JP5922614B2 - 高デンプン軽量石膏ウォールボード - Google Patents
高デンプン軽量石膏ウォールボード Download PDFInfo
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- JP5922614B2 JP5922614B2 JP2013101741A JP2013101741A JP5922614B2 JP 5922614 B2 JP5922614 B2 JP 5922614B2 JP 2013101741 A JP2013101741 A JP 2013101741A JP 2013101741 A JP2013101741 A JP 2013101741A JP 5922614 B2 JP5922614 B2 JP 5922614B2
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- stucco
- foaming agent
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- 229910052602 gypsum Inorganic materials 0.000 title claims description 155
- 239000010440 gypsum Substances 0.000 title claims description 155
- 229920002472 Starch Polymers 0.000 title claims description 21
- 239000008107 starch Substances 0.000 title claims description 18
- 235000019698 starch Nutrition 0.000 title description 19
- 239000000203 mixture Substances 0.000 claims description 73
- 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 59
- 239000002270 dispersing agent Substances 0.000 claims description 57
- 229920000881 Modified starch Polymers 0.000 claims description 45
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 27
- 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 23
- 239000000835 fiber Substances 0.000 claims description 9
- 229920000388 Polyphosphate Polymers 0.000 claims description 8
- 239000003365 glass fiber Substances 0.000 claims description 8
- 239000001205 polyphosphate Substances 0.000 claims description 8
- 235000011176 polyphosphates Nutrition 0.000 claims description 8
- 238000005452 bending Methods 0.000 claims description 6
- 239000003795 chemical substances by application Substances 0.000 claims description 2
- 239000004088 foaming agent Substances 0.000 claims 30
- 239000006260 foam Substances 0.000 claims 19
- 239000000853 adhesive Substances 0.000 claims 5
- 230000001070 adhesive effect Effects 0.000 claims 5
- 230000001143 conditioned effect Effects 0.000 claims 5
- 230000003750 conditioning effect Effects 0.000 claims 1
- 238000005303 weighing Methods 0.000 claims 1
- 239000002002 slurry Substances 0.000 description 74
- 238000009472 formulation Methods 0.000 description 35
- 239000007864 aqueous solution Substances 0.000 description 19
- AZSFNUJOCKMOGB-UHFFFAOYSA-K cyclotriphosphate(3-) Chemical compound [O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 AZSFNUJOCKMOGB-UHFFFAOYSA-K 0.000 description 17
- 239000000047 product Substances 0.000 description 17
- 238000000034 method Methods 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 8
- 239000007787 solid Substances 0.000 description 7
- 229920002261 Corn starch Polymers 0.000 description 6
- 239000008120 corn starch Substances 0.000 description 6
- 239000004615 ingredient Substances 0.000 description 5
- 125000005341 metaphosphate group Chemical group 0.000 description 5
- 239000000843 powder Substances 0.000 description 5
- 239000000654 additive Substances 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 229920000417 polynaphthalene Polymers 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- PASHVRUKOFIRIK-UHFFFAOYSA-L calcium sulfate dihydrate Chemical compound O.O.[Ca+2].[O-]S([O-])(=O)=O PASHVRUKOFIRIK-UHFFFAOYSA-L 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000000344 soap Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 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
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 2
- 241000612118 Samolus valerandi Species 0.000 description 2
- 240000008042 Zea mays Species 0.000 description 2
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 2
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 2
- 235000005822 corn Nutrition 0.000 description 2
- 239000008121 dextrose Substances 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 235000013312 flour Nutrition 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 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
- 150000003839 salts Chemical class 0.000 description 2
- 239000008399 tap water Substances 0.000 description 2
- 235000020679 tap water Nutrition 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 1
- 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
- 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 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 239000004368 Modified starch Substances 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical group [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 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
- 230000000996 additive effect Effects 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
- 239000004566 building material Substances 0.000 description 1
- 239000011575 calcium Chemical group 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 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 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
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 239000007859 condensation product Substances 0.000 description 1
- 239000013078 crystal Substances 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
- 238000000151 deposition Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 235000019426 modified starch Nutrition 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
- 238000004080 punching Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 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
- 239000002195 soluble material Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 150000003871 sulfonates Chemical class 0.000 description 1
- 230000002195 synergetic effect Effects 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
- 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 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
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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
- C04B11/00—Calcium sulfate cements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B37/00—Boring by making use of ultrasonic energy
-
- 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
- C04B24/16—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
-
- 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
-
- 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
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/0045—Polymers chosen for their physico-chemical characteristics
-
- 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
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/40—Surface-active agents, dispersants
- C04B2103/408—Dispersants
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
- C04B2111/0062—Gypsum-paper board like materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2973—Particular cross section
- Y10T428/2978—Surface characteristic
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
- Y10T428/31993—Of paper
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/665—Including a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Mechanical Engineering (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Paper (AREA)
- Laminated Bodies (AREA)
Description
石膏スラリーの配合を下記表1に示す。表1中のすべての値は、乾燥スタッコの重量に対する重量パーセントで示されている。括弧内の値は、ポンド(lb/MSF)での乾燥重量である。
Yuらの米国特許第6342284号及びYuらの第6632550号(これらは、参照されることにより本明細書に組み込まれる。)に従って、サンプルの石膏ウォールボードを作製した。ここには、上記特許の実施例5に記載されている、気泡の別途生成、及びそれ以外の成分からなるスラリーへの気泡の導入が含まれる。
スラリーの配合及び試験結果を含めて、さらなる石膏ウォールボードの例(ボードC、D及びE)を下記表3に示す。表3のスラリーの配合はスラリーの主要成分を含む。括弧内の値は、乾燥スタッコの重量に対する重量パーセントで示されている。
実験室で、Southard CKSボードスタッコ(United States Gypsum Corp.(Chicago、Illinois)から入手可能)、及び水道水を用いて湿潤立方体強度試験(wet cube strength test)を行い、その湿潤圧縮強度を測定した。以下の実験室試験方法を用いた。
スラリーの配合を含めて、別の試験を実施した(試験ボード1及び2)。試験結果を下記表5に示す。表5のスラリーの配合は、スラリーの主成分を含む。括弧内の値は、乾燥スタッコの重量に対する重量パーセントで示されている。
α化コーンスターチを水で10%の濃度に調製し(湿潤デンプンの調製)、HYONIC PFMセッケン(GEO Specialty Chemicals(Lafayette、Indiana)から入手可能)のブレンドを用いたこと以外は、実施例2と同様にして配合B(実施例1)を用いて、さらなる試験を実施した(試験ボード3及び4)。例えば、試験ボード3は、65〜70重量%/35〜30重量%の範囲のHYONIC PFM 10/HYONIC PFM 33のブレンドを用いて作製した。例えば、試験ボード4は、HYONIC PFM 10/HYONIC PFM 33の70/30 wt/wtのブレンドを用いて作製した。試験結果を下記表6に示す。
水、スタッコ、α化デンプン及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であって、
前記α化デンプンが、スタッコの重量に対して約0.5重量%〜約10重量%の量で存在し、前記ナフタレンスルホネート分散剤が、スタッコの重量に対して約0.1重量%〜約3.0重量%の量で存在する石膏含有スラリー。
[付記2]
前記ナフタレンスルホネート分散剤が、スタッコの重量に対して約0.25重量%〜約2.0重量%の量で存在する、付記1に記載の石膏含有スラリー。
[付記3]
前記ナフタレンスルホネート分散剤が、スタッコの重量に対して約0.3重量%〜約0.7重量%の量で存在する、付記1に記載の石膏含有スラリー。
[付記4]
スタッコの重量に対して少なくとも約0.12重量%の量で存在するトリメタリン酸ナトリウムをさらに含む、付記1に記載の石膏含有スラリー。
[付記5]
水、スタッコ、α化デンプン及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であって、
前記α化デンプンが、スタッコの重量に対して約0.5重量%〜約10重量%の量で存在し、前記ナフタレンスルホネート分散剤が、約40重量%〜約45重量%のナフタレンスルホネートを含む水溶液の形態のものであり、当該水溶液が、スタッコの重量に対して約0.5重量%〜約2.5重量%の量で存在する石膏含有スラリー。
[付記6]
前記ナフタレンスルホネート分散剤が、約40重量%〜約45重量%のナフタレンスルホネートを含む水溶液の形態のものであり、当該水溶液が、スタッコの重量に対して約0.5重量%〜約2.0重量%の量で存在する、付記5に記載の石膏含有スラリー。
[付記7]
前記ナフタレンスルホネート分散剤が、約40重量%〜約45重量%のナフタレンスルホネートを含む水溶液の形態のものであり、当該水溶液が、スタッコの重量に対して約0.7重量%〜約1.5重量%の量で存在する、付記5に記載の石膏含有スラリー。
[付記8]
スタッコの重量に対して少なくとも約0.12重量%の量で存在するトリメタリン酸ナトリウムをさらに含む、付記5に記載の石膏含有スラリー。
[付記9]
2枚の実質的に平行なカバーシートの間に形成された硬化石膏組成物を含む、高強度かつ低粉化性の軽量石膏ウォールボードであって、
前記硬化石膏組成物が、水、スタッコ、α化デンプン及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用いて作製されたものであり、
前記スラリーにおいて、前記α化デンプンが、スタッコの重量に対して約0.5重量%〜約10重量%の量で存在する軽量石膏ウォールボード。
[付記10]
前記ナフタレンスルホネート分散剤が、スタッコの重量に対して約0.1重量%〜約3.0重量%の量で存在する、付記9に記載の軽量石膏ウォールボード。
[付記11]
前記ナフタレンスルホネート分散剤が、スタッコの重量に対して約0.25重量%〜約2.0重量%の量で存在する、付記9に記載の軽量石膏ウォールボード。
[付記12]
前記ナフタレンスルホネート分散剤が、スタッコの重量に対して約0.3重量%〜約0.7重量%の量で存在する、付記9に記載の軽量石膏ウォールボード。
[付記13]
前記ナフタレンスルホネート分散剤が、約40重量%〜約45重量%のナフタレンスルホネートを含む水溶液の形態のものであり、当該水溶液が、スタッコの重量に対して約0.5重量%〜約2.5重量%の量で存在する、付記9に記載の軽量石膏ウォールボード。
[付記14]
前記ナフタレンスルホネート分散剤が、約40重量%〜約45重量%のナフタレンスルホネートを含む水溶液の形態のものであり、当該水溶液が、スタッコの重量に対して約0.5重量%〜約2.0重量%の量で存在する、付記9に記載の軽量石膏ウォールボード。
[付記15]
前記ナフタレンスルホネート分散剤が、約40重量%〜約45重量%のナフタレンスルホネートを含む水溶液の形態のものであり、当該水溶液が、スタッコの重量に対して約0.7重量%〜約1.5重量%の量で存在する、付記9に記載の軽量石膏ウォールボード。
[付記16]
スタッコの重量に対して約0.12重量%〜約0.4重量%の量で存在するトリメタリン酸ナトリウムをさらに含む、付記9に記載の軽量石膏ウォールボード。
[付記17]
約1000lb/MSF〜約1400lb/MSFの乾燥重量を有する、付記9に記載の軽量石膏ウォールボード。
[付記18]
約1000lb/MSF〜約1400lb/MSFの乾燥重量を有する、付記16に記載の軽量石膏ウォールボード。
[付記19]
約500lb/MSF〜約1000lb/MSFの乾燥重量を有する、付記16に記載の軽量石膏ウォールボード。
[付記20]
高強度かつ低粉化性の石膏ウォールボードを作製する方法であって、
(a)水、スタッコ、α化デンプン及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ステップと、
(b)前記石膏含有スラリーを第1のカバーシート上に堆積させるステップと、
(c)堆積したスラリーの上に第2のカバーシートを配置することによって、石膏ウォールボードを形成するステップと、
(d)前記石膏含有スラリーが切断に十分な程度に硬化した後、前記石膏ウォールボードを切断するステップと、
(e)前記石膏ウォールボードを乾燥させるステップと、
を含み、
前記スラリーにおいて、前記α化デンプンが、スタッコの重量に対して約0.5重量%〜約10重量%の量で存在し、前記ナフタレンスルホネート分散剤が、スタッコの重量に対して約0.1重量%〜約3.0重量%の量で存在する方法。
[付記21]
前記第1のカバーシート及び前記第2のカバーシートが紙製である、付記20に記載の方法。
[付記22]
前記スラリーが、スタッコの重量に対して約0.12重量%〜約0.4重量%の量で存在するトリメタリン酸ナトリウムをさらに含む、付記20に記載の方法。
Claims (22)
- 2枚のカバーシートの間に配置された硬化石膏組成物を含有する軽量石膏ボードであって、
前記硬化石膏組成物は、少なくとも、水、スタッコ、α化デンプン、ナフタレンスルホネート、及び起泡剤から形成され、
前記α化デンプンは、前記スタッコの重量に対して0.5重量%〜10重量%の量で存在し、
前記起泡剤は、相対的に不安定な泡を生成する起泡剤を大重量部、相対的に安定な泡を生成する起泡剤を少重量部含み、
前記気泡剤の量、及び前記相対的に安定な泡を生成する起泡剤に対する前記相対的に不安定な泡を生成する起泡剤の重量比は、前記硬化石膏組成物中に気泡分布を形成するために有効であり、
前記α化デンプン及び前記気泡分布は、34lb/ft3(約540kg/m3)以下の密度、及び、ASTM基準C−473に従って計測して、少なくとも11lb(約5kg)のコア硬度をもたらすために有効である、
ことを特徴とする軽量石膏ボード。 - 前記起泡剤は、前記相対的に不安定な泡を生成する起泡剤及び前記相対的に安定な泡を生成する起泡剤の混合物を含む、請求項1に記載の軽量石膏ボード。
- 前記起泡剤は、重量で65%の前記相対的に不安定な泡を生成する起泡剤を含む、請求項1又は2に記載の軽量石膏ボード。
- 前記起泡剤は、前記スタッコの重量に対して0.1重量%以下の量で存在する、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α化デンプンは、前記α化デンプンを含まない石膏と比べて前記硬化石膏組成物の前記コア硬度を増加するために有効である、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α化デンプンは、前記スタッコの重量に対して0.5重量%以下から6%の量で存在する、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。
- (a)相対湿度90%及び気温90°F(約32℃)の条件を生じるために十分な環境で6時間の間コンディショニングして(b)一定重量になるまで乾燥させた後で、少なくとも15lb(約6.8kg)の加湿接着荷重を有する、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α化デンプンは、前記α化デンプンを含有しない石膏組成物と比較して前記硬化石膏組成物の前記コア硬度を増加させるために有効であり、
前記ボードは、(a)相対湿度90%及び気温90°F(約32℃)の条件を生じるために十分な環境で6時間の間コンディショニングして(b)一定重量になるまで乾燥させた後で、少なくとも15lb(約6.8kg)の加湿接着荷重を有し、
1/2インチ(約1.3cm)のボードの厚さで、前記ボードは、ASTM基準C−473に従って計測して、少なくとも65lb(約29kg)の釘抜き抵抗を有する、
請求項1に記載の軽量石膏ボード。 - 前記起泡剤は、前記スタッコの重量に対して0.1重量%以下の量で存在し、
1/2インチ(約1.3cm)のボードの厚さで、前記ボードは、ASTM基準C−473に従って計測して、少なくとも72lb(約33kg)の釘抜き抵抗を有する、
請求項8に記載の軽量石膏ボード。 - 前記ボードは、(a)相対湿度90%及び気温90°F(約32℃)の条件を生じるために十分な環境で6時間の間コンディショニングして(b)一定重量になるまで乾燥させた後で、少なくとも17lb(約7.7kg)の加湿接着荷重を有し、
1/2インチ(約1.3cm)のボードの厚さで、前記ボードは、ASTM基準C−473に従って計測して、少なくとも77lb(約35kg)の釘抜き抵抗を有する、
請求項1に記載の軽量石膏ボード。 - 1/2インチ(約1.3cm)のボードの厚さで、前記ボードは、ASTM基準C−473に従って計測して、少なくとも流れ方向に36lb(約16kg)及び/又は直交方向に107lb(約48.5kg)の平均曲げ強度を有することを特徴とする、請求項9に記載の軽量石膏ボード。
- 前記硬化石膏組成物は、さらに、前記スタッコの重量に対して0.2重量%から3.0重量%のナフタレンスルホネート分散剤から形成され、
前記硬化石膏組成物は、前記スタッコに対する水の割合が0.7から1.2で形成され、
前記ボードは、(a)相対湿度90%及び気温90°F(約32℃)の条件を生じるために十分な環境で6時間の間コンディショニングして(b)一定重量になるまで乾燥させた後で、少なくとも17lb(約7.7kg)の加湿接着荷重を有する、請求項11に記載の軽量石膏ボード。 - 前記気泡分布は、24lb/ft3(約380kg/m3)〜31lb/ft3(約500kg/m3)のボード密度をもたらすために有効である、請求項1から12のいずれか1項に記載の計量石膏ボード。
- 2枚のカバーシートの間に配置された硬化石膏組成物を含有する軽量石膏ボードであって、
前記硬化石膏組成物は、少なくとも、水、スタッコ、α化デンプン、ナフタレンスルホネート分散剤、起泡剤、及びポリホスフェートから形成され、
前記スタッコは、少なくとも700lb/MSF(約3.4kg/m2)の量で存在し、
前記α化デンプンは、前記スタッコの重量に対して0.5重量%〜10重量%の量で存在し、
前記α化デンプンは、前記α化デンプンを含有しない石膏組成物と比較して前記硬化石膏組成物の前記コア硬度を増加させるために効率的であり、
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%〜3.0重量%の量で存在し、
前記ポリホスフェートは、前記スタッコの重量に対して0.12重量%〜0.4重量%の量で存在し、
前記ボードは、34lb/ft3(約540kg/m3)以下の密度を有し、
前記ボードは、ASTM基準C−473に従って計測して、少なくとも11lb(約5kg)の平均コア硬度を有することを特徴とする軽量石膏ボード。 - 前記スタッコは、少なくとも700lb/MSF(約3.4kg/m2)〜1300lb/MSF(約6.3kg/m2)の量で存在する、請求項14記載の軽量石膏ボード。
- 前記スタッコの重量に対して0.20重量%〜1.30重量%の紙繊維及び/又はガラス繊維をさらに含む、請求項14又は15に記載の軽量石膏ボード。
- 前記スタッコの重量に対して0.2重量%〜0.9重量%の促進剤をさらに含む、請求項14から16のいずれか1項に記載の軽量石膏ボード。
- 前記石膏組成物は、さらに、少なくとも促進剤から形成され、
前記スタッコは、少なくとも700lb/MSF(約3.4kg/m2)〜約1300lb/MSF(約6.3kg/m2)の量で存在し、
前記α化デンプンは、前記スタッコの重量に対して0.5重量%〜6重量%の量で存在し、
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0.2重量%〜3.0重量%の量で存在し、
前記起泡剤は、相対的に不安定な泡を生成する起泡剤を大重量部、相対的に安定な泡を生成する起泡剤を少重量部含み、
前記気泡剤の量、及び前記相対的に安定な泡を生成する起泡剤に対する前記相対的に不安定な泡を生成する起泡剤の重量比は、前記硬化石膏組成物中に気泡分布を形成するために有効であり、
前記起泡剤は、前記スタッコの重量に対して0.1重量%以下の量で存在し、
前記α化デンプン及び前記気泡分布は、24lb/ft3(約380kg/m3)〜34lb/ft3(約540kg/m3)のボード密度、1/2インチ(約1.3cm)のボードの厚さで、少なくとも11lb(約5kg)のコア硬度、並びに、ASTM基準C−473に従って計測して、少なくとも65lb(約29kg)の釘抜き抵抗、並びに、少なくとも流れ方向に36lb(約16kg)及び/又は直交方向に107lb(約48.5kg)の平均曲げ強度をもたらすのに有効であり、
前記ボードは、(a)相対湿度90%及び気温90°F(約32℃)の条件を生じるために十分な環境で6時間の間コンディショニングして(b)一定重量になるまで乾燥させた後で、少なくとも15lb(約6.8kg)の加湿接着荷重を有する、請求項14に記載の軽量石膏ボード。 - 前記起泡剤は、前記スタッコの重量に対して0.02重量%〜0.03重量%の量で存在する、請求項18に記載の軽量石膏ボード。
- 前記硬化石膏組成物は、さらに、少なくとも紙繊維及び/又はガラス繊維から形成され、
前記硬化石膏組成物は、前記スタッコに対する水の割合が0.7から1.2で形成され、
前記ポリホスフェートは、トリメタリン酸ナトリウムを含み、
前記紙繊維及び/又は前記ガラス繊維は、前記スタッコの重量に対して0.20重量%〜1.30重量%の量で存在し、
前記促進剤は、耐熱性促進剤を含み、
前記促進剤は、前記スタッコの重量に対して0.2重量%〜0.9重量%の量で存在し、
前記ボードは、(a)相対湿度90%及び気温90°F(約32℃)の条件を生じるために十分な環境で6時間の間コンディショニングして(b)一定重量になるまで乾燥させた後で、少なくとも17lb(約7.7kg)の加湿接着荷重を有する、請求項18に記載の軽量石膏ボード。 - 前記硬化石膏組成物は、さらに、少なくとも起泡剤から形成され、
前記起泡剤は、相対的に不安定な泡を生成する起泡剤を大重量部、相対的に安定な泡を生成する起泡剤を少重量部含み、
前記気泡剤の量、及び前記相対的に安定な泡を生成する起泡剤に対する前記相対的に不安定な泡を生成する起泡剤の重量比は、前記硬化石膏組成物中に気泡分布を形成するために有効である、請求項14から17のいずれか1項に記載の軽量石膏ボード。 - 前記ボードの密度は、24lb/ft3(約380kg/m3)〜31lb/ft3(約500kg/m3)である、請求項18から21のいずれか1項に記載の計量石膏ボード。
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