CN100354387C - Water-resistant additives for gypsum wood fiber products - Google Patents
Water-resistant additives for gypsum wood fiber products Download PDFInfo
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- CN100354387C CN100354387C CNB038256746A CN03825674A CN100354387C CN 100354387 C CN100354387 C CN 100354387C CN B038256746 A CNB038256746 A CN B038256746A CN 03825674 A CN03825674 A CN 03825674A CN 100354387 C CN100354387 C CN 100354387C
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Abstract
Emulsions are provided which are useful in imparting water-resistance to gypsum wood fiber products. In one embodiment, the emulsions comprise a wax or a combination of waxes, an alkyl phenol, at least one surfactant, Polynaphthalenesulfonic acid, and an alkali metal hydroxide. In another embodiment, the emulsions comprise a wax or a combination of waxes, an alkyl phenol, at least one surfactant, polynaphthalenesulfonic acid, an alkali metal hydroxide, and a complexed starch.
Description
Invention field
The present invention relates to a kind of additive, be used to improve the water-repellancy of wooden gypsum product.The present invention relates to a kind of emulsion, this emulsion comprises the mixture of a kind of wax or wax, a kind of alkylphenol, at least a tensio-active agent, a kind of poly-naphthene sulfonic acid and a kind of starch network and thing; Emulsion is used to improve the fire resistance characteristic of gypsum wood fiber product.The invention still further relates to a kind of method of producing described emulsion.
Background technology
The characteristic of gypsum (calcium sulfate two hydrates) is widely used on the Industry and Construction product it, especially plasterboard.It is the cheap starting material of widespread use, by dehydration and rehydrated process, can be made it become useful shape with mould or other instrument by casting mold again.The base mateiral of plasterboard is a synthetical, and this material is commonly referred to plaster from the hemihydrate of calcium sulfate (gypsum), and this plaster is to finish by this thermal conversion process of dispeling the water in two hydrates.
In the process of making plasterboard, gypsum mud must flow in the basic unit of a papery.In ensuing process, slurry/substrate combination is by casting mold, be about between this composition rolls by axle, and simultaneously in the process of casting mold, back shaped being formed in made of paper by on the gypsum mud of casting mold.Therefore, gypsum mud must have sufficient flowability, to such an extent as to can produce the suitable plasterboard of shape.Flowability is meant the flow capacity of gypsum mud.
Making the very important point for plasterboard is that gypsum mud can be by plastotype in limited degree.Foaminess is meant that it produces the foamy ability.When gypsum mud and link base layer made of paper are crossed axle that plastotype uses and rolled, must there be the gypsum mud of some amount to reflux, and be accumulated in axle and rolls on the folder, so so that the gypsum mud of regime flow is transported to plastotype with spool rolling part.Foaminess is very important in the ability that axle rolls the backflow of folder place to the mud gypsum.Can use the plastotype metal sheet, reduce the application of roller, but foaminess is very important for the control of finished product density.
Because the continuation property of plasterboard manufacturing processed, wherein gypsum mud stream is in basic unit, and link base layer is crossed the axle of plastotype and rolled, and gypsum mud mobile width is very crucial for the size that keeps the plasterboard finished product after plastotype.It is predefined that gypsum mud stops the mobile time.Therefore, the predefined time is the key property of gypsum mud.The specified time of gypsum mud also is its key property.Specified time is meant gypsum mud at heat drying, used time when solid gypsum board is finished.As in common knowledge in technical field, in successive plasterboard manufacturing processed, the specified time that gypsum mud has a unanimity is very important.
The plasterboard suction, this will reduce the intensity of wallboard.Product in the prior art, as common plasterboard, gypsum plate, plaster block, gypsum cast and similar material, all relative waterproof ability that has seldom.For example,, be immersed in the water, will absorb large quantity of moisture rapidly, and lose very hard intensity when common plasterboard.Actual test shows, when one the 2 feet right cylinder plasterboard core materials that multiply by 4 feet are immersed in the water of 70 , right cylinder shows 36% water-intake rate after soaking 40 minutes.
Gypsum wood fiber (GWF) is different from common gypsum wallboard product, and it combines with mud, gypsum and the wood fibre set up.For example, be used for building industry, also have timber, shaving board, fiberboard, wafer board, clamping plate, callable paper pulp and paper and high-density plate.These materials have tension force and flexural strength preferably with respect to gypsum.But their expense is higher, and fire line is poor, and when being exposed to wet environment following time, the distortion of expanding easily.Therefore, need the restricted characteristic that a kind of fibrous material improves these building productses.
Trial of the prior art is same and gypsum and cellulose fibre with needed characteristic, and particularly wood fibre combines, but has little effect.Trial in addition is that cellulose fibre is joined in gypsum plaster and/or the plasterboard core, but only produced seldom or intensity does not have the product promoted because before this, do not have real bonding between significant fiber and the gypsum finished.U.S. Patent number 4,238,178; 4,239,716; 4,392,896 and 4,645,548 disclose nearest example, and wherein wood fibre or other natural fibers are blended in the plaster (calcium sulfate half oxyhydroxide) to provide intensity to rehydrated plasterboard.
U.S. Patent number 4,734,163 have instructed a kind of method, primary or not the incinerating gypsum and added the water of 5-10% by fine grinding., formed a pie, and further roll dehydration by the dehydration of part by the material smashed to pieces with pressure, up to water and solid ratio less than 0.1.Cake is cut into green plate, wherein,, in two firm dishes, compresses, and put it in the autoclave, the temperature of autoclave is elevated to about 140 ℃ makes gypsum change calcium sulfate alpha half oxyhydroxide into by straight-cut.Next cool off in container, half oxyhydroxide is rehydrated to be two oxyhydroxides, and makes plasterboard complete.Plasterboard is promptly produced and is finished.
The U.S. Patent number 5,320,677 of Baig has been described a matrix material of producing with the host particles of gypsum and enhancement type material, as lignocellulose fiber.Matrix material is produced by the host particles of gypsum and enhancement type material mixed, as wood fibre, in a kind of dilute aqueous slurry.Mud is heated in autoclave, preferably under pressure, makes gypsum change calcium sulfate alpha half oxyhydroxide into.Mud heat, sex change gushes the banded transfer roller of a successive by head box, and model is similar in the paper used.The wherein mud dehydration of being tried one's best, dispeling bonded moisture, with hemihydrate rehydrated be mud before.Result's material is a homogeneous mass, comprises that the gypsum physical crystal is with the diffusing shape particulate combination of host.Mat is dried in heated convection or the high pressure stoving oven as a result, and needed plate is cut into the ideal three-D space structure.Baig has instructed a kind of mud crystalline modified, but instruction does not use other additive to improve the finished product water-repellancy.
Product of the prior art, as common plasterboard, the gypsum line, plaster block, gypsum cast, water-repellancy is poor.
The U.S. Pat 6,010,596 of Song has added the wax emulsion and has comprised a kind of paraffinic hydrocarbon, montanin wax, polyvinyl alcohol, water and emulsion to a kind of substrate gypsum and wood fibre warm sludge slurry of comprising.Emulsion comprises nonionic and a kind of cats product.When mud still hotter state the time, mud gushes the banded transfer roller of a successive by head box, and model is similar in the paper used.To form a filter block and to shift moisture as much as possible.Song does not instruct a kind of emulsion to comprise new composition, and said composition comprises wax, a kind of alkylphenol, at least a tensio-active agent, a kind of poly-naphthene sulfonic acid and a kind of alkali metal hydroxide.
Summary of the invention
Embodiment of the present invention provides a kind of additive emulsion and a kind of method for preparing emulsion, and described method is about in the gypsum wood fibre composite products is produced, relevant water-absorbent, viscosity controller, stability and slip fluidity.
In one embodiment, the invention provides a kind of emulsion, comprise at least a wax, a kind of alkylphenol, at least a tensio-active agent, a kind of poly-naphthene sulfonic acid, a kind of alkali metal hydroxide and water.Poly-naphthene sulfonic acid and the reaction of a kind of alkali metal hydroxide generate a kind of poly-naphthalene sulfonate salt.In that the emulsion of present embodiment can join heat or even the ebullient water, emulsion does not take place to separate or coagulates and change.Emulsion of the present invention at room temperature is dumpable liquid, and storage for some time that can be stable.Emulsion of the present invention joins in the production process of gypsum wood fiber composite product, can improve the water-repellancy of product.
In another embodiment, the invention provides a kind of emulsion, this emulsion comprises at least a wax, a kind of alkylphenol, at least a tensio-active agent, a kind of poly-naphthene sulfonic acid, a kind of alkali metal hydroxide, water and starch.
In another embodiment, the invention provides a kind of emulsion, this emulsion comprises at least a wax, a kind of alkylphenol, at least a tensio-active agent, a kind of poly-naphthene sulfonic acid, a kind of alkali metal hydroxide and a kind of complexed starch.
In another embodiment, the invention provides a kind of method, this method is used to prepare a kind of emulsion, comprises the steps:
(a) with a kind of composition, be heated to 185 to 210 , this composition comprises at least a wax, a kind of alkylphenol, at least a tensio-active agent, so that a kind of wax phase mixture is provided;
(b) with a kind of composition, be heated to 185 to 210 , this composition comprises poly-naphthene sulfonic acid, a kind of alkali metal hydroxide and water, so that a kind of aqueous mixture is provided;
(c) aqueous mixture and wax phase mixture are mixed;
(d) mixture in (c) step is homogenized;
(e) cooling homogenised mix, and refrigerative speed can effectively be controlled the stability and the viscosity of homogenised mix.
Another one embodiment of the present invention is to use the method for the Wood fiber composite material of emulsion of the present invention to compare with common paper process.
An alternative embodiment of the invention is, a kind of emulsion comprises first kind of wax, and fusing point is 120 , and content is the 30-45% based on the emulsion gross weight; A kind of saponified wax, content are the 3%-5% of emulsion gross weight; A kind of tensio-active agent of combination, content are the 0.5%-5% of emulsion gross weight; A kind of alkylphenol, content are that content is the 0.5%-10% of emulsion gross weight; A kind of poly-naphthene sulfonic acid, content are the 0.25%-5% of emulsion gross weight, and the content of water is the 45-65% of emulsion gross weight; And a kind of alkali metal hydroxide, content is the 0.5-3% of emulsion gross weight.
Detailed Description Of The Invention
Gypsum wood fiber product (GWF) is different from common gypsum wallboard product, and its is integrated as one with mud, gypsum and wood fibre of having set up, and ratio is 5 to 50 parts the wood fibre and the gypsum of respective numbers, to reach 100% composition.Be different from the gypsum wallboard product, the present invention mixes with mud mutually by a kind of mechanism, and need the subordinate additive, and this additive do not influence the flowability of mud in process of production, but intrinsic control foaming process, and the wet terminal head box of utilization, GWF mud is tilted in the vacuum metal net forming initial shape of cushion, and dehydration after compression, and roll by banded of a series of vacuum, enter into drying oven, carry out last dehydration.Adding can not cause plating or explosion as the emulsion of additive on the vacuum band.GWF of the present invention does not carry on the back in conjunction with paper and paper, but a non-core made of paper is arranged, and this core tool has similar performance with the product in the coverture production of conventional use.
Unique compositions and ratio thereof are C
24-C
36Perhaps longer polymerization alkylphenol, various waxes, two tensio-active agents of selecting from sorbitan ester, six oleate fatty acid esters, polyethoxye Sorbic Acid fatty acid ester, with a kind of poly naphthalene sulfonate, the stable wax emulsion that combines, this emulsion is suitable for being combined in the GWF matrix material.A kind of structure is as shown in table 1:
| The starting material composition | Weight (%) |
| Melting point metal is the wax of 145 | 37.9 |
| Saponified wax | 5.0 |
| C 24-C 34Alkylphenol | 5.0 |
| SPAN 60 | 0.3 |
| TWEEN 60 | 1.7 |
| 45.5％KOH | 0.1 |
| Poly-naphthene sulfonic acid | 1.0 |
| Water | 49.0 |
The method of the hydration buffering dispersion agent of various filamentary materials is known in the process of commercial production paper and slab products altogether.In this method, the hydration dispersion agent of fiber, adhesive agent and other compositions, as needs with necessity, trickling as Fourdrinier or Oliver cushion plastotype machinery, is used for dehydration on a mobile support coil, dispersion system can utilize gravity dehydration, and the equipment that uses vacuum to take out the phase afterwards draws water; Moist mat is compacted into specific thickness, axle roll and support coil between, to dispel unnecessary moisture content.The mat of compression is dried or is forced in process furnace by the air stoving oven, and the material of oven dry is cut and is needed space structure.
One embodiment of the present of invention have also further shown a kind of method, and this method can prepare the gypsum wood fiber product, comprising step
(a) comprise the wooden mud of 5-50% in the mixing mud, the gypsum of 5-50%, the emulsion of the present invention of 1-3%, above per-cent is based on the gross weight of mud and water;
(b) mud is placed a vacuum metal online, to form the mat profile;
(c) with the mat partially desiccated in the step (b);
(d) roll the mat in the compression step (c) by the banded axle of a series of vacuum
(e) in stoving oven, dry mat in the compression step (d).
Water-content in mud enough is used for mud is assigned to vacuum metal on the net to form shape of cushion, and different gypsum wood fiber products can be by this method manufactured, comprises wallboard and cover plate.
It has been found that, by using starch mixture, meliorative as acid, hydroxyethylated, oxidation and/or cationization starch, with as coordination reagent and poly naphthalene sulfonate, combine together with polymeric phenol, all in the middle of correct annexation, significant deficiency can be overcome, and the wax emulsion of gained has the performance of superpower suction control, and additive has just been made.Further be that the function of matrix material of the present invention is as anti-building additive, and wax system thing is placed on the vacuum band.
Find that further borate composition, molybdate compound, molybdenum compound are extremely effective coordination reagent.Herein, molybdate and molybdenum compound will be by preferred compositions as molybdenum among the present invention.The example of useful coordination reagent is (but being not limited to described example), Sodium Tetraborate, magnesium borate and other borate compounds; Ammonium molybdate, Sodium orthomolybdate, magnesium molybdate and other molybdate compounds; The compound of molybdenumdisulphide and other molybdenums.
Coordination reagent (for example, sodium tetraborate decahydrate, Sodium orthomolybdate two hydrates, molybdenumdisulphide or other compounds) and the ratio of treated starch on great talent's degree very, affect the control of other necessary characteristics in plate/mud method, as foam support and and the compatibility of mud additive.
Research finds that also these compositions, and the ratio between them are crucial for illustrating this stable wax shape emulsion that repeats to implement, and are the steps necessarys in specific production process.The scope of ratio, starch: borate, or starch: molybdate, or starch: the scope of molybdenum compound is approximately 4: 1 to 20: 1 (weight ratio).
Another embodiment among the present invention shows the gypsum wood fiber product, comprises wood fibre, the wax emulsion among gypsum and the present invention.In the gypsum wood fiber wallboard is produced, it is important to make finished product to have water-repellancy, thereby can realize control by a detailed plank water absorption test to maximum water-intake rate.For example, USS test material ASTM1396 and test as described below.
The preparation of emulsion, in one embodiment of the present of invention, water, coordination reagent (a kind of borate compound, perhaps molybdenum compound) and a kind of starch only are placed on together at first, so that complexed starch can be used for embodiment of the present invention.
The preparation of emulsion:
In one embodiment of the invention, water, a kind of coordination reagent (is a kind of borate compound, a kind of molybdate compound, perhaps a kind of molybdenum compound) and a kind of starch, be blended at first,, be used for embodiments of the invention to form complexed starch, ensuing, poly naphthalene sulfonate polymkeric substance and potassium hydroxide join in the mixing solutions of complexed starch.With this mixture as for 185 under the temperature of 205 , place, arrive its maximum gel state until starch, this gel state often occur in 20-to minute after.The alkylphenol of waxy compound with polymerization state combined, and at 185 under the temperature of 205 .Therefore, wax is added in the middle of the water, and reflects, forms the coordinate tensio-active agent.A kind of stain remover/dispersion agent forms by the reflection of composition and polymerization alkylphenol and poly naphthalene sulfonate, changing crystal structure of wax and to allow himself the plating or the coupling of crystal opposing of wax, and keep separate stage until them with electrodes transfer to gypsum.Reactive system is 2,000 to 4 by pressure, and the homogenizer of 000psi cools off under the speed of regulation afterwards, the stability of the wax emulsion of finishing with control and the control of viscosity.It is that 135 are in the homogenizer of 145 that the solution that homogenizes is present in temperature.Be cooled to 80 to 110 after the mixture.Want controlled chilling speed with the recrystallize of avoiding waxy substance and the destruction of solution.
Be used for vocabulary of the present invention " wax emulsion ", represent a kind of emulsion of hydration, this emulsion contains one or more wax, and wherein said wax can be emulsified by using one or more tensio-active agents.The wax emulsion must comprise a kind of wax or be suitable for providing the wax work of finished product fire resistance characteristic, and wax or wax work must can be incorporated in the gypsum of preparing product or the wood fibre and go.
Emulsion is made in a container with wax, a kind of alkylphenol and at least a tensio-active agent (wax phase mixture) of heating, and water, poly-sodium naphthalene sulfonate, a kind of alkali metal hydroxide (aqueous mixture) are in the another one container.Two kinds of mixtures all are heated, mix, the temperature of heating from 185 to 210 .Then, aqueous mixture is poured onto in the middle of the wax phase mixture.Last mixture is placed in the middle of the homogenizer.In the process of homogenizing, the dispersive capsule diameter is from 0.6 micron to 1.8 microns.
But the dispersed particles diameter can be from 0.5 micron to 2.5 microns.Homogenizing of this level can obtain, and for example, by making the diplopore homogenizer, 2, operates under the 000-4000psig condition, preferably 2500-3000psig.
The mixture that homogenizes is cooled, and after the step that homogenizes, refrigerative speed is the viscosity of control stiffness and homogenised mix effectively.The range of viscosities of homogenised mix is at 30-200cps., preferably 80-100cps.Most preferably, homogenised mix is cooled from 185 to 100 .This effect can be immersed in the water by a cooling cooling volume by the mixture that will homogenize, and keeps at room temperature.
HLB numerical value:
Hydrophile/lipophile balance (HLB) numerical value has been described mixture and its deliquescent relation in water.An emulsor has the numerical value of a low HLB, and become oily resolvability and high HLB numerical value will be tending towards water-soluble.Typically, a water miscible emulsor or their mixing are used to form an oil/water miscible liquid, and just as described herein, perhaps the oil of solubility or wax perhaps get the method for some scale removal.Therefore, HLB numerical value can be used to describe or be used to select suitable emulsor or emulsifying system.
When two or more composition were joined together, the HLB numerical value of mixture was the weighed average of individual HLB numerical value.Following formula can be used for the HLB numerical value of compounding substances.
Wherein, Q
1The weight of=material 1; HLB
1The HLB numerical value of=material 1
Q
2The weight of=material 2; HLB
2The HLB numerical value of=material 2
Q
nThe weight of=material n; HLB
nThe HLB numerical value of=material n
Water absorption test:
The soaking effect of matrix material of the present invention uses following process to measure:
1) makes paper pulp: mix 3.2 gram paper and 200 gram water in mixing tank, stirring at low speed is set 2 minutes;
2) stirring heating paper pulp up to 190 , add the B-basis plaster of 3.18 grams afterwards, and continuously stirring is up to reaching 190 on cooking-vessel.
3) on a heating plate and stir the mixture, add 0.32 gram and be subjected to heat resist additive (HRA), as incinerating gypsum and 0.067 gram paper grade (stock) alum.Residuum is removed out from cooking-vessel, calculate the water resisting property (WR) of emulsion of the present invention and use pipette arbitrarily.Method of calculation: 1/X restrains WR, and wherein X is a solids content in the emulsion.For example, if solids content is 40%, 1/0.4=2.5 gram emulsion is with respect to hot mixt.Proximately be the 3%WR usage level on production line.Mixture is placed on the heated plate, and stirring also kept temperature 1 minute.
4) vacuum-strainer-paper pulp/slurry mixture is produced the screening cake.Use aforesaid equipment, used 30 seconds.Dispel the screening cake on the aluminium dish, cutting filter paper.
Allow cake at room temperature to place 20 minutes, place the stove 30 minutes of 180 afterwards, be dried to constant weight at 100 then.
5) dried cake of weighing.Cake is immersed in the water 30 minutes, masks the water weight of transition, and once more cake is weighed.Calculate water-intake rate.
Material:
The gypsum of different sources can be used for composite prod of the present invention and go.Used in the present invention vocabulary " gypsum " has been represented at the calcium sulfate of stablizing two hydrate states; As: CaSO
42H
2O, and comprise wherein natural ore, two hydrate materials are calcium sulfate half oxyhydroxide or dehydrated gyp-, as employed vocabulary " calcium sulfate material " among the present invention, calcium sulfate can have any form of oneself, called after calcium sulfate dehydrated gyp-, calcium sulfate half oxyhydroxide, calcium sulfate two hydrates or their mixing.Gypsum can get from the ore calcination energy plant, as Du Ke Utilities Electric Co. and Kentucky Power.
Vocabulary as used herein " gypsum wood fiber " (GWF) has comprised the mixture of gypsum and host particles, as wood fibre.But, come the quantity of the required water of hydroxide gypsum sample will be with pure sample product different amts.The content of gypsum is 5-50 part in composition, based on mixture total weight.Wood fibre is widely used in the prior art that wood furniture is made.The example of wood fibre comprises, softwood sources is as pine tree, dragon spruce, fir; Hardwood sources, like wood, maple, eucalyptus, white poplar, beech.
Be used for making the wax work of of the present invention embodiment, can be selected from commercial known various waxes, the fusing point of these waxes is at 120 to 150 , preferably 135 to 145 .Such wax is representational to be end volatility, and in the thermogravimetric analysis of standard, the weight turnover rate is less than 10%.And the oil-contg of these waxes is less than 1% (weight).Wax is relative high molecular weight material, has average C
36Carbon chain lengths, promptly carbochain contains 36 carbon atoms or more.A kind of preferred wax is Honeywell 3816.The content range of this wax is the 30-45% of emulsion gross weight.
The wax of another preferred embodiment is the combination of montanin wax and Honeywell 3816.In this preferred embodiment, the content of montanin wax is the 3-5% of emulsion gross weight, and the content of Honeywell3816 is the 30-45% of emulsion gross weight.
In certain embodiments, one or more wax saponification are useful unexpectedly.In this method, the function of saponified wax is a kind of tensio-active agent of interpolation.The wax work that is used for this respect is limited to wax and has an acidity value or a kind of saponification value and fusing point greater than 120 .The saponification of this wax can be passed through with the same strong base mateiral of wax, as sodium hydroxide or potassium hydroxide etc.Can be comprised montanin wax, carnauba wax, beeswax, laurel wax, Semen Ricini wax, Japan tallow, coconut wax, spermaceti, sugar-cane wax, hair adipocere, other waxes among the present invention by saponified wax.The needed base mateiral of a kind of wax of saponification can be calculated, based on the saponification value of wax.For example, saponification value is divided into the potassium hydroxide of 1000 equal portions to join in every gram wax.
Alkali metal hydroxide is selected from sodium hydroxide and potassium hydroxide.The content range of alkali metal hydroxide is based on the 0.5-3% of emulsion gross weight.
Tensio-active agent comprises sorbitan ester.The sorbitan ester that is fit to includes, but are not limited to following example, sorbitan aliphatic ester, two tensio-active agents and a kind of poly naphthalene sulfonate, polysorbate and their combination that six oleate fatty acid esters, polyethoxye Sorbic Acid fatty acid ester are selected.Example be sorbitan-fatty acid ester to be used for example of the present invention be SPAN60, SPAN60 is.SPAN60 can be from ICIAmericas, Inc., and Wilmington, Delaware buys, and it is TWEEN60 that another sorbitan-fatty acid ester is used for example of the present invention, and wherein TWEEN60 is a polyoxyethylene sorboside monostearate.Wherein, TWEEN60 can be from ICI Americas, Inc., and Wilmington, Delaware buys.The content of tensio-active agent is the 0.5-5% of emulsion gross weight.
Can in emulsion, use more than a kind of tensio-active agent.The combination of preferred surfactants can be the stearic and sorbitol anhydride tristearin of poly-sorb acid anhydrides, and wherein the content range of tensio-active agent is 0.5-5%.
In one embodiment, the starch that is used for emulsion of the present invention is complexed starch.Starch can be by complexed in situ, in the emulsion production process, or starch can be in joining emulsion before, coordination in advance.Preferably, with starch and coordination reagent mix, coordination reagent such as borate compound or molybdenum compound.Composition as coordination reality comprises that other compounds that are used for complexed starch comprise heavy ammonium borate, penta boron ammonium, penta boron potassium, potassium tetraborate, lithium tetraborate and magnesium borate compound; Barium molybdate, calcium molybdate, lithium molybdate, Sodium orthomolybdate; With other molybdenum compounds.The starch that the present invention is used to form complexed starch comprises (but being not limited to these examples), corn, rice, wheat, potato, sago and other starch.The ratio of coordination reagent (a kind of borate compound, a kind of molybdate compound or a kind of molybdenum compound) and starch is functional extremely important for complexed starch in the emulsion.It has been found that ratio can hang down by 1: 20, based on weight ratio.Ratio can be up to 1: 3.5, still, has been found that at this ratio or more in the height ratio, in emulsion, needs a large amount of starch to keep the balance of the desired characteristic in gypsum mixtures and the gypsum product.These desired characteristic comprise, flowability, whipability and water-repellancy.
Alkylphenol is attached in the emulsion, has been found that this will be extremely important to the low water absorbable of end product.The phenylic acid composition of " alkylphenol " described herein has long chain alkyl group.Chain alkyl group can be straight chain or side chain.The hydroxyl group of long-chain can be C
24-C
34(24 to 34 carbon chain lengths).Such alkylphenol comprises long-chain, C
24-C
34, be polymerized to the methylene radical alkylphenol, phenolate, calcium phenylate, long-chain branch calcium phenylate, long linear calcium phenylate and do not have the ligand polymer of the toxilic acid that amine group replaces.An example that is used for matrix material of the present invention is as follows:
| Numbering | Describe | The source |
| 319H | C24-C34 polymerization methylene radical alkylphenol | Lubrizol Chem.Corp. Wycliffe，Ohio |
The content of alkylphenol is the 0.5-10% based on the emulsion gross weight in emulsion.
The starch composition be introduced in the emulsion as starch sour treated starch, hydroxide, oxidation and/or Ionized.Starch content is the 0.1-2% of emulsion gross weight.
Bactericide/fungicide can be included in the middle of the present invention, and an example METASOL D3TA of mycocide is 3,5-dimethyl-four hydrate-1,3,5,2H-thiadiazine-2-sulphur copper.METASOL D3TA can be from Ondo-Nalco, Houston, and Texas obtains.
The present invention need gather naphthalene sulfonate salt, and an example of poly-naphthalene sulfonate salt is that the poly-naphthene sulfonic acid of DISALGPS. and a kind of alkali metal hydroxide react, to obtain poly naphthalene sulfonate.DISAL GPS can be from Handy Chemical, Montreal, and Quebec, Canada obtains.
The wax emulsion that comprises poly-naphthene sulfonic acid:
The example that following table 2 provides emulsion to make is according to embodiments of the invention.Weight unit is gram:
Table 2
| Composition | Example 1 | Example 2 | Example 3 |
| Honeywell 3816D | 33.00 | 37.90 | 37.90 |
| Polyphenol 319H | 0.50 | 5.00 | 5.00 |
| Montanin wax | 1.50 | 5.00 | 5.00 |
| SPAN 60 | 0.15 | 0.30 | 0.30 |
| TWEEN 60 | 0.85 | 1.70 | 1.70 |
| 45.5％KOU | 0.1 | 0.1 | |
| DISAL GPS | |||
| Starch | 1.63 | ||
| Borax | 0.38 | ||
| Water | 61.25 | 50.00 | 49.00 |
Alternatively, emulsion of the present invention can include the coordination reagent of usefulness, as boric acid composition or molybdenum compound.Emulsion of the present invention comprises starch.Emulsion of the present invention can comprise complexed starch, and described complexed starch is by starch is formed with the coordination reagent mix, and coordination reagent is selected from the boric acid composition, molybdenum compound and similar composition.
According to aim of the present invention, a kind of emulsion is disclosed and with the plastering of this emulsion preparation.Emulsion is used to give plastering with water-repellancy.And certain embodiments and preferred forms of the present invention describe in detail at this, and these embodiment only are illustration character.For a person skilled in the art, substituting of the equivalent of various variations and element all do not departed from protection scope of the present invention.
Claims (38)
1. emulsion that is used for giving gypsum wood fiber product water resistance comprises:
At least a wax;
A kind of alkylphenol, described alkylphenol has the C of straight or branched
24-C
34Chain alkyl;
At least a tensio-active agent;
Poly-naphthene sulfonic acid;
A kind of alkali metal hydroxide;
Water; With
Complexed starch, described complexed starch comprise starch and a kind of coordination reagent, and described coordination reagent is selected from borate compound and molybdate compound.
2. emulsion according to claim 1, wherein said alkali metal hydroxide is sodium hydroxide or potassium hydroxide.
3. emulsion according to claim 1, wherein said alkylphenol is C
24-C
34Polymerization methylene radical alkylphenol.
4. as emulsion as described in the claim 3, wherein said C
24-C
34The content of polymerization methylene radical alkylphenol is emulsion gross weight 0.5-10%.
5. emulsion according to claim 1, wherein tensio-active agent is selected from sorbitan ester and polysorbate or their combination.
6. as emulsion as described in the claim 5, wherein sorbitan ester is.
7. as emulsion as described in the claim 6, wherein the content of is the 0.5-5% of emulsion gross weight.
8. as emulsion as described in the claim 5, wherein said polysorbate is a polyoxyethylene sorboside monostearate.
9. as emulsion as described in the claim 8, wherein the content of polyoxyethylene sorboside monostearate is the 0.5-5% of emulsion gross weight.
10. emulsion as described in wanting 1 as right, wherein tensio-active agent is made up of and polyoxyethylene sorboside monostearate.
11. as emulsion as described in the claim 10, the content of the combination of wherein said and polyoxyethylene sorboside monostearate is the 0.5-5% of emulsion gross weight.
12. emulsion according to claim 1, wherein the fusing point of first kind of wax is 120 , and second kind of wax is a kind of saponified wax.
13. as emulsion as described in the claim 12, wherein the content of first kind of wax is the 30-45% of emulsion gross weight, the content of second kind of wax is the 3-5% of emulsion gross weight.
14. emulsion according to claim 1, wherein the content of poly-naphthene sulfonic acid is the 0.25-5% of emulsion gross weight.
15. emulsion according to claim 1, wherein starch is selected from unmodified starch, sour treated starch, hydroxide starch, Sumstar 190 and cationic starch.
16. as emulsion as described in the claim 15, wherein starch is sour treated starch.
17. emulsion according to claim 1, wherein the weight ratio of coordination reagent and starch is 1: 4 to 1: 20.
18. a method for preparing emulsion comprises the steps:
(a) a kind of composition is heated to 185 to 210 , this composition comprises at least a wax, a kind of C of having
24-C
34The alkylphenol of chain alkyl, at least a tensio-active agent are so that provide a kind of wax phase mixture;
(b) with a kind of composition, be heated to 185 to 210 , this composition comprises poly-naphthene sulfonic acid, a kind of alkali metal hydroxide and water, so that a kind of aqueous mixture is provided;
(c) aqueous mixture and wax phase mixture are mixed;
(d) mixture in (c) step is homogenized;
(e) cooling homogenised mix, and refrigerative speed can effectively be controlled the stability and the viscosity of homogenised mix.
19. as method as described in the claim 18, wherein alkali metal hydroxide is sodium hydroxide or potassium hydroxide.
20. as method as described in the claim 18, wherein said alkylphenol is C
24-C
34Polymerization methylene radical alkylphenol.
21. as method as described in the claim 18, wherein tensio-active agent is the combination of sorbitan ester and polysorbate.
22. as emulsion as described in the claim 18, wherein the fusing point of first kind of wax is 120 , second kind of wax is saponified wax.
23. as method as described in the claim 18, wherein add a kind of complexed starch in aqueous mixture, described complexed starch comprises starch and a kind of coordination reagent, described coordination reagent is selected from borate compound and molybdenum compound.
24. an emulsion that is used for giving gypsum wood fiber product water resistance comprises:
First kind of wax, fusing point are 120 -150 , and content is the 30-45% of emulsion gross weight;
A kind of saponified wax, content are the 3-5% of emulsion gross weight;
A kind of composition of tensio-active agent, content are the 0.5-5% of emulsion gross weight;
A kind of have a C
24-C
34The alkylphenol of chain alkyl, content are the 0.5-10% of emulsion gross weight;
A kind of poly-naphthene sulfonic acid, content are the 0.25-5% of emulsion gross weight;
Water, content are the 45-65% of emulsion gross weight;
A kind of alkali metal hydroxide, content are the 0.5-3% of emulsion gross weight.
25. as emulsion as described in the claim 24, also comprise a kind of complexed starch, described complexed starch comprises a kind of starch and a kind of coordination reagent, described coordination reagent comprises borate compound and molybdenum compound.
26. a method for preparing the gypsum wood fiber product comprises the steps:
(a) comprise the wooden mud of 5-50% in the mixing mud, the gypsum of 5-50%, the described emulsion of the claim 25 of 1-3%, above per-cent is based on the gross weight of mud and water;
(b) mud is placed a vacuum metal online, to form the mat profile;
(c) with the mat partially desiccated in the step (b);
(d) roll the mat in the compression step (c) by the banded axle of a series of vacuum;
(e) in stoving oven, dry mat in the compression step (d).
27. as method as described in the claim 26, wherein said emulsion comprises:
First kind of wax, fusing point are 120 -150 , and content is the 30-45% of emulsion gross weight;
A kind of saponified wax, content are the 3-5% of emulsion gross weight;
A kind of composition of tensio-active agent, content are the 0.5-5% of emulsion gross weight;
A kind of alkylphenol, content are the 0.5-10% of emulsion gross weight;
A kind of poly-naphthene sulfonic acid, content are the 0.25-5% of emulsion gross weight;
Water, content are the 45-65% of emulsion gross weight;
A kind of alkali metal hydroxide, content are the 0.5-3% of emulsion gross weight.
28. as method as described in the claim 27, wherein emulsion also comprises a kind of complexed starch, this complexed starch comprises a kind of starch and a kind of coordination reagent, and described coordination reagent is selected from borate compound and molybdenum compound.
29. wallboard made from the described method of claim 26.
30. wallboard made from the described method of claim 27.
31. wallboard made from the described method of claim 28.
32. cover plate made from the described method of claim 26.
33. cover plate made from the described method of claim 27.
34. cover plate made from the described method of claim 28.
35. a gypsum wood fiber product comprises:
(a) a kind of wood fibre;
(b) gypsum and (c) the described emulsion of claim 1.
36. the described gypsum wood fiber product of claim 35, wherein said emulsion comprises:
First kind of wax, fusing point are 120 -150 , and content is the 30-45% of emulsion gross weight;
A kind of saponified wax, content are the 3-5% of emulsion gross weight;
A kind of composition of tensio-active agent, content are the 0.5-5% of emulsion gross weight;
A kind of alkylphenol, content are the 0.5-10% of emulsion gross weight;
A kind of poly-naphthene sulfonic acid, content are the 0.25-5% of emulsion gross weight;
Water, content are the 45-65% of emulsion gross weight; With
A kind of alkali metal hydroxide, content are the 0.5-3% of emulsion gross weight.
37. the described gypsum wood fiber product of claim 35, wherein said wood fibre is selected from hardwood or cork.
38. the described gypsum wood fiber product of claim 36, wherein said wood fibre is selected from hardwood or cork.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US43532902P | 2002-12-20 | 2002-12-20 | |
| US60/435,329 | 2002-12-20 | ||
| US60/454,131 | 2003-03-12 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1723255A CN1723255A (en) | 2006-01-18 |
| CN100354387C true CN100354387C (en) | 2007-12-12 |
Family
ID=35912835
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB038256746A Expired - Fee Related CN100354387C (en) | 2002-12-20 | 2003-06-05 | Water-resistant additives for gypsum wood fiber products |
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| Country | Link |
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| CN (1) | CN100354387C (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5120355A (en) * | 1990-04-07 | 1992-06-09 | Nippon Oil Co., Ltd. | Water-repellent composition |
| US6066201A (en) * | 1998-11-09 | 2000-05-23 | Ergon, Inc. | Thixotropic wax emulsion compositions |
| US6165261A (en) * | 1999-06-10 | 2000-12-26 | Ergon, Inc. | Water-resistant gypsum composition |
| US6251979B1 (en) * | 1998-11-18 | 2001-06-26 | Advanced Construction Materials Corp. | Strengthened, light weight wallboard and method and apparatus for making the same |
-
2003
- 2003-06-05 CN CNB038256746A patent/CN100354387C/en not_active Expired - Fee Related
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5120355A (en) * | 1990-04-07 | 1992-06-09 | Nippon Oil Co., Ltd. | Water-repellent composition |
| US6066201A (en) * | 1998-11-09 | 2000-05-23 | Ergon, Inc. | Thixotropic wax emulsion compositions |
| US6251979B1 (en) * | 1998-11-18 | 2001-06-26 | Advanced Construction Materials Corp. | Strengthened, light weight wallboard and method and apparatus for making the same |
| US6165261A (en) * | 1999-06-10 | 2000-12-26 | Ergon, Inc. | Water-resistant gypsum composition |
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| Publication number | Publication date |
|---|---|
| CN1723255A (en) | 2006-01-18 |
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