Method and Plasterboard

Patent metadata

Field	Value
Publication number	US-2025270142-A1
Application number	US-202318858419-A
Country	US
Kind code	A1
Filing date	Jul 26, 2023
Priority date	Jul 29, 2022
Publication date	Aug 28, 2025
Grant date	—

Abstract

According to the present invention. there is provided a method of manufacturing a plasterboard, the method comprising combining at least one recycled calcium sulphate material and at least one non-recycled calcium sulphate material to form a mixture of particles, combining at least the mixture of particles and water to form a settable slurry, and drying the settable slurry to form a plasterboard, wherein the ratio of the recycled calcium sulphate material to the non-recycled calcium sulphate material in the mixture of particles is at least 1:1, wherein the method further comprises calcining the mixture of particles before the mixture of particles is combined with water to form a settable slurry. A plasterboard is also provided.

First claim

1 . A method of manufacturing a plasterboard, said method comprising:
combining at least one recycled calcium sulphate material and at least one non-recycled calcium sulphate material to form a mixture of particles, combining at least said mixture of particles and water to form a settable slurry, and drying said settable slurry to form a plasterboard, wherein the ratio of said recycled calcium sulphate material to said non-recycled calcium sulphate material in said mixture of particles is at least 1:1, wherein said method further comprises calcining said mixture of particles before said mixture of particles is combined with water to form a settable slurry.

2 . The method of claim 1 , wherein said method further comprises grinding said mixture of particles before said mixture of particles is combined with water to form a settable slurry.

3 . The method of claim 2 , wherein a mean average residence time of particles within said mixture of particles in the grinder is less than 75 seconds.

4 . The method of claim 1 , wherein a Blaine value for the ground, calcined material is less than 8000 cm 2 /g.

5 . The method of claim 1 , wherein, post calcination, said mixture of particles comprises less than 20 wt. % calcium sulphate anhydrite.

6 . The method claim 1 , wherein said at least one non-recycled calcium sulphate material comprises calcium sulphate hemihydrate and/or calcium sulphate dihydrate.

7 . The method of claim 1 , wherein said at least one recycled calcium sulphate material comprises calcium sulphate dihydrate.

8 . The method of claim 1 , wherein said at least one recycled calcium sulphate material comprises calcium sulphate hemihydrate.

9 . The method of claim 1 , wherein said mixture of particles comprises 2.2 wt. % or less paper.

10 . The method of claim 1 , wherein said method produces equivalent plasterboard at a rate more than 80%, of the rate for an equivalent process where said mixture of particles excludes recycled calcium sulphate material.

11 . A plasterboard comprising recycled calcium sulphate material and non-recycled calcium sulphate material wherein the ratio of said recycled calcium sulphate material to said non-recycled calcium sulphate material is at least 1:1.

12 . The plasterboard of claim 11 , wherein said plasterboard comprises a core comprising paper in an amount of 2.2 wt. % or less.

13 . The plasterboard of claim 11 , wherein said plasterboard comprises fluidiser in an amount of less than or equal to 1 wt. % of the dry weight of calcium sulphate materials.

14 . The plasterboard of claim 11 , wherein said plasterboard has a density of between 680 and 760 kg/m 3 .

15 . A plasterboard comprising recycled calcium sulphate material and non-recycled calcium sulphate material wherein the ratio of said recycled calcium sulphate material to said non-recycled calcium sulphate material is at least 1:1, prepared by the method of claim 1 .

Assignees

• Saint Gobain Placo

Inventors

• Morlat Richard
• Baud David
• Vogl Amelie

Classifications

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• C04B11/262

  waste gypsum other than phosphogypsum · CPC title

• C04B18/167

  Recycled materials, i.e. waste materials reused in the production of the same materials · CPC title

• C04B11/26

  {strating from chemical gypsum}; starting from phosphogypsum or from waste, e.g. purification products of smoke (C04B11/02 takes precedence; chemical purification of smoke, fumes or exhaust gases B01D53/00 {purification of gypsum C01F11/46}) · CPC title

• C04B28/14 Primary

  containing calcium sulfate cements {(gypsum-paper plates E04C)} · CPC title