JP4322678B2 - 永久変形に対する耐性が増大した石膏含有組成物 - Google Patents
永久変形に対する耐性が増大した石膏含有組成物 Download PDFInfo
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Description
本発明は概して、石膏組成物に関する。より詳細には、本発明は、増大した、強度、寸法安定性、及び永久変形に対する耐性を示す硬化石膏含有組成物、それに関連する、方法、石膏含有組成物、及び製品に関する。
硬化石膏(硫酸カルシウム二水和物)は、多くのタイプの製品に一般に含まれる周知の原料である。例として、硬化石膏は、従来のプラスターを使用して製造される最終製品(例えば、プラスターで表面仕上げされたビル内壁)の主要成分であり、また、ビルの内壁や天井の典型的乾式壁建築で使用される紙の表面を持つ石膏板での主要成分である。更に、硬化石膏は、石膏/セルロース繊維の複合の板及び製品の主要成分であり、石膏板の端間の接合部を埋め、滑らかにする製品にも含まれる。また、精密に機械加工される、造形や型製造に有用な材料などの多くの特殊材料によって、硬化石膏を主要量含む製品が製造される。
本発明は、硫酸カルシウム材料を含む組成物、硬化石膏含有製品、及び、強度を維持もしくは増大させつつ、永久変形に対する増大した耐性を有する硬化石膏含有製品を製造する方法を提供する。
本発明は、硫酸カルシウム材料の硬化前処理におけるテトラメタホスフェートを提供する。本発明は、種々の硬化石膏含有製品を製造するために、従来技術で使用される組成物及び方法に類似した組成物及び方法を用いて実施できる。種々の硬化石膏含有製品を製造するための、本発明の幾つかの好ましい実施態様の組成物及び方法と従来技術で使用される組成物及び方法との本質的差異は、テトラメタホスフェート化合物(テトラメタホスフェート塩など)を含めることである。テトラメタホスフェート化合物を使用して本明細書記載の混合物を形成できるが、テトラメタホスフェートは、混合物中でイオンとして存在しうる(特に、水が存在し、硬化と乾燥前では)ことが当業者には理解されよう。従って、用語「テトラメタホスフェート化合物」は、このような化合物自体又はテトラメタホスフェートイオンを意味することを意図している。本発明は、本発明の方法の実施において硬化前処理において特に有用であるので、焼き石膏の再水和による硬化石膏の連結マトリックスの形成はテトラメタホスフェートイオンの存在下起こり、それによって本発明の利点が生じる。他の点では、本発明の組成物及び方法は、従来技術の対応する組成物及び方法と同じでありうる。
2P2O5+2H2O→H4P4O12
次いで、以下のように、この酸を水酸化ナトリウムと反応させて4水和物であるナトリウム テトラメタホスフェートを形成する。
H4P4O12+4NaOH→Na4P4O12・4H2O
ナトリウム テトラメタホスフェートは高溶性形態にあるので、塩又は溶媒を溶液生成物に加えて、ナトリウム テトラメタホスフェートを堆積させることができる。例えば、エタノール又は塩化ナトリウムが、この目的のために加えられうる。同様に、カリウム、リチウム、アルミニウムなどのテトラメタホスフェート塩を製造できる。シクロテトラホスフェートの合成は、例えば、Bell,R.N.;Audrieth,L.F.;Hill,O.F. Industrial and Engineering Chemistry 1952,44,568(これは、引用により本明細書に援用される)に記載されている。
硬化石膏含有板のサンプルを、本発明に基づき実験室で製造し、永久変形に対する耐性に関し、ナトリウム テトラメタホスフェートを含まない方法及び組成物を用い製造したサンプル板と比較した。
本実施例は、ホスフェート添加剤が存在しない場合(対照)及びナトリウム トリメタホスフェートが存在する場合の水和速度と比較した、本発明に基づく硬化前処理においてナトリウム シクロテトラホスフェートが存在する場合の焼き石膏から硫酸カルシウム二水和物への水和速度を示す。
本実施例は、硬化前処理においてテトラメタホスフェート化合物を含めて製造された立方体の圧縮強度を、ホスフェート添加剤無しで製造した立方体の圧縮強度、そして、硬化前処理においてナトリウム トリメタホスフェートを含めて製造された立方体と比較する。用いた試験方法は、ASTM C472−93に基づいた。
好適な実施態様を強調して本発明を記載したが、好適な実施態様のバリエーションを使用してもよく、本明細書に具体的に説明したのとは異なるように本発明を実施してもよいことが意図されることは当業者に明白であろう。従って、本発明は、以下の特許請求の範囲で規定された本発明の範囲内に包含される全ての改変物を含むものである。
Claims (50)
- 硫酸カルシウム材料と、水と、テトラメタホスフェート化合物との混合物を含む組成物であって、該組成物を成型して硬化石膏の連結マトリックスを含む1.27cmの石膏板を形成し、幅15cm×長さ61cm×高さ1.27cmの前記石膏板の長さ方向の両端を2つの1.27cm幅の支持体上に水平に置き、温度32℃、相対湿度90%の条件下、2週間、前記石膏板をこの位置に保った後、前記石膏板の端の上縁の間に延びる想像上の水平面からの、前記石膏板の上面中央の距離(cm)を測定する方法により、たわみを測定したとき、前記たわみが約0.25cm未満である、組成物。
- 混合物がα化デンプンを更に含む、請求項1に記載の組成物。
- 混合物が水性の泡を更に含む、請求項1に記載の組成物。
- 混合物がα化デンプンを更に含む、請求項3に記載の組成物。
- 水と混合したとき、機械加工できる硬化石膏含有製品の製造に有用な組成物であって、デンプンと、水再分散可能ポリマーの粒子と、硫酸カルシウム材料と、テトラメタホスフェート化合物との混合物を含む、組成物。
- 水と混合したとき、石膏板の端間の接合部を仕上げるために有用な組成物であって、結合剤と、増粘剤と、非レベリング剤と、硫酸カルシウム材料と、テトラメタホスフェート化合物との混合物を含む、組成物。
- 吸音タイル製造に有用な組成物であって、糊化デンプンと、鉱滓綿と、硫酸カルシウム材料と、水と、テトラメタホスフェート化合物との混合物を含む、組成物。
- 吸音タイル製造に有用な組成物であって、糊化デンプンと、発泡パーライト粒子と、繊維補強剤と、硫酸カルシウム材料と、水と、テトラメタホスフェート化合物との混合物を含む、組成物。
- 石膏板製造に有用な組成物であって、硫酸カルシウム材料と、水と、促進剤と、テトラメタホスフェート化合物との混合物を含む、組成物。
- 混合物がα化デンプンを更に含む、請求項9に記載の組成物。
- 混合物が水性の泡を更に含む、請求項9に記載の組成物。
- 混合物がα化デンプンを更に含む、請求項11に記載の組成物。
- 硫酸カルシウム材料と、水と、テトラメタホスフェート化合物との混合物を含む組成物であって、硬化石膏の連結マトリックスを含む製品を製造するために該組成物を使用するとき、テトラメタホスフェート化合物を混合物に含めなかった場合よりも大きな強度を該製品が有する、組成物。
- 混合物がα化デンプンを更に含む、請求項13に記載の組成物。
- 混合物が水性の泡を更に含む、請求項13に記載の組成物。
- 混合物がα化デンプンを更に含む、請求項15に記載の組成物。
- 永久変形に対する耐性が増大した硬化石膏含有製品の製造方法であって、
硫酸カルシウム材料と、水と、テトラメタホスフェート化合物との混合物を形成すること、及び、
硫酸カルシウム材料が、硬化石膏材料の連結マトリックスを形成するのに十分な条件下に混合物を維持すること
を含む方法であって、
永久変形に対してテトラメタホスフェート化合物を混合物に含めなかった場合よりも大きな耐性を硬化石膏含有製品が有する量で、テトラメタホスフェート化合物を混合物に含めている、方法。 - 混合物中のテトラメタホスフェート化合物の濃度が、硫酸カルシウム材料の重量に基づき約0.004〜約2.0重量%である、請求項17に記載の方法。
- 混合物中のテトラメタホスフェート化合物の濃度が、硫酸カルシウム材料の重量に基づき約0.04〜約0.16重量%である、請求項17に記載の方法。
- 混合物中のテトラメタホスフェート化合物の濃度が、硫酸カルシウム材料の重量に基づき約0.08重量%である、請求項17に記載の方法。
- 永久変形に対してより大きな耐性を有するのに加え、硬化石膏含有製品がまた、テトラメタホスフェート化合物を混合物に含めなかった場合よりも大きな強度を有する、請求項17に記載の方法。
- 混合物がα化デンプンを更に含む、請求項17に記載の方法。
- 硫酸カルシウム材料が、硫酸カルシウム硬石膏;硫酸カルシウム半水和物;又は、カルシウム及び硫酸のイオン;のうちの1つ以上を含む、請求項17に記載の方法。
- 硫酸カルシウム材料が、硫酸カルシウム半水和物を含む、請求項23に記載の方法。
- 請求項17に記載の方法によって製造された硬化石膏含有製品。
- 強度が増大した硬化石膏含有製品の製造方法であって、
硫酸カルシウム材料と、水と、テトラメタホスフェート化合物との混合物を形成すること、及び
硫酸カルシウム材料が、硬化石膏材料の連結マトリックスを形成するのに十分な条件下に混合物を維持すること
を含む方法であって、
テトラメタホスフェート化合物を混合物に含めなかった場合よりも大きな強度を硬化石膏含有製品が有する量で、テトラメタホスフェート化合物を混合物に含めている、方法。 - 混合物中のテトラメタホスフェート化合物の濃度が、硫酸カルシウム材料の重量に基づき約0.004〜約2.0重量%である、請求項26に記載の方法。
- 混合物中のテトラメタホスフェート化合物の濃度が、硫酸カルシウム材料の重量に基づき約0.04〜約0.16重量%である、請求項26に記載の方法。
- 混合物中のテトラメタホスフェート化合物の濃度が、硫酸カルシウム材料の重量に基づき約0.08重量%である、請求項26に記載の方法。
- 混合物がα化デンプンを更に含む、請求項26に記載の方法。
- 硫酸カルシウム材料が、硫酸カルシウム硬石膏;硫酸カルシウム半水和物;又は、カルシウム及び硫酸のイオン;のうちの1つ以上を含む、請求項26に記載の方法。
- 硫酸カルシウム材料が硫酸カルシウム半水和物を含む、請求項31に記載の方法。
- 請求項26に記載の方法によって製造された硬化石膏含有製品。
- 少なくとも焼き石膏、水、及び少なくとも1つのテトラメタホスフェート化合物から形成される硬化石膏の連結マトリックスを含む石膏板であって、
幅15cm×長さ61cm×高さ1.27cmの前記石膏板の長さ方向の両端を2つの1.27cm幅の支持体上に水平に置き、温度32℃、相対湿度90%の条件下、2週間、前記石膏板をこの位置に保った後、前記石膏板の端の上縁の間に延びる想像上の水平面からの、前記石膏板の上面中央の距離(cm)を測定する方法により、たわみを測定したとき、前記たわみが約0.25cm未満である、石膏板。 - テトラメタホスフェート化合物の量が、焼き石膏の約0.004〜約2.0重量%である、請求項34に記載の石膏板。
- 硬化石膏が、カバーシートの間に挟まれたコア材料の形態である、請求項34に記載の石膏板。
- カバーシートが紙を含む、請求項36に記載の石膏板。
- テトラメタホスフェート化合物が、ナトリウム テトラメタホスフェート、リチウム テトラメタホスフェート、カリウム テトラメタホスフェート、アンモニウム テトラメタホスフェート、アルミニウム テトラメタホスフェート、及びそれらの混合物からなる群から選択される、請求項34に記載の石膏板。
- テトラメタホスフェートがナトリウム テトラメタホスフェートである、請求項34に記載の石膏板。
- 硬化の完了後、過剰水の乾燥前に前記石膏板の長さと幅を測定し、次いで、乾燥後に再び前記石膏板の長さと幅を測定して、幅122cm当たり約0.15cm未満かつ長さ366cm当たり約0.76cm未満の乾燥収縮を有する、請求項34に記載の石膏板。
- 硬化の完了後、過剰水の乾燥前に前記石膏板の長さと幅を測定し、次いで、乾燥後に再び前記石膏板の長さと幅を測定して、その幅で約0.13%未満、その長さで約0.26%未満の乾燥収縮を有する、請求項34に記載の石膏板。
- α化デンプンを更に含む、請求項34に記載の石膏板。
- α化デンプンの量が、石膏の約0.08〜約0.5重量%である、請求項42に記載の石膏板。
- α化デンプンの量が、石膏の約0.16〜約0.4重量%である、請求項42に記載の石膏板。
- α化デンプンの量が、石膏の約0.3重量%である、請求項42に記載の石膏板。
- 硬化石膏が、その中に均一に分布した空隙を有する、請求項34に記載の石膏板。
- Yが、発泡剤の86〜99重量%では0である、請求項47に記載の石膏板。
- 硬化石膏が、α化デンプンから更に形成される、請求項46に記載の石膏板。
- カバーシートの間に挟まれた材料のコアを含む石膏板であって、コアが、硬化石膏の連結マトリックスを含み、該板が、
カバーシートの間に混合物を形成又は堆積させること(但し、混合物は、硫酸カルシウム材料、水、及び1つ以上のテトラメタホスフェート化合物を含む)、及び
硫酸カルシウム材料が、硬化石膏の連結マトリックスを形成するのに十分な条件下に混合物を維持すること
を含む方法によって製造され、
幅15cm×長さ61cm×高さ1.27cmの前記石膏板の長さ方向の両端を2つの1.27cm幅の支持体上に水平に置き、温度32℃、相対湿度90%の条件下、2週間、前記石膏板をこの位置に保った後、前記石膏板の端の上縁の間に延びる想像上の水平面からの、前記石膏板の上面中央の距離(cm)を測定する方法により、たわみを測定したとき、前記たわみが約0.25cm未満である、石膏板。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US10/015,066 US6815049B2 (en) | 2001-12-11 | 2001-12-11 | Gypsum-containing composition having enhanced resistance to permanent deformation |
PCT/US2002/039362 WO2003053878A1 (en) | 2001-12-11 | 2002-12-09 | Gypsum-containing composition having enhanced resistance to permanent deformation |
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JP2005512933A JP2005512933A (ja) | 2005-05-12 |
JP2005512933A5 JP2005512933A5 (ja) | 2009-04-09 |
JP4322678B2 true JP4322678B2 (ja) | 2009-09-02 |
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JP2003554596A Expired - Fee Related JP4322678B2 (ja) | 2001-12-11 | 2002-12-09 | 永久変形に対する耐性が増大した石膏含有組成物 |
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US (1) | US6815049B2 (ja) |
EP (1) | EP1453772B9 (ja) |
JP (1) | JP4322678B2 (ja) |
AR (1) | AR037768A1 (ja) |
AT (1) | ATE319666T1 (ja) |
AU (2) | AU2002351337B2 (ja) |
BR (2) | BRPI0214853A2 (ja) |
CA (1) | CA2469606C (ja) |
DE (1) | DE60209785T2 (ja) |
DK (1) | DK1453772T3 (ja) |
ES (1) | ES2260492T3 (ja) |
GB (1) | GB0524032D0 (ja) |
MX (1) | MXPA04005687A (ja) |
NO (1) | NO340938B1 (ja) |
NZ (1) | NZ533415A (ja) |
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NZ533415A (en) | 2005-11-25 |
BRPI0214853B1 (pt) | 2018-01-16 |
EP1453772B9 (en) | 2006-07-05 |
AU2008202979B2 (en) | 2011-03-24 |
ES2260492T3 (es) | 2006-11-01 |
EP1453772A1 (en) | 2004-09-08 |
BRPI0214853A2 (pt) | 2016-11-16 |
GB0524032D0 (en) | 2006-01-04 |
AU2002351337B2 (en) | 2008-04-10 |
DK1453772T3 (da) | 2006-06-26 |
JP2005512933A (ja) | 2005-05-12 |
US20030118803A1 (en) | 2003-06-26 |
WO2003053878A1 (en) | 2003-07-03 |
US6815049B2 (en) | 2004-11-09 |
ATE319666T1 (de) | 2006-03-15 |
EP1453772B1 (en) | 2006-03-08 |
AU2008202979A1 (en) | 2008-08-07 |
MXPA04005687A (es) | 2005-03-23 |
DE60209785D1 (de) | 2006-05-04 |
CA2469606C (en) | 2011-08-02 |
AU2002351337A1 (en) | 2003-07-09 |
NO340938B1 (no) | 2017-07-24 |
CA2469606A1 (en) | 2003-07-03 |
AR037768A1 (es) | 2004-12-01 |
PL370382A1 (en) | 2005-05-30 |
DE60209785T2 (de) | 2006-11-23 |
NO20042918L (no) | 2004-07-09 |
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