JP2014208589A - 軽量な石膏ボード - Google Patents
軽量な石膏ボード Download PDFInfo
- Publication number
- JP2014208589A JP2014208589A JP2014115911A JP2014115911A JP2014208589A JP 2014208589 A JP2014208589 A JP 2014208589A JP 2014115911 A JP2014115911 A JP 2014115911A JP 2014115911 A JP2014115911 A JP 2014115911A JP 2014208589 A JP2014208589 A JP 2014208589A
- Authority
- JP
- Japan
- Prior art keywords
- microns
- gypsum
- pore size
- gypsum board
- core
- 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.)
- Granted
Links
- 229910052602 gypsum Inorganic materials 0.000 title claims abstract description 323
- 239000010440 gypsum Substances 0.000 title claims abstract description 323
- 239000002002 slurry Substances 0.000 claims abstract description 86
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 72
- 239000011148 porous material Substances 0.000 claims abstract description 53
- 238000009826 distribution Methods 0.000 claims abstract description 22
- 239000013078 crystal Substances 0.000 claims abstract description 19
- 239000011159 matrix material Substances 0.000 claims abstract description 9
- 239000011800 void material Substances 0.000 claims description 100
- 239000002270 dispersing agent Substances 0.000 claims description 66
- PSZYNBSKGUBXEH-UHFFFAOYSA-M naphthalene-1-sulfonate Chemical compound C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-M 0.000 claims description 64
- 229920000881 Modified starch Polymers 0.000 claims description 43
- 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 28
- AZSFNUJOCKMOGB-UHFFFAOYSA-K cyclotriphosphate(3-) Chemical compound [O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 AZSFNUJOCKMOGB-UHFFFAOYSA-K 0.000 claims description 25
- 239000006260 foam Substances 0.000 claims description 22
- 229920002472 Starch Polymers 0.000 claims description 16
- 239000008107 starch Substances 0.000 claims description 16
- 235000019698 starch Nutrition 0.000 claims description 16
- 238000001878 scanning electron micrograph Methods 0.000 claims description 13
- 238000005452 bending Methods 0.000 claims description 10
- -1 trimetaphosphate compound Chemical class 0.000 claims description 9
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 claims description 4
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 claims description 4
- 229910052744 lithium Inorganic materials 0.000 claims description 4
- SUZJDLRVEPUNJG-UHFFFAOYSA-K tripotassium 2,4,6-trioxido-1,3,5,2lambda5,4lambda5,6lambda5-trioxatriphosphinane 2,4,6-trioxide Chemical compound [K+].[K+].[K+].[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 SUZJDLRVEPUNJG-UHFFFAOYSA-K 0.000 claims description 4
- 238000005516 engineering process Methods 0.000 claims description 2
- 239000000428 dust Substances 0.000 abstract description 83
- 238000012545 processing Methods 0.000 abstract description 10
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- 238000000034 method Methods 0.000 description 27
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- 238000005553 drilling Methods 0.000 description 11
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- 229920002261 Corn starch Polymers 0.000 description 8
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- 239000008120 corn starch Substances 0.000 description 8
- 238000001035 drying Methods 0.000 description 7
- 239000000835 fiber Substances 0.000 description 7
- 239000002131 composite material Substances 0.000 description 6
- 239000004615 ingredient Substances 0.000 description 6
- 230000008569 process Effects 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
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- 239000001205 polyphosphate Substances 0.000 description 5
- 235000011176 polyphosphates Nutrition 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 239000011230 binding agent Substances 0.000 description 4
- PASHVRUKOFIRIK-UHFFFAOYSA-L calcium sulfate dihydrate Chemical compound O.O.[Ca+2].[O-]S([O-])(=O)=O PASHVRUKOFIRIK-UHFFFAOYSA-L 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 239000012634 fragment Substances 0.000 description 4
- 125000005341 metaphosphate group Chemical group 0.000 description 4
- 229920000417 polynaphthalene Polymers 0.000 description 4
- 241000196324 Embryophyta Species 0.000 description 3
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 239000003139 biocide Substances 0.000 description 3
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- 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
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical group 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 2
- 230000009471 action Effects 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect 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
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000008121 dextrose Substances 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
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- 238000009434 installation Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
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- PSZYNBSKGUBXEH-UHFFFAOYSA-N naphthalene-1-sulfonic acid Chemical compound C1=CC=C2C(S(=O)(=O)O)=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-N 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 150000003871 sulfonates Chemical class 0.000 description 2
- 239000013589 supplement Substances 0.000 description 2
- 230000002195 synergetic effect Effects 0.000 description 2
- 239000008399 tap water Substances 0.000 description 2
- 235000020679 tap water Nutrition 0.000 description 2
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical group [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 241000531897 Loma Species 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical group [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 241000612118 Samolus valerandi Species 0.000 description 1
- 239000007983 Tris buffer Substances 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis 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
- 230000000996 additive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 125000002723 alicyclic group Chemical group 0.000 description 1
- 238000004458 analytical method 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
- VMDFASMUILANOL-WXXKFALUSA-N bisoprolol fumarate Chemical compound [H+].[H+].[O-]C(=O)\C=C\C([O-])=O.CC(C)NCC(O)COC1=CC=C(COCCOC(C)C)C=C1.CC(C)NCC(O)COC1=CC=C(COCCOC(C)C)C=C1 VMDFASMUILANOL-WXXKFALUSA-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
- 239000011575 calcium Chemical group 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Inorganic materials [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 1
- CKJFPVNRRHVMKZ-UHFFFAOYSA-L calcium;naphthalene-1-sulfonate Chemical compound [Ca+2].C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1.C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1 CKJFPVNRRHVMKZ-UHFFFAOYSA-L 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 238000002591 computed tomography Methods 0.000 description 1
- 239000007859 condensation product Substances 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 150000004683 dihydrates Chemical class 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 238000010410 dusting Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000007676 flexural strength test Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 239000002075 main ingredient Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000012074 organic phase Substances 0.000 description 1
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- 239000011505 plaster Substances 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 239000011591 potassium Chemical group 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 238000004626 scanning electron microscopy Methods 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
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- QPLUUBGVWZCEER-UHFFFAOYSA-H tricalcium 2,4,6-trioxido-1,3,5,2lambda5,4lambda5,6lambda5-trioxatriphosphinane 2,4,6-trioxide Chemical compound [Ca++].[Ca++].[Ca++].[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1.[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 QPLUUBGVWZCEER-UHFFFAOYSA-H 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Images
Classifications
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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
- 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
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- 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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- B32B13/04—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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- B32B13/04—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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- B32B13/14—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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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
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- C04B18/04—Waste materials; Refuse
- C04B18/18—Waste materials; Refuse organic
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- C04B18/241—Paper, e.g. waste paper; Paper pulp
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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
- 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
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- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
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- C04B24/226—Sulfonated naphtalene-formaldehyde condensation products
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- 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
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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
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- 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
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- 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
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- E—FIXED CONSTRUCTIONS
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- 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
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
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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
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
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Abstract
Description
ダストの捕捉の有効性は、硬化石膏芯の組成に依存する。ナフタレンスルホネート分散剤は、もし使用レベルが十分に高いと、乾燥後、ナフタレンスルホネート分散剤と橋かけ結合して石膏結晶をともに結合し、そのため石膏複合物の乾燥強さを増大させることが分かっている。
石膏スラリー処方物は、以下の表1に示される。表1中のすべての値は、乾燥スタッコの重量に基づいて重量%として表示される。括弧内の値は、乾燥重量(ポンド)(Lb/MSF)である。
サンプル石膏ウォールボードは、米国特許6342284および6632550(本明細書において参考として引用される)に従って製造された。これは、これらの特許の実施例5に記載されたように、フォームの別の発生、および他の成分のすべてのスラリー中へのフォームの導入を含む。
スラリー処方およびテスト結果を含むさらなる石膏ウォールボードの例(ボードC、DおよびE)は、以下の表3に示される。表3のスラリー処方は、スラリーの主な成分を含む。括弧内の値は、乾燥スタッコの重量に基づいて重量%として示される。
湿潤石膏キューブ強さテストは、実験室でUnited States GypsumCorp.Chicago,Illinoisから入手できるSouthard CKSボードスタッコおよび水道水を用いて行われて、それらの湿潤圧縮強さを測定した。以下の実験室のテスト手順を用いた。
スラリー処方物を含むさらなる試験が行われ(試験ボード1および2)、そしてテスト結果は以下の表5に示される。表5のスラリー処方は、スラリーの主な成分を含む。括弧内の値は、乾燥スタッコの重量に基づいて重量%として示される。
実施例2におけるように処方B(実施例1)を使用してさらなる試験を行ったが(試験ボード3および4)、ただし予めゼラチン化したとうもろこし澱粉は、10%濃度で水により調製され(湿潤澱粉の製造)、そしてHYONIC 25 ASおよびPFM 33石けん(GEO Speciality Chemicals,Lafayette,Indianaから入手)のブレンドを使用した。例えば、試験ボード3は、25ASが65−70重量%でありそして残りがPFM 33であるHYONIC 25ASおよびPFM
33のブレンドにより製造された。例えば、試験ボード4は、HYONIC 25AS/HYONIC PFM 33の70/30(w/w)ブレンドにより製造された。試験の結果を以下の表6に示す。
実施例2におけるように処方B(実施例1)を使用して空隙体積および密度(試験ボード5−13)を測定するために、さらなる試験を行ったが、ただし予めゼラチン化したとうもろこし澱粉は、10%濃度で水により調製され(湿潤澱粉の製造)、0.5%ガラスファイバーを用いそしてナフタレンスルホネート(DILOFLO)は、45%水溶液として1.2重量%のレベルで使用された。石けんフォームは、石けんフォーム発生器を使用してつくられ、そして望ましい密度を生ずるのに有効な量で石膏スラリーへ導入された。この実施例では、石けんは、0.25Lb(約114g)/MSFから0.45Lb(約204g)/MSFのレベルで使用された。すなわち、石けんフォームの使用量は、適切なように増加または減少された。各サンプルにおいて、ウォールボードの厚さは1/2インチ(約1.27cm)であり、そして芯の体積は39.1ft3(約1.17m3)/MSFにおいて均一であるとされた。空隙体積は、表面および裏面の紙がそれから除かれた幅4フィートのウォールボードサンプルについて測定された。表面および裏面の紙は、11−18ミルの範囲の厚さを有する(各側面)。空隙体積/細孔サイズおよび細孔サイズ分布は、走査電子顕微鏡(以下の実施例8参照)およびX線CTスキャニング技術(XMT)により測定された。
試験ボード10を製造するプラント試験からの注型石膏キューブ(2インチ×2インチ×2インチ(約5.1cm×約5.1cm×約5.1cm))は、走査電子顕微鏡(SEM)により分析された。気泡の空隙および蒸発性水空隙が、石膏結晶サイズおよび形状とともに観察され測定された。
もしウォールボードが実施例7におけるように本発明の教示に従って製造されるならば、ウォールボードを加工することで生成する石膏ダストが、直径約10ミクロンより大きい石膏破片を少なくとも50重量%含むことが予想される。切断、鋸挽き、丸のみによる削り、切り込み、折り、釘打ちまたはねじ留めまたは穴開けによってウォールボードを加工することにより発生する全ダストの少なくとも約30%以上が捕捉される。
[付記1]
2つの実質的に平行なカバーシートの間に形成され、約75−約95%の全空隙体積を有する硬化石膏芯を含むことを特徴とするダストの発生の少ない石膏ウォールボード。
[付記2]
硬化石膏芯が約80−約92%の全空隙体積を有する付記1のダストの発生の少ない石膏ウォールボード。
[付記3]
硬化石膏芯が約10−約30pcf(約0.16−約0.48g/cm3)の密度を有する付記1のダストの発生の少ない石膏ウォールボード。
[付記4]
硬化石膏芯が、水、スタッコ、予めゼラチン化した澱粉およびナフタレンスルホネート分散剤を含む石膏含有スラリーから製造され、予めゼラチン化した澱粉は、スタッコの重量に基づいて約0.5重量%から約10重量%の量で存在する付記1のダストの発生の少ない石膏ウォールボード。
[付記5]
ナフタレンスルホネート分散剤が、スタッコの重量に基づいて約0.1重量%から約3.0重量%の量で存在する付記4のダストの発生の少ない石膏ウォールボード。
[付記6]
ナフタレンスルホネート分散剤が、スタッコの重量に基づいて約0.3重量%から約0.7重量%の量で存在する付記4のダストの発生の少ない石膏ウォールボード。
[付記7]
ナフタレンスルホネート分散剤が、約40重量%から約45重量%のナフタレンスルホネートを含む水溶液の形であり、そして水溶液が、スタッコの重量に基づいて約0.5重量%から約2.5重量%の量で存在する付記4のダストの発生の少ない石膏ウォールボード。
[付記8]
石膏含有スラリーが、スタッコの重量に基づいて約0.12重量%から約0.4重量%の量で存在するナトリウムトリメタホスフェートをさらに含む付記4のダストの発生の少ない石膏ウォールボード。
[付記9]
ウォールボードが、約1200Lb(約545kg)/MSFから約1400Lb(約636kg)/MSFの乾燥重量を有する付記1のダストの発生の少ない石膏ウォールボード。
[付記10]
ウォールボードが、約500Lb(約227kg)/MSFから約1200Lb(約545kg)/MSFの乾燥重量を有する付記2のダストの発生の少ない石膏ウォールボード。
[付記11]
全空隙体積の少なくとも60%が、約100ミクロンより小さい平均直径を有する空気空隙よりなる付記2のダストの発生の少ない石膏ウォールボード。
[付記12]
全空隙体積の少なくとも10%が、約5ミクロンより小さい平均直径を有する水空隙よりなる付記2のダストの発生の少ない石膏ウォールボード。
[付記13]
全空隙体積の少なくとも65%が、約10ミクロンより大きい平均直径を有する空気空隙よりなる付記2のダストの発生の少ない石膏ウォールボード。
[付記14]
全空隙体積の少なくとも60%が、約20ミクロンより大きい平均直径を有する空気空隙よりなる付記2のダストの発生の少ない石膏ウォールボード。
[付記15]
全空隙体積の少なくとも60%が、約10ミクロンより大きい平均直径を有する空気空隙よりなり、全空隙体積の少なくとも10%が、約5ミクロンより小さい平均直径を有する水空隙よりなり、空気空隙および水空隙が硬化石膏芯全体にほぼ均一に分布している付記2のダストの発生の少ない石膏ウォールボード。
[付記16]
全空隙体積の少なくとも60%が、約100ミクロンより小さい平均直径を有する空気空隙よりなり、空気空隙がほぼ球状であり、空気空隙が互いにほぼ分離されている付記2のダストの発生の少ない石膏ウォールボード。
[付記17]
硬化石膏芯が、約10ミクロンより大きい平均直径を有する空気空隙および約5ミクロンより小さい平均直径を有する水空隙を含み、空気空隙対水空隙の比が約2.3:1から約1.8:1である付記2のダストの発生の少ない石膏ウォールボード。
[付記18]
硬化石膏芯が、約1ミクロンから約50ミクロンの平均細孔サイズ分布を有する空隙を含む付記2のダストの発生の少ない石膏ウォールボード。
[付記19]
硬化石膏芯が、全空隙の約20%の量の約100ミクロンより大きい空隙、全空隙の約30%の量の約50ミクロンから約100ミクロンの空隙、および全空隙の約50%の量の約50ミクロンより小さい空隙からなる細孔サイズ分布を有する空気空隙を含む付記2のダストの発生の少ない石膏ウォールボード。
[付記20]
石膏含有スラリーが、約0.25Lb(約116g)/MSFから約0.48Lb(約182g)/MSFの量で存在する石けんをさらに含む付記4のダストの発生の少ない石膏ウォールボード。
[付記21]
石膏含有スラリーが、スタッコの重量に基づいて約2重量%以内の量で存在する紙ファイバー、およびスタッコの重量に基づいて約2重量%以内の量で存在するガラスファイバーをさらに含む付記4のダストの発生の少ない石膏ウォールボード。
[付記22]
水/スタッコ比が約0.7から約1.3である付記4のダストの発生の少ない石膏ウォールボード。
[付記23]
カバーシートが紙からなる付記1のダストの発生の少ない石膏ウォールボード。
[付記24]
少なくとも1つのカバーシートが、繊維状マット、不織ガラスファイバーマット、織ったガラスマットおよび非セルロース性布帛からなる群から選ばれる付記1のダストの発生の少ない石膏ウォールボード。
[付記25]
2つの実質的に平行なカバーシートの間に形成された予めゼラチン化した澱粉およびナフタレンスルホネート分散剤を含む硬化石膏芯を含み、硬化石膏芯が約80%から約92%の全空隙体積を有し、全空隙体積の少なくとも60%が約100ミクロンより小さい平均直径を有する空気空隙からなり、そして硬化石膏芯が約10−約30pcf(約0.16−約0.48g/cm3)の密度を有することを特徴とするダストの発生の少ない石膏ウォールボード。
[付記26]
硬化石膏芯が、スタッコ、予めゼラチン化した澱粉およびナフタレンスルホネート分散剤から製造され、予めゼラチン化した澱粉が、スタッコの重量に基づいて約0.5重量%から約10重量%の量で存在する付記25のダストの発生の少ない石膏ウォールボード。
[付記27]
ナフタレンスルホネート分散剤が、スタッコの重量に基づいて約0.1重量%から約3.0重量%の量で存在する付記26のダストの発生の少ない石膏ウォールボード。
[付記28]
ナフタレンスルホネート分散剤が、スタッコの重量に基づいて約0.3重量%から約0.7重量%の量で存在する付記26のダストの発生の少ない石膏ウォールボード。
[付記29]
石膏含有スラリーが、スタッコの重量に基づいて約0.12重量%から約0.4重量%の量で存在するナトリウムトリメタホスフェートをさらに含む付記26のダストの発生の少ない石膏ウォールボード。
[付記30]
ウォールボードが、約500Lb(約227kg)/MSFから約1200Lb(約545kg)の乾燥重量を有する付記29のダストの発生の少ない石膏ウォールボード。
[付記31]
カバーシートが紙からなる付記25のダストの発生の少ない石膏ウォールボード。
[付記32]
(a)水、スタッコ、予めゼラチン化した澱粉およびナフタレンスルホネート分散剤を含む石膏含有スラリーを混合する工程、予めゼラチン化した澱粉は、スタッコの重量に基づいて約0.5重量%から約10重量%の量で存在し、ナフタレンスルホネート分散剤は、スタッコの重量に基づいて約0.1重量%から約3.0重量%の量で存在する、
(b)仕上げウォールボード中で約75%から約95%の全空隙体積を形成するのに十分な石けんフォームを石膏含有スラリーに添加する工程、
(c)石膏含有スラリーを第1のカバーシート上に付着させる工程、
(d)第2のカバーシートを付着したスラリーの上に置いて石膏ウォールボードを形成する工程、
(e)石膏含有スラリーが切断するのに十分な固さになった後石膏ウォールボードを切断する工程、および
(f)石膏ウォールボードを乾燥して仕上げウォールボード中に硬化石膏芯を設ける工程
からなることを特徴とする高強度のダストの発生の少ない石膏ウォールボードを製造する方法。
[付記33]
硬化石膏芯中に約80%から約92%の全空隙体積を形成するのに十分な石けんフォームが、工程(b)で添加される付記32の方法。
[付記34]
全空隙体積の少なくとも60%が、約100ミクロンより小さい平均直径を有する空気空隙を含む付記32の方法。
[付記35]
第1のカバーシートおよび第2のカバーシートが紙からつくられる付記32の方法。
[付記36]
少なくとも1つのカバーシートが、繊維状マット、不織ガラスファイバーマット、織ったガラスマットおよび非セルロース性布帛からなる群から選ばれる付記32の方法。
[付記37]
スラリーが、スタッコの重量に基づいて約0.12重量%から約0.4重量%の量で存在するナトリウムトリメタホスフェートをさらに含む付記32の方法。
[付記38]
ウォールボードが、約1200Lb(約545kg)/MSFから約1400Lb(約636kg)/MSFの乾燥重量を有する付記32の方法。
[付記39]
スラリーが、スタッコの重量に基づいて約0.12重量%から約0.4重量%の量で存在するナトリウムトリメタホスフェートをさらに含む付記33の方法。
[付記40]
ウォールボードが、約500Lb(約227kg)/MSFから約1200Lb(約545kg)の乾燥重量を有する付記39の方法。
[付記41]
(a)約75%から約95%の全空隙体積を有する硬化石膏芯をもつダストの発生の少ない石膏ウォールボードを製造する工程、その際全空隙体積の少なくとも60%が約10ミクロンより大きい平均直径を有する空気空隙からなりそして全空隙体積の少なくとも10%が約5ミクロンより小さい平均直径を有する水空隙からなる、
(b)ウォールボードを加工して石膏のダストを生成する工程、および
(c)空隙中の石膏のダストの実質的な部分を捕捉する工程
からなることを特徴とする加工される石膏ウォールボードのダストの発生が少ない方法。
[付記42]
加工が、切断、鋸挽き、丸のみによる削り、切り込み/折り、釘打ち、釘打ち、ねじ留めおよび穴開けからなる群から選ばれる付記41の方法。
[付記43]
硬化石膏芯の全空隙体積が約80%から約92%である付記41の方法。
[付記44]
捕捉された石膏のダストの部分が、生成した石膏のダストの少なくとも約20重量%である付記41の方法。
[付記45]
2つの実質的に平行なカバーシートの間に形成された予めゼラチン化した澱粉およびナフタレンスルホネート分散剤を含む硬化石膏芯を含み、
予めゼラチン化した澱粉およびナフタレンスルホネート分散剤は、直径約2ミクロンより大きい石膏の破片を生ずるのに十分な量で存在し、
硬化石膏芯は、約80%から約92%の全空隙体積を有し、
全空隙体積の少なくとも60%は、約10ミクロンより大きい平均直径および約10−約30pcf(約0.16−約0.48g/cm3)の密度を有することを特徴とするダストの発生の少ない石膏ウォールボード。
[付記46]
硬化石膏芯が、スタッコ、予めゼラチン化した澱粉およびナフタレンスルホネート分散剤を含む石膏含有スラリーから製造され、予めゼラチン化した澱粉はスタッコの重量に基づいて約0.5重量%から約10重量%の量で存在する付記45のダストの発生の少ない石膏ウォールボード。
[付記47]
ナフタレンスルホネート分散剤が、スタッコの重量に基づいて約0.1重量%から約3.0重量%の量で存在する付記46のダストの発生の少ない石膏ウォールボード。
[付記48]
石膏含有スラリーが、スタッコの重量に基づいて約0.12重量%から約0.4重量%の量で存在するナトリウムトリメタホスフェートをさらに含む付記47のダストの発生の少ない石膏ウォールボード。
[付記49]
ウォールボードが、約500Lb(約227kg)/MSFから約1200Lb(約545kg)の乾燥重量を有する付記48のダストの発生の少ない石膏ウォールボード。
[付記50]
2つの実質的に平行なカバーシートの間に形成された予めゼラチン化した澱粉およびナフタレンスルホネート分散剤を含む硬化石膏芯を含み、硬化石膏芯は約75%から約95%の全空隙体積を有し、繊維状マット、不織ガラスファイバーマット、織ったガラスマットおよび非セルロース性布帛からなる群から選ばれた少なくとも1つのカバーシートを含むことを特徴とするダストの発生の少ない石膏ウォールボード。
[付記51]
硬化石膏芯が、スタッコ、予めゼラチン化した澱粉およびナフタレンスルホネート分散剤を含む石膏含有スラリーから製造され、予めゼラチン化した澱粉は、スタッコの重量に基づいて約0.5重量%から約10重量%の量で存在する付記50のダストの発生の少ない石膏ウォールボード。
[付記52]
ナフタレンスルホネート分散剤が、スタッコの重量に基づいて約0.1重量%から約3.0重量%の量で存在する付記51のダストの発生の少ない石膏ウォールボード。
[付記53]
石膏含有スラリーが、スタッコの重量に基づいて約0.12重量%から約0.4重量%の量で存在するナトリウムトリメタホスフェートをさらに含む付記51のダストの発生の少ない石膏ウォールボード。
[付記54]
カバーシートの少なくとも1つが不織ガラスファイバーマットである付記50のダストの発生の少ない石膏ウォールボード。
Claims (45)
- 2つのカバーシートの間に配置される硬化石膏芯を含有する軽量石膏ボードであって、
水/スタッコ比が0.7から1.3であるスラリーから形成され、且つ、石膏結晶マトリックスを含有する前記硬化石膏芯は、(i)5ミクロン未満の直径の細孔サイズを有する水空隙、(ii)少なくとも5ミクロンから50ミクロンの直径の細孔サイズを有する空気空隙、(iii)50ミクロンから100ミクロンの直径の細孔サイズを有する空気空隙、及び、(iv)走査電子顕微鏡写真像を用いて空隙を計測して前記硬化石膏芯の全空隙体積の少なくとも20%を占める100ミクロンを超える直径の細孔サイズを有する空気空隙、から構成される細孔サイズ分布を有し、
前記石膏結晶マトリックスは、前記硬化石膏芯が、ASTM C−473に従って計測して、少なくとも11ポンド(約5kg)の平均の芯の固さを有するように形成されており、且つ、
前記ボードは31pcf(約500kg/m3)以下の密度を有することを特徴とする、軽量石膏ボード。 - 前記空隙が、空気空隙及び水空隙を含み、前記空気空隙の平均細孔サイズが、直径で100ミクロンより小さい請求項1に記載の軽量石膏ボード。
- 50ミクロンから100ミクロンの直径の細孔サイズを有する前記空気空隙が、前記硬化石膏芯の全空隙体積の少なくとも30%を占める請求項1又は2に記載の軽量石膏ボード。
- 前記空気空隙対水空隙の体積比は、2.3:1から9:1である、請求項1から3のいずれか1項に記載の軽量石膏ボード。
- 前記全空隙体積の少なくとも50%が、50ミクロンを超える直径の細孔サイズを有する空気空隙である、請求項1から4のいずれか1項に記載の軽量石膏ボード。
- 前記硬化石膏芯は、芯の体積の75%から92%の全空隙体積を有する、請求項1から5のいずれか1項に記載の軽量石膏ボード。
- 前記5ミクロン以上の細孔サイズを有する空気空隙と、5ミクロン未満の細孔サイズを有する空隙との体積比は、1.4:1から9:1である、請求項1から6のいずれか1項に記載の軽量石膏ボード。
- 前記ボードは、24pcf(約380kg/m3)〜31pcf(約500kg/m3)の密度を有する、請求項1から7のいずれか1項に記載の軽量石膏ボード。
- 前記ボードは、1/2インチ(約1.3cm)の厚さであるときに、(i)1000lb/MSF(約5kg/m2)〜1300lb/MSF(約6.3kg/m2)の乾燥重量を有する、請求項1から8のいずれか1項に記載の軽量石膏ボード。
- 前記ボードは、1/2インチ(約1.3cm)の厚さであるときに、(i)1000lb/MSF(約5kg/m2)〜1300lb/MSF(約6.3kg/m2)の乾燥重量、(ii)ASTM基準C−473に従ってそれぞれ計測して、4〜8の釘抜き抵抗対芯の固さの比、(iii)ASTM基準C−473に従って計測して、少なくとも65lb(29kg)の釘抜き抵抗、(iv)ASTM基準C−473に従って計測して、少なくとも36lb(16kg)の機械方向の平均曲げ強度、及び/又は、少なくとも107lb(48.5kg)の機械方向の横方向の平均曲げ強度、又は、(v)(i)から(iv)の任意の組み合わせを有する、請求項1から9のいずれか1項に記載の軽量石膏ボード。
- 前記スラリーは、フォーム、及び、ナフタレンスルホネート分散剤をさらに含む、請求項1から10のいずれか1項に記載の軽量石膏ボード。
- 前記ナフタレンスルホネート分散剤は、前記スタッコの重量に対して0.1重量%から3.0重量%の量で存在する、請求項11に記載の軽量石膏ボード。
- 前記スラリーは、ナトリウムトリメタホスフェート、カリウムトリメタホスフェート、リチウムトリメタホスフェート、及び、アンモニウムトリメタホスフェートからなる群より選択されるトリメタホスフェート化合物であって、前記スタッコの重量に対して0.12重量%から0.4重量%の量で存在するトリメタホスフェート化合物をさらに含む、請求項1から12のいずれか1項に記載の軽量石膏ボード。
- 前記スラリーは、予めゼラチン化した澱粉をさらに含む、請求項1から13のいずれか1項に記載の軽量石膏ボード。
- 2つのカバーシートの間に配置される硬化石膏芯を含有する軽量石膏ボードであって、
前記硬化石膏芯は、水/スタッコ比が0.7から1.3であるスラリーから形成され、且つ、石膏結晶マトリックスを含有しており、(i)5ミクロン未満の直径の細孔サイズを有する水空隙、(ii)少なくとも5ミクロンから50ミクロンの直径の細孔サイズを有する空気空隙、(iii)50ミクロンから100ミクロンの直径の細孔サイズを有する空気空隙、及び、(iv)X線CTスキャニング技術(XMT)により得られた3次元画像を用いて空隙を計測して前記硬化石膏芯の全空隙体積の少なくとも20%を占める100ミクロンを超える直径の細孔サイズを有する空気空隙、から構成される細孔サイズ分布を有し、
前記ボードは、1/2インチ(約1.3cm)の厚さであるときに、ASTM基準C−473に従ってそれぞれ計測して、4〜8の釘抜き抵抗対芯の固さの比を有し、且つ、
前記ボードは31pcf(約500kg/m3)以下の密度を有することを特徴とする、軽量石膏ボード。 - 前記空隙が、空気空隙及び水空隙を含み、前記空気空隙の平均細孔サイズが、直径で100ミクロンより小さい請求項15に記載の軽量石膏ボード。
- 50ミクロンから100ミクロンの直径の細孔サイズを有する前記空隙が、前記硬化石膏芯の全空隙体積の少なくとも30%を占める請求項15又は16に記載の軽量石膏ボード。
- 前記空気空隙対水空隙の体積比は、2.3:1から9:1である、請求項15から17のいずれか1項に記載の軽量石膏ボード。
- 前記5ミクロン以上の細孔サイズを有する空気空隙と、5ミクロン未満の細孔サイズを有する空隙との体積比は、1.4:1から9:1であり、かつ、前記全空隙体積の少なくとも50%が、50ミクロンを超える直径の細孔サイズを有する空気空隙である、請求項15から18のいずれか1項に記載の軽量石膏ボード。
- 前記ボードは、24pcf(約380kg/m3)〜31pcf(約500kg/m3)の密度を有する、請求項15から19のいずれか1項に記載の軽量石膏ボード。
- 前記ボードは、1/2インチ(約1.3cm)の厚さであるときに、(i)1000lb/MSF(約5kg/m2)〜1300lb/MSF(約6.3kg/m2)の乾燥重量を有する、請求項15から20のいずれか1項に記載の軽量石膏ボード。
- 前記ボードは、1/2インチ(約1.3cm)の厚さであるときに、(i)1000lb/MSF(約5kg/m2)〜1300lb/MSF(約6.3kg/m2)の乾燥重量、(ii)ASTM基準C−473に従ってそれぞれ計測して、4〜8の釘抜き抵抗対芯の固さの比、(iii)ASTM基準C−473に従って計測して、少なくとも65lb(29kg)の釘抜き抵抗、(iv)ASTM基準C−473に従って計測して、少なくとも36lb(16kg)の機械方向の平均曲げ強度、及び/又は、少なくとも107lb(48.5kg)の機械方向の横方向の平均曲げ強度、又は、(v)(i)から(iv)の任意の組み合わせを有する、請求項15から21のいずれか1項に記載の軽量石膏ボード。
- 前記スラリーは、フォーム、及び、ナフタレンスルホネート分散剤をさらに含む、請求項15から22のいずれか1項に記載の軽量石膏ボード。
- 前記ナフタレンスルホネート分散剤は、前記スタッコの重量に対して0.1重量%から3.0重量%の量で存在する、請求項23に記載の軽量石膏ボード。
- 前記スラリーは、ナトリウムトリメタホスフェート、カリウムトリメタホスフェート、リチウムトリメタホスフェート、及び、アンモニウムトリメタホスフェートからなる群より選択されるトリメタホスフェート化合物であって、スタッコの重量に対して0.12重量%から0.4重量%の量で存在するトリメタホスフェート化合物をさらに含む、請求項15から24のいずれか1項に記載の軽量石膏ボード。
- 前記スラリーは、予めゼラチン化した澱粉をさらに含む、請求項15から25のいずれか1項に記載の軽量石膏ボード。
- 水及びスタッコを含むスラリーから形成された硬化石膏芯を含有する軽量石膏ボードであって、前記硬化石膏芯は、(a)空気空隙及び水空隙が内部に分布する石膏結晶マトリックスであって、5ミクロン以上の細孔サイズを有する前記空気空隙の、5ミクロン未満の細孔サイズを有する水空隙に対する体積比が、1.8:1から9:1である石膏結晶マトリックス、(b)少なくとも5ミクロンから100ミクロンの細孔サイズを有する空気空隙分布、(c)走査電子顕微鏡写真像を用いて空隙を計測して前記硬化石膏芯の全空隙体積の少なくとも20%を占める100ミクロンを超える直径の細孔サイズを有する空気空隙、から構成される細孔サイズ分布を有し、かつ、(d)前記ボードは、24pcf(約380kg/m3)〜31pcf(約500kg/m3)の密度を有し、該密度(pcf)対ASTM基準C−473に従って計測した平均の芯の固さ(lb)の比は3.2未満であることを特徴とする、軽量石膏ボード。
- 前記空隙が、空気空隙及び水空隙を含み、前記空気空隙の平均細孔サイズが、直径で100ミクロンより小さい請求項27に記載の軽量石膏ボード。
- 50ミクロンから100ミクロンの直径の細孔サイズを有する前記空気空隙が、前記硬化石膏芯の全空隙体積の少なくとも30%を占める請求項27又は28に記載の軽量石膏ボード。
- 前記空気空隙対水空隙の体積比は、2.3:1から9:1である、請求項27から29のいずれか1項に記載の軽量石膏ボード。
- 50ミクロン未満の直径の細孔サイズを有する前記空隙は、10ミクロンから50ミクロンの細孔サイズを有する空隙を含有している、請求項27から30のいずれか1項に記載の軽量石膏ボード。
- 前記硬化石膏芯は、芯の体積の75%から92%の全空隙体積を有する、請求項27から31のいずれか1項に記載の軽量石膏ボード。
- 前記全空隙体積の少なくとも50%が、50ミクロンを超える直径の細孔サイズを有する空気空隙である、請求項27から32のいずれか1項に記載の軽量石膏ボード。
- 前記ボードは、1/2インチ(約1.3cm)の厚さであるときに、(i)1000lb/MSF(約5kg/m2)〜1300lb/MSF(約6.3kg/m2)の乾燥重量を有する、請求項27から33のいずれか1項に記載の軽量石膏ボード。
- 前記ボードは、1/2インチ(約1.3cm)の厚さであるときに、(i)1000lb/MSF(約5kg/m2)〜1300lb/MSF(約6.3kg/m2)の乾燥重量、(ii)ASTM基準C−473に従ってそれぞれ計測して、4〜8の釘抜き抵抗対芯の固さの比、(iii)ASTM基準C−473に従って計測して、少なくとも65lb(29kg)の釘抜き抵抗、(iv)ASTM基準C−473に従って計測して、少なくとも36lb(16kg)の機械方向の平均曲げ強度、及び/又は、少なくとも107lb(48.5kg)の機械方向の横方向の平均曲げ強度、又は、(v)(i)から(iv)の任意の組み合わせ、を有する、請求項27から34のいずれか1項に記載の軽量石膏ボード。
- 前記スラリーは、フォーム、及び、ナフタレンスルホネート分散剤をさらに含む、請求項27から35のいずれか1項に記載の軽量石膏ボード。
- 前記ナフタレンスルホネート分散剤は、前記スタッコの重量に対して0.1重量%から3.0重量%の量で存在する、請求項36に記載の軽量石膏ボード。
- 前記スラリーは、ナトリウムトリメタホスフェート、カリウムトリメタホスフェート、リチウムトリメタホスフェート、及び、アンモニウムトリメタホスフェートからなる群より選択されるトリメタホスフェート化合物であって、前記スタッコの重量に対して0.12重量%から0.4重量%の量で存在するトリメタホスフェート化合物をさらに含む、請求項27から37のいずれか1項に記載の軽量石膏ボード。
- 前記スラリーは、予めゼラチン化した澱粉をさらに含む、請求項27から38のいずれか1項に記載の軽量石膏ボード。
- 2つのカバーシートの間に配置される硬化石膏芯を含有する軽量石膏ボードであって、
前記硬化石膏芯が、水、スタッコ、予めゼラチン化した澱粉及びナトリウムトリメタホスフェートを含む石膏含有スラリーから製造され、前記予めゼラチン化した澱粉は、前記スタッコの重量に対して0.5重量%から10重量%の量で存在し、前記ナトリウムトリメタホスフェートは、前記スタッコの重量に対して0.12重量%から0.4重量%の量で存在し、
石膏結晶マトリックスを含有する前記硬化石膏芯は、(i)50ミクロン未満の直径の細孔サイズを有する空隙、(ii)50ミクロンから100ミクロンの直径の細孔サイズを有する空隙、及び、(iii)走査電子顕微鏡写真像を用いて空隙を計測して前記硬化石膏芯の全空隙体積の少なくとも20%を占める100ミクロンを超える直径の細孔サイズを有する空隙、から構成される細孔サイズ分布を有し、
前記石膏結晶マトリックスは、前記硬化石膏芯が、ASTM C−473に従って計測して、少なくとも11ポンド(約5kg)の平均の芯の固さを有するように形成されており、且つ、
前記ボードは35pcf(約560kg/m3)以下の密度を有することを特徴とする、軽量石膏ボード。 - 前記スラリーは、フォーム、及び、ナフタレンスルホネート分散剤をさらに含む、請求項40に記載の軽量石膏ボード。
- 前記ナフタレンスルホネート分散剤は、前記スタッコの重量に対して0.1重量%から3.0重量%の量で存在する、請求項41に記載の軽量石膏ボード。
- 前記硬化石膏芯の密度は、24pcf(約380kg/m3)〜31pcf(約500kg/m3)である、請求項40から42のいずれか1項に記載の軽量石膏ボード。
- 前記全空隙体積の少なくとも50%が、50ミクロンを超える直径の細孔サイズを有する空気空隙である、請求項40から43のいずれか1項に記載の軽量石膏ボード。
- 前記硬化石膏芯は、芯の体積の75%から92%の全空隙体積を有する、請求項40から44のいずれか1項に記載の軽量石膏ボード。
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