HIGH POROSITY GYPSUMBOARD PAPER AND/OR CARDBOARD INCLUDING WASTE PAPERS AS RAW MATERIAL

Abstract

A colored gypsumboard paper and/or cardboard and the production method thereof are provided. The colored gypsumboard paper and/or cardboard has/have high wetness resistance and has/have high porosity and obtained by means of waste paper recycling and can be used for ceiling, papier-m?ch? applications and at inner wall sections particularly in construction technical field.

Claims

1. A gypsumboard paper and/or cardboard product comprising recycled papers and/or cardboards as a raw material, wherein the gypsumboard paper and/or cardboard product has/have porosity values at a value between 12 and 40 seconds in accordance with a Gurley test method and is allowed to be configured for ceiling, papier-m?ch? applications and at inner wall sections particularly in construction structures.

2. The product according to claim 1, wherein the product comprises more than one kind of waste paper.

3. The product according to claim 1, wherein the product comprises waste office papers and waste magazine papers as a raw material.

4. The product according to claim 3, wherein the product comprises the waste office paper at a value between 40% and 55% by weight, and the waste magazine paper at the value between 40% and 55% by weight.

5. The product according to claim 1, wherein an amount of paper comprises: sodium hydroxide component at a value between 0.4% and 0.8% by weight, sodium silicate component at a value between 1.5% and 1.9% by weight, oleic acid component at a value between 0.6% and 1% by weight, hydrogen peroxide component at the value between 0.4% and 0.8% by weight, talc component at a value between 23% and 27% by weight.

6. The product according to claim 5, wherein the product comprises a dye component at a value between 0.9% and 1.5% by weight of amount of paper.

7. The product according to claim 2, wherein the product comprises waste office papers and waste magazine papers as a raw material.

8. The product according to claim 2, wherein an amount of paper comprises: sodium hydroxide component at a value between 0.4% and 0.8% by weight, sodium silicate component at a value between 1.5% and 1.9% by weight, oleic acid component at a value between 0.6% and 1% by weight, hydrogen peroxide component at the value between 0.4% and 0.8% by weight, talc component at a value between 23% and 27% by weight.

9. The product according to claim 3, wherein an amount of paper comprises: sodium hydroxide component at a value between 0.4% and 0.8% by weight, sodium silicate component at a value between 1.5% and 1.9% by weight, oleic acid component at a value between 0.6% and 1% by weight, hydrogen peroxide component at the value between 0.4% and 0.8% by weight, talc component at a value between 23% and 27% by weight.

10. The product according to claim 4, wherein an amount of paper comprises: sodium hydroxide component at a value between 0.4% and 0.8% by weight, sodium silicate component at a value between 1.5% and 1.9% by weight, oleic acid component at a value between 0.6% and 1% by weight, hydrogen peroxide component at the value between 0.4% and 0.8% by weight, talc component at a value between 23% and 27% by weight.

Description

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0034] In this detailed description, the subject matter relates to a gypsumboard paper and/or cardboard that has/have high wetness resistance and which has high porosity and obtained by means of waste paper recycling and that can be used for ceiling, papier-m?ch? applications and at inner wall sections particularly in construction structures, and is explained with references to examples without forming any restrictive effect only in order to make the subject more understandable.

[0035] In the invention, gypsumboard describes stone plates that have flat surface and that are produced with standard or special dimensions and particularly where both faces are coated with paper or cardboard and where the middle part is plaster. Gypsumboards describe a material frequently used at inner wall parts and at ceiling, papier-m?ch? applications in construction sector.

[0036] In the invention, gypsumboard paper describes a special paper which is resistant to 100? C. hot water and which has porous structure.

[0037] In the invention, porosity describes the average air flow amount which passes through unit area in unit time under unit pressure difference. In the invention, porosity describes the porosity amount.

[0038] In the invention, Gurley method is described by the meaning of measuring the duration that has to pass for passing of a specific air volume through a test sample.

[0039] In the invention, brightness describes capacity of reflection of light that falls on the paper. In accordance with TS 11610:2017 standard, brightness value which must exist in 80 grams of letter tab papers is 86%.

[0040] In the invention, ISO % Whiteness is described as the proportion of the light reflected from a substance to the reflection in a substance which completely reflects light. It is measured in accordance with ISO 11475 test method. R457 is a value measured in nm wavelength, and can numerically differ depending on whether the UV filter of the device, where measurement is made, is open or closed. For instance, the whiteness value, measured as 86 as a result of measurement made by means of a device whose UV filter is closed, can be measured as 93 by means of the same device while the UV filter is open.

[0041] In the invention, in accordance with TAPPI T560 test method, CIE whiteness and tone of the paper and cardboard which is optical whitener and not and which is white or close to white is measured.

[0042] In the invention, optic whitening agents describe the chemical compounds which absorb light in the ultraviolet and violet region (generally 340-370 nm) of electromagnetic spectrum and which emit light again in the blue region (typically 420-470 nm) by means of fluorescent. These additive substances are essentially used for improving the color appearance of paper for providing a visual blue-white shade. D65 illumination, which is the most frequent whiteness measure, represents the daylight of outside and this standard is called CIE Whiteness and has been developed by International Commission on Illumination (at the same time, it is also abbreviated as CIE). The values between ISO Whiteness and CIE Whiteness are differing thanks to these optical whiteners provided in the paper. In other words, differences occur between the values since the whiteness value of the paper is measured at different wavelengths at ISO whiteness and CIE whiteness.

[0043] In the invention, opacity (%) describes the extent of passing of the light by paper. As the opacity value of paper is higher, it transmits the light lesser. (Yilmaz, 2021).

[0044] In the invention, yellowness (E313) describes a measure of passing of the surface color of a paper from the preferred white (or colorless) to yellow. Measurement can be realized in accordance with ASTM E313 (Yilmaz, 2021).

[0045] In the invention, ERIC (Effective Residual Ink Concentration) is described as the amount of ink concentration which remains inside the paper pulp after recycling, and the measurement unit is ppm. (Tutus et al, 2009; Hu et al, 2017).

[0046] In the principle embodiment of the invention, the gypsumboard paper and/or cardboard comprises waste papers as the paper raw material. Preferably paper types, used in offices and/or known as magazine papers in the art, are used as waste paper. Preferably papers used in office at a value between 40% and 55% by weight and magazine papers at a value between 40% and 55% are used as waste paper such that the total thereof is 100% by weight.

[0047] In another arrangement of the invention, the gypsumboard paper comprises bleacher and optic whitening agents at a value between 0.5% and 0.9% by weight of the paper amount. In the invention, preferably hydrogen peroxide, formamidine sulphunic acid (FAS), hyposulphite are used as bleacher and optic whitening agents. In a preferred application, hydrogen peroxide is used as bleacher and optic whitening agents. Said bleacher and optic whitening agents are used for improving the optic characteristics of gypsumboard paper and cardboards.

[0048] The subject matter gypsumboard paper and/or cardboard comprises sodium silicate (it will be abbreviated as Na.sub.2SiO.sub.3) at a value between 1.5% and 1.9% by weight of the amount of paper. In the invention, Na.sub.2SiO.sub.3 is used for preventing loosening of ink particles on fibers and accumulating thereof on fibers again and for increasing dispersion of ink particles.

[0049] The subject matter gypsumboard paper and/or cardboard comprises oleic acid (it will be abbreviated as C.sub.18H.sub.34O.sub.2) at a value between 0.6% and 1% by weight of paper amount. In the invention, oleic acid component is used for catching the ink particles removed from fibers and for carrying thereof to the surface.

[0050] The subject matter gypsumboard paper and/or cardboard comprises talc component at a value between 23% and 27% by weight of paper amount. In the invention, talc component is used for the purpose of removing dirt and adhesives with big dimension that exists in waste papers.

[0051] The subject matter gypsumboard paper and/or cardboard comprises dye component at a value between 0.9% and 1.5% by weight of paper amount. By means of this, the final product to be obtained can have ivory, pink and/or green colors. By means of this, in the subject matter gypsumboard paper and/or cardboard, aesthetic compliancy to the medium, resistance against flame and/or resistance against water and humidity are provided.

[0052] The subject matter gypsumboard paper and/or cardboard comprises sodium hydroxide (it will be abbreviated as NaOH) at a value between 0.4% and 0.8% by weight of paper amount. In the invention, NaOH is used for the purpose of weakening of natural hydrogen bonds that exist between fibers in waste papers and inflating the fibers and removing of the inks that exist on fibers and for distributing thereof.

[0053] In the possible embodiment of the present invention, the pores of the subject matter gypsumboard paper and/or cardboards are obtained preferably at the range of 30 and 40 seconds determined as target in accordance with Gurley method, and the method is further improved, and successful results are detected on the targeted value range at the ranges of pores of gypsumboard paper and cardboards between 12 and 25 seconds. By means of this, by means of very rapidly removal of the humidity of wet plaster through the paper pores, more gypsumboard is produced in unit time.

[0054] In the invention, it is aimed at producing high porosity colored gypsumboard paper and cardboard. Accordingly, said production method comprises the following process steps; [0055] Pulpifying (high density pulper) process, [0056] Storing process, [0057] Ink elimination process, [0058] Kneading (dispersion) process, [0059] Bleaching process, [0060] Dyeing process.

[0061] In the possible embodiment of the present invention, pulpifying (in high density pulper) process is separated to suitable parts in accordance with International Association of the Deinking Industry (INGEDE Method 11) standard, and is protected from light and temperature and stored in polyethylene bags, and afterwards, high density pulper is realized and is subjected to pulpifying process. The chemicals given in Table 1 below are added into said pulper in accordance with INGEDE Method 11 after pre-heating realized in the first step. 25% talc has been used in addition to these chemicals, and pulpifying process is realized.

TABLE-US-00001 TABLE 1 Chemicals used in pulpifying process and the proportions of said chemicals Percent (%) proportions in The chemicals used accordance with paper amount ING Sodium hydroxide (NaOH) 0.4-0.8 Sodium silicate (Na.sub.2SiO.sub.3) 1.5-1.9 Oleic acid (C.sub.18H.sub.34O.sub.2) 0.6-1 Hydrogen peroxide (H.sub.2O.sub.2) 0.4-0.8 Talc 23-27

[0062] In the possible embodiment of the present invention, the storing process, the object of the storing process, after the pulpifying process of 50% waste office paper and 50% magazine paper mixture, the pulp mixture provides removal of ink particles in a more efficient manner from the fiber surface inflated by storage at 1 hour in 45? C. water bath with concentration of 5%, and at the same time, it increases the process activity of the chemicals, added to the system in pulpifying process, for the next step.

[0063] In the possible embodiment of the present invention, ink elimination process is the production of paper and cardboard which do not include ink particles with the desired optic characteristics and which cannot be seen with naked eye, and this necessitates removal of the ink particles with size 30-80 ?m from the pulp suspension.

[0064] After said pulpifying process, in the process of removal of ink particles, that are released in the pulp, from the fiber surface, Degussa Flotation Ink elimination device is used, and the ink elimination conditions given in Table 2 are applied, and the process of elimination of the ink of waste papers is realized.

TABLE-US-00002 TABLE 2 Ink elimination conditions applied to pulps Concentration (%) 0.8-1 Temperature (? C.) 45 Duration (minute) 30 Mixing speed (rev/minute) 1450 Hardness of water (ppm) 160 Air input (liters/minute) 2.5 Oleic acid (%) 1

[0065] During ink elimination, the oleic acid (with proportion of 1% by weight) added to the floating cell provides holding of the ink particles, that exist in the pulp suspension, to the air bubbles, and provides carrying thereof to the surface by means of the formed foam, and ink particles are removed from the medium with the help of rasp.

[0066] During said floating process, the activities like separation of the ink from the fibers, improving of the holding ability of ink particles to the air bubble, the formation of air bubble-ink particles complex, the movement of the complex to the suspension surface, and prevention of re-mixing of the ink and the pulp are realized in a controlled manner and at sufficient level.

[0067] In the possible embodiment of the present invention, kneading (dispersion) process is realized for removing ink particles which remain in the pulp after ink elimination process and removing of sticks from fibers or for reducing this dirt such that it cannot be seen with naked eye. In the dispersion process, Hobart type device is used, and in this process step, it is worked by being adhered to the kneading conditions given in Table 3.

TABLE-US-00003 TABLE 3 Dispersion process conditions NaOH Proportion (%) 0.5 H.sub.2O.sub.2 Proportion (%) 1.0 Na.sub.2SiO.sub.3 Proportion (%) 1.5 Temperature (? C.) 85 Duration (minute) 20 Concentration (%) 25

[0068] In the possible embodiment of the present invention, bleaching process is realized for the purpose of a chemical process applied for bleaching of the colors by using reducing and oxidizing chemical substances like residue lignin, dirt, ink, dye, shell, etc. which darkens the color of paper pulp or for increasing brightness and whiteness of cellulosic materials against removal of these substances from paper pulp and for decreasing the yellowness.

[0069] In the possible embodiment of the present invention, dyeing process is realized as a result of dyeing of paper pulps, gypsumboard paper and/or cardboards, obtained after bleaching, with pink and green colored dyes in a compliant manner to usage places and purposes. Dyeing processes are applied depending on standards by means of 1 bleached (ivory) and 2 different colored (pink and green) dyes for bleached pulps. The amount of dye used in dyeing of pulp with pink and green dyes is 1%.

[0070] In the invention, said ivory colored plaster is used in areas on plates where surface application shall be realized. In these areas, mostly the surfaces of plates are dyed or are covered with wallpaper.

[0071] In the invention, the papers and cardboards where the pink colored dye application is realized are used in production of gypsumboard that is resistant to flame. Resistance to flame is provided by adding to the plaster mortar mixture of the plate and not in paper and cardboards.

[0072] In the invention, the papers and cardboards where the green colored dye application is realized are used in production of gypsumboard that is resistant to water and humidity. Resistance to water and humidity is provided by means of different chemicals added to plaster mortar.

[0073] As a result, the freedom determinations of the pulps, obtained after each process step above, have been adjusted in the tool of Schopper Riegler tool in accordance with ISO 5267-1 (Anonymous, 1999) standard, papers with grams of 130, 140 and 150 are produced and cardboards with grams of 160, 170 and 180 are produced in laboratory type Rapid Kothen RK-21 paper machine.

[0074] For the produced papers and cardboards, after the papers are conditioned for 12 hours and the cardboards are conditioned for 24 hours in air-conditioning chamber where the temperature is 23?1? C. and relative humidity is 50%?2 in accordance with TAPPI T 402 om-88 standard (Anonymous, 1992), the physical and optic characteristics, stain analysis tests and effective residue ink concentration (ERIC) are detected depending on the standards given in Table 5 below.

[0075] The optical and physical characteristics of the papers and cardboards obtained after each of the abovementioned process step have been detected based on standards given in Table 5 below.

[0076] ERIC (Effective Residue Ink Concentration), stain analyses and ash determinations of papers and cardboards, obtained after each process step, have been detected depending on the standards given in Table 5 again. Stain analyses have been made by means of Perfection V850 Pro model device with brand EPSON, and the results show the numbers and dimensions of the inks that exist in one square meter.

TABLE-US-00004 TABLE 4 Standards used in optical and physical characteristic tests applied to the produced papers and cardboards Tests made Test Standards Grams (gr/m.sup.2) TAPPI T 410 om-88 (2) Thickness (?) ISO 534 (3) Breaking Length (km) TAPPI T 494 om-01 (2) Explosion Index (kPa m.sup.2/gram) TAPPI T 403 om-91 (2) Porosity (second) ISO 5636-5: 2013 (3) Water Suctioning Behaviors (COBB.sub.60) TAPPI T 441 (2) Water Vapor Transmission TAPPI T 464 om-2012 Speed (g/m.sup.2*d) Scott Bond (Layer Separation (J/m.sup.2)) TAPPI T 569 om-07 Whiteness (ISO %) ISO 2469: 2014 (3) Brightness (ISO %) ISO 2470-1: 2016 (3) Yellowness (E313) ASTM E313 (4) CIE Whiteness ISO/DIS 11475: 2017 (3) L* ISO/CD 5631-1: 2015 (3) a* b* Opacity (ISO %) ISO/DIS 2471: 2008 (3) Effective Residue Ink Concentration ISO 22754: 2008 (3) (ERIC)(ppm) Stain Analysis and Measurement TAPPI/ANSI T 437 om-12 (2) Ash Determination (%) TAPPI T 211 om-02 (2)

[0077] In the study of the subject matter high porosity colored gypsumboard paper and cardboard and production method study, it is aimed at producing colored gypsumboard paper and cardboard with porosity of 30-40. As a result of the present invention, when compared with the targeted porosity value of 30-40 seconds of said paper and cardboards, it is seen that substantially successful high porosity gypsumboard paper and cardboard production is realized in the range of 12-25 porosity.

[0078] When the physical and optical characteristics and ERIC values of paper and cardboards, obtained after pulpifying process and big-small sized dirt and dimensions of ink particles, are compared with the paper and cardboards obtained after the bleaching process, it is seen that the big and small sized dirt is reduced, and there are important improvements, that are over the targeted values, in the optic characteristics of the obtained paper and cardboards. In the studies realized in the subject matter method, the high porosity papers and cardboards, obtained by means of the methods applied above, have provided a capacity increase of approximately 10% in paper factory operation capacity and a capacity increase of approximately 20% in gypsumboard production.

[0079] The protection scope of the present invention is set forth in the annexed claims and cannot be restricted to the illustrative disclosures given above, under the detailed description. It is because a person skilled in the relevant art can obviously produce similar embodiments under the light of the foregoing disclosures, without departing from the main principles of the present invention.