JP6196477B2 - 軽量石膏ボード及びその製造方法 - Google Patents
軽量石膏ボード及びその製造方法 Download PDFInfo
- Publication number
- JP6196477B2 JP6196477B2 JP2013117709A JP2013117709A JP6196477B2 JP 6196477 B2 JP6196477 B2 JP 6196477B2 JP 2013117709 A JP2013117709 A JP 2013117709A JP 2013117709 A JP2013117709 A JP 2013117709A JP 6196477 B2 JP6196477 B2 JP 6196477B2
- Authority
- JP
- Japan
- Prior art keywords
- gypsum
- microns
- bubbles
- gypsum board
- lightweight
- 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.)
- Ceased
Links
- 229910052602 gypsum Inorganic materials 0.000 title claims description 266
- 239000010440 gypsum Substances 0.000 title claims description 266
- 238000004519 manufacturing process Methods 0.000 title claims description 15
- 239000002002 slurry Substances 0.000 claims description 63
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 54
- 239000002270 dispersing agent Substances 0.000 claims description 45
- PSZYNBSKGUBXEH-UHFFFAOYSA-N naphthalene-1-sulfonic acid Chemical compound C1=CC=C2C(S(=O)(=O)O)=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-N 0.000 claims description 36
- 229920000881 Modified starch Polymers 0.000 claims description 31
- 239000013078 crystal Substances 0.000 claims description 27
- 239000006260 foam Substances 0.000 claims description 22
- 229920002472 Starch Polymers 0.000 claims description 18
- 239000008107 starch Substances 0.000 claims description 18
- 235000019698 starch Nutrition 0.000 claims description 18
- 239000011148 porous material Substances 0.000 claims description 16
- 239000011159 matrix material Substances 0.000 claims description 13
- 238000001000 micrograph Methods 0.000 claims description 10
- 238000002591 computed tomography Methods 0.000 claims description 4
- 238000005516 engineering process Methods 0.000 claims description 4
- -1 stucco Substances 0.000 claims description 3
- 238000004458 analytical method Methods 0.000 claims 2
- 150000001875 compounds Chemical class 0.000 claims 1
- 229920000137 polyphosphoric acid Polymers 0.000 claims 1
- 239000000203 mixture Substances 0.000 description 64
- 238000009472 formulation Methods 0.000 description 56
- 238000012360 testing method Methods 0.000 description 45
- 239000000428 dust Substances 0.000 description 38
- 239000000344 soap Substances 0.000 description 23
- 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 description 23
- 239000003365 glass fiber Substances 0.000 description 21
- 239000000123 paper Substances 0.000 description 21
- 238000001878 scanning electron micrograph Methods 0.000 description 20
- 238000009826 distribution Methods 0.000 description 19
- AZSFNUJOCKMOGB-UHFFFAOYSA-N cyclotriphosphoric acid Chemical compound OP1(=O)OP(O)(=O)OP(O)(=O)O1 AZSFNUJOCKMOGB-UHFFFAOYSA-N 0.000 description 16
- 239000000047 product Substances 0.000 description 15
- 238000005520 cutting process Methods 0.000 description 12
- 238000005553 drilling Methods 0.000 description 12
- 238000000034 method Methods 0.000 description 12
- 229920002261 Corn starch Polymers 0.000 description 8
- 239000007864 aqueous solution Substances 0.000 description 8
- 210000004027 cell Anatomy 0.000 description 8
- 239000008120 corn starch Substances 0.000 description 8
- 238000004626 scanning electron microscopy Methods 0.000 description 8
- 239000007787 solid Substances 0.000 description 8
- 241000196324 Embryophyta Species 0.000 description 7
- 238000001035 drying Methods 0.000 description 7
- 238000005452 bending Methods 0.000 description 6
- 239000002131 composite material Substances 0.000 description 6
- 238000012545 processing Methods 0.000 description 6
- 230000002829 reductive effect Effects 0.000 description 6
- 229920000388 Polyphosphate Polymers 0.000 description 5
- PASHVRUKOFIRIK-UHFFFAOYSA-L calcium sulfate dihydrate Chemical compound O.O.[Ca+2].[O-]S([O-])(=O)=O PASHVRUKOFIRIK-UHFFFAOYSA-L 0.000 description 5
- 239000000835 fiber Substances 0.000 description 5
- 238000005259 measurement Methods 0.000 description 5
- 239000001205 polyphosphate Substances 0.000 description 5
- 235000011176 polyphosphates Nutrition 0.000 description 5
- 238000001704 evaporation Methods 0.000 description 4
- 239000004615 ingredient Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- PSZYNBSKGUBXEH-UHFFFAOYSA-M naphthalene-1-sulfonate Chemical compound C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-M 0.000 description 4
- 229920000417 polynaphthalene Polymers 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound 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 3
- 239000000654 additive Substances 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 210000002421 cell wall Anatomy 0.000 description 3
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- 230000000694 effects Effects 0.000 description 3
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- 230000009969 flowable effect Effects 0.000 description 3
- 239000012634 fragment Substances 0.000 description 3
- 239000011521 glass Substances 0.000 description 3
- 125000005341 metaphosphate group Chemical group 0.000 description 3
- 150000003839 salts Chemical class 0.000 description 3
- 239000011734 sodium Substances 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- 239000008399 tap water Substances 0.000 description 3
- 235000020679 tap water Nutrition 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
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 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 2
- 239000003139 biocide Substances 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Inorganic materials [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000010410 dusting Methods 0.000 description 2
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 2
- 238000011049 filling Methods 0.000 description 2
- 238000007676 flexural strength test Methods 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 239000008103 glucose Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 150000003871 sulfonates Chemical class 0.000 description 2
- 230000002195 synergetic effect Effects 0.000 description 2
- 238000004078 waterproofing Methods 0.000 description 2
- 239000013585 weight reducing agent Substances 0.000 description 2
- KZEVSDGEBAJOTK-UHFFFAOYSA-N 1-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)-2-[5-[2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidin-5-yl]-1,3,4-oxadiazol-2-yl]ethanone Chemical compound N1N=NC=2CN(CCC=21)C(CC=1OC(=NN=1)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F)=O KZEVSDGEBAJOTK-UHFFFAOYSA-N 0.000 description 1
- HMUNWXXNJPVALC-UHFFFAOYSA-N 1-[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]piperazin-1-yl]-2-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)ethanone Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)N1CCN(CC1)C(CN1CC2=C(CC1)NN=N2)=O HMUNWXXNJPVALC-UHFFFAOYSA-N 0.000 description 1
- LDXJRKWFNNFDSA-UHFFFAOYSA-N 2-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)-1-[4-[2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidin-5-yl]piperazin-1-yl]ethanone Chemical compound C1CN(CC2=NNN=C21)CC(=O)N3CCN(CC3)C4=CN=C(N=C4)NCC5=CC(=CC=C5)OC(F)(F)F LDXJRKWFNNFDSA-UHFFFAOYSA-N 0.000 description 1
- JQMFQLVAJGZSQS-UHFFFAOYSA-N 2-[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]piperazin-1-yl]-N-(2-oxo-3H-1,3-benzoxazol-6-yl)acetamide Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)N1CCN(CC1)CC(=O)NC1=CC2=C(NC(O2)=O)C=C1 JQMFQLVAJGZSQS-UHFFFAOYSA-N 0.000 description 1
- YJLUBHOZZTYQIP-UHFFFAOYSA-N 2-[5-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]-1,3,4-oxadiazol-2-yl]-1-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)ethanone Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)C1=NN=C(O1)CC(=O)N1CC2=C(CC1)NN=N2 YJLUBHOZZTYQIP-UHFFFAOYSA-N 0.000 description 1
- CONKBQPVFMXDOV-QHCPKHFHSA-N 6-[(5S)-5-[[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]piperazin-1-yl]methyl]-2-oxo-1,3-oxazolidin-3-yl]-3H-1,3-benzoxazol-2-one Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)N1CCN(CC1)C[C@H]1CN(C(O1)=O)C1=CC2=C(NC(O2)=O)C=C1 CONKBQPVFMXDOV-QHCPKHFHSA-N 0.000 description 1
- 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
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-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
- 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
- 125000002015 acyclic group Chemical group 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000007664 blowing Methods 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
- 230000009172 bursting Effects 0.000 description 1
- 238000001354 calcination Methods 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
- 238000004364 calculation method Methods 0.000 description 1
- 150000001720 carbohydrates Chemical class 0.000 description 1
- 235000014633 carbohydrates Nutrition 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000010960 commercial process Methods 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 230000002860 competitive effect Effects 0.000 description 1
- 230000003750 conditioning effect Effects 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 group 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 235000013312 flour Nutrition 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
- 238000010348 incorporation Methods 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 239000012074 organic phase Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 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
- 239000000843 powder Substances 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000000758 substrate Substances 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
- 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
Classifications
-
- 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
-
- 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
- B32B13/14—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
-
- 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
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
-
- 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
- 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
-
- 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
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
-
- 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
- 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
-
- 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
- C04B2111/40—Porous or lightweight 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.]
- Y10T428/249967—Inorganic matrix in void-containing component
- Y10T428/249968—Of hydraulic-setting material
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Structural Engineering (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Laminated Bodies (AREA)
- Finishing Walls (AREA)
- Building Environments (AREA)
- Panels For Use In Building Construction (AREA)
Description
ナフタレンスルホン酸分散剤はアルファ化デンプンと架橋して、乾燥後に石膏結晶に一緒に結合することが可能であり、それ故、石膏複合体の乾燥強度を高めることが可能であることもまた見出された。それ故、アルファ化デンプンとナフタレンスルホン酸分散剤との組み合わせは、固化した石膏結晶を一緒に結合するのり様効果をもたらす。トリメタリン酸塩は、石膏スラリーの水要求量に影響を与えると過去においては認識されていない。しかしながら、本発明者らは、特定の分散剤の存在下にトリメタリン酸塩のレベルをこれまで知られていないレベルにまで高めることで、高デンプンレベルの存在下であっても予想外に少ない水の量で適切なスラリー流動性を達成することが可能となることを発見した。
これは、次いで、乾燥のための燃料使用量が低減され、ならびに、その後の水除去プロセスステップに関連するプロセス時間が短縮されるために、当然のことながら非常に望ましい。それ故、本発明者らはまた、石膏ボードの乾燥強度は、ウォールボードの形成に用いられるスラリーにおいて、ナフタレンスルホン酸分散剤をアルファ化デンプンと組み合わせて用いることにより増大させることが可能であることも発見した。
総気泡容積の少なくとも60%が約10ミクロン超の平均直径を有する気泡を含み、総気泡容積の少なくとも10%が約5ミクロン未満の平均直径を有する水泡を含む。気泡および水泡として約80%〜約92%の固化石膏コアの総気泡容積(総コア気泡容積)を有する、この様式で調製された低密度ボードコアは、粉塵発生が顕著に低減されると共に風媒性とならないように、ボードの切断、鋸引き、ルータ加工、スナッピング、釘打あるいはねじ込み、またはドリリングに曝された気泡中に、相当の量の微細な粉塵および他のデブリを捕捉すると考えられている。より好ましくは、本ウォールボードの固化石膏コアは、
平均で直径約50ミクロン〜直径約300ミクロンの範囲にある気泡を有することが可能である。
加えて、図15〜19に示されているとおり、より小さい結晶サイズ(特にきわめて小さい、きわめて微細な針としての)および結晶のより高密度の充填は、より厚い気泡壁を形成する役割を有する。
図示された高密度化領域は壁の表面に沿って延びる。この強化された表面は、移行したアルファ化デンプン、分散剤、およびトリメタリン酸ナトリウムを含むと考えられている一方で、本発明者らは、この説明に束縛されることは意図しておらず、強化された表面はこれらの物質の全3種未満を含んでいてもよく、実際に、異なる供給源またはメカニズムに由来していてもよいと認識する。
および任意によりスタッコの重量に基づいて約0.2重量%以下の量で存在するガラス繊維を含む石膏含有スラリーから形成されている。
この過剰量のプロセス水は、一般に実質的に不規則な形状であると共に、他の水泡と相互に連続もしている石膏結晶マトリックス中に蒸発性の水泡をもたらして、固化石膏結晶の間の一般に連続的なネットワーク中に不規則なチャネルを形成する。対照的に、気泡(バブル)は、石鹸の泡を用いて石膏スラリー中に導入される。これらの気泡は、一般に、球状/丸い形状であると共に、一般に他の気泡からは分離されていて、それ故、一般に非連続的でもある。これらの水泡は、気泡の壁中に分布されていることが可能である(例えば、図8〜10を参照のこと)。
この配合物が特定の気泡容積および気泡分布と組み合わされる場合、仕上ウォールボードのけがき/スナッピングの際にはより大きなサイズの破片が発生することが、予想外に見出された。この結果は、本発明の増大された壁厚および強化された高密度化壁表面微小構造によってさらに強調される。より大きな石膏破片は、一般に、風媒性の低い粉塵をもたらす。対照的に、従来のウォールボード配合物が用いられる場合、より小さな破片が発生し、それ故、より多くの粉塵が発生する。例えば、従来のウォールボードは、鋸での切断の際に、約20〜30ミクロンの平均直径、および、約1ミクロンの最小直径を有する粉塵破片を発生させる可能性がある。対照的に、本発明の石膏ウォールボードは、鋸での切断の際に、約30〜50ミクロンの平均直径、および、約2ミクロンの最小直径を有する粉塵破片を発生させ;けがき/スナッピングは、さらに大きな破片をもたらすことが可能である。
殺生剤、および促進剤が挙げられる。本発明は、新たに配合された石膏含有スラリーに石鹸の泡を添加して、例えば石膏ウォールボードといった仕上石膏含有製品の密度を低減させること、ならびに、固化石膏コア中の小さい気泡(バブル)および水泡の形態での、約75%〜約95%、および、好ましくは約80%〜約92%の総気泡容積の導入により粉立を制御することが必要である。好ましくは、平均孔径分布は、約1ミクロン(水泡)〜約40〜50ミクロン(気泡)であろう。
より好ましくは分子量は約12,000〜17,000であることが好ましい。市販の製品としては、より高分子量の分散剤は、低分子量分散剤より高い粘度、および、より低固形分含有量を有する。有用なナフタレンスルホン酸塩としては、Cleveland,OhioのGEO Specialty Chemicals製のDILOFLO;Lexington,MassachusettsのHampshire Chemical Corp.製のDAXAD;および、Lafayette,IndianaのGEO Specialty Chemicals製のLOMAR Dが挙げられる。ナフタレンスルホン酸塩は、例えば35〜55重量%固形分含有量の範囲で水溶液として用いられることが好ましい。例えば約40〜45重量%固形分含有量の範囲で、水溶液の形態のナフタレンスルホン酸塩を用いることが最も好ましい。代替的に、適切な場合には、ナフタレンスルホン酸塩は、例えばLOMAR Dなどの乾燥固体または粉末形態で用いられることが可能である。
当該技術分野において公知である他の有用なカバーシート材料(例えば、繊維状ガラスマット)が用いられてもよい。紙カバーシートは石膏ウォールボードに強度特質をもたらす。有用カバーシート紙としては、Chicago,IllinoisのUnited States Gypsum Corporation製のManila 7−plyおよびNews−Line 5−ply;Newport,IndianaのCaraustar製のGrey−Back 3−plyおよびManila Ivory 3−ply;Chicago,IllinoisのUnited States Gypsum Corporation製のManila厚紙およびMH Manila HT(高張力)紙が挙げられる。紙カバーシートは、上面カバーシートまたは表紙、および、底面カバーシートまたは裏紙を含む。好ましい裏カバーシート紙は5−ply News−Lineである。好ましい表カバーシート紙としては、MH Manila HT(高張力)紙およびManila 7−plyが挙げられる。
サンプル石膏スラリー配合物
石膏スラリー配合物が以下の表1に示されている。表1中のすべての値は、乾燥スタッコの重量に基づく重量パーセントとして表記されている。括弧中の値は、ポンドでの乾燥重量(lb/MSF)である。
ウォールボードの調製
サンプル石膏ウォールボードを、本明細書において参照により援用される、Yuらへの米国特許第6,342,284号明細書およびYuらへの6,632,550号明細書に準拠して調製した。これらの特許の実施例5に記載されている、個別の泡の発生および他の処方成分のすべてスラリーへの泡の導入が含まれる。
1/2インチ石膏ウォールボード重量軽減試験
スラリー配合物およびテスト結果を含むさらなる石膏ウォールボード実施例(ボードC、DおよびE)が以下の表3に示されている。表3のスラリー配合物は、スラリーの主構成成分を含む。括弧中の値は、乾燥スタッコの重量に基づく重量パーセントとして表記されている。
湿潤石膏キューブ強度テスト
Chicago,IllinoisのUnited States Gypsum Corp.製のSouthard CKSボードスタッコおよび実験室における水道水を用いて湿潤キューブ強度テストを行って、これらの湿潤圧縮強度を測定した。以下の実験室テスト手法を用いた。
1/2インチ軽量石膏ウォールボードプラント製造試験
さらなる試験を実施し(試験ボード1および2)、スラリー配合を含むテスト結果が以下の表5に示されている。表5のスラリー配合は、スラリーの主構成成分を含む。括弧中の値は、乾燥スタッコの重量に基づく重量パーセントとして表記されている。
1/2インチ超軽量石膏ウォールボードプラント製造試験
さらなる試験(試験ボード3および4)を、配合物B(実施例1)を用いて、アルファ化コーンデンプンを10%濃度(湿潤デンプン調製)に水で調製すると共に、HYONIC 25 ASおよびPFM 33石鹸(Lafayette,IndianaのGEO Specialty Chemicals製)のブレンドを用いたこと以外は、実施例2のとおり実施した。例えば、試験ボード3を、65〜70重量%の範囲のHYONIC 25 ASでのHYONIC 25 ASおよびPFM 33のブレンドと、残量のPFM 33とで調製した。例えば、試験ボード4は、HYONIC 25AS/HYONIC PFM 33の70/30重量/重量ブレンドで調製した。試験結果が以下の表6に示されている。
ボード重量および鋸での切断結果の関数としての1/2インチ厚石膏ウォールボードコアにおける気泡容積割合計算
さらなる試験を、気泡容積および密度(試験ボードNo.5〜13)を測定するために、配合物B(実施例1)を用いて、アルファ化コーンデンプンを10%濃度(湿潤デンプン調製)に水で調製し、0.5%ガラス繊維を用い、およびナフタレンスルホン酸(DILOFLO)を45%水溶液として1.2重量%のレベルで用いたこと以外は実施例2のとおり実施した。石鹸の泡発生機を用いて石鹸泡を形成し、所望の密度をもたらすために効果的な量で石膏スラリー中に導入した。本実施例において、石鹸は、0.25lb/MSF〜0.45lb/MSFのレベルで用いた。すなわち、石鹸の泡の使用量は適切に増減した。各サンプルにおいて、ウォールボード厚は1/2インチであると共にコア容積は、39.1ft3/MSFで均一であると仮定した。気泡容積を、表紙および裏紙を除去した4ft幅のウォールボードサンプルにわたって計測した。表紙および裏紙は、11〜18milの範囲の厚さを有することが可能である(各面)。気泡容積/孔径および孔径分布は、走査電子顕微鏡検査(以下の実施例8を参照のこと)およびX線CTスキャンテクノロジー(XMT)により測定した。
試験ボードNo.10におけるエアバブル気泡サイズおよび水泡サイズの測定、ならびに、石膏結晶形態学
試験ボードNo.10を調製するためのプラント試験からのキャスト石膏キューブ(2インチ×2インチ×2インチ)を走査電子顕微鏡検査(SEM)により分析した。エアバブル気泡および蒸発性水泡、ならびに、石膏結晶サイズおよび形状を観察すると共に計測した。
またはドリリングの最中に曝された周囲の気泡中に捕捉されることとなると共に、風媒性とならないよう、気泡および水泡(総コア気泡容積)として十分な自由空間が形成されていることを実証する。
低粉塵石膏ウォールボードにおける粉塵捕捉
実施例7のとおり本発明の教示に基づいてウォールボードを調製した場合、ウォールボードの加工で生じる石膏粉塵は、少なくとも50重量%が直径約10ミクロンより大きい石膏破片を含むであろうことが予期される。切断、鋸引き、ルータ加工、けがき/スナッピング、釘打あるいはねじ込み、およびドリリングによるウォールボードの加工によって発生した粉塵の合計の少なくとも約30%以上が捕捉されるであろう。
追加の1/2インチ軽量石膏ウォールボードプラント製造試験配合物
実施例7〜9は、大きい気泡容積を有する軽量ウォールボードをもたらす。残りの実施例は、実施例7〜9のものに類似するが、ウォールボード微小構造の増大された壁厚および強化された高密度化気泡壁表面をもハイライトしている。これに関連して、実施例8の図5および6の顕微鏡写真は、本発明による大型の気泡および増大された厚さの壁の両方を含む微小構造を示すことに注目すべきである。
追加の1/2インチ軽量石膏ウォールボードプラント製造試験
プラント試験配合物14および実施例10の対照配合物Aを用いて形成した石膏ウォールボード、ならびに、2種の従来の競合するボードについてのテスト結果が以下の表9に示されている。70°F/50%相対湿度で24時間のコンディショニングの後、ウォールボードサンプルを、釘引抜き耐性、エッジ/コア硬度、曲げ強さ、および16時間加湿接合についてテストした。釘引抜き耐性、エッジ/コア硬度、加湿たわみ、および曲げ強さテストをASTM C−473に準拠して実施した。不燃性をASTM E−136に準拠して実施した。表面燃焼特質テストをASTM E−84に準拠して実施して、延焼指数(Flame Spread Index)(FSI)を測定した。ボードサンプルを、走査電子顕微鏡検査(以下の実施例12を参照のこと)およびエネルギー分散分光法(EDS)により分析した。ボードサンプルはまた、X線CTスキャンテクノロジー(XMT)により分析されることが可能である。
冠鋸引きによる粉塵発生を測定するために、4インチ径の5つの円を仕上ウォールボードサンプルに切り出して、得られた石膏粉塵を回収した。
対照ボードAおよび表9の他の従来の競合性石膏ボードと同等であるかまたはこれらを超えていた。
試験ボードNo.14におけるエアバブル表面特徴の測定、および石膏結晶形態学
実施例8と同様に、試験ボードNo.14を調製するためのプラント試験からのキャスト石膏キューブ(2インチ×2インチ×2インチ)を走査電子顕微鏡検査(SEM)により分析した。エアバブル気泡および蒸発性水泡、ならびに、石膏結晶サイズおよび形状を観察すると共に計測した。
風媒性とならないよう、気泡および水泡(総コア気泡容積)として十分な自由空間が形成されていることを実証する。
気泡の壁に沿って顕微鏡写真の右方向に延びている強化高密度化表面「A」を示す。
平均気泡サイズ、壁厚および高密度化強化壁表面の存在の測定
コアサンプルは、テストされるべきウォールボードサンプルをけがくことにより調製されればよく、コアをスナッピングして適切なサイズのサンプルに分けた。次いで、例えば、けがきがなされた領域にわたって強制空気流を向けることにより、ゆるいデブリが除去される。次いで、コアサンプルが、従来の走査型電子顕微鏡写真技術を用いて取り付けられると共にコートされる。
コアサンプルにおける無作為な位置で撮影した50×倍率での10枚の顕微鏡写真を準備する。これらの10枚の顕微鏡写真における気泡の各々にまたがる最大の断面距離を計測する。計測した距離を加算すると共に、平均最大断面距離を算出する。これが、サンプルの平均気泡サイズとなる。
コアサンプルにおける無作為な位置で撮影した50×倍率での10枚の顕微鏡写真を準備する。顕微鏡写真の水平縁部および垂直縁部が交差する気泡の各々間の距離を縁部に沿って計測する。すべての計測した距離を加算すると共に、平均距離を算出する。これがサンプルの平均壁厚である。
コアサンプルにおける無作為な位置で撮影した10枚の500×顕微鏡写真を準備する。これらの顕微鏡写真中に見られる拡大された気泡を、図15において特徴Aと識別されているもののような、気泡の縁に沿った太い白色のラインについて調べる。これらの太い白色のラインの存在が、サンプルにおける高密度化強化気泡壁表面の存在を示す。
[付記1]
2枚の実質的に平行なカバーシートの間に形成された固化石膏コアを含み、固化石膏コアは固化石膏コア全体にわたって分散された気泡を有し、前記気泡は約30〜約200ミクロンの平均厚を有する壁を有する石膏ウォールボード。
[付記2]
前記気泡の壁が約50〜約200ミクロンの平均厚を有する、付記1に記載の石膏ウォールボード。
[付記3]
前記気泡の壁が強化高密度化表面を有する、付記1に記載の石膏ウォールボード。
[付記4]
前記固化石膏コアが:
水、スタッコ、スタッコの重量に基づいて約0.5重量%〜約10重量%の量で存在するアルファ化デンプン、スタッコの重量に基づいて約0.2重量%〜約2重量%の量で存在するナフタレンスルホン酸分散剤、スタッコの重量に基づいて約0.1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、およびスタッコの重量に基づいて0〜約0.2重量%の量で存在するガラス繊維を含む石膏含有スラリーから形成されている、付記3に記載の石膏ウォールボード。
[付記5]
前記アルファ化デンプンが、スタッコの重量に基づいて約0.5重量%〜約4重量%の量で存在している、付記4に記載の石膏ウォールボード。
[付記6]
水/スタッコ比が約0.7〜約1.3である、付記4に記載の石膏ウォールボード。
[付記7]
前記カバーシートが紙を含む、付記1に記載の石膏ウォールボード。
[付記8]
少なくとも1枚のカバーシートが高張力紙である、付記7に記載の石膏ウォールボード。
[付記9]
少なくとも1枚のカバーシートが、繊維状マット、不織ガラス繊維マット、織ガラスマットおよび非セルロース系布からなる群から選択される、付記3に記載の石膏ウォールボード。
[付記10]
2枚の実質的に平行なカバーシートの間に形成された固化石膏コアを含み、前記固化石膏コアは固化石膏コア全体にわたって分散された気泡を有し、前記気泡は強化高密度化表面および約30〜約200ミクロンの平均厚を有する壁を有し、ならびに、前記固化石膏コアは約27pcf〜約30pcfの密度を有する、軽量石膏ウォールボード。
[付記11]
前記固化石膏コアが:
水、スタッコ、スタッコの重量に基づいて約0.5重量%〜約10重量%の量で存在するアルファ化デンプン、スタッコの重量に基づいて約0.2重量%〜約2重量%の量で存在するナフタレンスルホン酸分散剤、スタッコの重量に基づいて約0.1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およびスタッコの重量に基づいて0〜約0.2重量%の量で存在するガラス繊維を含む石膏含有スラリーから形成されている、
付記10に記載の軽量石膏ウォールボード。
[付記12]
前記アルファ化デンプンが、スタッコの重量に基づいて約0.5重量%〜約4重量%の量で存在している、付記11に記載の石膏ウォールボード。
[付記13]
少なくとも1枚のカバーシートが高張力紙である、付記10に記載の軽量石膏ウォールボード。
[付記14]
少なくとも1枚のカバーシートが、繊維状マット、不織ガラス繊維マット、織ガラスマットおよび非セルロース系布からなる群から選択される、付記10に記載の軽量石膏ウォールボード。
[付記15]
2枚の実質的に平行な紙カバーシートの間に形成された固化石膏コアを含み、前記固化石膏コアは固化石膏コア全体にわたって分散された気泡を有し、前記気泡は約70〜約120ミクロンの平均厚を有する壁を有し、前記固化石膏コアは:
水、スタッコ、スタッコの重量に基づいて約3重量%の量で存在するアルファ化デンプン、スタッコの重量に基づいて約1.5重量%の量で存在するナフタレンスルホン酸分散剤の45重量%水溶液、スタッコの重量に基づいて約0.3重量%の量で存在するトリメタリン酸ナトリウムおよびスタッコの重量に基づいて0〜約0.2重量%の量で存在するガラス繊維、ならびに、石鹸の泡を含む石膏含有スラリーから形成されており、
少なくとも1枚のカバーシートが高張力紙であり、
前記固化石膏コアが約29pcfの密度を有し、
ならびに、1/2インチ厚ボードについて約1200lb/MSFの乾燥重量、少なくとも約77lb/MSFの釘引抜き耐性、および少なくとも約11lb/MSFのコア硬度を有する軽量石膏ウォールボード。
Claims (20)
- 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軽量石膏ボードであって、
前記固化石膏コアは石膏結晶マトリックスを含み、
前記石膏結晶マトリックスは前記石膏結晶マトリックス内に気泡を画定し隔てる壁を有し、
前記壁は、走査型電子顕微鏡画像を用いて計測して、30ミクロンから200ミクロンの平均壁厚を有し、
前記石膏結晶マトリックスは、ASTM C−473に基づいて、前記固化石膏コアの平均コア硬度が少なくとも11ポンド(約5kg)となるように形成されており、
前記軽量石膏ボードの密度が12pcf(約190kg/m 3 )〜31pcf(約500kg/m3 )である、
ことを特徴とする軽量石膏ボード。 - 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軽量石膏ボードであって、
前記固化石膏コアは石膏結晶マトリックスを含み、
前記石膏結晶マトリックスは前記石膏結晶マトリックス内に気泡を画定し隔てる壁を有し、
前記壁は、走査型電子顕微鏡画像を用いて計測して、30ミクロンから200ミクロンの平均壁厚を有し、
前記気泡は、走査型電子顕微鏡画像を用いて計測して、100ミクロン未満の直径の平均孔径を有し、
前記石膏結晶マトリックスは、ASTM C−473に基づいて、前記固化石膏コアの平均コア硬度が少なくとも11ポンド(約5kg)となるように形成されており、
前記軽量石膏ボードの密度が12pcf(約190kg/m 3 )〜35pcf(約560kg/m3 )である、
ことを特徴とする軽量石膏ボード。 - 前記軽量石膏ボードの密度は、24pcf(約380kg/m3)〜34pcf(約545kg/m3)である、請求項2に記載の軽量石膏ボード。
- 前記軽量石膏ボードの密度は、24pcf(約380kg/m3)〜31pcf(約500kg/m3)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。
- 前記気泡の前記平均孔径は、10ミクロン〜100ミクロンである、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。
- 前記気泡の前記平均孔径は、20ミクロン〜100ミクロンである、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。
- 前記気泡の前記平均孔径は、50ミクロン〜100ミクロンである、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。
- 前記壁の平均厚さは、50ミクロン〜200ミクロンである、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。
- 前記壁の平均厚さは、70ミクロン〜120ミクロンである、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。
- 前記固化石膏コアは、水、スタッコ、及び、デンプンを含むスラリーから形成され、
前記デンプンは、前記固化石膏コアのコア硬度を、該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と比較して大きくするのに有効な量で存在する、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の製造方法。 - 前記スラリーは、さらに、泡、及び、ナフタレンスルホン酸分散剤を含む、請求項10に記載の軽量石膏ボードの製造方法。
- 前記デンプンは、アルファ化デンプンを含み、
ナフタレンスルホン酸分散剤がスタッコの重量に基づいて0.1重量%〜3重量%の量で存在し、
前記アルファ化デンプンは、スタッコの重量に基づいて0.5重量%〜10重量%の量で存在する、請求項10又は11に記載の軽量石膏ボードの製造方法。 - 前記スラリーは、さらに、水溶性ポリリン酸含有化合物を含む、請求項10から12のいずれか1項に記載の軽量石膏ボードの製造方法。
- 前記壁は、走査型電子顕微鏡画像を用いて孔径を計測したとき、(i)100ミクロン超の直径の孔径を有する気泡、(ii)50ミクロン〜100ミクロンの直径の孔径を有する気泡、及び(iii)50ミクロン未満の直径の孔径を有する気泡を画定する、請求項10から13のいずれか1項に記載の軽量石膏ボードの製造方法。
- 前記固化石膏コアは、0.7〜1.3の範囲の水/スタッコ比を用いて形成される、請求項10から14のいずれか1項に記載の軽量石膏ボードの製造方法。
- 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軽量石膏ボードであって、
前記固化石膏コアは石膏結晶マトリックスを含み、
前記石膏結晶マトリックスは前記石膏結晶マトリックス内に気泡を画定し隔てる壁を有し、
前記気泡間の前記壁の平均厚さは、X線CTスキャンテクノロジー解析による三次元画像を用いて計測して、30ミクロンから200ミクロンであり、
前記気泡は、X線CTスキャンテクノロジー解析による三次元画像を用いて計測して、100ミクロン未満の直径の平均孔径を有し、
前記石膏結晶マトリックスは、ASTM C−473に基づいて、前記固化石膏コアの平均コア硬度が少なくとも11ポンド(約5kg)となるように形成されており、
前記軽量石膏ボードの密度が12pcf(約190kg/m 3 )〜35pcf(約560kg/m3 )である、
ことを特徴とする軽量石膏ボード。 - 前記軽量石膏ボードの密度は、24pcf(約380kg/m3)〜34pcf(約545kg/m3)である、請求項16に記載の軽量石膏ボード。
- 前記軽量石膏ボードの密度は、24pcf(約380kg/m3)〜31pcf(約500kg/m3)である、請求項16又は17に記載の軽量石膏ボード。
- 前記壁の平均厚さは、70ミクロン〜120ミクロンである、請求項16から18のいずれか1項に記載の軽量石膏ボード。
- 前記気泡の前記平均孔径は、10ミクロン〜100ミクロンである、請求項16から19のいずれか1項に記載の軽量石膏ボード。
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KR20190124046A (ko) * | 2018-04-25 | 2019-11-04 | 주식회사 케이씨씨 | 새깅 방지용 조성물 |
KR102069853B1 (ko) * | 2018-04-25 | 2020-01-28 | 주식회사 케이씨씨 | 새깅 방지용 조성물 |
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