CN103930257B - 使用淀粉丸粒产生石膏板的***和方法 - Google Patents

使用淀粉丸粒产生石膏板的***和方法 Download PDF

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CN103930257B
CN103930257B CN201280045021.4A CN201280045021A CN103930257B CN 103930257 B CN103930257 B CN 103930257B CN 201280045021 A CN201280045021 A CN 201280045021A CN 103930257 B CN103930257 B CN 103930257B
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starch
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约翰·W·克雷吉
沙恩·里布瑙
马克·哈里斯
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Abstract

本发明涉及使用淀粉丸粒产生石膏板的***和方法。根据本揭示内容，以淀粉丸粒的形式提供板形成所需的所述淀粉。将这些丸粒在混合器中与石膏浆液混合。所述丸粒最初不可溶且并不溶解。然而，在后续干燥阶段期间，所述丸粒变得可溶且溶于所述石膏相中。此提供所需淀粉组份且还使得在所凝固的石膏内形成空隙。

Description

使用淀粉丸粒产生石膏板的***和方法
技术领域
本发明涉及石膏板的产生。更特定来说，本发明涉及发泡淀粉丸粒在产生轻量石膏板中的用途。
背景技术
石膏板是世界上最广泛使用且多用途的建筑材料之一。石膏板的一般构造包含二水合硫酸钙核心，其夹于相对的纸板材之间。核心最初以浆液的形式进行沉积；即，存于水中的半水合硫酸钙(CaSO4·1/2H2O)。在浆液沉积后，使其再水合以形成石膏。半水合物最初是在磨机中通过下列反应制得：
CaSo4·2H2O+热→CaSo4·1/2H2O+11/2H2O (蒸汽)
脱水硫酸钙称为煅烧石膏、灰泥或熟石膏(plaster of Paris)。石膏具有许多所需的物理性质，此使得其适于用作建筑材料。这些性质包含耐火性、压缩强度和中性pH。石膏还是有益的建筑材料，因为其可形成为各种形状且便宜而充裕。
业内还已知将添加剂与石膏一起使用。一种所述添加剂为淀粉。可在再水合之前添加淀粉。淀粉在凝固石膏内用作粘合剂并得到具有较高压缩强度和弯曲强度的板。其还强化所得板的边缘并改良纸与核心的结合。
业内另外已知形成具有石膏板内部的空隙作为用于减小板重量的方式。背景技术包含空隙形成的若干实例。一种技术描述于颁予赛斯拉曼(Sethuraman)的美国专利第6,706,128号中。赛斯拉曼的'128揭示添加具有不同相对稳定性的气泡的方法，借此气泡在浆液充分凝固之前不会破裂以防止浆液填充破裂气泡留下的空隙空间。结果得到具有减小重量的石膏板。
另一实例说明于颁予鲁滨逊(Robinson)的美国专利第1,776,325号中。鲁滨逊的'325揭示通过将充气淀粉纳入浆液中来制造蜂窝式壁板的方法。由于所述充气淀粉，赋予浆液所需孔隙率并形成蜂窝式核心。
最后，颁予苏西奇(Sucech)的美国专利第5,643,510号揭示使用发泡剂掺合物产生发泡石膏板的方法。控制第一发泡剂与第二发泡剂之间的比率以调节石膏核心内泡沫空隙的大小。
尽管上文所提及发明中的每一者实现其个别目标，但其都具有常见缺点。即，通过使用发泡剂形成空隙需要向石膏中添加其它化学物质。通过充气所添加的空隙形成同样需要其它机械。另外，在两种方法中，相关机械的控制较困难。在空隙形成的先前方法中，还难以形成具有适当大小的空隙。
发明内容
所揭示方法的优点之一在于使得在石膏建筑板内形成空隙。
另一优点在于可在并不添加其它发泡剂下增加空隙形成。
又一优点在于可控制和/或指定空隙大小。
另一优点在于所揭示丸粒向板提供所需淀粉组份，而同时在核心内提供空隙。
另一优点在于所提供淀粉增强了在淀粉溶解后所产生空隙的壁结构，这是因为一部分淀粉保留在空隙/固体界面处。
所揭示***和方法的又一优点在于提供较强且轻量的石膏板的产生。
这些和其它优点是通过涉及沿板生产线提供灰泥和发泡淀粉珠粒的混合物的***和方法来实现。淀粉丸粒在低于140℉的温度下微溶。然后将灰泥/发泡珠粒浆液沉积于相对的板材之间以形成复合面板。然后将凝固湿板转移到干燥器中。然后使用干燥器干燥面板。加热使得淀粉溶解，借此经溶解珠粒向纸的石膏核心和/或结合区域提供淀粉。经溶解珠粒还在核心内产生相当均匀的气泡结构。丸粒由此在凝固板内产生空隙。
前文已相当广泛地概述本发明的较多相关且重要的特征以可更好地理解本发明的下列详细说明，从而可更全面地了解本发明对业内的贡献。将在下文中描述本发明的其它特征，其形成本发明的权利要求书的主题。所属领域技术人员应了解，可容易地利用所揭示的概念和具体实施例作为基础用于修改或设计用于实施本发明的相同目的的其它结构。所属领域技术人员还应认识到，所述等效构造并不背离如在所附权利要求书中所阐明的本发明的精神及范围。
附图说明
为更全面理解本发明的性质和目标，应结合附图参照下列详细说明，其中：
图1为图解说明与所揭示方法有关的步骤的流程图。
图2为板生产线的正视图。
图3A为从图2获得的板的剖面图。
图3B为从图5获得的板的剖面图。
图4为板干燥器的入口的正视图。
图5为板干燥器的出口的正视图。
贯穿若干图式视图，类似参考字符是指类似部件。
具体实施方式
本发明涉及使用发泡淀粉珠粒产生石膏板的***和方法。根据本揭示内容，以个别发泡珠粒的形式提供优选板形成所需的淀粉。借助混合器将这些珠粒分散于石膏浆液内。丸粒最初不可溶且在石膏浆液存在下并不溶解。然而，在干燥器中的后续加热期间，珠粒变得可溶并溶于石膏相中。此溶解向石膏提供所需淀粉组份，而同时在核心内产生空隙。
借助挤出工艺形成优选淀粉珠粒或丸粒。在工艺期间，通过挤出机使空气与淀粉组合。所得发泡丸粒可具有不规则大小，但通常具有介于大约1/32英寸到1/64英寸之间的直径。还可使用不同大小丸粒的混合物。视挤出机的参数而定，可产生其它大小。同样可使用其它工艺来形成发泡淀粉丸粒。举例来说，可通过已知造粒工艺形成丸粒。其还可类似于聚苯乙烯制造方法制成微滴。在优选实施例中，发泡丸粒在低温下为疏水性的并在低于大约140℉的温度下抵抗溶解。
图1为图解说明根据本揭示内容实施的步骤的流程图。在第一步骤20中，将发泡丸粒与灰泥组合。在优选实施例中，丸粒构成整体浆液的大约5体积%到50体积%。优选地，在混合器之前组合丸粒和灰泥。
在步骤22中，将丸粒和灰泥与水在混合器中混合以产生浆液。混合器可为通常见于板生产线中的常规混合器。此掺和步骤将丸粒完全囊封于所得浆液内。然而，同样，丸粒此时保持不可溶且淀粉并不溶于石膏相中。然后在步骤24中将经掺和浆液沉积于相对的纸板材之间以形成面板。
然后在步骤26中于一系列干燥器中干燥具有浆液和所囊封丸粒的面板。随着面板干燥且板温度达到200℉，丸粒变得可溶并在石膏相中溶解为淀粉。经溶解丸粒在板内留下空隙。面板干燥，与此同时淀粉溶解。如在步骤28处所述，结果是得到凝固石膏板，其含有所需量的淀粉且具有空隙以减小板重量。
如图2中所述，沿板生产线32实施本揭示内容的***。适宜产品线更全面描述于颁予哈芭(Hauber)的共同拥有的美国专利第6,524,679号中，其内容完全并入本文中。生产线32通常包含具有不同出口34a、34b和34c的混合器34。这些出口可沉积变化的密度的浆液以形成具有不同物理性质的核心。还包含发泡丸粒和灰泥的供应装置(分别为36和38)。这些供应装置向容器42供应进料，在其中丸粒和灰泥进行最初组合。在优选实施例中，在干燥的同时混合发泡丸粒和灰泥。随后在混合器34处添加水以形成浆液并开始再水合工艺。如本文所述，丸粒和浆液优选地以介于大约5体积%与50体积%之间的比率进行组合。
容器42又向混合器34供应进料。此可为当前用于石膏板制造中的常规混合器。如本文所述，使用混合器34掺和丸粒和灰泥与水。此掺和将灰泥转化成浆液且确保个别丸粒由浆液囊封。如果需要，可根据石膏板的需要向混合器中添加其它添加剂。
生产线进一步包含两个或两个以上大的纸缠绕卷材44。在一个实施例中，包含两个用于形成石膏板52的上部和下部纸板材(分别为46和48)的卷材。可根据所得板的预期用途提供其它辊以用于包含纤维垫片或其它板材。混合器34将石膏浆液沉积于成型台54上的板材46和48之间。优选地大部分浆液于出口34b处分配。如果需要，则可在出口34a处将少量较稠密浆液施加到底部纸板材46上。同样可在出口34c处将较稠浆液施加到上部纸板材上。出口34a、34b和34c可都从混合器34递送具有丸粒的经掺和浆液。另一选择为，具有丸粒的经掺和石膏可限于出口34b处，且出口34a和34c供应没有丸粒的石膏浆液。
在任一选择中，在即将到达夹点56之前将顶部板材48施加于具有经掺和丸粒的所沉积石膏上。然后，使所得面板52通过铰合板58和挤出板62以确保面板52具有所需厚度。现再次参照图3A，可看到，在挤出机62后，面板52是包含底部纸板材46、具有经囊封丸粒66的经掺和石膏核心64和顶部纸板材48的复合物。另外，个别发泡丸粒66分布于石膏核心64的整个厚度内。在此阶段，丸粒未溶解，仅微溶，并完全包封于未凝固浆液的核心64内。在进入板干燥器68之前，石膏核心根据下列方程式发生凝固：
CaSo4·1/2H2O+11/2H2O→CaSo4·2H2O
然后，将复合面板在切割台(未展示)处切割成所需长度且然后通过皮带递送到一系列板干燥器68中。图4图解说明将复合面板递送到板干燥器68的入口，而图5图解说明复合面板离开板干燥器68。在干燥阶段期间，将面板暴露于超过140℉且通常大约200℉的温度。如业内所已知，使用干燥器68来干燥石膏浆液。然而，根据本揭示内容，过高温度使得囊封于石膏内的个别丸粒66变得极易溶解。在变得可溶之后，丸粒溶解66，借此淀粉溶于核心64的石膏相中。此淀粉在与石膏组合时会提供所需程度的板强度且还可改良饰面纸与核心之间的结合。
在溶解后，个别发泡丸粒66留下空隙72，其与丸粒66一样分布于凝固石膏核心64的整个厚度内(参见图3b)。结果是得到具有凝固石膏的核心64的石膏建筑面板52。此凝固石膏借助发泡丸粒66的溶解获得所需淀粉。另外，留下的空隙72可起到减小面板52的整体重量并提供额外强度的作用。每一个别空隙还包含周边衬层。淀粉溶解而使得在空隙衬层处的淀粉浓度高于剩余核心主体中的浓度。
本揭示内容包含含于所附权利要求书中者以及前述说明书中者。尽管以优选形式以某一特定程度描述了本发明，但应理解，仅以实例方式作出本揭示内容的优选形式，且可对构造的细节和部件的组合和布置作出诸多改变，此并不背离本发明的精神和范围。

Claims (11)

1.一种产生轻量石膏板的方法，所述方法利用包含混合器、成型台和干燥器的板生产线，所述方法包括：
提供多个发泡淀粉丸粒，所述丸粒是通过挤出工艺形成且具有介于1/32英寸到1/64英寸之间的粒径，所述丸粒在低于140°F的温度下仅微溶；
以介于5体积％到50体积％之间的比率将所述丸粒添加到石膏浆液中；
在所述混合器内掺和所述石膏浆液和所述丸粒，借此所述丸粒变得完全囊封于所述浆液内；
在所述混合器之前，将第一饰面板材供应到所述成型台；
从所述混合器排放所掺和的石膏和丸粒且排放到所述第一饰面板材上；
将顶部饰面板材供应到所述经掺和的石膏和丸粒上以形成复合面板；
在所述干燥器内将所述复合面板干燥到超过140°F的温度，所述干燥使得所述丸粒溶解且从所述板去除残余水分，借此所溶解的丸粒向所述石膏浆液提供淀粉并在所凝固的石膏内产生空隙。
2.一种产生建筑板的方法，所述方法包括：
提供灰泥和发泡淀粉丸粒的混合物，所述丸粒在低于140°F的温度下微溶；
将所述混合物分配于相对板材之间以形成复合面板；
干燥所述复合面板，所述干燥使得所述丸粒溶解并使得所述灰泥凝固，借此所溶解的丸粒向所述灰泥提供淀粉并在所凝固的灰泥内产生空隙。
3.根据权利要求2所述的方法，其中所述丸粒对所述灰泥比率介于5％到50％体积比体积之间。
4.根据权利要求2所述的方法，其中所述丸粒是通过挤出或其它发泡程序形成并具有介于1/32英寸到1/64英寸之间的粒径。
5.根据权利要求2所述的方法，其中将所述灰泥和所述丸粒掺和成混合物以确保所述丸粒被完全囊封。
6.根据权利要求2所述的方法，其中所述丸粒在低于140°F的温度下为疏水性的。
7.根据权利要求2所述的方法，其中从乙基化淀粉形成所述丸粒。
8.一种产生具备有空隙的核心的石膏板的方法，所述方法包括：
提供一定体积的石膏浆液；
向所述石膏浆液中添加发泡淀粉丸粒；
溶解所述发泡淀粉丸粒以在所述核心内产生所述空隙，所溶解的发泡淀粉丸粒在所述石膏板内提供一定浓度的淀粉。
9.根据权利要求8所述的方法，其中所述空隙包含衬层且其中所述经溶解的淀粉在所述空隙衬层处的浓度高于在所述核心主体中的浓度。
10.根据权利要求8所述的方法，其中所述丸粒具有大于1/32英寸的粒径。
11.根据权利要求8所述的方法，其中所述丸粒具有小于1/64英寸的粒径。
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