JP6189753B2 - 軽量かつ低密度の耐火性石膏パネル - Google Patents
軽量かつ低密度の耐火性石膏パネル Download PDFInfo
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Description
この一部継続出願は、2005年6月9日に出願された米国特許仮出願第60/688,839号明細書に対する優先権を主張する2010年6月8日に米国特許第7,731,794号明細書として発行された2006年6月7日に出願された米国特許出願第11/449,177号明細書の継続である2010年6月7日に出願された先の米国特許出願第12/795,125号明細書の利益を主張し、それらの全内容は、参照により本明細書中に援用される。
CaSO4・2H2O→CaSO4・1/2H2O+1と1/2H2O[1]
その半水和物は、硫酸カルシウムである無水石膏に変化するので(式2)、さらに250°F(120℃)に加熱すると、残存している結晶水が除去される:
CaSO4・1/2H2O→CaSO4+1/2H2O[2]
コアが392°F(200℃)に達するまでに、その石膏のすべてが、無水石膏相に変換される。これらの転移温度は、おおよそであり、石膏中の不純物または添加物によって変動し得る。反応[1]および[2]を引き起こすのに必要とされる脱水熱は、総計390Btu/lb(906kJ/kg)である。相変化反応によって吸収されるこのエネルギーおよび生成される水蒸気によって放出される熱は、実質的なヒートシンクとして作用し、防火材としての石膏のユニークな品質の多くに関与している。例えば、石膏を75°Fから400°F(24から204℃)に加熱するには、等質量のコンクリートを加熱するために必要なエネルギーの7倍超が必要である。
石膏スラリー中のシロキサンの使用は、シリコーン樹脂を原位置で形成することによって、完成したパネルに耐水性を付与する有用な手段であるが、シロキサンは、軽量かつ低密度のパネルを十分に保護しないと予想される。したがって、当該分野では、シロキサンによって通常付与される耐水性を増強することによって合理的なコストにおいて、改善された耐水性を有する軽量かつ低密度の耐火性石膏パネルを作製する方法が必要とされている。
サンプル石膏スラリーの配合。
パネルの作製
1/2インチ石膏パネルの重量減少試験。
湿潤石膏立方体の強度試験。
1/2インチの軽量石膏パネルの工場生産試験。
1/2インチの超軽量石膏パネルの工場生産試験。
本発明に従って作製された5/8インチの厚さの石膏パネルの高温断熱特性を調べるために、ASTM Pub.WK25392に論じられている手順に従った高温断熱試験を行った。
Δ/Δx(k(ΔT/Δx))+q=ρcp(ΔT/Δt)(1)
TI=t200℃−t40℃(2)
上記の実施例8に記載されたコア配合および紙カバーシートに従って作製された約1580lb/msfのパネル重量を有する公称5/8インチの厚さの石膏パネルを使用し、ULプロトコルU305の手順に従って、本発明のパネルを燃焼試験に供した。
この実施例では、実施例8のパネルを、この通常使用される基準においてパネルの強度特性を測定する釘引き抜き抵抗試験に供した。この釘引き抜き抵抗試験は、石膏パネルのコアの強度と、そのカバーシートの強度と、そのカバーシートと石膏との間の接着の強度との組み合わせの基準である。この試験は、ボードに主な亀裂が生じるまで頭部がパネルを通っている釘を引き抜くために必要な最大の力を測定する。この実施例の試験では、ASTM C473−09に従って釘引き抜き抵抗試験を行った。
石膏スラリー配合にシロキサンを加えること、およびアルファ化デンプンとともにシロキサンを加えることの影響、ならびにそのようなスラリーを用いて作製された本発明のパネルを評価するために、実験室サンプルを作製した。この試験において使用した配合を、下記の表8に詳述する。
(付記)
(付記1)
2枚のカバーシートの間に配置された固化石膏コアを含む石膏パネルであって、該パネルは、約27〜約37lb/ft 3 (約433〜約592kg/m 3 )の範囲の密度および少なくとも約17分の断熱指標を有する、石膏パネル。
(付記2)
前記パネルが、少なくとも約11lb(約5kg)のコア硬度を有し、約0.625インチ(約1.588cm)の公称パネル厚において、該パネルは、少なくとも約85lb(約39kg)の釘引き抜き抵抗を有し、該釘引き抜き抵抗は、ASTM規格C473−09に従って測定される、付記1記載の石膏パネル。
(付記3)
前記パネルが、約10%またはそれ以下の高温収縮を示す、付記1または付記2記載の石膏パネル。
(付記4)
前記パネルが、約5重量%またはそれ以下の吸水性を有し、該吸水性は、ASTM規格C473−09に従って測定される、付記1〜3のいずれか1つに記載の石膏パネル。
(付記5)
前記固化石膏コアが、少なくとも水、漆喰およびデンプンを、デンプンを含まないスラリーから形成された固化石膏コアよりも高いコア硬度を提供するのに有効な量で含むスラリーから形成される、付記1〜4のいずれか1つに記載の石膏パネル。
(付記6)
前記固化石膏コアが、少なくとも水;漆喰;該漆喰の重量に基づいて約0.5重量%〜約10重量%の量のデンプン;および該漆喰の重量に基づいて約0.1重量%〜約0.3重量%の量の鉱物繊維、ガラス繊維もしくは炭素繊維またはそれらの組み合わせを含むスラリーから形成される、付記1〜5のいずれか1つに記載の石膏パネル。
(付記7)
前記スラリーがさらに、(i)前記漆喰の重量に基づいて約0.1重量%〜約3重量%の量の分散剤;(ii)該漆喰の重量に基づいて約0.1重量%〜約0.5重量%の量のホスフェート含有成分;(iii)該漆喰の重量に基づいて少なくとも約0.4重量%の量のシロキサン;(iv)該漆喰の重量に基づいて少なくとも約2重量%の量のアルファ化デンプン;または(v)(i)〜(iv)の任意の組み合わせを含む、付記5または付記6記載の石膏パネル。
(付記8)
前記スラリーがさらに、(i)前記パネルが約5重量%またはそれ以下の吸水性を有するような該パネルの耐水性であって、該吸水性は、ASTM規格C473−09に従って測定される、耐水性;(ii)該パネルがシロキサンを含まないスラリーから形成された固化石膏コアを有するパネルの高温収縮より小さい高温収縮を示すような該パネルの高温収縮抵抗性;(iii)該パネルがシロキサンを含まないスラリーから形成された固化石膏コアを有するパネルの高温収縮の約半分またはそれ以下の高温収縮を示すような該パネルの高温収縮抵抗性;または(iv)(i)〜(iii)の任意の組み合わせを高めるのに有効な量のシロキサンを含む、付記5〜7のいずれか1つに記載の石膏パネル。
(付記9)
2枚のカバーシートの間に配置された固化石膏コアを含む耐火性石膏パネルであって、該パネルは、約27〜約37lb/ft 3 (約433〜約592kg/m 3 )の範囲の密度を有し、該パネルは、UL U419またはUL U305手順に従って作製された該パネルのアセンブリを通る熱の透過を阻害するのに有効であり、一方の表面は、熱源に暴露され、反対の非加熱面は、それに取り付けられた複数のセンサーを備え、該非加熱面上の単一センサーの最高温度は、約30分の経過時間において約415°F(約213℃)未満であり、該熱源は、ASTM規格E119−09aに従う時間温度曲線に従い、該センサーは、該アセンブリを作製するために使用された手順に従ったパターンで整列される、耐火性石膏パネル。
(付記10)
前記パネルが、前記アセンブリを通る熱の透過を阻害するのに有効であり、前記非加熱面上のセンサーの平均温度が、約30分の経過時間において約340°F(約171℃)未満である、付記9記載の耐火性石膏パネル。
(付記11)
(i)前記パネルが、少なくとも約11lb(約5kg)のコア硬度を有するか;(ii)該パネルが、約17分より高い断熱指標を有するか;(iii)約0.625インチ(約1.588cm)の公称パネル厚において、該パネルが、少なくとも約85lb(約39kg)の釘引き抜き抵抗を有し、該釘引き抜き抵抗は、ASTM規格C473−09に従って測定されるか;(iv)該パネルが、約10%またはそれ以下の高温収縮を示すか;(v)該パネルが、約5重量%またはそれ以下の吸水性を有し、該吸水性は、ASTM規格C473−09に従って測定されるか;または(vi)(i)〜(v)の任意の組み合わせである、付記9または付記10記載の耐火性石膏パネル。
(付記12)
前記アセンブリが、UL U305手順に従って作製されるとき、前記パネルは、該アセンブリを通る熱の透過を阻害するのに有効であり、
(a)前記非加熱面上の単一センサーの最高温度は、
(i)UL U305に従って測定したとき、約45分の経過時間において約415°F(約213℃)未満、もしくは
(ii)UL U305に従って測定したとき、約45分の経過時間において約270°F(約132℃)未満であるか;
(b)該非加熱面上のセンサーの平均温度は、
(i)UL U305に従って測定したとき、約30分の経過時間において約340°F(約171℃)未満、もしくは
(ii)UL U305に従って測定したとき、約45分の経過時間において約245°F(約118℃)未満であるか;または
(c)(a)および(b)の任意の組み合わせである、
付記9〜11のいずれか1つに記載の耐火性石膏パネル。
Claims (45)
- 2枚のカバーシートの間に配置された固化石膏コアを含む石膏パネルであって、
該固化石膏コアは、少なくとも水、漆喰およびアルファ化デンプンを含み、バーミキュライトを含まないスラリーから形成され、
該アルファ化デンプンは、該漆喰の重量に基づいて0.5重量%〜10重量%の量で存在し、
前記固化石膏コアは、石膏二水和物の結晶性マトリックスを含んでおり、該パネルは、30〜34lb/ft3(約480〜約545kg/m3)の範囲の密度、ASTM C473−09に従って少なくとも11lb(約5kg)の平均コア硬度、0.625インチ(約1.6cm)の厚さ、および少なくとも17分の断熱指標を有する、石膏パネル。 - 2枚のカバーシートの間に配置された固化石膏コアを含む石膏パネルであって、
該固化石膏コアは、少なくとも水、漆喰およびアルファ化デンプンを含み、バーミキュライトを含まないスラリーから形成され、
該アルファ化デンプンは、該漆喰の重量に基づいて0.5重量%〜10重量%の量で存在し、
前記固化石膏コアは、石膏二水和物の結晶性マトリックスを含んでおり、
該パネルは、30〜34lb/ft3(約480〜約545kg/m3)の範囲の密度、0.625インチ(約1.6cm)の厚さ、およびASTM C473−09に従って少なくとも11lb(約5kg)の平均コア硬度を有し、
UL U419に従って構成された、一層の前記パネルをそれぞれ第1面と第2面とに備えるアセンブリであって、前記第1面と前記第2面の前記パネルは前記アセンブリを通る熱の透過を阻害するように配置されているアセンブリを用いて、ASTM規格E119−09aに従いセンサーを配置して、前記第1面の前記パネルの表面を、ASTM規格E119−09aに従う時間温度曲線に従い、加熱したとき、温度センサーの最高単一温度は30分後で415°F(約213℃)未満である、石膏パネル。 - 2枚のカバーシートの間に配置された固化石膏コアを含む石膏パネルであって、
該固化石膏コアは、少なくとも水、漆喰およびアルファ化デンプンを含み、バーミキュライトを含まないスラリーから形成され、
該アルファ化デンプンは、該漆喰の重量に基づいて0.5重量%〜10重量%の量で存在し、
前記固化石膏コアは、石膏二水和物の結晶性マトリックスを含んでおり、
該パネルは、30〜34lb/ft3(約480〜約545kg/m3)の範囲の密度、0.625インチ(約1.6cm)の厚さ、およびASTM C473−09に従って少なくとも11lb(約5kg)の平均コア硬度を有し、
UL U305に従って構成された、一層の前記パネルをそれぞれ第1面と第2面とに備えるアセンブリであって、前記第1面と前記第2面の前記パネルは前記アセンブリを通る熱の透過を阻害するように配置されているアセンブリを用いて、ASTM規格E119−09aに従いセンサーを配置して、前記第1面の前記パネルの表面を、ASTM規格E119−09aに従う時間温度曲線に従い、加熱したとき、温度センサーの最高単一温度は30分後で415°F(約213℃)未満である、石膏パネル。 - 18分の断熱指標を有する、請求項1記載の石膏パネル。
- 前記パネルは、10%またはそれ以下の高温収縮を示す、請求項1記載の石膏パネル。
- 前記パネルは、5重量%またはそれ以下の吸水性を有し、該吸水性は、ASTM規格C473−09に従って測定される、請求項1記載の石膏パネル。
- 前記スラリーは、さらに、前記漆喰の重量に基づいて0.1重量%〜3重量%の量で分散剤を含む、請求項1記載の石膏パネル。
- 前記分散剤は、ナフタレンスルホネートである、請求項7記載の石膏パネル。
- 前記スラリーは、前記漆喰の重量に基づいて0.1重量%〜0.3重量%の量の少なくとも鉱物繊維、ガラス繊維もしくは炭素繊維またはそれらの組み合わせを、さらに含む、請求項1記載の石膏パネル。
- 前記スラリーは、さらに、前記漆喰の重量に基づいて0.1重量%〜0.5重量%の量でホスフェート含有成分を含む、請求項1記載の石膏パネル。
- 前記スラリーは、さらに、シロキサンを含む、請求項1記載の石膏パネル。
- 前記シロキサンは、前記漆喰の重量に基づいて少なくとも0.4重量%の量で存在する、請求項11記載の石膏パネル。
- 前記パネルの高温収縮が、シロキサンを含まない組成物から形成された固化石膏コアを有するパネルの高温収縮の50%またはそれ以下である、請求項12記載の石膏パネル。
- 固化石膏が、0.6〜1.2の水/漆喰比を有するスラリーから形成される、請求項1記載の石膏パネル。
- 前記パネルは、少なくとも85lb(約39kg)の釘引き抜き抵抗を有し、該釘引き抜き抵抗は、ASTM規格C473−09に従って測定される、請求項1〜14のいずれか1項記載の石膏パネル。
- 耐火性石膏パネルを作製するための方法であって、該方法は、
(a)少なくとも水、漆喰およびアルファ化デンプンを含み、バーミキュライトを含まない石膏スラリーを調製する工程であって、該アルファ化デンプンは、該漆喰の重量に基づいて0.5重量%〜10重量%の量で存在する、工程、
(b)該石膏スラリーを第1のカバーシートと第2のカバーシートとの間に配置することにより、固化石膏コアを含むアセンブリを形成する工程であって、該固化石膏コアは、石膏二水和物の結晶性マトリックスを含んでいる、工程、
(c)該アセンブリを所定の寸法のパネルに切断する工程、および
(d)該パネルを乾燥させる工程、
を備え、
該パネルは、30〜34lb/ft3(約480〜約545kg/m3)の範囲の密度、ASTM C473−09に従って少なくとも11lb(約5kg)の平均コア硬度、0.625インチ(約1.6cm)の厚さ、および少なくとも17分の断熱指標を有する、方法。 - (e)少なくとも1枚のカバーシートを耐水コーティングまたは誤用防止コーティングでコーティングする工程をさらに含む、請求項16記載の方法。
- 少なくとも1つの支持構造および請求項1記載の石膏パネルを備えるアセンブリであって、該石膏パネルが、少なくとも1つの締め付け要素を使用して該支持構造に取り付けられている、アセンブリ。
- 壁または天井システムを形成する、請求項18記載のアセンブリ。
- 請求項18または請求項19記載のアセンブリを作製する方法であって、
(a)少なくとも1つの支持構造を提供する工程、および
(b)少なくとも1つの締め付け要素を使用して該支持構造に前記石膏パネルを取り付けることにより、建築アセンブリを形成する工程
を包含する、方法。 - 前記パネルの前記密度は30〜32lb/ft3(約480〜約515kg/m3)の範囲である、請求項1記載の石膏パネル。
- 2枚のカバーシートの間に配置された固化石膏コアを含む石膏パネルであって、
該固化石膏コアは、少なくとも水、漆喰およびアルファ化デンプンを含むスラリーから形成され、
該アルファ化デンプンは、該漆喰の重量に基づいて0.5重量%〜10重量%の量で存在し、
前記固化石膏コアは、石膏二水和物の結晶性マトリックスを含んでおり、該パネルは、30〜32lb/ft3(約480〜約515kg/m3)の範囲の密度、ASTM C473−09に従って少なくとも11lb(約5kg)の平均コア硬度、および0.625インチ(約1.6cm)の厚さで測定した場合に少なくとも17分の断熱指標を有する、石膏パネル。 - 前記パネルの厚さは0.625インチ(約1.6cm)であり、
UL U419又はUL U305に従って構成された、一層の石膏パネルをそれぞれ第1面と第2面とに備えるアセンブリであって、前記第1面と前記第2面の前記パネルは前記アセンブリを通る熱の透過を阻害するように配置されているアセンブリを用いて、ASTM規格E119−09aに従いセンサーを配置して、前記第1面の前記パネルの表面を、ASTM規格E119−09aに従う時間温度曲線に従い、加熱したとき、温度センサーの最高単一温度は30分後で415°F(約213℃)未満である、請求項22記載の石膏パネル。 - 0.625インチ(約1.6cm)の厚さで測定した場合に少なくとも18分の断熱指標を有する、請求項22記載の石膏パネル。
- 前記パネルは、x−y方向において10%またはそれ以下の高温収縮を示す、請求項22記載の石膏パネル。
- 前記スラリーは、さらに、シロキサンを含み、該パネルは、5重量%またはそれ以下の吸水性を有し、該吸水性は、ASTM規格C473−09に従って測定される、請求項22記載の石膏パネル。
- 前記スラリーは、さらに、前記漆喰の重量に基づいて少なくとも0.4重量%の量でシロキサンを含む、請求項22記載の石膏パネル。
- 前記パネルは、シロキサンを含まないスラリーから形成された固化石膏コアを有するパネルの高温収縮より小さい高温収縮を示す、請求項27記載の石膏パネル。
- 前記スラリーは、前記漆喰の重量に基づいて0.1重量%〜0.3重量%の量の少なくとも鉱物繊維、ガラス繊維もしくは炭素繊維またはそれらの組み合わせを、さらに含む、請求項22記載の石膏パネル。
- 前記アルファ化デンプンが、前記漆喰の重量に基づいて0.5重量%〜4重量%の量で存在する、請求項22記載の石膏パネル。
- 前記スラリーは、さらに、前記漆喰の重量に基づいて0.1重量%〜3重量%の量で分散剤を含む、請求項22記載の石膏パネル。
- 前記分散剤は、ナフタレンスルホネートである、請求項31記載の石膏パネル。
- 前記スラリーは、さらに、前記漆喰の重量に基づいて0.12重量%〜0.4重量%の量でトリメタリン酸ナトリウムを含む、請求項22記載の石膏パネル。
- 前記アセンブリはUL U419に従って構成される、請求項23記載の石膏パネル。
- 前記アセンブリはUL U305に従って構成される、請求項23記載の石膏パネル。
- 2枚のカバーシートの間に配置された固化石膏コアを含む石膏パネルであって、
該固化石膏コアは、少なくとも水、漆喰、アルファ化デンプン、シロキサンを含むスラリーから形成され、
該アルファ化デンプンは、該漆喰の重量に基づいて0.3重量%〜10重量%の量で存在し、
前記パネルは、シロキサンを含まないスラリーから形成された固化石膏コアを有するパネルの高温収縮より小さい高温収縮を示し、
前記固化石膏コアは、石膏二水和物の結晶性マトリックスを含んでおり、該パネルは、27〜32lb/ft3(約430〜約515kg/m3)の範囲の密度、ASTM C473−09に従って少なくとも11lb(約5kg)の平均コア硬度、0.625インチ(約1.6cm)の厚さ、および少なくとも17分の断熱指標を有する、石膏パネル。 - UL U419に従って構成された、一層の石膏パネルをそれぞれ第1面と第2面とに備えるアセンブリであって、前記第1面と前記第2面の前記パネルは前記アセンブリを通る熱の透過を阻害するように配置されているアセンブリを用いて、ASTM規格E119−09aに従いセンサーを配置して、前記第1面の前記パネルの表面を、ASTM規格E119−09aに従う時間温度曲線に従い、加熱したとき、温度センサーの最高単一温度は30分後で415°F(約213℃)未満である、請求項36記載の石膏パネル。
- UL U305に従って構成された、一層の石膏パネルをそれぞれ第1面と第2面とに備えるアセンブリであって、前記第1面と前記第2面の前記パネルは前記アセンブリを通る熱の透過を阻害するように配置されているアセンブリを用いて、ASTM規格E119−09aに従いセンサーを配置して、前記第1面の前記パネルの表面を、ASTM規格E119−09aに従う時間温度曲線に従い、加熱したとき、温度センサーの最高単一温度は30分後で415°F(約213℃)未満である、請求項36記載の石膏パネル。
- 18分の断熱指標を有する、請求項36記載の石膏パネル。
- 前記パネルは、10%またはそれ以下の高温収縮を示す、請求項36記載の石膏パネル。
- 前記パネルは、5重量%またはそれ以下の吸水性を有し、該吸水性は、ASTM規格C473−09に従って測定される、請求項36記載の石膏パネル。
- 前記スラリーは、さらに、前記漆喰の重量に基づいて0.1重量%〜3重量%の量でナフタレンスルホネートを含む、請求項36記載の石膏パネル。
- 前記スラリーは、さらに、前記漆喰の重量に基づいて0.1重量%〜0.5重量%の量でホスフェート含有成分を含む、請求項36記載の石膏パネル。
- 前記シロキサンは、前記漆喰の重量に基づいて少なくとも0.4重量%の量で存在する、請求項36記載の石膏パネル。
- 前記パネルの高温収縮が、シロキサンを含まない組成物から形成された固化石膏コアを有するパネルの高温収縮の50%またはそれ以下である、請求項36記載の石膏パネル。
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