CN104947843A - 低尘石膏墙板 - Google Patents
低尘石膏墙板 Download PDFInfo
- Publication number
- CN104947843A CN104947843A CN201510248771.7A CN201510248771A CN104947843A CN 104947843 A CN104947843 A CN 104947843A CN 201510248771 A CN201510248771 A CN 201510248771A CN 104947843 A CN104947843 A CN 104947843A
- Authority
- CN
- China
- Prior art keywords
- microns
- diameter
- hole dimension
- gypsum
- air gap
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 229910052602 gypsum Inorganic materials 0.000 title claims abstract description 315
- 239000010440 gypsum Substances 0.000 title claims abstract description 315
- 239000000428 dust Substances 0.000 title abstract description 49
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 91
- 239000011800 void material Substances 0.000 claims abstract description 58
- 239000002270 dispersing agent Substances 0.000 claims abstract description 48
- 239000013078 crystal Substances 0.000 claims abstract description 47
- 239000002002 slurry Substances 0.000 claims abstract description 47
- 229920000881 Modified starch Polymers 0.000 claims abstract description 34
- 239000006260 foam Substances 0.000 claims abstract description 11
- 239000011505 plaster Substances 0.000 claims description 67
- 238000009826 distribution Methods 0.000 claims description 54
- 239000011159 matrix material Substances 0.000 claims description 37
- 239000011148 porous material Substances 0.000 claims description 28
- UGTZMIPZNRIWHX-UHFFFAOYSA-K sodium trimetaphosphate Chemical compound [Na+].[Na+].[Na+].[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 UGTZMIPZNRIWHX-UHFFFAOYSA-K 0.000 claims description 22
- 238000001878 scanning electron micrograph Methods 0.000 claims description 18
- 238000004458 analytical method Methods 0.000 claims description 10
- 238000002591 computed tomography Methods 0.000 claims description 10
- 238000005259 measurement Methods 0.000 claims description 10
- -1 trimetaphosphate compound Chemical class 0.000 claims description 8
- 229910052700 potassium Inorganic materials 0.000 claims description 5
- 239000011591 potassium Substances 0.000 claims description 5
- 229910052744 lithium Inorganic materials 0.000 claims description 4
- 239000000203 mixture Substances 0.000 abstract description 27
- 239000000344 soap Substances 0.000 abstract description 21
- 238000000034 method Methods 0.000 abstract description 19
- PSZYNBSKGUBXEH-UHFFFAOYSA-M naphthalene-1-sulfonate Chemical compound C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-M 0.000 abstract description 17
- 238000009472 formulation Methods 0.000 abstract description 15
- 238000004519 manufacturing process Methods 0.000 abstract description 13
- 238000005520 cutting process Methods 0.000 abstract description 9
- 230000000694 effects Effects 0.000 abstract description 7
- 238000005553 drilling Methods 0.000 abstract description 2
- 239000011575 calcium Substances 0.000 description 26
- 229910052791 calcium Inorganic materials 0.000 description 26
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 24
- 239000000123 paper Substances 0.000 description 22
- 239000000047 product Substances 0.000 description 20
- 229920002472 Starch Polymers 0.000 description 16
- 239000008107 starch Substances 0.000 description 16
- 235000019698 starch Nutrition 0.000 description 16
- 238000012360 testing method Methods 0.000 description 16
- AZSFNUJOCKMOGB-UHFFFAOYSA-K cyclotriphosphate(3-) Chemical compound [O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 AZSFNUJOCKMOGB-UHFFFAOYSA-K 0.000 description 13
- 238000005266 casting Methods 0.000 description 11
- 239000000835 fiber Substances 0.000 description 10
- 239000012634 fragment Substances 0.000 description 10
- 239000003365 glass fiber Substances 0.000 description 10
- 239000007864 aqueous solution Substances 0.000 description 9
- 229920002261 Corn starch Polymers 0.000 description 8
- 239000008120 corn starch Substances 0.000 description 8
- 239000010410 layer Substances 0.000 description 8
- 238000002360 preparation method Methods 0.000 description 8
- 238000012545 processing Methods 0.000 description 8
- 230000008569 process Effects 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- 239000002131 composite material Substances 0.000 description 6
- 230000001965 increasing effect Effects 0.000 description 6
- 238000011160 research Methods 0.000 description 6
- 239000011449 brick Substances 0.000 description 5
- PASHVRUKOFIRIK-UHFFFAOYSA-L calcium sulfate dihydrate Chemical compound O.O.[Ca+2].[O-]S([O-])(=O)=O PASHVRUKOFIRIK-UHFFFAOYSA-L 0.000 description 5
- 239000003795 chemical substances by application Substances 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 230000008020 evaporation Effects 0.000 description 4
- 238000001704 evaporation Methods 0.000 description 4
- TVHALOSDPLTTSR-UHFFFAOYSA-H hexasodium;[oxido-[oxido(phosphonatooxy)phosphoryl]oxyphosphoryl] phosphate Chemical compound [Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[O-]P([O-])(=O)OP([O-])(=O)OP([O-])(=O)OP([O-])([O-])=O TVHALOSDPLTTSR-UHFFFAOYSA-H 0.000 description 4
- 125000005341 metaphosphate group Chemical group 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Inorganic materials [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 239000003292 glue Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229920000417 polynaphthalene Polymers 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 230000000844 anti-bacterial effect Effects 0.000 description 2
- 239000003899 bactericide agent Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- ZOMBKNNSYQHRCA-UHFFFAOYSA-J calcium sulfate hemihydrate Chemical compound O.[Ca+2].[Ca+2].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O ZOMBKNNSYQHRCA-UHFFFAOYSA-J 0.000 description 2
- 235000011132 calcium sulphate Nutrition 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 230000000875 corresponding effect Effects 0.000 description 2
- 239000008121 dextrose Substances 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000011152 fibreglass Substances 0.000 description 2
- 239000013505 freshwater Substances 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- PSZYNBSKGUBXEH-UHFFFAOYSA-N naphthalene-1-sulfonic acid Chemical class C1=CC=C2C(S(=O)(=O)O)=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-N 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000008399 tap water Substances 0.000 description 2
- 235000020679 tap water Nutrition 0.000 description 2
- 241000196324 Embryophyta Species 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 229920000388 Polyphosphate Polymers 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 241000612118 Samolus valerandi Species 0.000 description 1
- 208000034189 Sclerosis Diseases 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000016383 Zea mays subsp huehuetenangensis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- VEUACKUBDLVUAC-UHFFFAOYSA-N [Na].[Ca] Chemical compound [Na].[Ca] VEUACKUBDLVUAC-UHFFFAOYSA-N 0.000 description 1
- 125000002015 acyclic group Chemical group 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- WQZGKKKJIJFFOK-VFUOTHLCSA-N beta-D-glucose Chemical compound OC[C@H]1O[C@@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-VFUOTHLCSA-N 0.000 description 1
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 1
- 239000004327 boric acid Substances 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 150000001669 calcium Chemical class 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 239000007859 condensation product Substances 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 230000002079 cooperative effect Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 150000004683 dihydrates Chemical group 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 230000001815 facial effect Effects 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000011507 gypsum plaster Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 235000009973 maize Nutrition 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000012074 organic phase Substances 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000001205 polyphosphate Substances 0.000 description 1
- 235000011176 polyphosphates Nutrition 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- PVGBHEUCHKGFQP-UHFFFAOYSA-N sodium;n-[5-amino-2-(4-aminophenyl)sulfonylphenyl]sulfonylacetamide Chemical compound [Na+].CC(=O)NS(=O)(=O)C1=CC(N)=CC=C1S(=O)(=O)C1=CC=C(N)C=C1 PVGBHEUCHKGFQP-UHFFFAOYSA-N 0.000 description 1
- HIEHAIZHJZLEPQ-UHFFFAOYSA-M sodium;naphthalene-1-sulfonate Chemical compound [Na+].C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1 HIEHAIZHJZLEPQ-UHFFFAOYSA-M 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 238000012956 testing procedure Methods 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B1/00—Layered products having a non-planar shape
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- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
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- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
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- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
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- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/38—Fibrous materials; Whiskers
- C04B14/42—Glass
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/18—Waste materials; Refuse organic
- C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
- C04B18/241—Paper, e.g. waste paper; Paper pulp
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
- C04B22/08—Acids or salts thereof
- C04B22/16—Acids or salts thereof containing phosphorus in the anion, e.g. phosphates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/08—Fats; Fatty oils; Ester type waxes; Higher fatty acids, i.e. having at least seven carbon atoms in an unbroken chain bound to a carboxyl group; Oxidised oils or fats
-
- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/16—Sulfur-containing compounds
- C04B24/20—Sulfonated aromatic compounds
- C04B24/22—Condensation or polymerisation products thereof
- C04B24/226—Sulfonated naphtalene-formaldehyde condensation products
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/24—Macromolecular compounds
- C04B24/38—Polysaccharides or derivatives thereof
- C04B24/383—Cellulose or derivatives thereof
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0051—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity
- C04B38/0054—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity the pores being microsized or nanosized
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0051—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity
- C04B38/0061—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity closed porosity
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
-
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Abstract
本发明涉及低尘石膏墙板,提供具有高空隙体积的低尘低密度石膏墙板产品,其对应于约10-30pcf的低密度。该墙板具有一形成于两个大体平行的板层之间的凝固石膏芯,该凝固石膏芯优选总空隙体积为约80%-92%,并由包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的浆体制成。预凝胶淀粉和萘磺酸盐分散剂的组合还为凝固石膏晶体粘结在一起时提供一种胶状作用。该墙板配方,和小气泡空隙(以及水隙)一起,在切割、锯、掘、折、钉或拧紧、或钻孔该含石膏产品时提供粉尘控制。本发明还提供一种制造所述低尘低密度石膏产品的方法,包括在凝固石膏芯中引入足够量的肥皂泡沫以形成包含气隙、优选约80%-92%的总空隙体积,对应于凝固石膏芯密度为约10pcf-30pcf。按照本方法生产的墙板大大减少在加工期间产生的粉尘。
Description
本申请是申请日为2007年10月9日、申请号为200780046773.1、发明名称为“低尘石膏墙板”的发明专利申请的分案申请。
本申请是2006年6月7日提交的美国专利申请No.11/449,177的部分继续申请,也是2006年6月2日提交的美国专利申请No.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No.60/688,839的权益。在此引入上述各项专利申请的全部内容作为参考。
技术领域
本发明涉及一种生产石膏墙板的方法,其中加工墙板期间粉尘的产生大大降低。更具体地,该方法包括引入足够量的肥皂泡沫以在凝固石膏芯中形成约80%-90%的总空隙体积,对应于凝固石膏芯密度为约10pcf-30pcf,该方法在加工期间提供明显降低的粉尘形成。本发明还涉及一种利用该方法制造的低尘石膏墙板。
背景技术
石膏(二水合硫酸钙)的某些性能使其在制造工业和建筑产品如石膏墙板的应用中很受欢迎。石膏是一种丰富和廉价的原料,其通过脱水和再水合过程,可以铸造、模塑或以其它方式形成有用的形状。作为石膏墙板和其它石膏产品制造来源的基底材料是硫酸钙的半水合物形式(CaSO4·1/2H2O),通常称作“灰泥”,它是由硫酸钙的二水合物形式(CaSO4·2H2O)加热转化,从中除去1-1/2分子水产生。
传统的含石膏产品如石膏墙板具有很多优点,例如低成本和易于加工,然而当这些产品被切割或钻孔时会产生大量的石膏粉尘。利用淀粉作为制造含石膏产品的浆体成分已经在制造这些产品方面实现了各种改进。预凝胶淀粉,像胶水一样,可增强包括石膏墙板在内的含石膏产品的抗弯强度和耐压强度。已知的石膏墙板包含小于约10lbs/MSF水平的淀粉。
为了保证浆体有适当的流动性,在含预凝胶淀粉的石膏浆中还有必要使用大量的水。但是,大部分水最终必须通过干燥去除,而干燥费用昂贵,因为干燥过程使用高成本的燃料。干燥步骤也很费时。研究发现使用萘磺酸盐分散剂能增强浆体的流动性,由此克服对水的需求问题。此外,研究还发现如果使用水平(量)够高,萘磺酸盐分散剂能交联到预凝胶淀粉上,以便在干燥后将石膏晶体粘合到一起,由此增强石膏复合品的干强度。因此,预凝胶淀粉和萘磺酸盐分散剂的结合在粘合凝固石膏晶体中提供了类似胶水的作用。在过去,人们没有认识到三偏磷酸盐影响石膏浆的水需求。然而,本发明人发现在特定分散剂的存在下,将三偏磷酸盐的水平增加到目前未知的水平上可能以出人意料地减少的水量,甚至在高水平淀粉存在下,实现浆体适当的流动性。这当然是非常可取的,因为它反过来减少了干燥的燃料用量以及与后来水去除处理步骤相关的处理时间。因此,本发明人还发现石膏墙板的干强度可通过在用于制造墙板的浆体中使用萘磺酸盐分散剂结合预凝胶淀粉来增强。
本发明的石膏板应区别于不具有夹层(face sheet)的吸声板或砖。并且,本发明的石膏板应区别于包含聚苯乙烯作为轻量骨料的吸声板或砖。重要的是,上述吸声板或砖不符合适用于石膏墙板的很多ASTM标准。例如,已知的吸声板不具有包括本发明在内的石膏墙板所需的抗弯强度。相反,为了使吸声板或砖符合ASTM标准,吸声板或砖的暴露表面需要具有中空空洞或凹陷,这在石膏墙板中是不合需要的,并且会对钉拉阻力性质产生不利影响。
粉尘产生是所有墙板安装时的潜在问题。例如,当石膏墙板通过切割、锯、掘、折、钉或拧紧、或钻孔被加工时会产生大量的石膏粉尘。对于本发明揭露内容而言,“粉尘”和“粉尘产生”指在含石膏产品加工期间,例如通过切割、锯、掘、刻/折、钉或拧紧、或钻孔该板,粉尘释放进入周围工作空间。加工通常还可包括正常板处理,包括在运输、携带和安装期间意外地刮或刨削该板时产生的粉尘。如果找到一种粉尘产生大大降低的生产低密度墙板的方法,将是对本领域特别有用的贡献。
发明内容
本发明通常包括一种低尘石膏墙板,其包括在两个大体平行的板层之间形成的一凝固石膏芯,该凝固石膏芯具有约75%-95%的总空隙体积,该石膏芯是由包含水、灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成,其中预凝胶淀粉是以基于灰泥重量约0.5-10%重量的量存在。优选地,萘磺酸盐分散剂是以基于干灰泥重量约0.1-3.0%重量的量存在。可选地,三偏磷酸钠是以基于灰泥重量至少约0.12%重量的量存在。在一种优选的实施方式中,三偏磷酸钠是以基于干灰泥重量约0.12-0.4%重量的量存在。
在一种优选的实施方式中,本发明包括一种低尘石膏墙板,其包括在两个大体平行的板层之间形成的含有预凝胶淀粉和萘磺酸盐分散剂的一凝固石膏芯,该凝固石膏芯具有约80%-92%的总空隙体积,其中总空隙体积的至少60%包含平均直径小于约100微米的气隙(air void),且凝固石膏芯的密度为约10pcf-30pcf。术语“pcf”定义为磅每立方英尺(lb/ft3)。该凝固石膏芯由包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成,其中预凝胶淀粉是以基于灰泥重量约0.5-10%重量的量存在。优选地,萘磺酸盐分散剂是以基于干灰泥重量约0.1-3.0%重量的量存在。
根据本发明制造的石膏墙板具有高强度,但重量比传统墙板低的多。此外,研究发现通过确保凝固石膏芯的总芯空隙体积为约70%-95%,并优选为约80%-92%,在切割、锯、掘、折、钉或拧紧、或钻孔根据本发明制造的墙板时,产生的粉尘也减少很多。
在另一种实施方式中,本发明建立一种制造高强度、低粉尘的石膏墙板的方法,即通过混合包含水、灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆,其中萘磺酸盐分散剂是以基于干灰泥重量约0.1-3.0%重量的量存在,预凝胶淀粉是以基于灰泥重量,至少约0.5%高至约10%重量的量存在,并且添加足够的肥皂泡沫至含石膏浆,以在成品墙板中形成约75%-95%的包含气隙的总空隙体积。将产生的含石膏浆沉积在第一纸的或其它适当板层上,然后将第二纸或其它适当板层置于该沉积浆体上以形成石膏墙板。当含石膏浆硬化到足以用于切割时,切割该石膏墙板,并干燥由此产生的石膏墙板,以在成品墙板中提供具有约75%-95%的包含气隙的总空隙体积的凝固石膏芯。所述含石膏浆可选择地包含三偏磷酸盐,例如三偏磷酸钠。其它常规成分也可用于该浆体中,视情况包含促进剂、粘结剂、防水剂、纸纤维、玻璃纤维、粘土、杀菌剂和其它已知成分。
在另一种实施方式中,本发明建立一种使用低尘石膏墙板的方法,即通过提供具有一总空隙体积为约75%-95%的凝固石膏芯的低尘石膏墙板,其中总空隙体积的至少60%包含平均直径小于约100微米的气隙以及包含平均直径小于约5微米的水隙(water void),以产生石膏粉尘的方式(如切割、锯、掘、刻/折、钉或拧紧、或钻孔)加工该墙板;以及在空隙中捕获相当大一部分石膏粉尘。
附图简要说明
图1是说明本发明一种实施方式的铸造石膏立方体样品(11:08)15X放大的扫描电子显微照片。
图2是说明本发明一种实施方式的铸造石膏立方体样品(11:30)15X放大的扫描电子显微照片。
图3是说明本发明一种实施方式的铸造石膏立方体样品(11:50)15X放大的扫描电子显微照片。
图4是说明本发明一种实施方式的铸造石膏立方体样品(11:08)50X放大的扫描电子显微照片。
图5是说明本发明一种实施方式的铸造石膏立方体样品(11:30)50X放大的扫描电子显微照片。
图6是说明本发明一种实施方式的铸造石膏立方体样品(11:50)50X放大的扫描电子显微照片。
图7是说明本发明一种实施方式的铸造石膏立方体样品(11:50)500X放大的扫描电子显微照片。
图8是说明本发明一种实施方式的铸造石膏立方体样品(11:50)2500X放大的扫描电子显微照片。
图9-10是说明本发明一种实施方式的铸造石膏立方体样品(11:50)10000X放大的扫描电子显微照片。
具体实施方式
研究结果意外地发现,用含有灰泥、预凝胶淀粉和萘磺酸盐分散剂以及适量泡沫的含石膏浆制成的石膏墙板,当凝固石膏芯的总空隙体积为约80%-92%时,不仅具有非常低的约10-30pcf的板芯密度(因此有轻的板重量),而且在正常板处理和加工,例如切割、锯、掘、刻/折、钉或拧紧、或钻孔时具有低份尘。因此这种墙板比其它已知产品更易于切割。肥皂泡沫的引入产生小气(泡)隙,其直径平均可小于约100微米,但通常直径都大于约10微米,且优选直径大于约20微米。本发明要求这些小气泡,与蒸发的水隙(通常直径约5微米或更小,正常情况下直径小于约2微米)一起,通常均匀地分布在成品墙板产品的整个凝固石膏芯中。例如,凝固石膏芯的总空隙体积可以为约80%-92%,其中总空隙体积的至少60%包含平均直径大于约10微米的气隙,且总空隙体积的至少10%包含平均直径小于约5微米的水隙。可以认为以这种方式制备的低密度板芯,其具有的凝固石膏芯的总空隙体积作为气隙和水隙(总芯空隙体积)为约80%-92%,当切割、锯、掘、折、钉或拧紧、或钻孔该板时,在暴露的空隙中捕获了相当大量的小粉尘和其它碎片,使得粉尘产生大大减少且不会浮在空中。
半水合硫酸钙(灰泥)的再水合以及随之发生的硬化需要具体的、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,工业化过程通常需要过量的水。这种过量的工艺水在石膏晶体基质中产生蒸发水隙,通常其形状相当不规则,并且还与其它水隙相连,在凝固石膏晶体之间以通常连续的网状形成不规则通道。相反,气(泡)隙是利用肥皂泡沫引至石膏浆中。气隙通常为球形/圆形形状,且通常与其它气隙分开,因此一般是不连续的。水隙可以分布于气隙的壁内(参见如图8-10)。
粉尘捕获的效力取决于石膏芯的组分。研究发现萘磺酸盐分散剂如果用量足够高,能交联到预凝胶淀粉以将石膏晶体干燥后结合在一起,由此增强石膏复合物的干强度。此外,研究意外地发现预凝胶淀粉和萘磺酸盐分散剂(有机相)的结合在将凝固石膏晶体结合到一起时提供了一种胶样(glue-like)作用,且当该配方与特定的空隙体积和空隙分布相结合时,刻/折成品墙板时会产生较大尺寸的碎片。较大的石膏碎片通常产生较少扬尘。相反,如果使用传统墙板配方,就会产生较小碎片并因此有更多粉尘。例如,传统墙板能在锯切时产生平均直径约20-30微米、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、最小直径约2微米的粉尘碎片;刻/折时可产生甚至更大的碎片。
在较软墙板中,粉尘可以在水隙和气隙中被捕获(如捕获作为单晶粉尘的小石膏针体)。较硬的墙板有利于粉尘在气隙中的捕获,因为凝固石膏芯的较大块或碎片是在加工这些板时产生。在这种情况下,粉尘碎片对于水隙来说太大,但可在气隙中被捕获。根据本发明的一种实施方式,通过在凝固石膏芯中引入优选的空隙/孔径分布,有可能实现增强的粉尘捕获。优选的是具有小的和大的空隙尺寸的分布,作为气隙和水隙的分布。在一种实施方式中,优选的气隙分布可用肥皂泡沫制备。参见以下实施例6和7。
凝固石膏芯中气隙(大于约10微米)和水隙(小于约5微米)的比率可以为约1.8:1至约9:1。凝固石膏芯中气隙(大于约10微米)和水隙(小于约5微米)的优选比率可以为约2:1至约3:1。在一种实施方式中,凝固石膏芯中空隙/孔尺寸分布应为测得的总空隙的百分比的约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,凝固石膏芯中气隙(大于10微米)和水隙(小于5微米)的比率为约2.3:1至约9:1。在一种优选实施方式中,凝固石膏芯中空隙/孔尺寸分布应为30-35%的空隙小于5微米以及约65-70%的空隙大于约10微米,占测定的总空隙的百分比。换个方式说,凝固石膏芯中气隙(大于10微米)和水隙(小于5微米)的比率为约1.8:1至约2.3:1。
优选的是平均气(泡)隙尺寸的直径小于约100微米。在优选的实施方式中,凝固石膏芯中空隙/孔尺寸分布为:大于100微米(20%),约50微米-100微米(30%)和小于约50微米(50%)。也就是说,优选的中值空隙/孔尺寸为约50微米。
在凝固石膏芯中优选将肥皂泡沫引入并控制气(泡)隙尺寸和分布,以及控制该凝固石膏芯的密度。肥皂的优选范围为约0.2lb/MSF-0.6lb/MSF;肥皂的更优选水平为约0.45lb/MS。
肥皂泡沫必须以有效地产生所需密度的量,并以控制的方式加入。为了控制该过程,操作者必须监测板成型线的源头,并保持封袋充满。如果封袋未保持充满,会产生带有中空边缘的墙板,因为浆体不能充满所需要的体积。封袋体积是通过增加肥皂用量以避免板生产期间气泡的破裂(为了更好地保留气泡),或通过增加空气***率保持充满。因此,通常封袋体积是通过增加或降低肥皂用量,或通过增加或降低气体***率来控制和调节的。控制源头的技术包括通过添加肥皂泡沫以增加浆体体积,或通过减少泡沫用量以减少浆体体积来调整台上的“动态浆”。
根据本发明的一种实施方式,提供了用包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成的成品含石膏产品。萘磺酸盐分散剂是以基于干灰泥重量的约0.1%-3.0%重量的量存在。预凝胶淀粉是以基于配方中干灰泥重量的至少约0.5%、高至10%重量的量存在。浆体中可能使用的其它成分包括粘合剂、防水剂、纸纤维、玻璃纤维、粘土、杀菌剂和促进剂。本发明需要添加肥皂泡沫至新配制的含石膏浆中以降低成品含石膏产品(例如石膏墙板)的密度,并通过在凝固石膏芯中以小气(泡)隙和水隙的形式引入约75%-95%,优选约80%-92%的总空隙体积以控制粉尘。优选地,平均孔径分布将为约1微米(水隙)-约40-50微米(气隙)。
可选择地,约0.5%重量-约10%重量的预凝胶淀粉、约0.1%重量-约3.0%重量的萘磺酸盐以及至少约0.2%重量-约0.4%重量的三偏磷酸盐(全部基于石膏浆中使用的干灰泥重量)的组合,出人意料且大大地增加了该石膏浆的流动性。这大大降低了需要的水量以生产用于制造含石膏产品如石膏墙板的有足够流动性的石膏浆。三偏磷酸盐的水平至少为标准配方中(为三偏磷酸钠)的约两倍,被认为可以提高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浆中。用于本发明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,其为萘磺酸和甲醛的缩合产物。尤其可取的聚萘磺酸盐包括萘磺酸钠和萘磺酸钙。萘磺酸盐的平均分子量可以为约3000-27000,但优选的是该分子量为约8000-22000,更优选的是该分子量为约12000-17000。作为商业产品,较高分子量的分散剂比较低分子量的分散剂具有更高的粘性和更低的固体内容物。有用的萘磺酸盐包括购自GEO特种化学品公司(俄亥俄州,克里夫兰)的DILOFLO;购自罕布什尔化学公司(马萨诸塞州,列克星敦)的DAXAD;购自GEO特种化学品公司(印第安纳州,拉斐特)的LOMAR D。萘磺酸盐优选作为固体内容物35-55%重量的水溶液使用,例如固体内容物约40-45%重量。或者,在适当情况下,萘磺酸盐可以干燥固体或粉末形式使用,例如LOMAR D。
本发明有用的聚萘磺酸盐具有结构通式(I):
其中n>2,M为钠、钾、钙等。
萘磺酸盐分散剂,优选作为约45%重量的水溶液,以基于石膏复合配方中干灰泥重量的约0.5%-3.0%重量使用。萘磺酸盐分散剂更优选的范围为基于干灰泥重量的约0.5%-2.0%重量,且最优选的范围为基于干灰泥重量的约0.7%-2.0%重量。相反,已知的石膏墙板包含该分散剂的水平为基于干灰泥重量的约0.4%重量或更低。
换个方式说,萘磺酸盐分散剂,在干重基础上,以基于石膏复合配方中干灰泥重量的约0.1%-1.5%重量使用。萘磺酸盐分散剂更优选的范围,在干燥固体基础上,是基于干灰泥重量的约0.25%-0.7%重量,最优选的范围(在干燥固体基础上)是基于干灰泥重量的约0.3%-0.7%重量。
该含石膏浆可选择地包含三偏磷酸盐,例如三偏磷酸钠。根据本发明任何合适的水溶性偏磷酸盐或聚磷酸盐均可使用。优选的是使用三偏磷酸盐,包括复盐,即具有两个阳离子的三偏磷酸盐。尤其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、三偏磷酸铵等,或其结合。优选的三偏磷酸盐为三偏磷酸钠。优选的是三偏磷酸盐作为水溶液使用,例如固体内容物约10-15%重量。还可使用其它的环或非环聚磷酸盐,如Yu等的美国专利No.6,409,825中所述,在此纳入作为参考。
三偏磷酸钠是含石膏组合物中已知的添加剂,但它通常以基于石膏浆中所用干灰泥重量的约0.05%-0.08%重量使用。在本发明的实施方式中,三偏磷酸钠(或其它水溶性偏磷酸盐或聚磷酸盐)可以以基于石膏复合配方中所用干灰泥重量的约0.12%-0.4%重量存在。三偏磷酸钠(或其它水溶性偏磷酸盐或聚磷酸盐)的优选范围是基于石膏复合配方中所用干灰泥重量的约0.12%-0.3%重量。
灰泥有两种形式,α和β。灰泥的这两种类型是由不同的煅烧手段产生。本发明中灰泥的α或β形式均可使用。
淀粉,尤其包括预凝胶淀粉,必须用在根据本发明制备的石膏浆中。优选的预凝胶淀粉是预凝胶玉米淀粉,例如购自Bunge Milling(密苏里州,圣路易斯)公司的预凝胶玉米粉,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%,灰分0.3%;生强度0.48psi;和松密度35.0lb/ft3。预凝胶玉米淀粉应以基于含石膏浆中所用干灰泥重量的至少约0.5%重量、高至约10%的重量使用。
本发明人进一步发现,在约0.1%-3%重量的萘磺酸盐分散剂存在下,通过使用至少约0.5%重量,高至约10%重量的预凝胶淀粉(优选预凝胶玉米淀粉)可获得(尤其在墙板中)干强度的意外增强(淀粉和萘磺酸盐水平均基于配方中干灰泥的重量)。不管水溶性偏磷酸盐或聚磷酸盐是否存在,都可获得这一出人意料的结果。
此外,发明人意外地发现,预凝胶淀粉可以至少约10lb/MSF或更高水平用于根据本发明制备的干石膏墙板中,还能实现高强度和低重量。石膏墙板中预凝胶淀粉高达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,还产生了具有优良强度的1042lb/MSF的板重量。在该实例(配方B)中,作为45%重量水溶液的萘磺酸盐是以1.28%重量的水平使用。
当萘磺酸盐分散剂-三偏磷酸盐组合与预凝胶玉米淀粉、并可选地与纸纤维或玻璃纤维相结合时,本发明还得到更加意外的结果。由包含这三种成分的配方制成的石膏墙板具有增强的强度和降低的重量,并且由于在其制造时减少了水需求而更加经济可行。纸纤维的有用水平可以是基于干灰泥重量的约2%重量。玻璃纤维的有用水平可以是基于干灰泥重量的约2%重量。
本发明的含石膏组合物中可使用如Yu等的美国专利No.6,409,825所述的促进剂,在此纳入作为参考。一种可取的耐热促进剂(HRA)可由干研磨的建筑石膏(二水合硫酸钙)制成。少量添加剂(通常约5%重量)如糖、右旋糖、硼酸和淀粉可用于制备该HRA。一般优选糖或右旋糖。其它有用的促进剂是美国专利No.3,573,947所述的“气候稳定型促进剂”,在此纳入作为参考。
水/灰泥(w/s)比率是一个重要的参数,因为过量的水最后必须通过加热除去。在本发明的实施方式中,通常优选的w/s比率为约0.7-1.3。
其它石膏浆添加剂可包括促进剂、粘结剂、防水剂、纸或玻璃纤维以及其它已知组分。
板层可以像传统石膏墙板一样用纸制成,但也可使用其它本领域已知的有用的板层材料(如玻璃纤维垫)。纸板层在石膏墙板中提供强度特性。有用的板层纸包括美国石膏公司(伊利诺斯州,芝加哥)的马尼拉7层纸(Manila 7-ply)和News-Line5层纸(News-Line 5-ply);和购自Caraustar公司(印第安纳,新港)的灰底白板3层纸(Grey-Back 3-ply)和马尼拉白3层纸(Manila Ivory 3-ply)。纸板层包括顶部板层或面纸、和底部板层或背纸。优选的背板层纸为5层News-Line纸。优选的面板层纸为马尼拉7层纸。
纤维垫也可以用作一个或两个板层。一种有用的纤维垫是玻璃纤维垫,其中玻璃纤维丝通过粘合剂粘结在一起。最优选地,无纺玻璃纤维垫将具有重的树脂涂层。例如,可使用购自约翰-曼维尔公司的重量约1.2-2.0lb/100ft2的Duraglass无纺玻璃纤维垫,该垫重量的约40-50%来自树脂涂层。其它有用的纤维垫包括但不限于纺织玻璃垫和非纤维素织物。
以下实施例进一步阐明本发明。它们不应被视为以任何形式限制本发明的范围。
实施例1样品石膏浆配方
石膏浆配方如下表1所示。表1中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
组分 | 配方A | 配方B |
灰泥(lb/MSF) | (732) | (704) |
三偏磷酸钠 | 0.20(1.50) | 0.30(2.14) |
分散剂(萘磺酸盐) | 0.18(1.35) | 0.581(4.05) |
预凝胶淀粉(干粉) | 2.7(20) | 6.4(45) |
板淀粉 | 0.41(3.0) | 0 |
耐热促进剂(HRA) | (15) | (15) |
玻璃纤维 | 0.27(2.0) | 0.28(2.0) |
纸纤维 | 0 | 0.99(7.0) |
肥皂* | 0.03(0.192) | 0.03(0.192) |
总水量(lb.) | 805 | 852 |
水/灰泥比率 | 1.10 | 1.21 |
*用于预产生泡沫
11.28%重量的45%水溶液
实施例2墙板的制备
根据Yu等的美国专利No.6,342,284和No.6,632,550制备样品石膏墙板,在此纳入作为参考。该方法包括单独产生泡沫,并把该泡沫引入到这些专利实施例5中所述的所有其它成分的浆体中。
用实施例1的配方A和配方B制备的石膏墙板以及普通对照板的测试结果如下表2所示。在该实施例和以下其它实施例中,钉拉阻力、芯硬度和抗弯强度测试均按照ASTM C-473执行。此外,应注意,通常的石膏墙板约1/2英寸厚,且重量为约1600-1800磅每1000平方英尺材料,或lb/MSF。(“MSF”在本领域为1000平方英尺的标准缩写;它可用于盒子、瓦楞纸媒介和墙板的面积测量)
表2
MD:纵向(机器方向)
XMD:横向(跨机器方向)
如表2所示,用配方A和B制备的石膏墙板与对照板相比重量大大降低。再参见表1,配方A板和配方B板的对比非常明显。配方A和配方B中水/灰泥(w/s)比率相似。配方B还使用了明显较高水平的萘磺酸盐分散剂。而且,配方B使用了明显较多的预凝胶淀粉,约6%重量,比配方A增加100%多,并伴随着显著的强度增加。即便如此,配方B浆体中产生所需流动性的需水量仍然很低,与配方A相比约为10%的差异。在这两个配方中低需水量是因为石膏浆体中萘磺酸盐分散剂和三偏磷酸钠组合的协调效应,其即使在大量较高水平的预凝胶淀粉存在下,也能增强石膏浆的流动性。
如表2所示,与用配方A浆体制备的墙板相比,用配方B浆体制备的墙板具有大大增加的强度。通过合并加量的预凝胶淀粉和加量的萘磺酸盐分散剂和三偏磷酸钠,配方B板的钉拉阻力比配方A板提高了45%。还观察到配方B板中抗弯强度与配方A板相比大大增加。
实施例3 1/2英寸石膏墙板重量降低试验
进一步的石膏墙板实施例(板C、D和E),包括浆体配方和测试结果,如下表3所示。表3的浆体配方包括浆体的主要组分。括号中的值表示基于干灰泥重量的重量百分比。
表3
ASTM标准:77lb
1DILOFLO为45%的萘磺酸盐水溶液
如表3所示,与对照板相比,板C、D和E是由大量增加的淀粉、DILOFLO分散剂和三偏磷酸钠制成(淀粉和分散剂百分比为约两倍增加,三偏磷酸盐为两到三倍增加),同时保持w/s比率不变。然而,板重量显著降低,且通过钉拉阻力测得的强度没有受到明显影响。因此,在本发明实施方式的该实施例中,新配方(如板D)可以在可用的、易流动的浆体中提供增加的淀粉,同时保持相同的w/s比率和足够的强度。
实施例4湿石膏立方体强度测试
利用购自美国石膏公司(伊利诺斯州,芝加哥)的Southard CKS板灰泥和实验室的自来水进行湿立方体强度测试,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),CAS(2g)和约70°F的自来水(1200cc)用于各个湿石膏立方体铸造。预凝胶玉米淀粉(20g,基于灰泥重量的2.0%)和CAS(2g,基于灰泥重量的0.2%)在与含萘磺酸盐分散剂和三偏磷酸钠的自来水溶液混合之前,首先在塑料袋中与灰泥彻底干混合。使用的分散剂为DILOFLO分散剂(1.0-2.0%,如表4所示)。使用了不同用量的三偏磷酸钠,同样如表4所示。
干成分和水溶液先在实验室告警搅拌器中混合,产生的混合物浸泡10s,然后该混合物在低速下混合10s以便制成浆体。由此形成的浆体被铸入三个2”X2”X2”的立方体模子。然后将铸造的立方体从模子中移出,称重,并密封在塑料袋中以防止在进行抗压强度测试前的水分损失。用ATS机器测量该湿立方体的抗压强度,并以磅每平方英寸(psi)记录平均数。所得结果如下:
表4
1DILOFLO为45%的萘磺酸盐水溶液
如图4所示,本发明的三偏磷酸钠水平约0.12-0.4%的样品4-5,10-11和17,与三偏磷酸钠水平超出该范围的样品相比,普遍提供更好的湿立方体抗压强度。
实施例5 1/2英寸轻量石膏墙板厂产品试验
对试验板1和2进行了进一步的试验,包括浆体配方和测试结果如下表5所示。表5的浆体配方包括浆体的主要组分。括号中的值表示基于干灰泥重量的重量百分比。
表5
ASTM标准:77lb
MD:纵向
XMD:横向
1DILOFLO为45%的萘磺酸盐水溶液
290°F/90%相对湿度
3应清楚地理解,在这些测试条件下,破坏率百分比<50%都是可以接受的。
如表5所示,与对照板相比,试验板1和2由含大量增加的淀粉、DILOFLO分散剂和三偏磷酸钠的浆体制成,同时w/s比率略有下降。然而,通过钉拉阻力和弯曲测试测得的强度都得到保持或改善,且板重量明显下降。因此,在本发明实施方式的该实施例中,新配方(如,试验板1和2)能在可用的、易流动的浆体中提供增加的三偏磷酸盐和淀粉,同时保持大体相同的w/s比率和足够的强度。
实施例6 1/2英寸超轻量石膏板厂产品试验
同实施例2一样,用配方B(实施例1)进行进一步的试验(试验板3和4),不同的是该预凝胶玉米淀粉是以10%浓度用水制备(湿淀粉制备),并使用HYONIC 25AS和PFM 33肥皂(购自GEO特种化学品公司,印第安纳州,拉斐特)的混合物。例如,试验板3用HYONIC 25AS和25AS的混合物制备,其中65-70%重量为25AS,而剩余的为PFM33。例如,试验板4用HYONIC 25AS/HYONIC PFM 33的70/30wt./wt.的混合物制备。试验结果如下表6所示。
表6
除标明的以外
1n=4
MD:纵向
XMD:横向
aASTM标准:77lb
bASTM标准:11lb
cASTM标准:36lb
dASTM标准:107lb
如表6所示,通过钉拉阻力和芯硬度测得的强度特征均高于ASTM标准。测得的抗弯强度也高于ASTM标准。此外,在本发明实施方式的该实施例中,新配方(例如试验板3和4)能在可用的、易流动的浆体中提供增加的三偏磷酸盐和淀粉,同时保持足够的强度。
实施例7 1/2英寸厚石膏墙板芯空隙体积百分比计算结果对板重量和锯切结果的函数关系
同实施例2一样,用配方B(实施例1)进行进一步的试验以便测定空隙体积和密度(试验板5-13),不同的是该预凝胶玉米淀粉是以10%浓度用水制备(湿淀粉制备),使用了0.5%的玻璃纤维,并且以45%的水溶液形式使用了1.2%重量的萘磺酸盐(DILOFLO)。肥皂泡沫是用肥皂泡沫发生器制造,并以有效地提供所需密度的量被引入石膏浆体。在本发明的实施例中,肥皂是以0.25lb/MSF-0.45lb/MSF的水平使用。也就是说,肥皂泡沫的用量可酌情增加或减少。在各个样品中,墙板厚度为1/2英寸,且芯体积假定统一为39.1ft3/MSF。空隙体积是跨4英尺宽的墙板样品测量,该墙板样品上的正面和背面纸被除去。正面和背面纸的厚度为11-18密尔(每一侧)。通过扫描电子显微镜(见以下实施例8)和X射线CT扫描技术(XTT)测定空隙体积/孔尺寸和孔径分布。
表7
1>10微米气(泡)隙
2<5微米水隙
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)-纸板层的重量(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所示,制成总芯空隙体积为79.0%-92.1%的试验板样品,其分别对应于板芯密度28pcf下低至10pcf。举个例子,锯切总空隙体积为81.8%、板密度为23pcf的试验板10,产生的粉尘比对照板少30%。举另一个例子,如果传统配方的含有较少粘合剂(淀粉作为粘合剂,有或没有分散剂)的墙板,其具有明显较少的约75%-80%的总芯空隙体积,那么在切割、锯、掘、折、钉或拧紧、或钻孔时预计会产生明显较多的粉尘。例如,传统墙板在锯切时会产生平均直径约20-30微米、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将产生平均直径约30-50微米、最小直径约2微米的粉尘碎片;刻/折时将产生甚至更大的碎片。
研究发现用于制造含石膏浆的几种关键成分,即灰泥、萘磺酸盐分散剂、预凝胶玉米淀粉、三偏磷酸钠,以及玻璃和/或纸纤维的组合,与足够的有效量的肥皂泡沫相结合,在生产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、刻/折、钻孔以及正常板处理时也显著减少石膏粉尘形成。
实施例8试验板10中气泡空隙尺寸和水隙尺寸、以及石膏晶体形态的测定
通过扫描电子显微镜(SEM)分析工厂试验下制备试验板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隙,以及石膏晶体尺寸和形状。
制成三个样品立方体并分别标记为11:08,11:30和11:50。图1-3说明了各个样品在15X放大时的气泡空隙尺寸和分布。图4-6说明了各个样品在50X放大时的气泡空隙尺寸和分布。
在较高放大倍数时,例如在通常较大的气泡空隙壁中,可观察到水隙,如图7-10中样品立方体11:50高达10000X放大时所示。几乎所有的石膏晶体均为针状物;极少观察到小片状。这些针状物的密度和填充在气泡空隙的表面上是不同的。在气泡空隙壁的水隙中也能观察到石膏针状物。
该SEM结果证明在根据本发明制备的含石膏产品中,气隙和水隙通常均匀分布在整个凝固石膏芯。观察到得空隙尺寸和空隙分布也证明足够的自由空间随着气隙和水隙(总芯空隙体积)形成,这样很大部分的产生的石膏粉尘将在正常板处理和在切割、锯、掘、折、钉或拧紧、或钻孔时暴露的周围的空隙中被捕获,并且不会浮在空中。
实施例9低尘石膏墙板中的粉尘捕获
如果墙板是根据本发明如实施例7中的教导制成,可以预见在加工该墙板时产生的石膏粉尘包括至少50%重量的直径大于约10微米的石膏碎片。通过切割、锯、掘、刻/折、钉或拧紧、以及钻孔加工该墙板时,产生的总粉尘的至少约30%或更多将被捕获。
在描述本发明的上下文(特别是权利要求书上下文)中所用的术语“一”、“一个”,“这个/该”(a,an,the)及类似指称应理解为包括单数和复数,除非本文另有说明或者明确地否认。此处数值范围的列举仅作为一种逐个指出落入该范围的每个独立值的速记方法,除非本文另有说明,并且每个独立的值被纳入说明书中,犹如其被本文单独列出。本文描述的所有方法可以任何适合的顺序完成,除非本文另有说明或明确地否认。本文提供的任何和所有实施例,或示范性语言(如“例如”),仅为了更好地解释说明本发明,并不限制本发明的范围,除非另有声明。说明书中的语言不应解释为将任何未要求的元素作为本发明实践的要素。
在此描述了本发明的优选实施方式,包括发明人知道的用于实施本发明的最佳实施方式。应理解的是,阐明的实施方式仅是示范性的,不应视为对本发明范围的限制。
Claims (39)
1.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的空隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的空隙,(iii)具有直径约50微米-约100微米的孔尺寸的空隙,和(iv)具有直径大于约100微米的孔尺寸的空隙,具有直径大于约100微米的孔尺寸的空隙占所述凝固石膏芯的总空隙体积的至少约20%,使用扫描电子显微照片图像测量空隙;
平均气隙尺寸为直径小于约100微米;
配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
2.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的空隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的空隙,(iii)具有直径约50微米-约100微米的孔尺寸的空隙,和(iv)具有直径大于约100微米的孔尺寸的空隙,具有直径大于约100微米的孔尺寸的空隙占所述凝固石膏芯的总空隙体积的至少约20%,使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙;
平均气隙尺寸为直径小于约100微米;
配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
3.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
其中,该凝固石膏芯包含:
(a)具有配置于其中的气隙和水隙分布的石膏晶体基质,该气隙具有约5微米或更大的孔尺寸,且该水隙具有小于约5微米的孔尺寸,气隙与水隙的体积比率为约1.8:1-约9:1,(b)具有至少约5微米至小于约100微米的孔尺寸的气隙分布,(c)进一步具有直径大于约100微米的孔尺寸的气隙分布,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,
使用扫描电子显微照片图像测量空隙,平均气隙尺寸为直径小于约100微米;和
(d)该轻量石膏板具有约24pcf-33pcf的密度,配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度。
4.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
其中,该凝固石膏芯包含:
(a)具有配置于其中的气隙和水隙分布的石膏晶体基质,该气隙具有约5微米或更大的孔尺寸,且该水隙具有小于约5微米的孔尺寸,气隙与水隙的体积比率为约1.8:1-约9:1,(b)具有至少约5微米至小于约100微米的孔尺寸的气隙分布,(c)进一步具有直径大于约100微米的孔尺寸的气隙分布,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,
使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙,平均气隙尺寸为直径小于约100微米;和
(d)该轻量石膏板具有约24pcf-33pcf的密度,配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度。
5.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
从至少含有水和灰泥的浆体形成该凝固石膏芯,水/灰泥的比为约0.7-约1.3,该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的水隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的气隙,(iii)具有直径约50微米-约100微米的孔尺寸的气隙,和(iv)具有直径大于100微米的孔尺寸的气隙,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,其中,使用扫描电子显微照片图像测量空隙;
平均气隙尺寸为直径小于约100微米;
形成该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
6.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
从至少含有水和灰泥的浆体形成该凝固石膏芯,水/灰泥的比为约0.7-约1.3,该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的水隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的气隙,(iii)具有直径约50微米-约100微米的孔尺寸的气隙,和(iv)具有直径大于100微米的孔尺寸的气隙,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,其中,使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙;
平均气隙尺寸为直径小于约100微米;
形成该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
7.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的空隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的空隙,(iii)具有直径约50微米-约100微米的孔尺寸的空隙,和(iv)具有直径大于约100微米的孔尺寸的空隙,具有直径大于约100微米的孔尺寸的空隙占所述凝固石膏芯的总空隙体积的至少约20%,使用扫描电子显微照片图像测量空隙;
具有最大频率的气隙尺寸为直径约100微米或更小;
配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有约33pcf或更低的密度。
8.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的空隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的空隙,(iii)具有直径约50微米-约100微米的孔尺寸的空隙,和(iv)具有直径大于约100微米的孔尺寸的空隙,具有直径大于约100微米的孔尺寸的空隙占所述凝固石膏芯的总空隙体积的至少约20%,使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙;
具有最大频率的气隙尺寸为直径约100微米或更小;
配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有约33pcf或更低的密度。
9.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
其中,该凝固石膏芯包含:
(a)具有配置于其中的气隙和水隙分布的石膏晶体基质,该气隙具有约5微米或更大的孔尺寸,且该水隙具有小于约5微米的孔尺寸,气隙与水隙的体积比率为约1.8:1-约9:1,(b)具有至少约5微米至小于约100微米的孔尺寸的气隙分布,(c)进一步具有直径大于约100微米的孔尺寸的气隙分布,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,
使用扫描电子显微照片图像测量空隙,具有最大频率的气隙尺寸为直径约100微米或更小;和
(d)该轻量石膏板具有约24pcf-33pcf的密度,配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度。
10.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
其中,该凝固石膏芯包含:
(a)具有配置于其中的气隙和水隙分布的石膏晶体基质,该气隙具有约5微米或更大的孔尺寸,且该水隙具有小于约5微米的孔尺寸,气隙与水隙的体积比率为约1.8:1-约9:1,(b)具有至少约5微米至小于约100微米的孔尺寸的气隙分布,(c)进一步具有直径大于约100微米的孔尺寸的气隙分布,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,
使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙,具有最大频率的气隙尺寸为直径约100微米或更小;和
(d)该轻量石膏板具有约24pcf-33pcf的密度,配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度。
11.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
从至少含有水和灰泥的浆体形成该凝固石膏芯,水/灰泥的比为约0.7-约1.3,该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的水隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的气隙,(iii)具有直径约50微米-约100微米的孔尺寸的气隙,和(iv)具有直径大于约100微米的孔尺寸的气隙,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,使用扫描电子显微照片图像测量空隙;
具有最大频率的气隙尺寸为直径约100微米或更小;
形成该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
12.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
从至少含有水和灰泥的浆体形成该凝固石膏芯,水/灰泥的比为约0.7-约1.3,该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的水隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的气隙,(iii)具有直径约50微米-约100微米的孔尺寸的气隙,和(iv)具有直径大于100微米的孔尺寸的气隙,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙;
具有最大频率的气隙尺寸为直径约100微米或更小;
形成该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
13.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的空隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的空隙,(iii)具有直径约50微米-约100微米的孔尺寸的空隙,和(iv)具有直径大于约100微米的孔尺寸的空隙,具有直径大于约100微米的孔尺寸的空隙占所述凝固石膏芯的总空隙体积的至少约20%,使用扫描电子显微照片图像测量空隙;
平均气隙尺寸为直径小于约200微米;
配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
14.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的空隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的空隙,(iii)具有直径约50微米-约100微米的孔尺寸的空隙,和(iv)具有直径大于约100微米的孔尺寸的空隙,具有直径大于约100微米的孔尺寸的空隙占所述凝固石膏芯的总空隙体积的至少约20%,使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙;
平均气隙尺寸为直径小于约200微米;
配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
15.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
其中,该凝固石膏芯包含:
(a)具有配置于其中的气隙和水隙分布的石膏晶体基质,该气隙具有约5微米或更大的孔尺寸,且该水隙具有小于约5微米的孔尺寸,气隙与水隙的体积比率为约1.8:1-约9:1,(b)具有至少约5微米至小于约100微米的孔尺寸的气隙分布,(c)进一步具有直径大于约100微米的孔尺寸的气隙分布,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,
使用扫描电子显微照片图像测量空隙,平均气隙尺寸为直径小于约200微米;和
(d)该轻量石膏板具有约24pcf-33pcf的密度,配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度。
16.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
其中,该凝固石膏芯包含:
(a)具有配置于其中的气隙和水隙分布的石膏晶体基质,该气隙具有约5微米或更大的孔尺寸,且该水隙具有小于约5微米的孔尺寸,气隙与水隙的体积比率为约1.8:1-约9:1,(b)具有至少约5微米至小于约100微米的孔尺寸的气隙分布,(c)进一步具有直径大于约100微米的孔尺寸的气隙分布,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,
使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙,平均气隙尺寸为直径小于约200微米;和
(d)该轻量石膏板具有约24pcf-33pcf的密度,配置该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度。
17.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
从至少含有水和灰泥的浆体形成该凝固石膏芯,水/灰泥的比为约0.7-约1.3,该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的水隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的气隙,(iii)具有直径约50微米-约100微米的孔尺寸的气隙,和(iv)具有直径大于约100微米的孔尺寸的气隙,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,使用扫描电子显微照片图像测量空隙;
具有最大频率的气隙尺寸为直径约200微米或更小;
形成该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
18.轻量石膏板,其包含:
置于两个板层之间的凝固石膏芯;
从至少含有水和灰泥的浆体形成该凝固石膏芯,水/灰泥的比为约0.7-约1.3,该凝固石膏芯包含具有孔尺寸分布的石膏晶体基质,该孔尺寸分布包含:
(i)具有直径小于约5微米的孔尺寸的水隙,(ii)具有直径至少约5微米且小于约50微米的孔尺寸的气隙,(iii)具有直径约50微米-约100微米的孔尺寸的气隙,和(iv)具有直径大于100微米的孔尺寸的气隙,使得具有直径大于约100微米的孔尺寸的气隙占所述凝固石膏芯的总空隙体积的至少约20%,使用X射线CT-扫描分析(XMT)获得的三维图像测量空隙;
具有最大频率的气隙尺寸为直径约200微米或更小;
形成该石膏晶体基质,使得凝固石膏芯具有根据ASTM C-473所确定的至少约11磅的平均芯硬度;且
该轻量石膏板具有33pcf或更低的密度。
19.权利要求1-2、5-8、11-14和17-18任一项的轻量石膏板,其中,总空隙体积的至少约50%为具有直径大于约50微米的孔尺寸的气隙。
20.权利要求1-18任一项的轻量石膏板,所述凝固石膏芯由包含水、泡沫、灰泥、萘磺酸盐分散剂和预凝胶淀粉的浆体制成。
21.权利要求20的轻量石膏板,其中,萘磺酸盐分散剂为基于灰泥重量约0.1%重量-约3.0%重量的量。
22.权利要求1-18任一项的轻量石膏板,所述凝固石膏芯由包含水、泡沫、灰泥和预凝胶淀粉的浆体制成,该预凝胶淀粉为基于灰泥重量约0.5%重量-约10%重量的量。
23.权利要求22的轻量石膏板,其中该浆体还包含选自三偏磷酸钠、三偏磷酸钾、三偏磷酸锂和三偏磷酸铵的三偏磷酸盐化合物,该三偏磷酸盐化合物为基于灰泥重量约0.12%重量-约0.4%重量的量。
24.权利要求1-18任一项的轻量石膏板,所述凝固石膏芯由包含水、泡沫、灰泥和三偏磷酸盐化合物的浆体制成,该三偏磷酸盐化合物选自三偏磷酸钠、三偏磷酸钾、三偏磷酸锂和三偏磷酸铵,该三偏磷酸盐化合物为基于灰泥重量约0.12%重量-约0.4%重量的量。
25.权利要求24的轻量石膏板,其中,该浆体还包含萘磺酸盐分散剂,该萘磺酸盐分散剂为基于灰泥重量约0.1%重量-约3.0%重量的量。
26.权利要求5-6、11-12和17-18任一项的轻量石膏板,其中气隙与水隙的体积比率为约1.8:1-约9:1。
27.权利要求3-6、9-12和15-18任一项的轻量石膏板,其中气隙和水隙的体积比率为约2.3:1-约9:1。
28.权利要求1-18任一项的轻量石膏板,其中,当该轻量石膏板为约1/2英寸厚度时,该石膏板具有约1000lb/MSF-约1300lb/MSF的干重。
29.权利要求1-18任一项的轻量石膏板,所述凝固石膏芯由包含水、泡沫、灰泥、萘磺酸盐分散剂和预凝胶淀粉的浆体制成,其中萘磺酸盐分散剂为基于灰泥重量约0.1%重量-约3.0%重量的量,且预凝胶淀粉为基于灰泥重量约0.5%重量-约10%重量的量。
30.权利要求29的轻量石膏板,其中该浆体还包含选自三偏磷酸钠、三偏磷酸钾、三偏磷酸锂和三偏磷酸铵的三偏磷酸盐化合物,该三偏磷酸盐化合物为基于灰泥重量约0.12%重量-约0.4%重量的量。
31.权利要求1-2、5-8、11-14和17-18任一项的轻量石膏板,其中具有约5微米或更大孔尺寸的空隙与具有小于约5微米孔尺寸的空隙的体积比率为约1.4:1至约2.3:1。
32.权利要求1-2、5-8、11-14和17-18任一项的轻量石膏板,其中具有约5微米或更大孔尺寸的空隙与具有小于约5微米孔尺寸的空隙的体积比率为约2.3:1至约9:1。
33.权利要求1-2、5-8、11-14和17-18任一项的轻量石膏板,其中具有直径约50微米至约100微米孔尺寸的空隙占所述凝固石膏芯的总空隙体积的至少约30%。
34.权利要求3-6、9-12和15-18任一项的轻量石膏板,其中具有约5微米或更大孔尺寸的气隙与具有小于约5微米孔尺寸的空隙的体积比率为约1.4:1至约9:1,且其中所述总空隙体积的至少约50%为具有直径大于约50微米孔尺寸的气隙。
35.权利要求1-2、5-8、11-14和17-18任一项的轻量石膏板,其中具有直径至少约5微米且小于约50微米孔尺寸的空隙包含具有至少约10微米且小于约50微米孔尺寸的气隙。
36.权利要求15-18任一项的轻量石膏板,其中平均气隙尺寸为直径小于约150微米。
37.权利要求1-18任一项的轻量石膏板,其中该轻量石膏板的密度为约24pcf至约33pcf或更低。
38.权利要求1-18任一项的轻量石膏板,其中该轻量石膏板的密度为约24pcf至约32pcf或更低。
39.权利要求1-18任一项的轻量石膏板,其中该轻量石膏板的密度为约24pcf至约31pcf或更低。
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US11/592,481 US9802866B2 (en) | 2005-06-09 | 2006-11-02 | Light weight gypsum board |
CN200780046773.1A CN101563220B (zh) | 2006-11-02 | 2007-10-09 | 低尘石膏墙板 |
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CA2934677C (en) | 2013-12-20 | 2024-06-18 | Eli Stav | Gypsum board with improved starch binder |
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