JP2021533296A - 高レベルの塩化物塩を有する石膏からの石膏ボードおよびそれに関連する有孔シートおよび方法 - Google Patents
高レベルの塩化物塩を有する石膏からの石膏ボードおよびそれに関連する有孔シートおよび方法 Download PDFInfo
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- JP2021533296A JP2021533296A JP2021506551A JP2021506551A JP2021533296A JP 2021533296 A JP2021533296 A JP 2021533296A JP 2021506551 A JP2021506551 A JP 2021506551A JP 2021506551 A JP2021506551 A JP 2021506551A JP 2021533296 A JP2021533296 A JP 2021533296A
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- cover sheet
- gypsum
- board
- holes
- weight
- Prior art date
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- Granted
Links
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- 229910052602 gypsum Inorganic materials 0.000 title claims abstract description 300
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- 238000000034 method Methods 0.000 title claims abstract description 35
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- 239000012792 core layer Substances 0.000 claims abstract description 63
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- 239000000347 magnesium hydroxide Substances 0.000 description 1
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
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- UEZVMMHDMIWARA-UHFFFAOYSA-M phosphonate Chemical compound [O-]P(=O)=O UEZVMMHDMIWARA-UHFFFAOYSA-M 0.000 description 1
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- 229940048086 sodium pyrophosphate Drugs 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
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- RYCLIXPGLDDLTM-UHFFFAOYSA-J tetrapotassium;phosphonato phosphate Chemical compound [K+].[K+].[K+].[K+].[O-]P([O-])(=O)OP([O-])([O-])=O RYCLIXPGLDDLTM-UHFFFAOYSA-J 0.000 description 1
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- UNXRWKVEANCORM-UHFFFAOYSA-I triphosphate(5-) Chemical compound [O-]P([O-])(=O)OP([O-])(=O)OP([O-])([O-])=O UNXRWKVEANCORM-UHFFFAOYSA-I 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
- B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
-
- 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
- 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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- 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
-
- 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
- B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- 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
- B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
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- 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
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
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- 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
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- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
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- 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
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- 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
- E04C2/043—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 of plaster
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Abstract
Description
CaSO4・2H2O→CaSO4・0.5H2O+1.5H2O
CaCO3+SO2→CaSO3+CO2
次に、亜硫酸カルシウムは次の反応で硫酸カルシウムに変換される。
CaSO3+2H2O+1/2O2→CaSO4・2H2O
次に、半水和物の形態は、天然石膏に使用されるのと同様の方法でか焼によって生成される場合がある。
特に、本発明は、石膏ボードであって、
凝結石膏を含むボードコア層、
外面および内面を有し、内面がボードコアの第1の面に接触する前側紙カバーシート、および
外面および内面を有し、内面がボードコア層の第2の面に接触する後側紙カバーシート層を含み、
ボードコア層は、前側紙カバーシートと後側紙カバーシートとの間に配置されており、後側紙カバーシートは、これを貫通した複数の孔を含み、
ボードコア層は、第1のカバーシートと第2のカバーシートとの間における水およびスタッコを含む水性スラリーの凝結から生じ、スタッコは硫酸カルシウム半水和物および1つ以上の塩化物塩を含み、水性スラリーは、
乾燥(水を含まない)ベースでの、少なくとも60質量パーセントの前記硫酸カルシウム半水和物、
1,000,000重量部の前記硫酸カルシウム半水和物あたり約500ppm〜約3000ppmの塩化物アニオン、および
0.2:1〜1.2:1の、水と硫酸カルシウム半水和物との重量比における水を含む、石膏ボードを提供する。
水およびスタッコの混合物を含む水性スラリーを調製することを含み、前記スタッコは硫酸カルシウム半水和物を含み、前記水性スラリーは、
乾燥ベースにおける少なくとも60質量パーセントの前記硫酸カルシウム半水和物、
1,000,000重量部(pbw)の前記硫酸カルシウム半水和物あたり約500ppm〜約3000ppmの塩化物アニオン、および
0.2:1〜1.2:1の、水と硫酸カルシウム半水和物との重量比における水を含む、混合物を含み、
前側紙カバーシートと後側紙カバーシートとの間に水性スラリーを配置することを含み、各紙カバーシートは内面および外面を有し、水性スラリーは、前側紙カバーシートおよび後側紙カバーシートの内面に接触し、
後側紙カバーシートは、これを貫通した複数の孔を含み、
硫酸カルシウム二水和物を含むボードコア層を含むパネルを形成するために前記硫酸カルシウム半水和物を凝結させることを含み、
パネルを乾燥させ、パネルを1つ以上の所定の寸法を有する石膏ボードに切断することを含む。
1,000,000重量部の前記硫酸カルシウム半水和物あたり約500ppm〜約3000ppmの塩化物アニオンとは、1,000,000重量部の前記硫酸カルシウム半水和物に対して、存在する塩化物アニオンの量が約500ppm〜約3000ppmであることを意味する。
図1は、石膏コア(ボードコア層)12(例えば、厚さ0.5インチ)が、それぞれ単層または多層の紙であってもよいバッカー紙カバーシート(後側カバーシート)14とフェイサー紙カバーシート(前側カバーシート)18との間に挟まれている本発明の壁板パネル(石膏ボード)10の断面図を示す。後側紙カバーシート(後側カバーシート)14は、孔20を有する。バッカー紙カバーシート14の内面は、石膏コア12に面するバッカー紙カバーシート14の結合面24を形成している。フェイサー紙カバーシート18の内面は、石膏コア12に面する結合面28を形成している。バッカー紙カバーシート14の外面は、壁板パネル10が内壁として設置された後、部屋の壁フレーミング(図3を参照)に面する。壁板パネル10を内壁として設置した後、フェイサー紙カバーシート18の外面が室内に面する。
硫酸カルシウム半水和物および大量の塩化物塩を含む水性石膏スラリーから本発明の石膏ボードを調製するために様々な方法を使用することができる。しかしながら、従来の石膏源の代わりに、上記のように、1つ以上の塩化物塩を含む石膏源が、製造プロセスにおいて代用される場合がある。
水およびスタッコの混合物を含む水性スラリーを調製することを含み、前記スタッコは硫酸カルシウム半水和物を含み、前記水性スラリーは、
乾燥ベースにおける少なくとも60質量パーセントの前記硫酸カルシウム半水和物、
1,000,000重量部(pbw)の前記硫酸カルシウム半水和物あたり約500ppm〜約3000ppmの塩化物アニオン、および
0.2:1〜1.2:1の、水と硫酸カルシウム半水和物との重量比における水を含む、混合物を含み、
前側紙カバーシートと後側紙カバーシートとの間に水性スラリーを配置することを含み、各紙カバーシートは内面および外面を有し、水性スラリーは、前側紙カバーシートおよび後側紙カバーシートの内面に接触し、
後側紙カバーシートは、これを貫通した複数の孔を含み、
硫酸カルシウム二水和物を含むボードコア層を含むパネルを形成するために前記硫酸カルシウム半水和物を凝結させることを含み、
パネルを乾燥させ、パネルを1つ以上の所定の寸法を有する石膏ボードに切断することを含む。
石膏パネルコアの結晶マトリックスを形成するために使用される硫酸カルシウム半水和物(通常、スタッコまたは焼石膏として知られる原材料で提供される)成分は、通常、天然源または合成源から得られる、ベータ硫酸カルシウム半水和物、水溶性硫酸カルシウム無水石膏、アルファ硫酸カルシウム半水和物、またはこれらのいずれかまたはすべての混合物を含む。いくつかの態様において、スタッコは、石膏源に関連した、またはスタッコのか焼、加工および/またはミキサへのスタッコの送達中に加えられる少量のクレーまたは他の成分などの、非石膏鉱物を含む場合がある。スタッコは、繊維質または非繊維質であり得る。通常は、生のスタッコは、少なくとも70質量%の硫酸カルシウム半水和物、好ましくは少なくとも80質量%の硫酸カルシウム半水和物、より好ましくは少なくとも85質量%の硫酸カルシウム半水和物、さらに好ましくは少なくとも90質量%の硫酸カルシウム半水和物を有する。
本発明の石膏ボードを形成するための水性石膏スラリーは、水およびスタッコを含み、水性石膏スラリーはまた、塩化物アニオンを含む。塩化物アニオンは、あらゆる供給源からの1つ以上の塩化物塩から生じる場合がある。一般に、1つ以上の塩化物塩は、本発明のボードのコアを形成するために使用される石膏源に存在する。したがって、1つ以上の塩化物塩のすべてまたは少なくとも大部分は、使用される石膏の供給源から石膏スラリーに導入される場合がある。石膏源は、合成石膏源、特に発電所の排煙流から得られる低品質の合成石膏である場合がある。そのような低品質の石膏源は、本発明による少なくとも1つのデンプン層を使用せずには壁板を形成するのに適していない場合がある。1つ以上の塩化物塩は、水性石膏スラリーを作製するために使用される水中の1つ以上の塩化物塩などの不純物から生じる場合もある。
ボードコア層を形成するために使用される石膏スラリーに存在する場合がある他の添加剤は、増粘剤、発泡体(適切な発泡剤から調製される)、分散剤、ポリリン酸塩(例えば、トリメタリン酸ナトリウム)、遅延剤、促進剤、再焼成阻害剤、バインダー、接着剤、二次分散助剤、レベリング剤または非レベリング剤、増粘剤、殺菌剤、殺菌剤、pH調整剤、緩衝剤、着色剤、補強材、難燃剤、撥水剤(例えばシロキサン)、充填剤、およびそれらの混合物を含む場合があるが、これらに限定されない。
水は、スラリーを流動可能にするあらゆる量でスラリーに添加される。使用される水の量は、それが使用される用途、使用されるまさにその分散剤、硫酸カルシウム半水和物の特性、および使用される添加剤によって大きく変化する。
後側紙カバーシートおよび前側紙カバーシートは、あらゆる適切な坪量を有するあらゆる適切な紙材料から作製される場合がある。
図3は、本外壁システムで使用される場合がある典型的な外部被覆システム30の斜視図である。図3は、複数の金属スタッド34、上部トラック36、下部トラック38を含む金属スタッド壁「骨格」32を示している。石膏ボード10(図1)は、壁を閉じ、壁または天井の1つ以上の内面を形成するために、あらゆる公知の方法で金属スタッド34の片側または両側に固定される場合がある。典型的な金属スタッド壁「骨格」は、参照により本明細書に組み込まれるコリンズらの米国特許第6,694,695号に従って製造される場合があり、これは、本発明の外壁システムを達成するための外部被覆パネルとの組み合わせに適している。この金属フレームシステムは、他の金属フレームが使用される場合もあるので、単に例示として提供されている。さらに代替的に、スタッド壁が代替的に木製スタッドを含む。
下記の条項は、本発明の様々な態様を説明する。
凝結石膏を含むボードコア層、
外面および内面を有し、内面がボードコアの第1の面に接触する前側紙カバーシート、および
外面および内面を有し、内面がボードコア層の第2の面に接触する後側紙カバーシート層を含み、
ボードコア層は、前側紙カバーシートと後側紙カバーシートとの間に配置されており、後側有孔紙カバーシートは、これを貫通した複数の孔を含み、
ボードコア層は、第1のカバーシートと第2のカバーシートとの間における水およびスタッコを含む水性スラリーの凝結から生じ、スタッコは硫酸カルシウム半水和物を含み、水性スラリーは、
乾燥ベースにおける少なくとも60質量パーセントの前記硫酸カルシウム半水和物、
1,000,000重量部の前記硫酸カルシウム半水和物あたり約500ppm〜約3000ppmの塩化物アニオン、および
0.2:1〜1.2:1の、水と硫酸カルシウム半水和物との重量比における水を含む、石膏ボード。
水およびスタッコの混合物を含む水性スラリーを調製することであって、スタッコは硫酸カルシウム半水和物を含み、水性スラリーは、
乾燥ベースにおける少なくとも60質量パーセントの前記硫酸カルシウム半水和物、
1,000,000重量部の前記硫酸カルシウム半水和物あたり約500ppm〜約3000ppmの塩化物アニオン、および
0.2:1〜1.2:1の、水と硫酸カルシウム半水和物との重量比における水の混合物を含む、調製することと、
前側カバーシートと後側カバーシートとの間に水性スラリーを配置することであって、各カバーシートは内面および外面を有し、
後側カバーシートは、貫通した複数の孔を含み、水性スラリーは、前側カバーシートおよび後側カバーシートの内面に接触する、配置することと、
硫酸カルシウム二水和物を含むボードコア層を含むパネルを形成するために硫酸カルシウム半水和物を凝結さることと、
パネルを乾燥させ、パネルを1つ以上の所定の寸法を有する石膏ボードに切断することと、を含む、方法。
Claims (10)
- 石膏ボードであって、
凝結石膏を含むボードコア層、
外面および内面を有し、前記内面が前記ボードコア層の第1の面に接触する前側紙カバーシート、および
外面および内面を有し、前記内面が前記ボードコア層の第2の面に接触する後側紙カバーシートを含み、
前記ボードコア層は、前記前側紙カバーシートと前記後側紙カバーシートとの間に配置されており、後側有孔紙カバーシートは、これを貫通した複数の孔を含み、
前記ボードコア層は、前記第1のカバーシートと前記第2のカバーシートとの間における水およびスタッコを含む水性スラリーの凝結から生じ、前記スタッコは硫酸カルシウム半水和物を含み、前記水性スラリーは、
乾燥ベースにおける少なくとも60重量パーセントの前記硫酸カルシウム半水和物、
1,000,000重量部の前記硫酸カルシウム半水和物あたり約500ppm〜約3000ppmの塩化物アニオン、および
0.2:1〜1.2:1の、前記水と前記硫酸カルシウム半水和物との重量比における水を含む、石膏ボード。 - 前記前側カバーシートが前側紙カバーシートであり、前記後側カバーシートが後側紙カバーシートである、請求項1記載の石膏ボード。
- 各孔は、約0.005インチ〜約0.1インチのサイズの範囲の開口部を規定する、請求項1記載の石膏ボード。
- 前記後側カバーシートは、約5孔/in2〜約50孔/in2の範囲の孔被覆密度を有する、請求項1記載の石膏ボード。
- 前記凝結石膏は、1つ以上の塩化物塩を含む合成石膏から形成されており、前記塩化物塩は、前記塩化物アニオンの少なくとも一部を提供する、請求項1記載の石膏ボード。
- 前記水性スラリーが、1,000,000重量部の前記硫酸カルシウム半水和物あたり約1000ppm〜約3000ppmの前記塩化物アニオンを有する、請求項5記載の石膏ボード。
- 石膏ボードを製作する方法であって、
水およびスタッコの混合物を含む水性スラリーを調製することであって、前記スタッコは硫酸カルシウム半水和物を含み、前記水性スラリーは、
乾燥ベースにおける少なくとも60質量パーセントの前記硫酸カルシウム半水和物、
1,000,000重量部の前記硫酸カルシウム半水和物あたり約500ppm〜約3000ppmの前記塩化物アニオン、および
0.2:1〜1.2:1の、水と硫酸カルシウム半水和物との重量比における前記水の混合物を含む、調製することと、
前側カバーシートと後側カバーシートとの間に水性スラリーを配置することであって、各カバーシートは内面および外面を有し、
前記後側カバーシートは、貫通した複数の孔を含み、前記水性スラリーは、前記前側カバーシートおよび前記後側カバーシートの内面に接触する、配置することと、
硫酸カルシウム二水和物を含むボードコア層を含むパネルを形成するために前記硫酸カルシウム半水和物を凝結さることと、
前記パネルを乾燥させ、前記パネルを1つ以上の所定の寸法を有する石膏ボードに切断することと、を含む、方法。 - 壁板穿孔装置によって前記後側カバーシートに複数の孔を導入することをさらに含む、請求項7記載の方法。
- 前記後側紙カバーシート用の前記紙がローラーから供給され、前記後側カバーシートが前記水性スラリーと接触する前に前記後側カバーシートに複数の孔が存在する、請求項7記載の方法。
- 前記前側カバーシートの前記外面が前記フレーミングとは反対側を向いている、請求項1記載の少なくとも1つの石膏ボードが取り付けられているフレーミングを含む壁システム。
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US16/401,675 US11186066B2 (en) | 2018-08-14 | 2019-05-02 | Gypsum board from gypsum having high level of chloride salt and a perforated sheet and methods associated therewith |
PCT/US2019/046091 WO2020036839A1 (en) | 2018-08-14 | 2019-08-12 | Gypsum board from gypsum having high level of chloride salt and a perforated sheet and methods associated therewith |
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US11186066B2 (en) | 2021-11-30 |
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