US20210107832A1 - Alkyl sulfate / alkyl ether sulfate gypsum foamer - Google Patents
Alkyl sulfate / alkyl ether sulfate gypsum foamer Download PDFInfo
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- US20210107832A1 US20210107832A1 US16/497,606 US201816497606A US2021107832A1 US 20210107832 A1 US20210107832 A1 US 20210107832A1 US 201816497606 A US201816497606 A US 201816497606A US 2021107832 A1 US2021107832 A1 US 2021107832A1
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- alkyl
- sulfate
- alkyl ether
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- alkyl sulfate
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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
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/16—Sulfur-containing compounds
-
- 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
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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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
- C04B38/106—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam by adding preformed foams
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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
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/0028—Aspects relating to the mixing step of the mortar preparation
- C04B40/0039—Premixtures of ingredients
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/36—Sulfur-, selenium-, or tellurium-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/36—Sulfur-, selenium-, or tellurium-containing compounds
- C08K5/41—Compounds containing sulfur bound to oxygen
-
- 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
Definitions
- the disclosed technology relates generally to the manufacture of gypsum wallboard, and more particularly to a surfactant composition used to foam the gypsum slurry incorporated into the gypsum wallboard between the facing sheets.
- the purpose of foaming the gypsum slurry is to reduce the weight of the gypsum wallboard while still enabling it to perform its functions as a building material.
- a surfactant composition comprising:
- the linear or branched alkyl sulfate comprises the structure of Formula (1):
- R 1 is linear or branched alkyl having from 6 to 14 carbon atoms and M 1 is a cation.
- the alkyl ether sulfate comprises the structure of Formula (2):
- R 2 is branched alkyl or linear alkyl or a combination thereof having from 6 to 14 carbon atoms
- y has an average value from 0.1 to 5, preferably from 0.8 to 3
- M 2 is a cation.
- M 1 and M 2 can be independently selected, and can be the same or different.
- a surfactant composition comprising:
- a surfactant composition comprising:
- a gypsum board according to any of the first, second, and third embodiments comprising a core and facing sheets, the core comprising the gypsum slurry according to the embodiment.
- the core has multiple foam voids, which are also sometimes referred to as bubbles, with the same meaning.
- FIG. 1 is a schematic diagram of a gypsum wallboard manufacturing line according to any embodiment.
- Second foam water composition 170 Pipe 180 Fluid meter 190 Pipe 200 Pipe or trough 210 Foam feeder 220 Pipe or trough 225 Stucco 230 Bin 240 Chute 250 Dry material feeder 270 Mixing vessel 275 Gauge water 280 Tank 290 Drain 300 Metering feeder 310 Pipe 315 Pipe 320 Foamed gypsum slurry 330 Metering feeder 335 Still gypsum slurry 340 Pipe 350 Mixing vessel 360 Vessel or trough 370 Depositing point 380 Running lower web 390 Running upper web 400 Gypsum board
- the surfactant compositions of the first, second, or third embodiment briefly described above comprise one or more surfactants, water, and optionally other ingredients.
- the proportions in the net surfactant composition to be combined with the stucco, from one or more feed streams, optionally of different composition if from more than one feed stream, can be from 70 to 100 wt. %, optionally 90 to 100 wt. %, optionally 93 to 99 wt. % by total surfactant weight of a linear or branched alkyl sulfate, which optionally can be a mixture of two or more linear or branched alkyl sulfates having an alkyl chain length of 6 to 14 carbon atoms; and from 0 to 30 wt.
- % optionally 0 to 10 wt. %, optionally 1 to 7 wt. % by total surfactant weight of a linear or branched alkyl ether sulfate, which optionally can be a mixture of two or more linear or branched alkyl ether sulfates having an alkyl chain length of 6 to 14 carbon atoms.
- the alkyl sulfate of the first embodiment comprises the structure of Formula (1):
- R 1 is linear or branched alkyl having from 6 to 14 carbon atoms, and M 1 is a cation.
- R 1 has at least 9 carbon atoms, alternatively at least 10 carbon atoms, alternatively at least 11 carbon atoms, alternatively at most about 14 carbon atoms.
- Specific alkyl sulfates of the first embodiment contemplated here and commercially available are C 8 , C 8-10 , C 9 , C 10 , C 10-12 , C 12-14 , or C 9-11 alkyl sulfates, and mixtures of any two or more of these. Any of these alkyl sulfate species can be linear, branched (as shown and described in more detail in WO2016205170), or a combination of linear and branched species.
- linear R 1 or any branching of R 1 is contemplated in the first embodiment.
- Any suitable cation may be used, including but not limited to calcium, sodium, ammonium, or any combination of two or more of these.
- alkyl ether sulfate of the first embodiment contemplated here comprises the structure of Formula (2):
- R 2 is branched alkyl or linear alkyl or a combination thereof having from 6 to 14 carbon atoms, optionally 6 to 11 carbon atoms, y has an average value from 0.1 to 5, optionally 0.8 to 3, optionally 1.8 to 2.8, and M 2 is any suitable cation, including but not limited to calcium, sodium, ammonium, or any combination of two or more of these.
- alkyl ether sulfates of the first embodiment contemplated here can be made by ethoxylating the corresponding alkyl sulfates described above to the desired degree, using well-known technology. Specifically contemplated here are C 8 , C 8-10 , C 9 , C 10 , C 10-12 , C 12-14 , or C 9-11 alkyl ether sulfates, and mixtures of any two or more of these.
- the alkyl moiety of any of these alkyl ether sulfate species can be linear, branched (as shown and described in more detail in WO2016205170), or a combination of linear and branched species.
- M 1 and M 2 of the first embodiment are independently selected, meaning they can be the same or different.
- M 1 and M 2 can each be ammonium (NH 4 + ).
- M 1 and M 2 can each be sodium (Na + ).
- M 1 is sodium and M 2 is ammonium.
- M 1 is ammonium and M 2 is sodium.
- a second embodiment is like the first embodiment, except that the contemplated surfactant composition comprises:
- a third embodiment is like the first and second embodiments, except that the contemplated surfactant composition comprises:
- a gypsum slurry of any embodiment is made by combining stucco, water, and a surfactant comprising the corresponding embodiment of the surfactant composition described above.
- “Gypsum” technically refers to the hydrated mineral that can either be mined or produced by combining calcined gypsum—stucco—with water. Since the present compositions contain water, the slurry is specified here as a gypsum slurry, even though, if still not fully cured, some of this mineral persists as stucco.
- the range of proportions of stucco addition is well known to those skilled in the art. For example, useful proportions of stucco (for example, about 72 wt.
- foaming surfactant typically from about 0.005 wt. % to about 0.03 wt. %), and water (balance, for example about 28 wt. %) can be used.
- foaming surfactant typically from about 0.005 wt. % to about 0.03 wt. %)
- water balance, for example about 28 wt. %
- slurry set retarders or accelerators such as finely ground gypsum and/or potassium sulfate
- ball mill accelerators for example containing starch or dextrose
- water-reducing agents dispersants
- moisture-resistant agents for example containing starch or dextrose
- fire-retardant agents for example containing starch or dextrose
- boric acid for example containing starch or dextrose
- a gypsum board 400 of any embodiment is contemplated comprising a foamed gypsum core 320 and facing sheets 380 and 390 as shown in FIG. 1 .
- the core 320 comprises gypsum plus any surfactant composition embodiment described above.
- the core 320 has multiple foam voids.
- a first foam water composition 90 of any embodiment is provided, for example disposed in a vessel 100 , comprising 0.05 to 1 wt. % active weight of an alkyl sulfate surfactant.
- the alkyl sulfate surfactant of the first foam water composition comprises a linear or branched alkyl sulfate surfactant as described above.
- the first foam water composition can thus be a pure linear alkyl sulfate or a mixture of linear alkyl sulfate with a branched alkyl sulfate, optionally further combined with other materials.
- One specific example of an additional material contemplated here is one or more alkyl ether sulfates, which usually is combined in a minor proportion relative to the amount of one or more alkyl sulfates.
- a second foam water composition 165 of any embodiment is also provided, for example disposed in a vessel 160 , which has a composition somewhat different in proportions or ingredients from the first foam water composition, so they can be mixed in different proportions during production to control production specifications such as median foam void diameter.
- a surfactant mixture having more alkyl sulfate surfactant and less alkyl ether sulfate surfactant, or a less-highly-ethoxylated alkyl ether sulfate, or a greater proportion of branched alkyl sulfate, or a shorter chain alkyl sulfate, may produce larger median foam void diameters.
- the water used to make the foam water compositions may equally be added before or after the linear and branched alkyl sulfate surfactants, and/or an alkyl ether sulfate surfactant or other ingredients, are mixed. Regardless of the order of addition of the water, surfactants, or other ingredients, this process step is regarded as combining the first and second foam water compositions.
- the first foam water composition 90 of any embodiment in the tank 100 can be exhausted through a pipe 120 , metered in a specific proportion at any given time by a fluid meter 130 , and passed by an outlet pipe 140 to a mixer 145 .
- the second foam water composition 165 in the tank 160 can be exhausted through a pipe 170 , metered in a specific proportion at any given time by a fluid meter 180 , and passed to the mixer 145 .
- the mixer 145 mixes the first and second foam water composition to form a final or net foam water composition, and passes the final or net foam water composition via a pipe 190 to the foam generator 150 .
- the foam generator 150 employs mechanical energy, such as rotation of an impeller, to generate foam 110 from the foam water.
- first and second foam water compositions can be foamed independently, for example in separate foam generators, and the respective streams of foam combined either before or as the foam and stucco are mixed in the slurry mixer.
- a third foam water composition can also be prepared and mixed into the gypsum slurry in any embodiment.
- the third foam water composition optionally can be combined with one or both of the first and second foam water compositions as a still composition or as separately generated foam.
- the third foam water composition can be added directly to the gypsum slurry mixer in the form of foam.
- a gypsum slurry is formed by combining the foam 110 , stucco 225 , optionally gauge water 275 , and optionally minor proportions of other ingredients. Any method, order of steps, or equipment can be used.
- stucco 225 provided in a suitable bin 230 can be conveyed via a chute 240 by a dry material feeder 250 , such as a screw feeder, to a mixing vessel 270 .
- a dry material feeder 250 such as a screw feeder
- Gauge water 275 provided in a suitable tank 280 can be conveyed via a drain 290 , a metering feeder 300 , and a pipe 310 to the mixing vessel 270 , optionally an in-line or other type of continuous mixer, where the stucco 225 and gauge water 275 can be mixed to form a still (unfoamed) gypsum slurry 335 .
- the still gypsum slurry 335 can leave the mixing vessel 270 via a pipe 315 , a metering feeder 330 , and a pipe 340 to a further mixing vessel 350 .
- the foam 110 can be conveyed via a pipe or trough 200 , a foam feeder 210 , and a pipe or trough 220 to the further mixing vessel 350 , which for example can be a pin mixer, a pinless mixer, or any other useful type of slurry mixer.
- the further mixing vessel 350 is operated to mix the foam 110 and the still gypsum slurry 335 to form a foamed gypsum slurry 320 .
- the stucco 225 , gauge water 275 , and foam 110 could be combined in a single mixer to form a foamed gypsum slurry 320 .
- the foam water 90 and the foam water 165 could be separately foamed and the two streams of foam could be mixed together either upstream of or directly with the stucco 225 and gauge water 275 in a single mixer 350 to form a foamed gypsum slurry 320 .
- the foamed gypsum slurry 320 can leave the further mixing vessel 350 via a pipe or trough 360 and can be deposited at the deposition point 370 on a running lower web 380 of paper or another type of facing sheet.
- the foamed gypsum slurry can be sandwiched to form a gypsum board 400 by applying a running upper web 390 of paper or other material on the foamed gypsum slurry.
- the foamed gypsum slurry 320 contained between its facing sheets defined by the running lower web 380 and running upper web 390 , is then cured, dried, and cut to form gypsum wallboards or another product.
- Also contemplated in any embodiment is a new method of changing the median foam void diameter in a gypsum board while forming the board.
- the method can be used, for example, to correct a deviation from the intended median foam void diameter, preferably while the board forming line remains operating to minimize or eliminate down time.
- First and second foam water compositions 90 and 165 and stucco 225 as described above are provided, again optionally including additional ingredients.
- a foamed gypsum slurry 320 is formed comprising the first foam water composition 90 , the second foam water composition 165 , and stucco 225 and delivered at the delivery point 270 . While the foamed gypsum slurry 320 is being formed, the proportions of the first and second foam water compositions 90 and 165 are changed to change the median foam void diameter of the gypsum slurry, and thus the median foam void diameter in the gypsum board 400 .
- Foamers are provided, each made from one or more alkyl sulfates and in some cases one or more alkyl ether sulfates having the respective alkyl chain lengths, proportions, and one of the alternative ranges or degrees of ethoxylation specified in Tables 1-15.
- Range A or B and Species C, D, or E in Table 15 are alternative proportions of ethoxylation specified for each listed species.
- Species 1 of Table 1 provides five different species, respectively 1A, 1B, 1C, 1D, and 1E, as do the other numbered species in the respective rows of Tables 1-15.
- the selected gypsum foaming surfactant (sometimes referred to as a “foamer”) is combined with room temperature tap water in suitable proportions, for example, from about 0.005 wt. % to about 0.03 wt. % surfactant (by weight of the complete gypsum slurry).
- gauging water is prepared by combining, for example, tap water, a retarder, and a dispersant in suitable proportions.
- dry ingredients for example stucco, boric acid, a ball mill accelerator (BMA) containing 5% dextrose, and starch are mixed in suitable proportions.
- BMA ball mill accelerator
- the foam water and dry ingredients are combined.
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Abstract
Description
- This application claims the priority of U.S. Provisional Ser. No. 62/482,416, filed Apr. 6, 2017, which is incorporated by reference in its entirety to provide continuity of disclosure.
- The disclosed technology relates generally to the manufacture of gypsum wallboard, and more particularly to a surfactant composition used to foam the gypsum slurry incorporated into the gypsum wallboard between the facing sheets. The purpose of foaming the gypsum slurry is to reduce the weight of the gypsum wallboard while still enabling it to perform its functions as a building material.
- U.S. Patent Application Publication 2008/0223258 A1 (“Bruce et al.”) provides a description of preexisting knowledge in the formation of gypsum wallboard using foaming agents. Other patent documents providing background in this area are U.S. Pat. Nos. 4,156,615; 5,085,929; 5,116,671; 5,240,639; 5,643,510; 5,714,001; 7,033,431; 7,220,373; WO2014172469; and WO2016205170. Each of these patent documents is incorporated by reference in its entirety.
- In a first embodiment, a surfactant composition is contemplated comprising:
-
- from 70 to 100 wt. % by total surfactant weight of a linear or branched alkyl sulfate; and
- from 0 to 30 wt. % by total surfactant weight of a linear or branched alkyl ether sulfate.
- The linear or branched alkyl sulfate comprises the structure of Formula (1):
-
R1—OSO3 − +M1 (1) - in which R1 is linear or branched alkyl having from 6 to 14 carbon atoms and M1 is a cation. The alkyl ether sulfate comprises the structure of Formula (2):
-
R2—(OCH2CH2)yOSO3 − +M2 (2) - in which R2 is branched alkyl or linear alkyl or a combination thereof having from 6 to 14 carbon atoms, y has an average value from 0.1 to 5, preferably from 0.8 to 3, and M2 is a cation. M1 and M2 can be independently selected, and can be the same or different.
- In a second embodiment, a surfactant composition is contemplated comprising:
-
- from 91 to 99.5 wt. % by total surfactant weight of a linear or branched alkyl sulfate having the structure of Formula (1), an average number of carbon atoms, nm, in R1 between 10 and 11, and the following proportions by weight of species of Formula (1):
- 7% to 12% in which R1 is straight or branched C9H19;
- 42% to 59% in which R1 is straight or branched C10H21;
- 15% to 29% in which R1 is straight or branched C11H23;
- 7% to 15% in which R1 is straight or branched C12H25; and
- from 0.5 to 9 wt. % by total surfactant weight of a linear or branched alkyl ether sulfate having the structure of Formula (2), an average number of carbon atoms, nm, in R2 between 10 and 11, and an average value of y from 0.5 to 2.5.
- from 91 to 99.5 wt. % by total surfactant weight of a linear or branched alkyl sulfate having the structure of Formula (1), an average number of carbon atoms, nm, in R1 between 10 and 11, and the following proportions by weight of species of Formula (1):
- In a third embodiment, a surfactant composition is contemplated comprising:
-
- from 97.5 to 99.5 wt. % by total surfactant weight of a linear or branched alkyl sulfate having the structure of Formula (1), an average number of carbon atoms, nm, in R1 between 9 and 10, and the following proportions by weight of species of Formula (1):
- 25% to 47% in which R1 is straight or branched C8H17;
- 38% to 55% in which R1 is straight or branched C10H21;
- 12% to 20% in which R1 is straight or branched C12H25; and
- from 0.5 to 2.5 wt. % by total surfactant weight of a linear or branched alkyl ether sulfate having the structure of Formula (2), an average number of carbon atoms, nm, in R2 between 9 and 10, and an average value of y from 0.5 to 2.5.
- from 97.5 to 99.5 wt. % by total surfactant weight of a linear or branched alkyl sulfate having the structure of Formula (1), an average number of carbon atoms, nm, in R1 between 9 and 10, and the following proportions by weight of species of Formula (1):
- A gypsum slurry according to any of the first, second, and third embodiments is contemplated comprising gypsum, water, and the surfactant composition of the embodiment.
- A gypsum board according to any of the first, second, and third embodiments is contemplated comprising a core and facing sheets, the core comprising the gypsum slurry according to the embodiment. The core has multiple foam voids, which are also sometimes referred to as bubbles, with the same meaning.
- Still other aspects and variations are also provided, as will be evident to a person of ordinary skill in the gypsum wallboard manufacturing art, after considering this specification and the other knowledge possessed by such a person.
-
FIG. 1 is a schematic diagram of a gypsum wallboard manufacturing line according to any embodiment. - The following reference characters are used in the
FIG. 1 : -
90 First foam water composition 100 Vessel 110 Foam 120 Pipe 130 Fluid meter 140 Outlet pipe 145 Mixer 150 Foam generator 160 Vessel 165 Second foam water composition 170 Pipe 180 Fluid meter 190 Pipe 200 Pipe or trough 210 Foam feeder 220 Pipe or trough 225 Stucco 230 Bin 240 Chute 250 Dry material feeder 270 Mixing vessel 275 Gauge water 280 Tank 290 Drain 300 Metering feeder 310 Pipe 315 Pipe 320 Foamed gypsum slurry 330 Metering feeder 335 Still gypsum slurry 340 Pipe 350 Mixing vessel 360 Vessel or trough 370 Depositing point 380 Running lower web 390 Running upper web 400 Gypsum board - The surfactant compositions of the first, second, or third embodiment briefly described above comprise one or more surfactants, water, and optionally other ingredients. The proportions in the net surfactant composition to be combined with the stucco, from one or more feed streams, optionally of different composition if from more than one feed stream, can be from 70 to 100 wt. %, optionally 90 to 100 wt. %, optionally 93 to 99 wt. % by total surfactant weight of a linear or branched alkyl sulfate, which optionally can be a mixture of two or more linear or branched alkyl sulfates having an alkyl chain length of 6 to 14 carbon atoms; and from 0 to 30 wt. %, optionally 0 to 10 wt. %, optionally 1 to 7 wt. % by total surfactant weight of a linear or branched alkyl ether sulfate, which optionally can be a mixture of two or more linear or branched alkyl ether sulfates having an alkyl chain length of 6 to 14 carbon atoms.
- “By total surfactant weight” means that these proportions only reflect the amount of these particular active surfactants, not including any amount of water, gypsum, or non-surfactant ingredients present in the surfactants as supplied or as formulated.
- The alkyl sulfate of the first embodiment comprises the structure of Formula (1):
-
R1—OSO3 − +M1 (1) - in which R1 is linear or branched alkyl having from 6 to 14 carbon atoms, and M1 is a cation. Alternatively in this first embodiment, R1 has at least 9 carbon atoms, alternatively at least 10 carbon atoms, alternatively at least 11 carbon atoms, alternatively at most about 14 carbon atoms. Specific alkyl sulfates of the first embodiment contemplated here and commercially available are C8, C8-10, C9, C10, C10-12, C12-14, or C9-11 alkyl sulfates, and mixtures of any two or more of these. Any of these alkyl sulfate species can be linear, branched (as shown and described in more detail in WO2016205170), or a combination of linear and branched species.
- Broadly speaking, linear R1 or any branching of R1 is contemplated in the first embodiment.
- Any suitable cation may be used, including but not limited to calcium, sodium, ammonium, or any combination of two or more of these.
- The alkyl ether sulfate of the first embodiment contemplated here comprises the structure of Formula (2):
-
R2—(OCH2CH2)yOSO3 − +M2 (2) - in which R2 is branched alkyl or linear alkyl or a combination thereof having from 6 to 14 carbon atoms, optionally 6 to 11 carbon atoms, y has an average value from 0.1 to 5, optionally 0.8 to 3, optionally 1.8 to 2.8, and M2 is any suitable cation, including but not limited to calcium, sodium, ammonium, or any combination of two or more of these.
- Specific alkyl ether sulfates of the first embodiment contemplated here can be made by ethoxylating the corresponding alkyl sulfates described above to the desired degree, using well-known technology. Specifically contemplated here are C8, C8-10, C9, C10, C10-12, C12-14, or C9-11 alkyl ether sulfates, and mixtures of any two or more of these. The alkyl moiety of any of these alkyl ether sulfate species can be linear, branched (as shown and described in more detail in WO2016205170), or a combination of linear and branched species.
- M1 and M2 of the first embodiment are independently selected, meaning they can be the same or different. Optionally, M1 and M2 can each be ammonium (NH4 +). Optionally, M1 and M2 can each be sodium (Na+). Alternatively in the first embodiment M1 is sodium and M2 is ammonium. Alternatively in the first embodiment M1 is ammonium and M2 is sodium.
- A second embodiment is like the first embodiment, except that the contemplated surfactant composition comprises:
-
- from 91 to 99.5 wt. % by total surfactant weight of a linear or branched alkyl sulfate having the structure of Formula (1), an average number of carbon atoms, nm, in R1 between 10 and 11, and the following proportions by weight of species of Formula (1):
- 7% to 12% in which R1 is straight or branched C9H19;
- 42% to 59% in which R1 is straight or branched C10H21;
- 15% to 29% in which R1 is straight or branched C11H23;
- 7% to 15% in which R1 is straight or branched C12H25; and
- from 0.5 to 9 wt. % by total surfactant weight of a linear or branched alkyl ether sulfate having the structure of Formula (2), an average number of carbon atoms, nm, in R2 between 10 and 11, and an average value of y from 0.5 to 2.5.
- from 91 to 99.5 wt. % by total surfactant weight of a linear or branched alkyl sulfate having the structure of Formula (1), an average number of carbon atoms, nm, in R1 between 10 and 11, and the following proportions by weight of species of Formula (1):
- A third embodiment is like the first and second embodiments, except that the contemplated surfactant composition comprises:
-
- from 97.5 to 99.5 wt. % by total surfactant weight of a linear or branched alkyl sulfate having the structure of Formula (1), an average number of carbon atoms, nm, in R1 between 9 and 10, and the following proportions by weight of species of Formula (1):
- 25% to 47% in which R1 is straight or branched C8H17;
- 38% to 55% in which R1 is straight or branched C10H21;
- 12% to 20% in which R1 is straight or branched C12H25; and
- from 0.5 to 2.5 wt. % by total surfactant weight of a linear or branched alkyl ether sulfate having the structure of Formula (2), an average number of carbon atoms, nm, in R2 between 9 and 10, and an average value of y from 0.5 to 2.5.
- A gypsum slurry of any embodiment is made by combining stucco, water, and a surfactant comprising the corresponding embodiment of the surfactant composition described above. “Gypsum” technically refers to the hydrated mineral that can either be mined or produced by combining calcined gypsum—stucco—with water. Since the present compositions contain water, the slurry is specified here as a gypsum slurry, even though, if still not fully cured, some of this mineral persists as stucco. The range of proportions of stucco addition is well known to those skilled in the art. For example, useful proportions of stucco (for example, about 72 wt. %), foaming surfactant (typically from about 0.005 wt. % to about 0.03 wt. %), and water (balance, for example about 28 wt. %) can be used. A person of ordinary skill can vary and adapt these proportions and ingredients to particular processing conditions and desired compositions.
- Various optional ingredients can be employed in the present gypsum slurries of any embodiment. Some examples of such optional ingredients, including many mentioned in ¶¶0075-0081 of Bruce et al., incorporated by reference, are slurry set retarders or accelerators (such as finely ground gypsum and/or potassium sulfate), ball mill accelerators (for example containing starch or dextrose), water-reducing agents, dispersants, moisture-resistant agents, fire-retardant agents, paper fiber and/or chopped glass fibers, boric acid, or other ingredients. Among the effects that these additives are known to achieve are: a reduction in the amount of water required to produce a workable gypsum board core slurry; a reduced slurry viscosity; the retardation of the onset of setting of the slurry to a solid gypsum board core until after the fully formulated foamed gypsum board core has been formed into its final width; the acceleration of the setting of the calcined gypsum slurry on the setting belt; an increased resistance to product over-drying during manufacture; an increased resistance of the final product to moisture and fire; and an increased resistance to damage during shipping, handling and the installation of the manufactured gypsum board.
- A
gypsum board 400 of any embodiment is contemplated comprising a foamedgypsum core 320 and facingsheets FIG. 1 . Thecore 320 comprises gypsum plus any surfactant composition embodiment described above. Thecore 320 has multiple foam voids. - A first
foam water composition 90 of any embodiment is provided, for example disposed in avessel 100, comprising 0.05 to 1 wt. % active weight of an alkyl sulfate surfactant. The alkyl sulfate surfactant of the first foam water composition comprises a linear or branched alkyl sulfate surfactant as described above. The first foam water composition can thus be a pure linear alkyl sulfate or a mixture of linear alkyl sulfate with a branched alkyl sulfate, optionally further combined with other materials. One specific example of an additional material contemplated here is one or more alkyl ether sulfates, which usually is combined in a minor proportion relative to the amount of one or more alkyl sulfates. - A second
foam water composition 165 of any embodiment is also provided, for example disposed in avessel 160, which has a composition somewhat different in proportions or ingredients from the first foam water composition, so they can be mixed in different proportions during production to control production specifications such as median foam void diameter. For example, it has been found that using a surfactant mixture having more alkyl sulfate surfactant and less alkyl ether sulfate surfactant, or a less-highly-ethoxylated alkyl ether sulfate, or a greater proportion of branched alkyl sulfate, or a shorter chain alkyl sulfate, may produce larger median foam void diameters. - It is also contemplated that the water used to make the foam water compositions may equally be added before or after the linear and branched alkyl sulfate surfactants, and/or an alkyl ether sulfate surfactant or other ingredients, are mixed. Regardless of the order of addition of the water, surfactants, or other ingredients, this process step is regarded as combining the first and second foam water compositions.
- The first
foam water composition 90 of any embodiment in thetank 100 can be exhausted through apipe 120, metered in a specific proportion at any given time by afluid meter 130, and passed by anoutlet pipe 140 to amixer 145. The secondfoam water composition 165 in thetank 160 can be exhausted through apipe 170, metered in a specific proportion at any given time by afluid meter 180, and passed to themixer 145. Themixer 145 mixes the first and second foam water composition to form a final or net foam water composition, and passes the final or net foam water composition via apipe 190 to thefoam generator 150. Thefoam generator 150 employs mechanical energy, such as rotation of an impeller, to generate foam 110 from the foam water. - Alternatively in any embodiment, the first and second foam water compositions can be foamed independently, for example in separate foam generators, and the respective streams of foam combined either before or as the foam and stucco are mixed in the slurry mixer.
- A third foam water composition can also be prepared and mixed into the gypsum slurry in any embodiment. The third foam water composition optionally can be combined with one or both of the first and second foam water compositions as a still composition or as separately generated foam. Alternatively, the third foam water composition can be added directly to the gypsum slurry mixer in the form of foam.
- Separately, a gypsum slurry is formed by combining the foam 110,
stucco 225, optionally gaugewater 275, and optionally minor proportions of other ingredients. Any method, order of steps, or equipment can be used. - Referring again to
FIG. 1 , when forming a gypsum slurry,stucco 225 provided in asuitable bin 230 can be conveyed via achute 240 by adry material feeder 250, such as a screw feeder, to a mixingvessel 270.Gauge water 275 provided in asuitable tank 280 can be conveyed via adrain 290, ametering feeder 300, and apipe 310 to the mixingvessel 270, optionally an in-line or other type of continuous mixer, where thestucco 225 and gaugewater 275 can be mixed to form a still (unfoamed)gypsum slurry 335. - The still gypsum
slurry 335 can leave the mixingvessel 270 via apipe 315, ametering feeder 330, and apipe 340 to afurther mixing vessel 350. The foam 110 can be conveyed via a pipe ortrough 200, afoam feeder 210, and a pipe ortrough 220 to thefurther mixing vessel 350, which for example can be a pin mixer, a pinless mixer, or any other useful type of slurry mixer. Thefurther mixing vessel 350 is operated to mix the foam 110 and the stillgypsum slurry 335 to form a foamedgypsum slurry 320. - Alternatively, the
stucco 225,gauge water 275, and foam 110 could be combined in a single mixer to form a foamedgypsum slurry 320. - Alternatively, the
foam water 90 and thefoam water 165 could be separately foamed and the two streams of foam could be mixed together either upstream of or directly with thestucco 225 and gaugewater 275 in asingle mixer 350 to form a foamedgypsum slurry 320. - The foamed
gypsum slurry 320 can leave thefurther mixing vessel 350 via a pipe ortrough 360 and can be deposited at thedeposition point 370 on a runninglower web 380 of paper or another type of facing sheet. The foamed gypsum slurry can be sandwiched to form agypsum board 400 by applying a runningupper web 390 of paper or other material on the foamed gypsum slurry. The foamedgypsum slurry 320, contained between its facing sheets defined by the runninglower web 380 and runningupper web 390, is then cured, dried, and cut to form gypsum wallboards or another product. - Alternatively, the apparatus and methods described in Bruce et al., incorporated by reference above, can be used.
- Also contemplated in any embodiment is a new method of changing the median foam void diameter in a gypsum board while forming the board. The method can be used, for example, to correct a deviation from the intended median foam void diameter, preferably while the board forming line remains operating to minimize or eliminate down time.
- The method can be carried out as follows in any embodiment. First and second
foam water compositions stucco 225 as described above are provided, again optionally including additional ingredients. A foamedgypsum slurry 320 is formed comprising the firstfoam water composition 90, the secondfoam water composition 165, andstucco 225 and delivered at thedelivery point 270. While the foamedgypsum slurry 320 is being formed, the proportions of the first and secondfoam water compositions gypsum board 400. - The following examples illustrate the practice of the present technology of any embodiment without limiting the technology.
- Foamers are provided, each made from one or more alkyl sulfates and in some cases one or more alkyl ether sulfates having the respective alkyl chain lengths, proportions, and one of the alternative ranges or degrees of ethoxylation specified in Tables 1-15. (Range A or B and Species C, D, or E in Table 15 are alternative proportions of ethoxylation specified for each listed species.) Thus the row identified as Species 1 of Table 1 provides five different species, respectively 1A, 1B, 1C, 1D, and 1E, as do the other numbered species in the respective rows of Tables 1-15.
- To prepare foam water, the selected gypsum foaming surfactant (sometimes referred to as a “foamer”) is combined with room temperature tap water in suitable proportions, for example, from about 0.005 wt. % to about 0.03 wt. % surfactant (by weight of the complete gypsum slurry). Separately, gauging water is prepared by combining, for example, tap water, a retarder, and a dispersant in suitable proportions.
- The dry ingredients, for example stucco, boric acid, a ball mill accelerator (BMA) containing 5% dextrose, and starch are mixed in suitable proportions.
- To prepare the gypsum slurry, the foam water and dry ingredients are combined.
-
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LENGTHY TABLES The patent application contains a lengthy table section. A copy of the table is available in electronic form from the USPTO web site (https://seqdata.uspto.gov/?pageRequest=docDetail&DocID=US20210107832A1). An electronic copy of the table will also be available from the USPTO upon request and payment of the fee set forth in 37 CFR 1.19(b)(3).
Claims (30)
R1—OSO3 − +M1 (1)
R1—OSO3 − +M1 (1)
R2−(OCH2CH2)yOSO3 − +M2 (2)
R1—OSO3 − +M1 (1)
R2—(OCH2CH2)yOSO3 − +M2 (2)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/497,606 US20210107832A1 (en) | 2017-04-06 | 2018-04-05 | Alkyl sulfate / alkyl ether sulfate gypsum foamer |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US201762482416P | 2017-04-06 | 2017-04-06 | |
PCT/US2018/026242 WO2018187560A1 (en) | 2017-04-06 | 2018-04-05 | Alkyl sulfate / alkyl ether sulfate gypsum foamer |
US16/497,606 US20210107832A1 (en) | 2017-04-06 | 2018-04-05 | Alkyl sulfate / alkyl ether sulfate gypsum foamer |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2018/026242 A-371-Of-International WO2018187560A1 (en) | 2017-04-06 | 2018-04-05 | Alkyl sulfate / alkyl ether sulfate gypsum foamer |
Related Child Applications (1)
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US18/199,529 Division US20230303443A1 (en) | 2017-04-06 | 2023-05-19 | Alkyl sulfate / alkyl ether sulfate gypsum foamer |
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US20210107832A1 true US20210107832A1 (en) | 2021-04-15 |
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ID=63712254
Family Applications (2)
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US16/497,606 Abandoned US20210107832A1 (en) | 2017-04-06 | 2018-04-05 | Alkyl sulfate / alkyl ether sulfate gypsum foamer |
US18/199,529 Pending US20230303443A1 (en) | 2017-04-06 | 2023-05-19 | Alkyl sulfate / alkyl ether sulfate gypsum foamer |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US18/199,529 Pending US20230303443A1 (en) | 2017-04-06 | 2023-05-19 | Alkyl sulfate / alkyl ether sulfate gypsum foamer |
Country Status (7)
Country | Link |
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US (2) | US20210107832A1 (en) |
EP (1) | EP3606884A4 (en) |
CN (1) | CN110914215A (en) |
BR (1) | BR112019020950B1 (en) |
CA (1) | CA3057888A1 (en) |
MX (1) | MX2019011525A (en) |
WO (1) | WO2018187560A1 (en) |
Family Cites Families (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA1085880A (en) * | 1977-10-13 | 1980-09-16 | Samuel Cukier | Foaming agents for gypsum board manufacture |
US5240639A (en) * | 1988-04-07 | 1993-08-31 | Stepan Company | Foaming agent |
DE68910366T2 (en) * | 1988-04-07 | 1994-05-19 | Stepan Canada Inc | Foaming agent. |
CA2158820C (en) * | 1994-09-23 | 2004-11-23 | Steven W. Sucech | Producing foamed gypsum board |
US6348076B1 (en) * | 1999-10-08 | 2002-02-19 | International Business Machines Corporation | Slurry for mechanical polishing (CMP) of metals and use thereof |
FR2814459B1 (en) * | 2000-09-22 | 2002-12-06 | Lafarge Platres | SURFACTANT COMPOSITION FOR PLASTERBOARDS |
FR2821838B1 (en) * | 2001-03-06 | 2003-06-06 | Lafarge Platres | METHOD FOR LIGHTENING PLASTERBOARDS |
JP4965821B2 (en) * | 2005-06-08 | 2012-07-04 | 花王株式会社 | Surfactant composition |
US20080223258A1 (en) * | 2007-03-12 | 2008-09-18 | Robert Bruce | Method and System for Manufacturing Lightweight, High-Strength Gypsum Products |
AU2010294400B2 (en) * | 2009-09-02 | 2014-03-20 | Basf Construction Solutions Gmbh | Formulation and its use |
JP6025731B2 (en) * | 2010-10-11 | 2016-11-16 | ビーエーエスエフ コンストラクション ポリマース ゲゼルシャフト ミット ベシュレンクテル ハフツングBASF Construction Polymers GmbH | Dispersant containing gypsum slurry |
DE102011005484A1 (en) * | 2011-03-14 | 2012-09-20 | Evonik Goldschmidt Gmbh | Composition for the optimization of mineral building materials |
WO2016205170A1 (en) * | 2015-06-17 | 2016-12-22 | Stepan Company | Branched alkyl sulfate gypsum foamer |
US20180305258A1 (en) * | 2015-10-14 | 2018-10-25 | Csr Building Products Limited | Surfactant composition |
EP3414211B1 (en) * | 2016-02-08 | 2021-07-07 | Etex Building Performance International SAS | Plaster composition |
-
2018
- 2018-04-05 CN CN201880037329.1A patent/CN110914215A/en active Pending
- 2018-04-05 WO PCT/US2018/026242 patent/WO2018187560A1/en unknown
- 2018-04-05 MX MX2019011525A patent/MX2019011525A/en unknown
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- 2018-04-05 EP EP18780761.5A patent/EP3606884A4/en active Pending
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WO2018187560A1 (en) | 2018-10-11 |
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US20230303443A1 (en) | 2023-09-28 |
CN110914215A (en) | 2020-03-24 |
EP3606884A1 (en) | 2020-02-12 |
BR112019020950A2 (en) | 2020-05-05 |
MX2019011525A (en) | 2020-02-12 |
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