodiment 20. The second liner has a capacity of 250 kJ / m 2 (For example, 200 kJ / m³) 2 The following, or 100 kJ / m³ 2 A plasterboard according to any one of Embodiments 1 to 18, having the heat dissipation amount per unit area as follows. Embodiment 21. The second liner has a load of at least 50 kJ / m³ 2 (For example, at least 60 kJ / mm2 Or at least 75 kJ / m³ 2 A plasterboard according to any one of Embodiments 1 to 20, having a heat dissipation amount per unit area of ​​). Embodiment 22. The second liner has a capacity of 50-450 kJ / m 2 , or 50-400 kJ / m 2 , or 50-350 kJ / m³ 2 , or 50-300 kJ / m 2 , or 50-250 kJ / m³ 2 , or 50-200 kJ / m³ 2 , or 75-500 kJ / m 2 , or 75-450 kJ / m 2 , or 75-400 kJ / m 2 , or 75-350 kJ / m 2 , or 75-300 kJ / m 2 , or 75-250 kJ / m³ 2 , or 75-200 kJ / m³ 2 A plasterboard according to any one of embodiments 1 to 20, having a heat dissipation amount per unit area within the range of [specified range]. Embodiment 23. A plasterboard according to any one of Embodiments 1 to 22, wherein the first liner has a surface roughness (Rz) of 35 microns or less, for example, 30 microns or less. Embodiment 24. A plasterboard according to any one of Embodiments 1 to 22, wherein the first liner has a surface roughness (Rz) in the range of 10 to 40 microns, for example, 10 to 35 microns, or 10 to 30 microns, or 15 to 40 microns, or 15 to 35 microns, or 15 to 30 microns. Embodiment 25. A plasterboard according to any one of Embodiments 1 to 24, wherein the second liner has a surface roughness (Rz) of at least 85 microns, for example, at least 90 microns. Embodiment 26. A plasterboard according to any one of Embodiments 1 to 24, wherein the second liner has a surface roughness (Rz) in the range of 80 to 1000 microns, for example, 80 to 750 microns, or 80 to 500 microns, or 85 to 1000 microns, or 85 to 750 microns, or 85 to 500 microns, or 90 to 1000 microns, or 90 to 750 microns, or 90 to 500 microns. Embodiment 27. A plasterboard according to any one of Embodiments 1 to 26, wherein the first liner is a paper liner. Embodiment 28. The plasterboard according to Embodiment 27, wherein the paper liner has an L* value of at least 70, an a* value of 5 or less, and a b* value of 5 or less, as measured in the CIELAB color space. Embodiment 29. A plasterboard according to any one of Embodiments 1 to 4 and 8 to 26, wherein the first liner is a polymer film. Embodiment 30. A plasterboard according to any one of Embodiments 1-4 and 8-6, wherein the first liner is a glass mat (e.g., a coated glass mat). Embodiment 31. A plasterboard according to any one of Embodiments 1 to 30, wherein the second liner is a glass mat. Embodiment 32. The plasterboard according to Embodiment 31, wherein the second liner is an uncoated glass mat. Embodiment 33. The plasterboard according to Embodiment 31, wherein the second liner is a coated glass mat. Embodiment 34. The plasterboard according to Embodiment 33, wherein the second liner has a coating which is a coating of particulate inorganic material bonded by a polymer binder. Embodiment 35. The first liner is 125-350 g / m² 2 range (for example, 125-300 g / m 2 , or 125-250g / m 2 , or 175-350g / m 2 , or 175-300g / m 2 , or 175-2500g / m² 2, or 200-350g / m 2 , or 200-300g / m 2 , or 200-250g / m 2 A plasterboard according to any one of embodiments 1 to 34, having an area mass within the range of ( ). Embodiment 36. The second liner is 150 g / m² 2 (For example, 125g / m²) 2 The following, or 100g / m² 2 A plasterboard according to any one of Embodiments 1 to 35, having the area mass of the following: Embodiment 37. The second liner is 50-150 g / m² 2 range (for example, 50-125 g / m²) 2 , or 50-100g / m 2 , or 65-150g / m 2 , or 65-125 g / m 2 , or 65-100g / m 2 , or 80-150g / m 2 , or 80-125 g / m 2 , or 80-100g / m 2 A plasterboard according to any one of embodiments 1 to 35, having an area mass of the range of ( ). Embodiment 38. A plasterboard according to any one of Embodiments 1 to 37, wherein the second liner has an ASTM E-96 water permeability at 75% rh and 23°C that is within 50% of that of the first liner, for example, within 20% of that ASTM E-96 water permeability at 75% rh and 23°C. Embodiment 39. A plasterboard according to any one of Embodiments 1 to 38, wherein the plaster material is a gypsum material, for example, the plaster material comprises at least 75% by weight of gypsum, for example, at least 80% by weight of gypsum, or at least 85% by weight of gypsum. Embodiment 40. A plasterboard according to any one of Embodiments 1 to 38, wherein the plaster material comprises a base material which is lime or cement. Embodiment 41. A plasterboard according to any one of Embodiments 1 to 40, wherein the plaster material further comprises one or more accelerators, fluidizers, retarders, dispersants, foaming agents, and / or glass fibers. Embodiment 42. A plasterboard according to any one of Embodiments 1 to 41, wherein the plaster material further comprises silicone oil. Embodiment 43. A plasterboard according to any one of Embodiments 1 to 42, wherein the plasterboard has a thickness substantially equal to 0.375 inches between the first surface and the second surface. Embodiment 44. A plasterboard according to any one of Embodiments 1 to 43, wherein the plasterboard has a thickness substantially equal to 0.5 inches between the first surface and the second surface. Embodiment 45. A plasterboard according to any of Embodiments 1 to 44, wherein the plasterboard has a thickness of more than 0.25 inches and 2 inches or less (for example, in the range of 0.25 to 0.75 inches or 0.25 to 0.5 inches) between the first surface and the second surface. Embodiment 46. A plasterboard according to any one of Embodiments 1 to 45, wherein the plasterboard has fire resistance exceeding the 1-hour target specified in the ANSI / UL263 test standard. Embodiment 47. A plasterboard according to any one of Embodiments 1 to 46, having a final dry density in the range of 1700 to 2500 lbs / MSF. Embodiment 48. A method for forming a plasterboard according to any one of Embodiments 1 to 47, having a first surface and a second surface on the opposite side, To provide a slurry containing a plaster precursor and water, The slurry is placed between the first liner and the second liner, The slurry is cured to form a wet plaster core, This includes drying a wet plaster core to provide a hardened plaster material. The present invention provides a method in which a hardened plaster material is placed between a first liner on a first surface of a building board and a second liner on a second surface of a building board. Embodiment 49. The method according to Embodiment 48, wherein the weight ratio of the plaster precursor to water is 2:1 or less (for example, 7:4 or less, or 3:2 or less). Embodiment 50. The method according to Embodiment 48, wherein the weight ratio of plaster precursor to water is in the range of 2:1 to 1:2 (for example, in the range of 2:1 to 4:7, or 2:1 to 2:3, or 2:1 to 1:1, or 7:4 to 1:2, or 7:4 to 4:7, or 7:4 to 2:3, or 7:1 to 1:1, or 3:2 to 1:2, or 3:2 to 4:7, or 3:2 to 2:3, or 3:2 to 1:1). Embodiment 51. The method according to any one of Embodiments 48 to 50, wherein the plaster precursor comprises a base material which is a stucco material. Embodiment 52. The method according to Embodiment 51, which provides a hardened plaster material having stucco present in a slurry and containing at least 75% by weight of gypsum, for example, at least 80% by weight of gypsum or at least 85% by weight of gypsum. Embodiment 54. A method according to any one embodiment of Embodiments 48 to 50, wherein the plaster precursor comprises a base material which is lime or cement. Embodiment 54. The method according to any one of Embodiments 48 to 54, wherein each of the first liner and the second liner is as defined in any one of Embodiments 1 to 38. Embodiment 55. The method according to any one of Embodiments 48 to 54, wherein the plasterboard is as defined in any one of Embodiments 39 to 47. Embodiment 56. The method according to any one of Embodiments 48 to 55, wherein drying is performed at a temperature in the range of 100 to 350°C (for example, in the range of 100 to 325°C or 100 to 300°C). Embodiment 57. A building having an interior space defined by plasterboard as described in any one of Embodiments 1 to 48, wherein the first liner faces toward the interior space and the second liner faces toward away from the interior space. Embodiment 58. The building according to Embodiment 56, wherein the building comprises one or more frame members (e.g., studs, joists, sills, headers, rafters), and plasterboard is attached to one or more frame members such that the second liner faces toward the frame members and the first liner faces toward away from the one or more frame members. Embodiment 59. A wall cavity comprising a space and one or more frame members, wherein the space is defined by a plasterboard as described in any one of Embodiments 1 to 48, and the plasterboard is attached to one or more frame members such that a first liner faces away from the space, a second liner faces toward the space, and the second liner faces toward the frame members and the first liner faces away from one or more frame members. Embodiment 60. The wall cavity according to Embodiment 59, wherein the space has air within it. Embodiment 61. A wall cavity according to Embodiment 59 or Embodiment 60, wherein the space has an insulating material within it.

[0084] The details provided herein are, for example, for illustrative purposes only, for the purpose of describing preferred embodiments of the Disclosure and are presented to provide what is considered to be the most useful and readily understandable description of the principles and conceptual aspects of the various embodiments of the Disclosure. In this regard, no attempt has been made to provide structural details of the Disclosure in more detail than is necessary for a basic understanding of the Disclosure, and the descriptions made in conjunction with the drawings and / or examples will make it clear to those skilled in the art how some forms of the Disclosure may actually be embodied. Therefore, before the disclosed processes and devices are described, it should be understood that the embodiments described herein are not limited to any particular embodiment, apparatus, or configuration, and are therefore naturally subject to change. It should also be understood that the terms used herein are intended solely to describe a particular embodiment and are not intended to be limiting unless specifically defined herein.

[0085] In the context describing this disclosure (particularly in the context of the following claims), the terms “a,” “an,” “the,” and similar reference subjects should be interpreted as encompassing both singular and plural, unless otherwise indicated herein or unless the context clearly contradicts this interpretation. Enumerations of value ranges herein are intended merely as a concise way of individually referring to each distinct value falling within that range. Unless otherwise specifically indicated herein, individual values ​​are incorporated herein as they would be if individually listed herein. It will be further understood that each endpoint of a range is significant both in relation to the other endpoints and independently of the other endpoints.

[0086] All methods described herein may be carried out in any preferred order of steps, unless otherwise indicated herein or unless the context clearly contradicts otherwise. Any use of any examples or exemplary language provided herein (e.g., "etc.") is intended solely to better illustrate this disclosure and does not limit the scope of the invention as otherwise claimed. No word herein should be construed as indicating any unclaimed element essential to the practice of this disclosure.

[0087] Unless the context clearly indicates otherwise, throughout this specification and the claims, words such as “comprise” and “comprising” should be interpreted in a comprehensive sense, as opposed to an exclusive or exhaustive sense, i.e., “including, but not limited to.” Words used in the singular or plural also include the plural and singular, respectively. Furthermore, when used in this application, the words “in this specification,” “above,” and “below,” and words of similar intent, refer to the entire application and not to any particular part thereof.

[0088] As those skilled in the art will understand, each embodiment disclosed herein includes, is essentially composed of, or may consist of the specific elements, steps, components, or constituents described herein. As used herein, the transitional phrases “comprise” or “comprises” mean, not limited to, to include and take into consideration, even in large numbers, non-specific elements, steps, components, or constituents. The transitional phrase “consists of” excludes any elements, steps, components, or constituents that are not specified. The transitional phrase “essentially consists of” limits the scope of the embodiment to specific elements, steps, components, or constituents and those that do not substantially affect the embodiment.

[0089] Unless otherwise indicated, the numerical parameters described herein and in the appended claims are approximations that may vary depending on the desired characteristics sought by this disclosure. Each numerical parameter should be interpreted by applying the usual rounding technique, taking into account at least the number of significant figures reported, and not as an attempt to limit the application of the doctrine of equivalents to the claims.

[0090] Although the numerical ranges and parameters representing the broad scope of this disclosure are approximations, the numerical values ​​shown in specific examples are reported as accurately as possible. However, any numerical value inherently contains certain errors that inevitably arise from the standard deviation found in their respective test measurements.

[0091] The grouping of alternative elements or embodiments of the disclosure disclosed herein should not be construed as limitation. Each member of each group may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group may be included in or removed from a group for convenience and / or patentability reasons. In any case where any such inclusion or removal is made, this specification shall be deemed to include the modified group and thus satisfy the written description of all Markush groups used in the appended claims.

[0092] Several embodiments of the Disclosure, including the best mode known to the inventors for carrying out the Disclosure, are described herein. Naturally, variations of these described embodiments will be apparent to those skilled in the art by reading the foregoing description. The inventors anticipate that those skilled in the art will use such variations as appropriate, and the inventors intend that the Disclosure will be carried out in ways other than those specifically described herein. Accordingly, the Disclosure includes all variations and equivalents of the subject matter described in the claims appended herein, as permitted by applicable law. Furthermore, any combination of the above elements in all possible variations is encompassed herein unless otherwise shown herein or unless it is clearly inconsistent with the context.

[0093] Furthermore, it should be understood that the embodiments of the Disclosure disclosed herein are illustrative of the principles of the Disclosure. Other modifications that may be used are within the scope of the Disclosure. Accordingly, alternative configurations of the Disclosure may be used, not as an example but as an example, in accordance with the teachings herein. Accordingly, the Disclosure is not limited to those precisely illustrated and described.

Claims

1. A plasterboard having a first surface and a second surface on the opposite side, A body of hardened plaster material extending from the first surface of the plasterboard to the second surface of the plasterboard, A first liner is disposed on the first surface of the plasterboard and has a surface roughness (Rz) of 40 microns or less, Distributed on the second surface of the plasterboard, at 600°C, 60 g / m² ２ The following mass losses and / or 400 kJ / m ２ A plasterboard comprising a second liner having the following heat dissipation capacity.

2. The first liner has a density of at least 70 g / m² at 600°C. ２ (For example, at least 100 g / m ２ ) has a mass loss of, The second liner is 60 g / m² at 600°C. ２ The plasterboard according to claim 1, having the following mass loss.

3. The first liner has a capacity of at least 500 kJ / m ２ It has a heat dissipation capacity, The second liner has a load of 400 kJ / m ２ A plasterboard according to claim 1 or 2, having the following heat dissipation capacity.

4. The first liner has a density of at least 115 g / m² at 600°C. ２ A plasterboard according to any one of claims 1 to 3, having a mass loss.

5. The second liner has a mass loss of 50 g / m at 600 °C ２ The plasterboard according to any one of claims 1 to 4, having the following mass loss

6. The first liner has a capacity of at least 1150 kJ / m ２ A plasterboard according to any one of claims 1 to 5, having a heat dissipation amount per unit area.

7. The first liner has a load of 5000 kJ / m ２ A plasterboard according to any one of claims 1 to 6, having the following heat dissipation amount per unit area.

8. The plasterboard according to any one of claims 1 to 7, wherein the first liner has a surface roughness (Rz) of 35 microns or less.

9. The plasterboard according to any one of claims 1 to 8, wherein the second liner has a surface roughness (Rz) of at least 80 microns.

10. The plasterboard according to any one of claims 1 to 9, wherein the first liner is a paper liner.

11. The plasterboard according to any one of claims 1 to 10, wherein the second liner is a glass mat, for example, an uncoated glass mat.

12. The plasterboard according to any one of claims 1 to 11, wherein the plaster material is a gypsum material.

13. A building having an interior space whose boundary is defined by plasterboard as described in any one of claims 1 to 12, wherein the first liner faces toward the interior space and the second liner faces toward away from the interior space.

14. The building according to claim 13, wherein the building comprises one or more frame members (e.g., studs, joists, sills, headers, rafters), and the plasterboard is attached to one or more frame members such that the second liner faces toward the frame members and the first liner faces toward away from the one or more frame members.

15. A wall cavity comprising a space and one or more frame members, wherein the space is defined by a plasterboard according to any one of claims 1 to 12, the first liner faces away from the space, the second liner faces toward the space, and the plasterboard is attached to the one or more frame members such that the second liner faces toward the frame members and the first liner faces away from the one or more frame members.

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