CN103057199A - 用高的淀粉以及高的分散剂水平制造的石膏墙板的微结构特征 - Google Patents
用高的淀粉以及高的分散剂水平制造的石膏墙板的微结构特征 Download PDFInfo
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- CN103057199A CN103057199A CN2013100081521A CN201310008152A CN103057199A CN 103057199 A CN103057199 A CN 103057199A CN 2013100081521 A CN2013100081521 A CN 2013100081521A CN 201310008152 A CN201310008152 A CN 201310008152A CN 103057199 A CN103057199 A CN 103057199A
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- gypsum
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Abstract
本发明涉及用高的淀粉以及高的分散剂水平制造的石膏墙板的微结构特征,提供了具有一种独特微结构的石膏墙板,其中增加了在空隙之间的壁的厚度和强度以实质性地改进这些墙板的强度和处理特性。在此还提供了制造轻质石膏墙板的一种方法。
Description
本申请是申请日为2008年9月29日、申请号为200880108747.1、发明名称为“用高的淀粉以及高的分散剂水平制造的石膏墙板的微结构特征”的发明专利申请的分案申请。
上述发明专利申请是2006年11月2日提交的美国专利申请号11/592,481的部分继续申请,也是2006年6月7日提交的美国专利申请号11/449,177的部分继续申请,并且也是2006年6月2日提交的美国专利申请号11/445,906的部分继续申请,各项申请都要求2005年6月9日提交的美国临时申请号60/688,839的权益。上述各项专利申请的全部内容均通过引用结合在此。
技术领域
本发明涉及一种具有一种微结构的轻质石膏墙板,该微结构包括多个大的空气的空隙,这些空隙具有不同寻常地厚的壁,这些厚壁具有增强的致密表面。它还涉及制造具有这种微结构的轻质墙板的方法。
背景技术
石膏(二水合硫酸钙)的某些特性使它在制造工业和建筑产品(如石膏墙板)的应用中很受欢迎。石膏是一种充裕的并且总体上廉价的原料,通过脱水和再水合的方法,可以将其铸造、模塑或以其他方式形成有用的形状。制造石膏墙板和其他石膏产品所来源的基体材料是硫酸钙的半水合物形式(CaSO4·1/2H2O),通常称作“灰泥”,它是通过硫酸钙的二水合物形式(CaSO4·2H2O)的加热转化(从中去除了1-1/2水分子)而生成的。
常规的含石膏产品(如石膏墙板)具有许多优点,例如低成本和 易于加工性,然而当这些产品被切割或钻孔时会产生大量的石膏粉尘。使用淀粉作为在用于制造这些产品的浆料中的成分已经在制造这些含石膏产品中实现了不同的改进。预胶凝淀粉,像胶水一样,可以提高包括石膏墙板的含石膏产品的挠曲强度和抗压强度。己知的石膏墙板包含小于约10lbs/MSF水平的淀粉。
为了保证该浆料有适当的可流动性,在含预胶凝淀粉的石膏浆料中还有必要使用大量的水。不幸的是,该水的大部分最终必须通过干燥除去,而这是昂贵的,因为在该干燥过程中使用高成本的燃料。这一干燥步骤也是费时的。已经发现使用萘磺酸盐分散剂能提高这些浆料的流动性,由此克服该需水问题。此外,还已经发现如果使用水平足够高,这些萘磺酸盐分散剂能交联到该预胶凝淀粉上,以便在干燥后将石膏晶体粘合到一起,由此提高该石膏复合物的干强度。因此,该预胶凝淀粉和该萘磺酸盐分散剂的组合在将凝固石膏晶体粘合到一起上提供了类似胶水的作用。在过去,没有认识到三偏磷酸盐影响石膏浆料的水需求。然而,诸位发明人已经发现,在一种特定分散剂的存在下将该三偏磷酸盐的水平增加到迄今未知的水平上使之有可能用出人意料地减少的水实现浆料的适当的可流动性量,甚至是在高淀粉水平的存在下。这当然是所非常希望的,因为它进而减少了用于干燥的燃料使用连同与随后的除水处理步骤相关的加工时间。因此,诸位发明人还已经发现,石膏板的干强度可以通过在用于制造该墙板的浆料中使用与预胶凝淀粉结合的一种萘磺酸盐分散剂而提高。
本发明的石膏墙板应区别于不具有面层薄板的吸声板或砖。并且,本发明的墙板应区别于包括聚苯乙烯作为一种轻质骨料的吸声板或砖。重要的是,上述吸声板或砖不符合适用于石膏墙板的多项ASTM标准。例如,已知的吸声板不具有石膏墙板(包括本发明的那些)所要求的挠曲强度。相反,为了使吸声板或砖符合ASTM标准,这些吸声板或砖的暴露表面需要具有中空的空隙或凹陷,这些空隙或凹陷在石膏墙板中是不希望的,并且会对拔钉阻力以及表面硬度特性产生不利影响。
粉尘产生是在所有墙板安装的过程中的一个潜在问题。例如,当石膏墙板通过切割、锯割、开槽、折断、钉或螺钉固定、或钻孔进行加工时,会产生大量的石膏粉尘。为了本披露的目的,“起尘”和“粉尘产生”是指在一种含石膏产品的加工过程中,例如通过切割、锯割、开槽、划刻/折断、钉或螺钉固定、或钻孔该墙板,气载尘埃释放进入周围的工作空间中。加工总体上还可以包括正常的板处理,包括在运输、搬运、和安装过程中意外地刮削或磕碰这些板时产生的粉尘。如果可以找到一种方法来生产低密度墙板,其中显著降低这种粉尘产生,将是对本领域的一项特别有用的贡献。
而且,如果可以找到一种提高石膏墙板的强度同时降低板重量的方法,也将是对本领域的一项有用的贡献。在已知的墙板产品中的空气空隙具有相对薄的壁,其中在空隙之间的壁厚为平均约20到30微米。如果一种新型的石膏墙板可以具有一种包括空气空隙的微结构,这些空气空隙所具有的这些壁具有增强的厚度以及一个增强的致密表面以及由此增加的壁强度,则将对本领域做出一项重要并且有用的贡献。另外,如果可以找到一种方法来增加空隙尺寸而同时增加在这些空隙之间的壁的厚度以及表面密度以生产一种具有增加的强度和处理特性的低密度墙板,则也将是对本领域的另一项重要的贡献。
发明内容
本发明总体上包括一种轻质石膏墙板,该轻质石膏墙板包括在两个基本上平行的覆盖薄板之间形成的一个凝固石膏芯,该凝固石膏芯具有总体上遍及该凝固石膏芯分散的多个空隙,这些空隙所具有的壁具有至少约30微米到约200微米的平均厚度以及增强的致密表面。该凝固石膏芯是由一种含石膏的浆料制成的,该含石膏的浆料包括:水、灰泥、以基于灰泥的重量从按重量计约0.5%到按重量计约10%的量存在的预胶凝淀粉、以基于灰泥的重量从按重量计约0.2%到按重量计约2%的量存在的一种萘磺酸盐分散剂、以基于灰泥的重量从按重量计约0.1%到按重量计约0.4%的量存在的三偏磷酸钠、以及任选以基 于灰泥的重量高达按重量计约0.2%的量存在的玻璃纤维。最后,肥皂泡将以有效地提供从约27pcf到约30pcf的凝固石膏芯密度的量存在。术语“pcf”被定义为磅每立方英尺(lb/ft3)。
根据本发明制造的石膏墙板具有高强度,但重量比常规墙板低得多。此外,已经发现根据本发明的实施方案制造的轻质石膏墙板具有大的空气空隙,这些空气空隙具有不同寻常地厚的壁,这些厚壁具有增强的表面,它们一起增强该墙板芯的微结构,从而生产具有出色的强度和处理特性的墙板。此外,我们将描述制造这些具有出色的强度和处理特性的轻质石膏墙板的方法。
附图简要说明
图1是展示本发明的一个实施方案的一个铸造石膏立方体样品(11:08)的15X放大的扫描电子显微照片。
图2是展示本发明的一个实施方案的一个铸造石膏立方体样品(11:30)的15X放大的扫描电子显微照片。
图3是展示本发明的一个实施方案的一个铸造石膏立方体样品(11:50)的15X放大的扫描电子显微照片。
图4是说展示本发明的一个实施方案的一个铸造石膏立方体样品(11:08)的50X放大的扫描电子显微照片。
图5是说展示本发明的一个实施方案的一个铸造石膏立方体样品(11:30)的50X放大的扫描电子显微照片。
图6是说展示本发明的一个实施方案的一个铸造石膏立方体样品(11:50)的50X放大的扫描电子显微照片。
图7是展示本发明的一个实施方案的一个铸造石膏立方体样品(11:50)的500X放大的扫描电子显微照片。
图8是展示本发明的一个实施方案的一个铸造石膏立方体样品(11:50)的2,500X放大的扫描电子显微照片。
图9-10是展示本发明的一个实施方案的一个铸造石膏立方体样品(11:50)的10,000X放大的扫描电子显微照片。
图11是展示在该凝固石膏芯中的空气空隙分布、空隙尺寸、在空隙之间的平均壁厚以及壁的增强表面的一个对照板样品的15X放大的扫描电子显微照片。
图12是展示在根据本发明的一个实施方案的凝固石膏芯中的空气空隙分布、空隙尺寸、在空隙之间的平均壁厚以及壁的增强表面的一个根据本发明的墙板样品的15X放大的扫描电子显微照片。
图13是展示在该凝固石膏芯中的空气空隙分布、空隙尺寸、在空隙之间的平均壁厚以及壁的增强表面的一个图11的对照板样品的50X放大的扫描电子显微照片。
图14是展示在根据本发明的一个实施方案的凝固石膏芯中的空气空隙分布、空隙尺寸、在空隙之间的平均壁厚以及壁的增强表面的一个图12的墙板样品的50X放大的扫描电子显微照片。
图15是展示在根据本发明的一个实施方案的凝固石膏芯中的在空隙之间的平均壁厚以及微结构特征的一个图12的墙板样品的500X放大的扫描电子显微照片。
图16是展示在根据本发明的一个实施方案的凝固石膏芯中的在空隙之间的平均壁厚以及微结构特征的一个图12的墙板样品的250X放大的扫描电子显微照片。
图17是展示在根据本发明的一个实施方案的凝固石膏芯中的在空隙之间的平均壁厚以及微结构特征的一个图16的墙板样品的500X放大的扫描电子显微照片。
图18是展示在根据本发明的一个实施方案的凝固石膏芯中的在空隙之间的平均壁厚以及微结构特征的一个图16的墙板样品的1,000X放大的扫描电子显微照片。
图19是说明在根据本发明的一个实施方案的凝固石膏芯中的在空隙之间的平均壁厚以及微结构特征的一个图16的墙板样品的2,500X放大的扫描电子显微照片。
实施本发明的最佳方式
出乎意料地发现,使用包括灰泥、预胶凝淀粉、一种萘磺酸盐分散剂、三偏磷酸钠、任选玻璃纤维、以及适量的肥皂泡的一种含石膏的浆料制造的石膏墙板提供了增加的空气空隙体积,其中围绕这些空气空隙(并且因此还在这些空气空隙之间)的壁是实质性更厚的并且具有增强的表面并且因此比在常规墙板中发现的空气空隙更强。该增加的空气空隙体积减少了板密度和重量,并且这些更厚的增强壁通过增强该凝固石膏芯的微结构使该墙板更强。其结果是,根据本发明制造的成品轻质墙板具有出色的拔钉阻力、挠曲强度、芯/边硬度、以及其他非常希望的特性。另外,在一个优选的实施方案中,根据本发明制造的1/2英寸的成品轻质石膏墙板的干重可以从约1150lb/MSF变化到约1260lb/MSF,具有约27pcf到约30pcf的低板芯密度。
该肥皂泡的引入产生了小的空气(泡)空隙,其直径平均可小于约100微米,但总体上直径大于约10微米,并且优选直径大于约20微米,并且更优选直径大于约50微米。本发明要求这些小气泡,与蒸发水的空隙(总体上直径约5微米或更小,通常直径小于约2微米)一起,总体上遍及在这些成品墙板产品中的凝固石膏芯而均匀地分布。例如,该凝固石膏芯的总空隙体积可以为从约75%到约95%,并且优选从约80%到约92%,其中该总空隙体积的至少60%包括平均直径大于约10微米的空气空隙,并且该总空隙体积的至少10%包括平均直径小于约5微米的水空隙。人们相信以这种方式制备的低密度板芯(该凝固石膏芯的总空隙体积的从约80%到约92%作为空气空隙和水空隙(总芯空隙体积)),当切割、锯割、开槽、折断、钉或螺钉固定、或钻孔这些板时,在暴露的空隙中捕获了大量的小粉尘和其他碎片,这样粉尘产生显著减少并且不会浮游在空气中。更优选地,这些墙板的凝固石膏芯可以具有平均而言在直径约50微米到直径约300微米的范围内的空气空隙。
在一个实施方案中,这些空气空隙的壁的平均厚度平均为大于约30微米、高达约200微米。优选地,这些空隙的壁厚平均为至少约50微米。更优选地,这些空隙的壁厚平均为从约70微米到约120微米。 此外,如图15至19所示,这些晶体的较小的晶体尺寸(特别像很小很细的针)以及更致密的堆积同产生较厚的空气空隙壁有关。
这些壁的表面的增强被认为是起因于该预胶凝淀粉/分散剂/三偏磷酸钠在该板的最初干燥过程中迁移到该空气空隙表面上以填充在该壁面上的针状空隙中并且由此使该表面致密。这增强了该凝固石膏芯的微结构,从而生产了具有提高的强度以及增强的处理特性的墙板。所产生的增强的致密表面例如在图15中的“A”处可见,其中所说明的致密面积沿该壁的表面而延伸。虽然人们认为这种增强的表面包括迁移的预胶凝淀粉、分散剂以及三偏磷酸钠,诸位发明人并非旨在受这种解释约束,并且认识到该增强表面可以包括少于这些材料中的所有三种并且的确可以从一种不同的来源或机理得到。
在一个优选实施方案中,该轻质石膏墙板包括在两个基本上平行的覆盖薄板之间形成的一个凝固石膏芯,该凝固石膏芯具有总体上遍及该凝固石膏芯分散的多个空隙,这些空隙由具有增强的致密表面的增厚的壁来定义。一种优选的凝固石膏芯是由一种含石膏的浆料制成的,该含石膏的浆料包括:水、灰泥、以基于灰泥的重量从按重量计约0.5%到按重量计约10%的量存在的预胶凝淀粉、以基于灰泥的重量从按重量计约0.2%到按重量计约2%的量存在的一种萘磺酸盐分散剂、以基于灰泥的重量从按重量计约0.1%到按重量计约0.4%的量存在的三偏磷酸钠、以及任选以基于灰泥的重量高达按重量计约0.2%的量存在的玻璃纤维。
半水合硫酸钙(灰泥)的再水合以及随之发生的硬化需要特定的、理论量的水(1-1/2摩尔水/摩尔灰泥)以形成二水合硫酸钙晶体。然而,该商业方法普遍需要过量的水。这种过量的处理水在该石膏晶体基质中产生蒸发的水空隙,总体上这些蒸发的水空隙的形状相当不规则,并且还与其他水空隙互连,在凝固石膏晶体之间以总体上连续的网状形成不规则通道。相反,空气(泡)空隙用肥皂泡被引入该石膏浆料中。空气空隙的形状总体上是球形/圆形的,并且还是总体上与其他空气空隙分开的,并且因此总体上是不连续的。这些水空隙可以分 布在这些空气空隙的壁内(参见例如图8-10)。
粉尘捕获的效力取决于该凝固石膏芯的构成。已经发现如果使用水平足够高,这些萘磺酸盐分散剂能交联到该预胶凝淀粉上,以便在干燥后将石膏晶体粘合到一起,由此提高该石膏复合物的干强度。
此外,现在已经出乎意料地发现该预胶凝淀粉和该萘磺酸盐分散剂(有机相)的组合在将这些凝固石膏晶体粘合到一起上提供了类似胶水的作用,并且当该配方与一个特定的空隙体积和空隙分布相结合时,在划刻/折断该成品墙板时会产生较大尺寸的碎片。这个结果进一步被本发明的扩大的壁厚以及增强的致密壁面微结构而增强。较大的石膏碎片总体上产生较少的游浮粉尘。相反,如果使用一种常规墙板配方,则会产生较小的碎片并且因此产生更多粉尘。例如,常规墙板在锯切时会产生平均直径约20-30微米、并且最小直径约1微米的粉尘碎片。相反,本发明的石膏墙板在锯切时产生平均直径约30-50微米、并且最小直径约2微米的粉尘碎片;划刻/折断可产生甚至更大的碎片。
在较软墙板中,粉尘可以在水空隙和空气空隙两者中被捕获(如作为单晶粉尘捕获小石膏针状体)。较硬的墙板有利于在空气空隙中的粉尘捕获,因为该凝固石膏芯的较大的块或碎片是在加工这些板时产生的。在这种情况下,这些粉尘碎片对于水空隙来说过大,但是陷入空气空隙中。根据本发明的一个实施方案,通过在该凝固石膏芯内引入优选的空隙/孔尺寸分布,有可能实现提高的粉尘捕获。优选的是具有小的和大的空隙尺寸的分布,作为空气空隙和水空隙的分布。在一个实施方案中,优选的空气空隙分布可用肥皂泡制备。参见以下实例6和7。
在该凝固石膏芯内的空气空隙(大于约10微米)和水空隙(小于约5微米)的比率可以在从约1.8:1到约9:l的范围。在该凝固石膏芯内的空气空隙(大于约10微米)与水空隙(小于约5微米)的优选比率可以为从约2:1到约3:1。在一个实施方案中,在该凝固石膏芯内的空隙/孔尺寸分布作为所测得的总空隙的百分比应为约10–30%的空隙 小于5微米并且约70–90%的空隙大于约10微米。换个方式说,在该凝固石膏芯内的空气空隙(大于10微米)和水空隙(小于5微米)的比率在从约2.3:到约9:1的范围。在一个优选实施方案中,在该凝固石膏芯内的空隙/孔尺寸分布作为测得的总空隙的百分比应为约30–35%的空隙小于5微米以及约65–70%的空隙大于约10微米。换个方式说,在该凝固石膏芯内的空气空隙(大于10微米)与水空隙(小于5微米)之比为从约1.8:1到约2.3:1。
优选的是平均空气(泡)空隙尺寸的直径小于约100微米。在一个优选的实施方案中,在该凝固石膏芯内的空隙/孔尺寸分布为:大于约100微米(20%),从约50微米到约100微米(30%),以及小于约50微米(50%)。也就是说,优选的中值空隙/孔尺寸大小为约50微米。
这些空气空隙可以降低在发泡的低密度凝固石膏芯和覆盖薄板之间的粘合强度。因为大于按体积计一半的复合石膏板可能由于泡沫由空气空隙组成,所以该泡沫可以干扰在该发泡的低密度凝固石膏芯和这些纸覆盖薄板之间的粘合。这通过任选地在将这些覆盖薄板施加到该芯之前在该顶部覆盖薄板或者该底部覆盖薄板或者该顶部覆盖薄板和该底部覆盖薄板两者的石膏芯接触面上提供一个非发泡的(或发泡减少的)粘合高密度层来解决。这种非发泡的或可替代的发泡减少的粘合高密度层配方典型地将与该石膏浆料芯配方相同,除了或者将不加入肥皂、或者将加入实质性减少量的肥皂(泡沫)之外。任选地,为了形成这种粘合层,可以将泡沫机械地从该芯配方中除去,或者可以将一种不同的无泡沫的配方应用在该发泡的低密度凝固石膏芯/面层纸的界面上。
优选将肥皂泡引入并控制在该凝固石膏芯中的空气(泡)空隙的尺寸和分布,并且控制该凝固石膏芯的密度。肥皂的优选范围为从约0.2lb/MSF到约0.7lb/MSF;肥皂的更优选的水平为约0.45lb/MSF到约0.5lb/MSF。
肥皂泡必须以有效地产生所希望的密度的量、并且以受控的方式 加入。为了控制该过程,操作者必须监测该板成型线的源头,并保持该封袋是充满的。如果该封袋未保持充满,则会产生具有中空边缘的墙板,因为该浆料不能充满所需要的体积。该封袋体积是通过增加肥皂的使用以防止在该板的制造过程中气泡的破裂(为了更好地保留这些气泡)、或通过增加该空气泡沫率而保持充满的。因此,总体上该封袋体积是通过增加或减少肥皂的使用、或通过增加或减少空气泡沫速率来控制和调节的。控制该源头的技术包括通过加入肥皂泡以增加浆料体积,或通过减少肥皂泡的使用以减少浆料体积来调整台上的“动态浆料”。
根据本发明的一个实施方案,在此提供了由包含灰泥、预胶凝淀粉、以及一种萘磺酸盐分散剂的含石膏的浆料制成的成品含石膏产品。该萘磺酸盐分散剂是以基于干灰泥重量的按重量计约0.1%–3.0%的量存在的。该预胶凝淀粉是以基于该配方中的干灰泥重量按重量计至少约0.5%高达按重量计10%的量存在的。在该浆料中可能使用的其他成分包括粘合剂、防水剂、纸纤维、玻璃纤维、粘土、杀虫剂、和促进剂。本发明需要添加一种肥皂泡到该新配制的含石膏的浆料中以降低该成品含石膏产品如石膏墙板的密度,并通过在该凝固石膏芯中以小的空气(泡)空隙和水空隙的形式引入从约75%到约95%、并且优选从约80%到约92%的总空隙体积以控制起尘。优选地,平均孔径分布将为从约1微米(水空隙)到约40-50微米(空气空隙)。
任选地,从按重量计约0.5%到按重量计约10%的预胶凝淀粉、从按重量计约0.1%高达按重量计约3.0%的萘磺酸盐分散剂、以及最少的至少按重量计约0.12%高达按重量计约0.4%的三偏磷酸盐(全部基于在该石膏浆料中使用的干灰泥的重量)的组合,出乎意料且显著地增加了该石膏浆料的流动性。这相当大地降低了生产将用于制造含石膏产品(如石膏墙板)的有足够的可流动性的一种石膏浆料所需要的水量。三偏磷酸盐的水平(它至少为标准配方(像三偏磷酸钠)的约两倍)被认为可以提高该萘磺酸盐分散剂的分散活性。
萘磺酸盐分散剂必须用于根据本发明制备的含石膏的浆料中。在 本发明中使用的萘磺酸盐分散剂包括聚萘磺酸及其盐(聚萘磺酸盐)和衍生物,它们是萘磺酸和甲醛的缩合产物。特别可取的聚萘磺酸盐包括萘磺酸钠和萘磺酸钙。这些萘磺酸盐的平均分子量可以从约3,000变化到27,000,但优选的是该分子量的范围是从约8,000到22,000,并且更优选的是该分子量的范围是约12,000到17,000。作为一种商业产品,一种较高分子量的分散剂比一种较低分子量的分散剂具有更高的粘度和更低的固体含量。有用的萘磺酸盐包括从GEO特种化学品公司(俄亥俄州,克里夫兰)可获得的DILOFLO;从罕布什尔化学公司(马萨诸塞州,列克星敦)可获得的DAXAD;以及从GEO特种化学品公司(印第安纳州,拉斐特)可获得的LOMAR D。例如,这些萘磺酸盐优选作为固体含量在按重量计35-55%的范围内的水溶液使用。最优选的是使用处于例如固体含量在按重量计约40-55%的范围内的水溶液形式的萘磺酸盐。例如,可替代地,适当时,这些萘磺酸盐能以干燥固体或粉末如LOMAR D的形式使用。
在本发明中使用的聚萘磺酸盐具有以下通用结构(I):
其中n>2,并且其中M为钠、钾、钙、以及类似物。
该萘磺酸盐分散剂(优选作为按重量计约45%的水溶液)可以按基于在该石膏复合配方中使用的干灰泥重量的从按重量计约0.5%到约3.0%的范围使用。萘磺酸盐分散剂更优选的范围是基于干灰泥重量的从按重量计约0.5%到约2.0%,并且最优选的范围是基于干灰泥重 量的从按重量计约0.7%到约2.0%。相比之下,已知的石膏墙板以基于干灰泥重量的按重量计约0.4%或更低的水平包含这种分散剂。
换个方式说,该萘磺酸盐分散剂,在干重基础上,可以基于在该石膏复合配方中使用的干灰泥的重量以从按重量计约0.1%到约1.5%的范围使用。萘磺酸盐分散剂的更优选的范围,在干燥固体基础上,是基于干灰泥的重量从按重量计约0.25%到约0.7%,并且最优选的范围(在干燥固体基础上)为基于干灰泥的重量从按重量计约0.3%到约0.7%。
该含石膏的浆料可任选地包含一种三偏磷酸盐,例如三偏磷酸钠。根据本发明任何适当的水溶性偏磷酸盐或聚磷酸盐均可使用。优选的是使用一种三偏磷酸盐,包括复盐,即具有两个阳离子的三偏磷酸盐。特别有用的三偏磷酸盐包括三偏磷酸钠、三偏磷酸钾、三偏磷酸钙、三偏磷酸钠钙、三偏磷酸锂、三偏磷酸铵、以及类似物,或它们的组合。优选的三偏磷酸盐为三偏磷酸钠。优选的是该三偏磷酸盐作为水溶液(例如在按重量计约10-15%的范围内的固体含量)使用。还可使用其他的环的或非环的多磷酸盐,如Yu等在美国专利号6,409,825中所描述的,通过引用结合在此。
三偏磷酸钠是在含石膏组合物中的一种己知的添加剂,但它总体上以基于在该石膏浆料中使用的干灰泥的重量从按重量计约0.05%到约0.08%的范围使用。在本发明的实施方案中,三偏磷酸钠(或其他水溶性偏磷酸盐或多磷酸盐)可以基于在该石膏复合配方中使用的干灰泥的重量以从按重量计约0.10%到约0.4%的范围存在。三偏磷酸钠(或其他水溶性偏磷酸盐或多磷酸盐)的优选范围是基于在该石膏复合配方中使用的干灰泥的重量从按重量计约0.12%到约0.3%。
灰泥有两种形式,α和β。灰泥的这两种类型是由不同的锻烧手段产生的。在本发明中灰泥的β或α形式均可使用。
淀粉,特别是包括预胶凝淀粉,必须用在根据本发明制备的含石膏的浆料中。一种优选的预胶凝淀粉是预胶凝玉米淀粉,例如从Bunge Milling(密苏里州,圣路易斯)公司可获得的预胶凝玉米粉,具有如 下典型分析:水分7.5%,蛋白质8.0%,油0.5%,粗纤维0.5%,灰0.3%;具有0.48psi的生坯强度;并且具有35.0lb/ft3的松密度。预胶凝玉米淀粉应以基于在该含石膏的浆料中使用的干灰泥的重量按重量计至少约0.5%高达按重量计10%的量使用。在一个更优选的实施方案中,预胶凝淀粉是以基于在该含石膏的浆料中使用的干灰泥的重量从按重量计约0.5%到按重量计约4%的量存在。
诸位发明人进一步发现,在按重量计约0.1%到按重量计约3.0%的萘磺酸盐分散剂的存在下,通过使用至少按重量计约0.5%高达按重量计约10%的预胶凝淀粉(优选预胶凝玉米淀粉)可获得干强度(特别是在墙板中)的出乎意料的提高(淀粉和萘磺酸盐的水平均基于在该配方中存在的干灰泥的重量)。不管水溶性偏磷酸盐或多磷酸盐是否存在,都可获得这一出乎意料的结果。
此外,出乎意料地发现,预胶凝淀粉可以按至少约10lb/MSF或更高的水平用于根据本发明制造的干石膏墙板中,而还能实现高强度和低重量。在该石膏墙板中的预胶凝淀粉高达35-45lb/MSF的水平已经被证明是有效的。例如,如下表1和表2所示的配方B包括45lb/MSF,而还产生了具有优异强度的1042lb/MSF的板重量。在该实例(配方B)中,一种作为按重量计45%的萘磺酸盐分散剂的水溶液是以按重量计1.28%的水平使用的。
当该萘磺酸盐分散剂三偏磷酸盐组合与预胶凝玉米淀粉、并任选地与纸纤维或玻璃纤维相结合时,用本发明实现了更加出乎意料的结果。由包含这三种成分的配方制成的石膏墙板具有增加的强度和减少的重量,并且由于在它们的制造中减少了水需求而更加经济可行。纸纤维的有用的水平可以是基于干灰泥的重量高达按重量计约2%。玻璃纤维的有用的水平可以是基于干灰泥的重量高达按重量计约2%。
在本发明的含石膏组合物中可使用如Yu等在美国专利号6,409,825中所描述的促进剂,通过引用结合在此。一种可取的耐热促进剂(HRA)可由建筑石膏(二水合硫酸钙)的干研磨而制成。少量添加剂(通常按重量计约5%)如糖、右旋糖、硼酸和淀粉可用于制 造这种HRA。当前优选糖、或右旋糖。另一种有用的促进剂是如在美国专利号3,573,947中所描述的“气候稳定型促进剂”或“气候稳定的促进剂”(CSA),通过引用结合在此。
水/灰泥(w/s)之比是一个重要的参数,因为过量的水最后必须通过加热除去。在本发明的实施方案中,优选的w/s之比为从约0.7到约1.3。
其他石膏浆料添加剂可包括促进剂、粘合剂、防水剂、纸或玻璃纤维、粘土、杀虫剂、以及其他已知的组分。
覆盖薄板可以像常规石膏墙板一样由纸制成,但也可使用其他本领域己知的有用的覆盖薄板材料(如玻璃纤维垫)。纸覆盖薄板在该石膏墙板中提供强度特性。有用的覆盖薄板纸包括从美国石膏公司(伊利诺斯州,芝加哥)可获得的Manila7-层纸(Manila7-ply)和News-Line5-层纸;从Caraustar公司(印第安纳,新港)可获得的Grey-Back3-层纸和Manila Ivory3-层纸;从美国石膏公司(伊利诺斯州,芝加哥)可获得的Manila重磅纸(Manila heavy paper)和MH Manila HT(高强度)纸。这些纸质覆盖薄板包括顶部覆盖薄板或面层纸、以及底部覆盖薄板或背层纸。优选的背面覆盖薄板纸为5层News-Line纸。优选的面层覆盖薄板纸包括MH Manila HT(高强度)纸以及Manila7层纸。
纤维垫也可以用作一个或两个覆盖薄板。一种有用的纤维垫是一种玻璃纤维垫,其中玻璃纤维丝通过一种粘合剂粘合在一起。优选地,这些纤维垫将是非纺织玻璃纤维垫,其中玻璃纤维细丝通过一种粘合剂粘合在一起。最优选地,这些非纺织玻璃纤维垫将具有一个重的树脂涂层。例如,可使用从Johns-Manville可获得的重量约1.2-2.0lb/100ft2的Duraglass非纺织玻璃纤维垫,其中该垫重量的约40-50%来自该树脂涂层。其他有用的纤维垫包括但不限于纺织玻璃垫和非纤维素织物。
以下实例进一步说明本发明。它们不应被视为以任何方式限制本发明的范围。
实例1
样品石膏浆料配方
石膏浆料配方如下表1所示。在表1中的所有值均以基于干灰泥重量的重量百分比表示。括号中的值为以磅计的干重(lb/MSF)。
表1
*用于预产生泡沫。
1作为一种45%的水溶液按重量计1.28%。
实例2
墙板的制备
根据Yu等的美国专利号6,342,284以及Yu等的6,632,550制备样品石膏墙板,通过引用结合在此。该方法包括单独产生泡沫,并将该泡沫引入到如在这些专利的实例5中所描述的所有其他成分的浆料中。
用实例1的配方A和B制造的石膏墙板以及普通对照板的试验结果如下表2所示。在该实例和以下其他实例中,拔钉阻力、芯硬度和挠曲强度试验均按照ASTM C-473进行。此外,应注意,典型的石膏 墙板约1/2英寸厚,并且具有在每1,000平方英尺(或lb/MSF)材料约1600到1800磅之间的重量。(“MSF”在本领域中为一千平方英尺的标准缩写;它是盒、波纹媒介和墙板的一个面积量度。)
表2
实验室试验结果 | 对照板 | 配方A板 | 配方B板 |
板重量(lb/MSF) | 1587 | 1066 | 1042 |
拔钉阻力(lb) | 81.7 | 50.2 | 72.8 |
芯硬度(lb) | 16.3 | 5.2 | 11.6 |
潮湿的粘合负荷(lb) | 17.3 | 20.3 | 15.1 |
潮湿的粘合失效(%) | 0.6 | 5 | 11.1 |
挠曲强度,面朝上(MD)(lb) | 47 | 47.2 | 52.6 |
挠曲强度,面朝下(MD)(lb) | 51.5 | 66.7 | 78.8 |
挠曲强度,面朝上(XMD)(lb) | 150 | 135.9 | 173.1 |
挠曲强度,面朝下(XMD)(lb) | 144.4 | 125.5 | 165.4 |
MD:机器方向(machine direction)
XMD:横跨机器方向(across machine direction)
如表2所示,用配方A和B浆料制备的石膏墙板与该对照板相比重量显著减少。再参照表1,配方A板和配方B板的对比最明显。在配方A和配方B中水/灰泥(w/s)之比相似。在配方B中还使用了显著更高水平的萘磺酸盐分散剂。而且,在配方B中使用了实质性更多的预胶凝淀粉,按重量计约6%,比配方A增加大于100%,并伴随着显著的强度增加。虽然如此,在配方B浆料中用于产生所需要的可流动性的需水量仍然很低,与配方A相比差异约为10%。在这两个配方中的低需水量都是因为在该石膏浆料中萘磺酸盐分散剂和三偏磷酸钠组合的协同效应,这即使在实质性更高水平的预胶凝淀粉的存在下,也能提高该石膏浆料的流动性。
如表2所示,与用配方A浆料制备的墙板相比,用配方B浆料制备的墙板具有实质性增加的强度。通过将增加量的预胶凝淀粉与增加量的萘磺酸盐分散剂和三偏磷酸钠相结合,在配方B板中的拔钉阻力比配方A板提高了45%。还观察到在配方B板中挠曲强度与配方A 板相比实质性地增加了。
实例3
1/2英寸石膏墙板重量降低试验
进一步的石膏墙板实例(板C、D和E),包括浆料配方和试验结果在下表3中示出。表3的浆料配方包括这些浆料的主要组分。括号中的值以基于干灰泥重量的重量百分比表示。
表3
1DILOFLO为一种45%的在萘磺酸盐水中的溶液
如表3所示,与对照板相比,板C、D和E是由实质性增加量的淀粉、DILOFLO分散剂和三偏磷酸钠(淀粉和分散剂在百分比基础上为约两倍增加,并且三偏磷酸盐为两到三倍增加)制成的,同时保持w/s之比不变。然而,板重量显著减少,并且通过拔钉阻力测得的强度没有受到显著影响。因此,在本发明的一个实施方案的本实例中,该新配方(例如像板D)可以提供在一种可用的、可流动的浆料中配制的增加的淀粉,同时保持相同的w/s之比和适当的强度。
实例4
湿石膏立方体强度试验
使用从美国石膏公司(伊利诺斯州,芝加哥)可获得的Southard CKS板灰泥以及实验室中的自来水进行湿立方体强度试验,以测定它们的湿抗压强度。使用了以下实验室测试程序。
将灰泥(1000g)、CSA(2g)、以及在约70°F下的自来水(1200cc)用于各个湿石膏立方体铸造。预胶凝玉米淀粉(20g,基于灰泥的重量2.0%)和CSA(2g,基于灰泥的重量0.2%)在与含萘磺酸盐分散剂和三偏磷酸钠两者的一种自来水溶液混合之前,首先在一个塑料袋中与该灰泥充分地干混合。使用的分散剂为DILOFLO分散剂(1.0–2.0%,如表4所示)。使用了不同量的三偏磷酸钠,同样如表4所示。
将这些干成分和水溶液首先在一个实验室报警掺混机中合并,允许产生的混合物浸泡10秒,并且然后将该混合物在低速下混合10秒以便制造该浆料。将由此形成的这些浆料铸入三个2”X2”X2”的立方体模具中。然后将这些铸造的立方体从这些模具中移出,称重,并密封在塑料袋内部以防止在进行该抗压强度试验之前的水分损失。用一台ATS机器测量该湿立方体的抗压强度,并以磅每平方英寸(psi)记录平均值。所得结果如下:
表4
1DILOFLO为一种45%的萘磺酸盐在水中的溶液
如图4所示,具有在本发明的约0.12-0.4%范围内的三偏磷酸钠水平的样品4-5、10-11以及17,与三偏磷酸钠超出该范围的样品相比,总体上提供了优秀的湿立方体抗压强度。
实例5
1/2英寸轻质石膏墙板工厂生产试验
对试验板1和2进行了进一步的试验包括浆料配方和试验结果如下表5所示。表5的浆料配方包括这些浆料的主要组分。括号中的值以基于干灰泥重量的重量百分比表示。
表5
ASTM标准:77lb
MD:机器方向
XMD:横跨机器方向
1DILOFLO为一种45%的萘磺酸盐在水中的溶液
290°F/90%相对湿度
3应很好地理解,在这些试验条件下,失效率百分比<50%是可接受的。
如表5所示,与这些对照板相比,试验板1和2由具有实质性增加量的淀粉、DILOFLO分散剂、以及三偏磷酸钠的一种浆料制成,同时w/s之比略有下降。然而,通过拔钉阻力和弯曲测试测量的强度都得到保持或改善,并且板重量显著下降。因此,在本发明的一个实施方案的本实例中,该新配方(例如试验板1和2)可以提供在可用的、可流动的浆料中配制的增加的三偏磷酸盐和淀粉,同时保持基本上相同的w/s之比和适当的强度。
实例6
1/2英寸轻质石膏墙板工厂生产试验
同实例2一样,用配方B(实例1)进行进一步的试验(试验板3和4),除了该预胶凝玉米淀粉是以10%的浓度用水制备(湿淀粉制备)的、并使用HYONIC25AS和PFM33肥皂(从GEO特种化学品公司可获得的,印第安纳州,拉斐特)的共混物之外。例如,试验板3用HYONIC25AS和PFM33的共混物制备,其中按重量计从65-70%的范围是25AS,并且余量为PFM33。例如,试验板4用HYONIC25AS/HYONIC PFM33的70/30wt./wt.的共混物制备。这些试验结果如下表6所示。
表6
*除所标记的之外。
1n=4
MD:机器方向
XMD:横跨机器方向
a ASTM标准:77lb
b ASTM标准:11lb
c ASTM标准:36lb
d ASTM标准:107lb
应注意,在该实例中所描述的配方(它们在2006年11月2日提交的原美国专利申请号11/592,481中出现)生产了如在以下实例7-9中所描述的具有大的空气空隙的石膏墙板,这些空气空隙具有不同寻 常地厚的壁,这些厚壁具有增强的致密表面。如表6所展示,通过拔钉阻力和芯硬度测得的强度特性高于ASTM标准。测得的挠曲强度也高于ASTM标准。此外,在本发明的一个实施方案的本实例中,该新配方(例如试验板3和4)可以提供在可用的、可流动的浆料中配制的增加的三偏磷酸盐和淀粉,同时保持适当的强度。
实例7
在1/2英寸厚石膏墙板芯中作为板重量的一个函数的空隙体积百分比的计算以及锯切结果
同实例2一样,用配方B(实例1)进行进一步的试验以便测定空隙体积和密度(试验板编号5至13),除了该预胶凝玉米淀粉是以10%的浓度用水制备(湿淀粉制备)的、使用0.5%的玻璃纤维、并且以45%的水溶液形式使用以按重量计1.2%的水平的萘磺酸盐(DILOFLO)之外。肥皂泡是用一台肥皂泡发生器制造的,并以有效地提供所需要的密度的量引入该石膏浆料中。在本实例中,肥皂是以从0.25lb/MSF到0.45lb/MSF的水平使用的。也就是说,肥皂泡的使用度适当时可增加或减少。在各个样品中,墙板厚度为1/2英寸,并且芯体积假定统一为39.1ft3/MSF。空隙体积是跨过4ft宽的墙板样品测量的,从这些墙板样品中除去了正面纸和背面纸。这些正面纸和背面纸的厚度可以为在11-18mil(每一侧)范围内。通过扫描电子显微镜法(参见以下实例8)和X射线CT扫描技术(XMT)测定空隙体积/孔径大小和孔径分布。
表7
1>10微米的空气(泡)空隙
2<5微米的水空隙
3基于统一的芯体积=39.1ft3/MSF,即总芯空隙体积=泡沫空隙体积+蒸发空隙体积/39.1X100
4基于统一的芯体积=39.1ft3/MSF,即板芯密度(pcf)=板重量(lb/MSF)–纸覆盖薄板的重量(lb/MSF)/39.1ft3/MSF=板重量(lb/MSF)–90lb/MSF/39.1ft3/MSF
测量的总空隙的百分比
如表7所展示,制造了总芯空隙体积范围从79.0%到92.1%的试验板样品,它们分别对应于范围从28pcf下至10pcf的板芯密度。作为一个例子,锯切具有81.8%的总空隙体积以及23pcf的板密度的试验板10,产生了比对照板少约30%的粉尘。作为另一个例子,如果用具有更少粘合剂的一种常规配方(像淀粉,有或没有分散剂)制造墙板(其具有显著更少的约75–80%的总芯空隙体积),那么在切割、锯割、开槽、折断、钉或螺钉固定、或钻孔时预期会产生显著更多的粉尘。例如,常规墙板在锯切时会产生平均直径约20-30微米、并且最小直径约1微米的粉尘碎片。相反,本发明的石膏墙板在锯切时会产生平均直径约30-50微米、并且最小直径约2微米的粉尘碎片;划刻/折断会产生甚至更大的碎片。
已经表明,用于制造该含石膏的浆料的几种重要组分,即:灰泥、 萘磺酸盐分散剂、预胶凝玉米淀粉、三偏磷酸钠、以及玻璃和/或纸纤维的组合,与足够的并且有效量的肥皂泡相结合,在生产一种有用的低密度石膏墙板中可具有协同效应,这种效应在刀切、锯切、划刻/折断、钻孔以及正常板处理的过程中显著地减少石膏粉尘形成。
实例8
在试验板编号10中的气泡空隙尺寸和水空隙尺寸以及石膏晶体形态的测定
通过扫描电子显微镜法(SEM)分析从工厂试验制备试验板编号10的铸造石膏立方体(2英寸X2英寸X2英寸)。观察到并测量了气泡空隙和蒸发的水空隙、连同石膏晶体的尺寸和形状。
制成了三个样品立方体并分别标记为11:08、11:30、以及11:50。图1至3展示了各个样品15X放大的气泡空隙尺寸和分布。图4至6展示了各个样品50X放大的气泡空隙尺寸和分布。
在更高的放大倍数下,观察到了水空隙,例如在总体上实质性更大的气泡空隙的壁中,如图7至10所示对于样品立方体11:50高达10,000X放大时。几乎所有的石膏晶体均为针状体;极少观察到片晶。这些针状体的密度和堆积在这些气泡空隙的表面上是不同的。在这些气泡空隙壁中的水空隙中也能观察到石膏针状体。
这些SEM结果说明在根据本发明制造的含石膏产品中,空气空隙和水空隙总体上遍及该凝固石膏芯而均匀分布。这些观察到的空隙尺寸和空隙分布也证明了足够的自由空间随着空气空隙和水空隙(总芯空隙体积)而形成,这样大量的所产生的石膏粉尘将在正常板处理时以及在切割、锯割、开槽、折断、钉或螺钉固定、或钻孔的过程中在暴露的周围的空隙中被捕获,并且不会浮游在空中。
实例9
低尘石膏墙板中的粉尘捕获
如果一种墙板是根据本发明如实例7中的传授内容制备的,预期 在加工该墙板时产生的石膏粉尘将包括至少按重量计50%的直径大于约10微米的石膏碎片。通过切割、锯割、开槽、划刻/折断、钉或螺钉固定、以及钻孔加工该墙板时,至少约30%或更多的所产生的总粉尘将被捕获。
实例10
另外的1/2英寸轻质石膏墙板工厂生产试验配方
实例7至9提供了具有增加的空隙体积的一种轻质墙板。剩余的实例与实例7至9的那些平行,但是还强调了该墙板微结构的增加的壁厚以及增强的致密空隙壁面。应注意,在此方面,实例8的图5和6的显微照片示出了根据本发明的包括大的空气空隙以及增大厚度的壁二者的一种微结构。
因此制备了另外的浆料配方(试验板14),如下表8所示。表8的浆料配方包括这些浆料的主要组分。括号中的值以基于干灰泥重量的重量百分比表示。
表8
1DILOFLO为一种45%的萘磺酸盐在水中的溶液
2HYONIC25AS和PFM33肥皂的95/5wt./wt.共混物。注意:在动态制造过程中,该肥皂比的范围可以从70/30向上到一个所希望的目标范围,例如从70/30到80/20到85/15或者高达90/10。
实例11
另外的1/2英寸轻质石膏墙板工厂生产试验
用实例10的工厂试验配方14和对照配方A制造的石膏墙板以及两个常规竞争板的试验结果如下表9所示。在70°F/50%的相对湿度下调节24小时之后,测试这些墙板样品的拔钉阻力、边/芯硬度、挠曲强度、以及16小时潮湿的粘合。根据ASTM C-473进行拔钉阻力、边/芯硬度、潮湿的挠度以及挠曲强度试验。根据ASTM E-136进行不燃性。根据ASTM E-84进行表面燃烧特性试验以测定火焰蔓延指数(FSI)。通过扫描电子显微镜法(参见以下实例12)和能量色散光谱法(EDS)分析板样品。还可通过X射线CT扫描技术(XMT)分析板样品。
通过锯切和钻孔试验测量粉尘产生。为了测定钻孔产生的粉尘,用一个钻孔机在一个成品墙板样品中钻50个孔,并且收集所产生的石膏粉尘。为了测定手锯产生的粉尘,切割成品墙板的五个1英尺长的切片,并且收集所产生的石膏粉尘。为了测定孔锯产生的粉尘,在一个成品墙板样品中切割直径为4英寸的五个圆,并且收集所产生的石膏粉尘。
表9
190°F/90%相对湿度
如表9所展示,通过拔钉阻力、挠曲强度、以及边/芯硬度测得的试验板14的强度特性均优于常规竞争板并且超过ASTM标准。潮湿的挠度(垂度)优于常规竞争板并且超过ASTM标准。潮湿的粘合:除了优异的纸到芯的粘合(没有失效)之外,试验板编号14对于粘合强度具有最好的结果,如表9所示。最后,除了通过在ASTM标准下的不燃性试验之外,试验板编号14被确定为在ASTM标准下的一种A级材料。
此外,试验板编号14样品的处理、分段和安装顺序通过评估外观、板滑动、挠曲试验、消防员搬运、角旋转、边阻力、边下降、划刻和折断、锉、孔切、螺钉装配、钉装配、以及10英尺半径来做出评价。该评估的结论是试验板编号14的处理特性等于或超过表9中的对照板A和其他常规竞争石膏板。
实例12
试验板编号14中的气泡表面特征以及石膏晶体形态的测定
同实例8一样,通过扫描电子显微镜法(SEM)分析来自工厂试验以制备试验板编号14的铸造石膏立方体(2英寸X2英寸X2英寸)。观察到并测量了气泡空隙和蒸发的水空隙、连同石膏晶体的尺寸和形状。
这些SEM结果再次说明在根据本发明制造的含石膏产品中,空气空隙和水空隙总体上均匀分布在整个凝固石膏芯中。这些观察到的空隙尺寸和空隙分布还说明足够的自由空间随着空气空隙和水空隙(总芯空隙体积)而形成,这样大量的所产生的石膏粉尘将在正常板处理时以及在切割、锯割、开槽、折断、钉或螺钉固定、或钻孔的过程中在暴露的周围的空隙中被捕获,并且不会浮游在空中。
图11-19的SEM结果说明与早先的实例8的SEM显微照片平行的以增大的放大倍数的壁厚。这些SEM结果,如图13和14所示,分别比较试验板编号14和对照板A,证明了以下两个改进:1)在该试验板中的气泡空隙实质性地大于那些在该对照板中的气泡空隙,以及2)在该试验板中的空隙之间的平均壁厚比在该对照板中的空隙之间的平均壁厚大得多。总的来说,在试验板编号14中的空隙之间的平均壁厚为至少约50微米高达约200微米。相比之下,在对照板A中的空隙之间的平均壁厚为总体上约20-30微米。另外,图15的500X显微照片表明,增强的致密表面“A”沿一个空隙的壁延伸到该显微照片的右侧。
如以上所讨论的,在这些空气空隙之间的更大的平均壁厚为该成品墙板提供了更高的强度,即更好的拔钉阻力、更好的芯/边硬度、以及更好的处理特性,如在钻孔、切割以及锯时粉尘的减少。
实例13
测定平均空隙尺寸、壁厚以及致密的增强壁面的存在
一个芯样品可通过划刻该有待测试的墙板样品并且跨过该芯折断以分离出一个适当尺寸的样品而制备。然后例如通过使受压的空气流穿过该有刻痕的面积而除去松散的碎片。然后使用常规的扫描电子显微摄影技术安装该芯样品被且进行涂覆。
平均空隙尺寸
准备十个在该芯样品中的随机位置处采集的50X放大的显微照片。测量在这十个显微照片中跨过每个空隙的最大截面距离。将测得的距离相加并计算平均最大截面距离。这将是该样品的平均空隙尺寸。
平均壁厚
准备十个在该芯样品中的随机位置处采集的50X放大的显微照片。沿着边缘测量由该显微照片的水平边和垂直边交叉的各个空隙之间的距离。将所有测得的距离相加并计算平均距离。这是该样品的平均壁厚。
致密的增强壁面
准备十个在该芯样品中的随机位置处采集的500X显微照片。对这些显微照片中出现的放大的空隙沿着这些空隙边缘的粗白线进行检查,如对在图15中识别为特征A的那些一样。这些粗白线的存在表明在该样品中存在致密的增强空隙壁面。
在描述本发明的上下文中(尤其是在以下权利要求书的上下文中)使用的术语“一个”以及“一种”以及“该”以及类似指代词应被解释为既覆盖单数也覆盖复数,除非在此另有说明或者通过上下文明确地与此相矛盾。除非在此另有说明,在此列举的数值范围仅旨在作为逐个指出落入该范围内的每个单独值的一种简化方法,并且每个单独的值均被结合到本说明书中,犹如每个单独值在此被单独列出。在此描述的所有方法都可以任何适当的顺序进行,除非在此另有说明或者另外通过上下文明确地与此相矛盾。在此提供的任何的和所有的实例,或示例性语言(例如,“如”)的使用,仅旨在更好地阐明本发明,并不对本发明的范围加以限制,除非另有声明。本说明书中的语言不应被解释为表示任何未提出权利要求的元素对于本发明的实施是必不可少 的。
在此描述了本发明的优选实施方案,包括诸位发明人已知的用于实现本发明的最佳方式。应理解的是,所展示的这些实施方案仅是示例性的,并且不应视为对本发明范围的限制。
Claims (53)
1.一种轻质石膏板,其包括:配置在两个覆盖薄板之间的凝固石膏芯;该凝固石膏芯包括石膏晶体基质,该石膏晶体基质具有限定和分隔该石膏晶体基质中的空气空隙的壁,该空气空隙之间的壁的平均厚度大于约30微米,平均壁厚采用扫描电子显微照片图像测量,且形成的石膏晶体基质使得凝固石膏芯具有根据ASTM C-473确定的至少约11磅(约5kg)的平均芯硬度;该板具有约35pcf(约560kg/m3)或更小的密度。
2.权利要求1所述的轻质石膏板,其中,该壁具有至少约50微米的平均厚度。
3.权利要求1所述的轻质石膏板,其中,该壁具有约30微米至约200微米的平均厚度。
4.权利要求1所述的轻质石膏板,其中,该壁具有约70微米至约120微米的平均厚度。
5.权利要求1所述的轻质石膏板,其中,该壁限定:(i)具有直径大于约100微米的空隙尺寸的空气空隙,(ii)具有直径为约50微米至约100微米的空隙尺寸的空气空隙,及(iii)具有直径小于约50微米的空隙尺寸的空气空隙,该空隙尺寸采用扫描电子显微照片图像测量。
6.权利要求5所述的轻质石膏板,其中,具有直径大于约100微米的空隙尺寸的空气空隙占该凝固石膏芯的总空隙体积的至少约20%。
7.权利要求1-6任一项所述的轻质石膏板,其中,至少一部分壁包括增强的致密壁面。
8.权利要求1所述的轻质石膏板,其中,在凝固石膏芯中配置壁和空气空隙使得当该板为约1/2英寸(约1.3cm)厚时,该板具有根据ASTM C-473确定的至少65磅(29kg)的拔钉阻力。
9.权利要求1所述的轻质石膏板,其中,在凝固石膏芯中配置壁和空气空隙使得当该板为约1/2英寸(约1.3cm)厚时,该板在机器方向具有至少36磅(16kg)的挠曲强度和/或在横跨机器方向具有至少107磅(48.5kg)的挠曲强度,每个挠曲强度都根据ASTM C-473确定。
10.权利要求1所述的轻质石膏板,其中,至少一个覆盖薄板包括多层纸,且当该板为约1/2英寸(约1.3cm)厚时,该板具有根据ASTMC-473确定的至少65磅(29kg)的拔钉阻力。
11.权利要求1所述的轻质石膏板,其中,当该板为约1/2英寸(约1.3cm)厚时,该板显示约4至约8的拔钉阻力与芯硬度的比,该拔钉阻力和芯硬度都是根据ASTM C-473确定的。
12.权利要求11所述的轻质石膏板,其中,至少一个覆盖薄板包括纸,该纸具有至少约45lb/MSF(约0.22kg/SQM)的重量。
13.权利要求1所述的轻质石膏板,其中,在约1/2英寸(约1.3cm)的板厚的情况下,该板具有约1000lb/MSF(约5kg/SQM)至约1400lb/MSF(约6.8kg/SQM)的干重。
14.权利要求1所述的轻质石膏板,其中,在约1/2英寸(约1.3cm)的板厚的情况下,该板具有约1000lb/MSF(约5kg/SQM)至约1300lb/MSF(约6.3kg/SQM)的干重。
15.权利要求1所述的轻质石膏板,其中,该板具有约24pcf(约380kg/m3)至约35pcf(约560kg/m3)的密度。
16.权利要求1所述的轻质石膏板,其中,该凝固石膏芯由包括水、灰泥和一定量的淀粉的浆料形成,该一定量的淀粉对于提高该凝固石膏芯相对于由没有淀粉的浆料形成的凝固石膏芯的硬度是有效的。
17.权利要求16所述的轻质石膏板,其中,该淀粉包括基于灰泥的重量按重量计约0.5%至约10%的量的预胶凝淀粉。
18.权利要求1所述的轻质石膏板,其中,该凝固石膏芯由包括水、灰泥、泡沫和分散剂的浆料形成。
19.权利要求18所述的轻质石膏板,其中,该分散剂包括萘磺酸盐分散剂。
20.权利要求19所述的轻质石膏板,其中,该浆料还包括预胶凝淀粉,萘磺酸盐分散剂的量为基于灰泥重量按重量计约0.1%至约3%,且预胶凝淀粉的量为基于灰泥重量按重量计约0.5%至约10%。
21.权利要求20所述的轻质石膏板,其中,该浆料还包括含水溶性聚磷酸盐的化合物。
22.权利要求1所述的轻质石膏板,其中,该凝固石膏芯由包括水、灰泥和含水溶性聚磷酸盐的化合物的浆料形成。
23.权利要求22所述的轻质石膏板,其中,含水溶性聚磷酸盐的化合物的量为基于灰泥重量按重量计约0.1%至约0.4%。
24.权利要求1所述的轻质石膏板,其中,该凝固石膏芯由包括水、灰泥和肥皂泡的浆料形成,当在没有大量肥皂泡的情况下制备该浆料且将其铸造为2立方英寸(5cm3)时,该浆料具有至少约320psi(约2200kPa)的湿抗压强度。
25.权利要求1所述的轻质石膏板,其中,该凝固石膏芯由包括水、灰泥和肥皂泡的浆料形成,当在没有大量肥皂泡、水与灰泥的重量比为1.2的情况下制备该浆料且将其铸造为2立方英寸(5cm3)时,该浆料具有至少约340psi(约2340kPa)的湿抗压强度。
26.权利要求1所述的轻质石膏板,其中,该凝固石膏芯包括玻璃纤维。
27.权利要求1所述的轻质石膏板,其中,至少一个覆盖薄板包括纤维垫、非织造玻璃纤维垫、纺织玻璃垫或非纤维素织物。
28.一种轻质石膏板,其包括:配置在两个覆盖薄板之间的凝固石膏芯;该凝固石膏芯包括石膏晶体基质,该石膏晶体基质具有限定和分隔该石膏晶体基质中的空气空隙的壁,一些壁具有至少约50微米的平均壁厚,一些空气空隙具有直径大于约100微米的孔尺寸,该平均壁厚和孔尺寸采用扫描电子显微照片图像测量,形成的石膏晶体基质使得凝固石膏芯具有根据ASTM C-473确定的至少约11磅(约5kg)的平均芯硬度;该板具有约24pcf(约380kg/m3)至约35pcf(约560kg/m3)的密度。
29.权利要求28所述的轻质石膏板,其中,一些空气空隙具有直径约50微米至约100微米的孔尺寸,具有直径大于约50微米的孔尺寸的空气空隙占凝固石膏芯总空隙体积的至少约50%,其中,该空隙采用扫描电子显微图像测量。
30.权利要求28或29所述的轻质石膏板,其中,具有直径大于约100微米的孔尺寸的空气空隙占凝固石膏芯总空隙体积的至少约20%。
31.一种轻质石膏板,其包括:配置在两个覆盖薄板之间的凝固石膏芯;该凝固石膏芯包括石膏晶体基质,该石膏晶体基质具有限定和分隔该石膏晶体基质中的空气空隙的壁,该空气空隙之间的壁的平均厚度大于约30微米,平均壁厚采用扫描电子显微照片图像测量,且形成的石膏晶体基质使得当该板为约1/2英寸(约1.3cm)厚时,该板显示约4至约8的拔钉阻力与芯硬度的比,该拔钉阻力和芯硬度都是根据ASTM C-473确定的;且该板具有约35pcf(约560kg/m3)或更小的密度。
32.权利要求31所述的轻质石膏板,其中,该壁具有至少约50微米的平均厚度。
33.权利要求31所述的轻质石膏板,其中,该壁具有约30微米至约200微米的平均厚度。
34.权利要求31所述的轻质石膏板,其中,该壁具有约70微米至约120微米的平均厚度。
35.权利要求31所述的轻质石膏板,其中,在凝固石膏芯中配置壁和空气空隙,使得根据ASTM C-473确定的芯硬度为至少约11磅(约5kg)。
36.权利要求31所述的轻质石膏板,其中,一些空气空隙具有直径为约50微米至约100微米的孔尺寸,一些空气空隙具有直径大于约100微米的孔尺寸,且具有直径大于约100微米的孔尺寸的空气空隙占凝固石膏芯的总空隙体积的至少约20%,该孔尺寸采用扫描电子显微照片图像测量。
37.权利要求36所述的轻质石膏板,其中,具有直径大于约50微米的孔尺寸的空气空隙占凝固石膏芯的总空隙体积的至少约50%。
38.权利要求31-37任一项所述的轻质石膏板,其中,该凝固石膏芯由包括水、灰泥和一定量的淀粉的浆料形成,该一定量的淀粉对于提高该凝固石膏芯相对于由没有淀粉的浆料形成的凝固石膏芯的硬度是有效的。
39.权利要求38所述的轻质石膏板,其中,该浆料还包括泡沫和分散剂。
40.权利要求39所述的轻质石膏板,其中,该分散剂包括萘磺酸盐分散剂。
41.权利要求40所述的轻质石膏板,其中,该淀粉包括预胶凝淀粉,萘磺酸盐分散剂的量为基于灰泥重量以重量计约0.1%至约3%,预凝胶淀粉的量为基于灰泥重量以重量计约0.5%至约10%。
42.权利要求41所述的轻质石膏板,其中,该浆料还包括含水溶性聚磷酸盐的化合物。
43.权利要求42所述的轻质石膏板,其中,该含水溶性聚磷酸盐的化合物包括基于灰泥重量以重量计至少约0.12%的量的选自三偏磷酸钠、三偏磷酸钾、三偏磷酸锂和三偏磷酸铵的三偏磷酸盐。
44.一种制备轻质石膏板的方法,该方法包括:
(A)制备在其中分散有泡沫的石膏浆料;
(B)将该石膏浆料配置在第一覆盖薄板和第二覆盖薄板之间以形成板;
(C)将该板切割成预定尺寸的板;和
(D)干燥该切割成预定尺寸的板;
使得凝固石膏芯包括形成于覆盖薄板之间的石膏晶体基质,使得
(1)该石膏晶体基质具有限定和分隔该石膏晶体基质中的空气空隙的壁,该空气空隙之间的壁的平均厚度大于约30微米,平均壁厚采用扫描电子显微照片图像测量,
(2)该凝固石膏芯具有根据ASTM C-473确定的至少约11磅(约5kg)的平均芯硬度,和
(3)干板密度为约35pcf(约560kg/m3)或更小。
45.权利要求44所述的制备轻质石膏板的方法,其中,该石膏浆料还包括至少一种强度增强添加剂。
46.权利要求44所述的制备轻质石膏板的方法,其中,该石膏浆料包括以基于灰泥重量按重量计约0.1%至约3.0%的量存在的萘磺酸盐分散剂,和以基于灰泥重量按重量计约0.5%至约10%的量存在的预胶凝淀粉。
47.权利要求44所述的制备轻质石膏板的方法,其中,该石膏晶体基质的壁具有至少约50微米的平均厚度。
48.权利要求44所述的制备轻质石膏板的方法,其中,该石膏晶体基质的壁具有约30微米至约200微米的平均厚度。
49.权利要求44-47任一项所述的制备轻质石膏板的方法,其中,该石膏晶体基质的壁具有约70微米至约120微米的平均厚度。
50.权利要求46所述的制备轻质石膏板的方法,其中,凝固且干燥的石膏墙板具有约24pcf(约380kg/m3)至约35pcf(约560kg/m3)的密度。
51.权利要求46所述的制备轻质石膏板的方法,其中,该石膏浆料还包括含水溶性聚磷酸盐的化合物。
52.权利要求44所述的制备轻质石膏板的方法,其中,当凝固且干燥的石膏墙板为约1/2英寸(约1.3cm)厚时,其具有(i)至少65磅(29kg)的拔钉阻力,或(ii)在机器方向至少36磅(16kg)的平均挠曲强度和/或在横跨机器方向至少107磅(48.5kg)的平均挠曲强度,该拔钉阻力和平均挠曲强度都根据ASTM C-473确定。
53.权利要求44所述的制备轻质石膏板的方法,当在没有大量泡沫、且水与灰泥的重量比为1.2的情况下制备石膏浆料且将其铸造为2立方英寸(5cm3)时,该石膏浆料具有至少约340psi(约2340kPa)的湿抗压强度。
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