CN101203466A - 利用二重复单元分散剂的石膏产品和其制备方法 - Google Patents
利用二重复单元分散剂的石膏产品和其制备方法 Download PDFInfo
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- CN101203466A CN101203466A CNA200680020276XA CN200680020276A CN101203466A CN 101203466 A CN101203466 A CN 101203466A CN A200680020276X A CNA200680020276X A CN A200680020276XA CN 200680020276 A CN200680020276 A CN 200680020276A CN 101203466 A CN101203466 A CN 101203466A
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- Prior art keywords
- gypsum
- repeating unit
- dispersion agent
- slurries
- gypsum slurries
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- 239000010440 gypsum Substances 0.000 title claims abstract description 90
- 229910052602 gypsum Inorganic materials 0.000 title claims abstract description 90
- 239000002270 dispersing agent Substances 0.000 title claims abstract description 20
- 238000000034 method Methods 0.000 title description 18
- 239000002002 slurry Substances 0.000 claims abstract description 69
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 47
- 150000003839 salts Chemical class 0.000 claims abstract description 17
- 150000002148 esters Chemical class 0.000 claims abstract description 5
- 239000003795 chemical substances by application Substances 0.000 claims description 108
- 239000006185 dispersion Substances 0.000 claims description 79
- 239000002253 acid Substances 0.000 claims description 29
- 239000000654 additive Substances 0.000 claims description 19
- 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 claims description 14
- 239000000463 material Substances 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 12
- 229920002472 Starch Polymers 0.000 claims description 11
- 230000000996 additive effect Effects 0.000 claims description 11
- 235000019698 starch Nutrition 0.000 claims description 11
- 239000008107 starch Substances 0.000 claims description 11
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 10
- 239000004568 cement Substances 0.000 claims description 10
- 230000015271 coagulation Effects 0.000 claims description 10
- 238000005345 coagulation Methods 0.000 claims description 10
- 125000000217 alkyl group Chemical group 0.000 claims description 9
- 239000006260 foam Substances 0.000 claims description 9
- -1 siloxanes Chemical class 0.000 claims description 9
- 125000001931 aliphatic group Chemical group 0.000 claims description 8
- 150000001336 alkenes Chemical group 0.000 claims description 8
- 125000002877 alkyl aryl group Chemical group 0.000 claims description 8
- 125000003710 aryl alkyl group Chemical group 0.000 claims description 8
- 125000003118 aryl group Chemical group 0.000 claims description 8
- AZSFNUJOCKMOGB-UHFFFAOYSA-K cyclotriphosphate(3-) Chemical compound [O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 AZSFNUJOCKMOGB-UHFFFAOYSA-K 0.000 claims description 8
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 7
- 239000003139 biocide Substances 0.000 claims description 7
- 229910052739 hydrogen Inorganic materials 0.000 claims description 7
- 239000001257 hydrogen Substances 0.000 claims description 7
- 230000003115 biocidal effect Effects 0.000 claims description 6
- PASHVRUKOFIRIK-UHFFFAOYSA-L calcium sulfate dihydrate Chemical compound O.O.[Ca+2].[O-]S([O-])(=O)=O PASHVRUKOFIRIK-UHFFFAOYSA-L 0.000 claims description 5
- 239000011148 porous material Substances 0.000 claims description 5
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 4
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 4
- 239000004571 lime Substances 0.000 claims description 4
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 claims description 4
- 125000003107 substituted aryl group Chemical group 0.000 claims description 4
- QAOWNCQODCNURD-UHFFFAOYSA-N sulfuric acid group Chemical group S(O)(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N Acrylic acid Chemical compound OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- 239000006071 cream Substances 0.000 claims description 3
- 239000000839 emulsion Substances 0.000 claims description 3
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 claims description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 claims description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 2
- 235000014633 carbohydrates Nutrition 0.000 claims description 2
- 150000001720 carbohydrates Chemical class 0.000 claims description 2
- UEZVMMHDMIWARA-UHFFFAOYSA-M phosphonate Chemical compound [O-]P(=O)=O UEZVMMHDMIWARA-UHFFFAOYSA-M 0.000 claims description 2
- 150000003016 phosphoric acids Chemical class 0.000 claims description 2
- 239000011162 core material Substances 0.000 claims 3
- 229920000570 polyether Polymers 0.000 abstract description 6
- 239000004721 Polyphenylene oxide Substances 0.000 abstract description 5
- 229920005646 polycarboxylate Polymers 0.000 abstract description 3
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 abstract 2
- 125000003903 2-propenyl group Chemical group [H]C([*])([H])C([H])=C([H])[H] 0.000 abstract 1
- 125000000896 monocarboxylic acid group Chemical group 0.000 abstract 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 abstract 1
- 229920002554 vinyl polymer Polymers 0.000 abstract 1
- 239000011505 plaster Substances 0.000 description 33
- 238000002156 mixing Methods 0.000 description 14
- 238000004519 manufacturing process Methods 0.000 description 13
- 238000002360 preparation method Methods 0.000 description 13
- 238000001035 drying Methods 0.000 description 10
- 230000008859 change Effects 0.000 description 7
- 239000003607 modifier Substances 0.000 description 7
- 238000012360 testing method Methods 0.000 description 7
- 239000013078 crystal Substances 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 6
- 229920000881 Modified starch Polymers 0.000 description 5
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 229920000642 polymer Polymers 0.000 description 5
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Substances [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 5
- 235000015320 potassium carbonate Nutrition 0.000 description 5
- 238000012546 transfer Methods 0.000 description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 238000010276 construction Methods 0.000 description 4
- 230000004927 fusion Effects 0.000 description 4
- 238000006703 hydration reaction Methods 0.000 description 4
- 239000011159 matrix material Substances 0.000 description 4
- 230000009467 reduction Effects 0.000 description 4
- FQENQNTWSFEDLI-UHFFFAOYSA-J sodium diphosphate Chemical compound [Na+].[Na+].[Na+].[Na+].[O-]P([O-])(=O)OP([O-])([O-])=O FQENQNTWSFEDLI-UHFFFAOYSA-J 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 230000003111 delayed effect Effects 0.000 description 3
- 238000001704 evaporation Methods 0.000 description 3
- 239000000446 fuel Substances 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- OSBMVGFXROCQIZ-UHFFFAOYSA-I pentasodium;[bis(phosphonatomethyl)amino]methyl-hydroxyphosphinate Chemical compound [Na+].[Na+].[Na+].[Na+].[Na+].OP([O-])(=O)CN(CP([O-])([O-])=O)CP([O-])([O-])=O OSBMVGFXROCQIZ-UHFFFAOYSA-I 0.000 description 3
- 239000000523 sample Substances 0.000 description 3
- 239000001488 sodium phosphate Substances 0.000 description 3
- 235000019818 tetrasodium diphosphate Nutrition 0.000 description 3
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 description 3
- 229910000406 trisodium phosphate Inorganic materials 0.000 description 3
- 235000019801 trisodium phosphate Nutrition 0.000 description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 2
- 239000004327 boric acid Substances 0.000 description 2
- 239000000292 calcium oxide Substances 0.000 description 2
- 235000012255 calcium oxide Nutrition 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 239000004567 concrete Substances 0.000 description 2
- 239000013068 control sample Substances 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 230000008020 evaporation Effects 0.000 description 2
- JEIPFZHSYJVQDO-UHFFFAOYSA-N ferric oxide Chemical compound O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 238000005243 fluidization Methods 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- 230000036571 hydration Effects 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 235000010755 mineral Nutrition 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 230000004044 response Effects 0.000 description 2
- 239000000344 soap Substances 0.000 description 2
- 235000017550 sodium carbonate Nutrition 0.000 description 2
- 229910000029 sodium carbonate Inorganic materials 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 description 1
- 208000006558 Dental Calculus Diseases 0.000 description 1
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 1
- XYFCBTPGUUZFHI-UHFFFAOYSA-N Phosphine Natural products P XYFCBTPGUUZFHI-UHFFFAOYSA-N 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 description 1
- 241001486234 Sciota Species 0.000 description 1
- 125000003342 alkenyl group Chemical group 0.000 description 1
- 229940037003 alum Drugs 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 125000003368 amide group Chemical group 0.000 description 1
- 229910052925 anhydrite Inorganic materials 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- 235000011132 calcium sulphate Nutrition 0.000 description 1
- 150000001735 carboxylic acids Chemical group 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000013016 damping Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- 230000008014 freezing Effects 0.000 description 1
- 238000007710 freezing Methods 0.000 description 1
- 230000002538 fungal effect Effects 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 125000003827 glycol group Chemical group 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000011440 grout Substances 0.000 description 1
- 239000011507 gypsum plaster Substances 0.000 description 1
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 229910003002 lithium salt Inorganic materials 0.000 description 1
- 159000000002 lithium salts Chemical class 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 229910000073 phosphorus hydride Inorganic materials 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000001103 potassium chloride Substances 0.000 description 1
- 235000011164 potassium chloride Nutrition 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000004062 sedimentation Methods 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 125000002769 thiazolinyl group Chemical group 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
- C04B2111/0062—Gypsum-paper board like materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/665—Including a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Crystallography & Structural Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Emulsifying, Dispersing, Foam-Producing Or Wetting Agents (AREA)
Abstract
本发明涉及一种石膏浆液,所述石膏浆液包含水、含灰泥水硬组份和聚羧酸系物分散剂。所述分散剂具有两种重复单元,其中第一重复单元是烯烃不饱和单羧酸重复单元或酯或盐,而第二重复单元是通过醚键键结到聚醚的乙烯基或烯丙基。所述浆液可制成石膏板。
Description
相关申请案交叉参考
本申请案是于2005年6月14日申请的标题为”Gypsum Products Utilizing aTwo-Repeating Unit Dispersant and a Method of Making Them”的美国专利第11/152,418号的部分接续申请案,其以引用方式并入本文中。
本申请案涉及标题为″Modifiers for Gypsum Products and Method of Using Them″的共同待决的美国专利第11/152,317号;标题为″Method of Making a Gypsum Slurrywith Modifiers and Dispersants″的美国专利第11/152,323号,以及标题为″Effective Useof Dispersants in Wallboard Containing Foam″的美国专利第11/152,404号,所有上述专利均在2005年6月14日申请,而且所有内容均以引用方式并入本文中。
此外,本申请案涉及标题为″Modifiers for Gypsum Products and Method of UsingThem″的美国专利第11/xxx,xxx号(代理文号2033.75338);标题为″Method of Makinga Gypsum Slurry with Modifiers and Dispersants″的美国专利第11/xxx,xxx号(代理文号2033.75339),以及标题为″Effective Use of Dispersants in Wallboard Containing Foam″的美国专利第11/xxx,xxx号(代理文号2033.75341),上述所有专利均与本申请案同时提出申请,而且均以引用方式并入本文中。
技术领域
本发明涉及快干石膏产品。更具体而言,本发明涉及一种石膏浆液和一种比习用产品需要更短干燥时间或更少能量的壁板。
背景技术
石膏基建筑产品普遍用于建筑中。用石膏制备的壁板可阻燃并可用于建筑几乎任何形状的墙壁。其主要用作内墙和天花板产品。石膏具有隔音特性。如果受到损坏其可相对容易地加以修补或替换。有许多可施用到壁板的装饰性保护层,包括涂剂和壁纸。即使具有所有这些优点,其仍是一种相对便宜的建筑材料。
壁板成本低的一个原因是其是通过快速高效的方法来制造的。使用包含半水合硫酸钙和水的浆液形成核心,并使其连续沉积到在混合机下方移动的纸覆盖薄板上。将第二层纸覆盖薄板施用其上并使所得总成形成板状。半水合硫酸钙与足量水反应以将半水合物转化成互锁二水合硫酸钙晶体基质,使其凝固并变坚硬。将由此形成的连续板条输送到带上直至经煅烧石膏凝固,然后将所述板条切割形成具有所期望长度的板,输送所述板通过干燥炉来去除多余水分。由于这些步骤每个只消耗数分钟,所以任一过程步骤中的微小变化可导致制造过程效率大大降低。
经添加以形成浆液的水量超过完成水合反应所需的量。添加到石膏浆液中的水部分是用来水合经煅烧石膏(也称为半水合硫酸钙)以形成二水合硫酸钙晶体的互锁基质。多余的水分提供给浆液足够的流动性,使其能从混合机中流出到面板材料上而形成适宜的宽度和厚度。产品潮湿时,其很重不易而移动并且相对较脆。通过蒸发将多余水分从板中去除。如果容许多余水分在室温下蒸发,在允许壁板风干的同时就要占用很大空间来堆放和储存壁板或具有一足够长的输送机来提供充足的干燥时间。在板凝固且相对干之前,其有点易碎,因此必须保护其以防止被压碎或损坏。
为了在相对短时间内使板干燥,通常通过在升高温度下(例如在烘箱或炉中)蒸发多余水分来干燥壁板产品。建造和运行高温干燥炉相对较贵,尤其在矿物燃料成本升高时。可以通过降低存在于经凝固石膏板中,之后要通过蒸发去除的多余水分含量来达成制造成本的降低。
要减少水分的另一原因是石膏产品的强度与在其制造中所使用的水量成反比,尤其在全密度浆液中。随着多余水分蒸发,其在基质中留下曾由水所占据的空隙。倘若使用大量水来流化石膏浆液,当其完全干燥时产品中会残留更多更大的空隙。在最终产品中这些空隙会降低产品密度和强度。
已知分散剂可与石膏共同使用来帮助流化水和半水合硫酸钙混合物以使制备可流动浆液所需水分降低。萘磺酸分散剂为人所熟知,但其效力有限。聚羧酸系物分散剂经常与水泥共同使用,并在较低程度上与石膏共同使用。由术语“聚羧酸系物分散剂”(polycarboxylate dispersant)表示的化合物种类范围很大,并且很难预期个体化合物在不同介质中如何反应。
尽管有大量关于聚羧酸系物分散剂的先前文献,但很难预期任一具体化合物对其所用于产品的效应。通常认为聚羧酸系物可改良水泥的流动性。但这并不意味着聚羧酸系物在石膏产品中一定能产生相同的效果。在聚羧酸系物溶液中石膏和水泥形成分散不同的不同晶体模式。这些水硬材料的凝固时间极不相同,使得某些在水泥中可忽略的聚羧酸系物延迟效应在石膏壁板的凝固中起关键作用。甚至在石膏产品范围内也有不同,某些聚羧酸系物对特定石膏来源有效而对其他来源无效。在制造方法有局限性的情况下,不能预测聚羧酸系物在石膏或水泥中的功效使得在很难制备低含水量壁板产品。
另一已知缺陷是在石膏产品中聚羧酸系物可与其他添加剂反应。比如,可将泡沫添加到石膏板中以降低板重量。然而,某些聚羧酸系物使某些泡沫不稳定,导致其破裂并在板凝固前失去其有效性。通常根据所使用具体聚羧酸系物分散剂的化学结构的知识不能预测所述聚羧酸系物与泡沫的反应。
除了用作分散剂之外,已知聚羧酸系物可延迟水硬浆液的凝固。水泥浆液数分钟的凝固延迟是可忽略的。然而,在高速壁板生产线上,数分钟的凝固延迟会使板过软而无法切割、过脆而不能移动到炉中或甚至过软而不能在生产线上输送。用刀具切割壁板时其应凝固约50%以经受后续处理。若使用高剂量聚羧酸系物来制备水与灰泥比率低的可流动浆液,会使凝固时间大大延迟至需要降低板生产线的速率,而严重降低效率。因此,仅数分钟的产品凝固时间延迟就可能使板生产线的生产力降低一半,而在水泥类材料的加工中此一延迟可忽略不计。
此外,通过添加习用凝固促进剂不是总能克服因使用聚羧酸系物分散剂导致的凝固时间延迟。向混合机添加凝固促进剂缩短凝固时间,但也使得在浆液离开混合机前就形成二水合晶体,导致过早稠化和浆液流动性降低。因此,使用凝固促进剂来克服凝固延迟会使最初添加聚羧酸系物分散剂来增强流动性的目的不能达成。
如果能研发出一种可以用来制备不需要干燥炉干燥或长干燥时间的壁板的石膏浆液,这将是一大进步。此外,经改良浆液可快速干燥同时凝固时间不因使用聚羧酸系物分散剂而延长。
发明内容
通过本发明的经改良石膏浆液和壁板产品和其制备方法可改善此类和其他需求。石膏浆液包含水、基于水硬组份重量含有至少50%半水合硫酸钙的水硬组份以及特定二重复单元聚羧酸系物分散剂。
聚羧酸系物分散剂是一种包含第一和第二重复单元的共聚物,其中所述第一重复单元是烯烃不饱和单羧酸重复单元或其酯或盐,或烯烃不饱和硫酸重复单元或其盐,而所述第二重复单元具有以下通式:
其中R1由下式表示:
R2是氢或脂肪族C1至C5烃基。R3是未经取代或经取代芳基,优选为苯基。R4是氢或脂肪族C1至C20烃基团、环酯族C5至C8烃基团、经取代C6至C14芳基或符合下式的基团:
R5和R7各自独立地代表烷基、芳基、芳烷基或烷芳基而R6是二价烷基、芳基、芳烷基或烷芳基,p为0至3且包括0和3,m和n分别为2至4且包括2和4的整数,x和y分别为55至350且包括55和350的整数。z值为0至200且包括0和200。
本发明第二态样是包含二水合硫酸钙核心和上述分散剂的石膏板。
本发明的石膏浆液、其制备方法和以其制备的石膏板使得可节省烘箱燃料负担的成本。需要从石膏产品孔中驱除的水分减少,使得烘箱温度可降低或产品在烘箱中所费时间可缩短。可保留矿物燃料并由此实现节省成本。
用于本发明的分散剂延迟性也比可达成相同流动性的其他聚羧酸系物分散剂更低。此可降低对凝固促进剂的需求和相关成本。这也使得石膏板中水与灰泥的比率可进一步降低以免产品原始强度不足以继续制造。
附图说明
具体实施方式
自半水合硫酸钙、水和特定二重复单元分散剂制备石膏浆液。分散剂包括羧酸重复单元和烯基聚醚二醇重复单元。
水硬材料包括含量优选为至少50%的任一半水合硫酸钙(也称为灰泥或经煅烧石膏)。优选地,半水合硫酸钙的含量为至少75%、至少80%或至少85%灰泥。在许多壁板调配物中,水硬材料实质上全部是半水合硫酸钙。可使用任何形式的经煅烧石膏,包括但不限于α或β灰泥。本发明也涵盖硫酸钙硬石膏、合成石膏或建筑石膏粉的使用,但优选地以小于20%的低含量使用。浆液中视需要可包含其他水硬材料,包括水泥和粉煤灰。
尽管任何灰泥均可得益于本发明,但不同来源的灰泥包含不同含量和类型的盐和杂质。如果半水合硫酸钙含有相对高浓度的天然生成的盐,本发明浆液的效力降低。低盐灰泥定义为具有小于300百万份数可溶盐的灰泥。高盐含量灰泥包括具有至少600百万份数可溶盐的灰泥。来自Southard、OK、Little Narrows、Nova、Scotia、Fort Dodge、IA、Sweetwater、TX、Plaster City、CA和其他许多地方的石膏沉积物可满足此要求。
而R1衍生自式II不饱和(聚)伸烷基二醇醚基团。
参照式I和II,烯基重复单元在聚合物主链和醚键之间视需要包含C1至C3烷基。P值为0-3且包含0和3的整数。优选地,p为0或1。R2为氢原子或脂肪族C1至C5烃基团,其可为直链、具支链、饱和或不饱和。R3是未经取代或经取代芳基,优选为苯基。优选重复单元实例包括丙烯酸和甲基丙烯酸。
式II的聚醚基团包括多个C2-C4烷基,包括通过氧原子相连的至少两个烷基。m和n分别为2-4并包括2和4的整数,优选地,m和n至少一个为2。x和y分别为55-350并包括55和350的整数。z值为0至200并包括0和200。R4为氢或脂肪族C1至C20烃基团、环脂族C5至C8烃基团、经取代C6至C14芳基或符合式III(a)、式III(b)和式III(c)至少之一的基团。
在上述式中,R5和R7各自独立地代表烷基、芳基、芳烷基或烷芳基。R6为二价烷基、芳基、芳烷基或烷芳基。
将称为“PCE211型”分散剂的此类特别有用的分散剂命名为PCE211(下文称为“211”)。已知可用于壁板中的其他此系列聚合物包括PCE111。此类分散剂和其制备方法另外阐述于2005年6月14日申请的标题为”Polyether-Containing Copolymer”的美国专利第11/152,678号中,其以引用方式并入本文中。
分散剂的分子量优选为约20,000至约60,000道尔顿。令人惊讶地,已发现低分子量分散剂所引起的凝固时间延迟比分子量大于60,000道尔顿的分散剂短。一般使总分子量增加的更长侧链长度提供更佳可分散性。然而,对石膏的测试表明分子量大于60,000道尔顿的分散剂的效力降低。
许多聚合物可使用相同的两种重复单元以其不同分配加以制备。含酸重复单元与含聚醚重复单元的比率与电荷密度直接相关。优选地,共聚物的电荷密度在约300至约3000微当量(μequiv)电荷/克共聚物范围内。已发现,在此类分散剂中经测试降低水含量最有效的分散剂MELFLUX 2651电荷密度最高。MELFLUX分散剂是由Degussa Construction Polymers,GmbH(Trostberg,Germany)制造,并由Degussa公司(Kennesaw,GA)(下文中称为“Degussa”)在美国出售。(MELFLUX是DegussaConstruction Polymers,GmbH的经注册商标。)
然而,同样发现电荷密度的增加另外导致分散剂的延迟效应增强。低电荷密度分散剂,例如MELFLUX 2500L的凝固时间延迟短于电荷密度高的MELFLUX 2651F分散剂。由于凝固时间的延迟随着使用高电荷密度分散剂所获得效力的增强而延长,因此制备具有低水含量、良好流动性和适当凝固时间的浆液需要将电荷密度保持在中间范围内。更优选地,共聚物的电荷密度在约600至约2000微当量电荷/克共聚物范围内。
此分散剂尤其适合与石膏共同使用。尽管不期望受理论束缚,据信当主链上的第二重复单元长聚醚链实施分散功能时酸重复单元键结至半水合晶体上。在设计石膏用分散剂中,聚醚链长度的平衡、总分子量和电荷密度均是重要因素。因为其延迟性弱于其他分散剂,所以其对石膏产品制造工艺的破坏性也较低。以任一有效量使用分散剂。在很大程度上,所选分散剂数量取决于浆液的期望流动性。由于水含量降低,需要更多分散剂来维持恒定的浆液流动性。优选地,以占灰泥干重约0.01%至约0.5%的含量使用分散剂。更优选地,以占灰泥干重约0.05%至约0.2%的含量使用分散剂。在测量液态分散剂中,计算分散剂剂量时只考虑聚合物固体,并在计算水/灰泥比率时考虑来自分散剂的水分。此分散剂容许高速壁板制造方法的设计,其中壁板在5分钟内凝固至少50%。即使不存在促进剂也可在10分钟内达成至少50%凝固。
在分散剂浓度选择中另一重要因素可能是与面板材料的结合。高分散剂剂量下某些纸需要其他组份以形成令人满意的结合。不同的结合系统,例如聚乙烯醇,是有用的。有助于纸结合的另一技术为将凝固促进剂(例如明矾)施用到纸上来使浆液加速凝固到面板材料上。
由熟习此项技术者通过任何已知方法实施重复单元的聚合以制备共聚物分散剂。优选聚合技术教示于在2005年6月14日申请的标题为”Polyether-ContainingCopolymer”的美国专利第11/152,678号中,其在上文中以引用方式并入本文中。
以可达成可流动浆液的任一量向浆液中添加水。将使用的水含量根据其应用、所使用的具体分散剂、灰泥的性质和所使用的添加剂而迥异。壁板中水与灰泥的比率(”WSR”)基于灰泥干重优选为约0.1至约0.8。通常WSR优选为约0.2至约0.6。地板组合物优选地使用约0.17至约0.45的WSR,优选地为约0.17至约0.34。可模塑或可铸产品优选地以约0.1至约0.3,优选地以约0.16至约0.25的WSR使用水。在实验室测试中基于适度添加PCE211型分散剂可将WSR降低至0.1或更低。
于制备浆液的水应尽可能纯,以达成对浆液和凝固石膏二者特性的最佳控制。人们熟知盐和有机化合物可改变浆液的凝固时间,从促进剂到凝固抑制剂相差极大。某些杂质可使诸如二水合晶体形式的互锁基质等结构不规则,而降低凝固产品的强度。由此,可通过使用尽可能无污染的水来增强产品强度和一致性。
视需要石膏浆液也包含一或多种可增强聚羧酸系物分散剂流化浆液能力的改性剂,由此改良其效力。此处所用二重复单元分散剂尤其易受改性剂效应的影响。优选改性剂包括水泥、石灰(也称为生石灰或氧化钙)、熟石灰(也称为氢氧化钙)、苏打灰(也称为碳酸钠)、和其他碳酸盐、硅酸盐、膦酸盐和磷酸盐。端视所用改性剂和其应用,改性剂剂量为0.05%至约1%。使用改性剂时,分散剂的效力增强而达成新水平流动性,或聚羧酸系物分散剂含量可降低而减少聚羧酸系物支出。关于改性剂和其用途的其他信息阐述于标题为”Modifiers For Polycarboxylate Dispersants”的美国专利第11/152,317中,其在上文中以引用方式并入本文中。
已发现若在分散剂接触经煅烧石膏后才将改性剂添加到浆液中改性剂的效力降低。优选地在添加半水合物前将改性剂和分散剂添加到混合机水中。如果改性剂和分散剂二者均以干燥形式存在,可将其彼此预掺合并与灰泥共同添加。此添加顺序可更增强分散剂的效力。标题为”Method of Making a Gypsum Slurry with Modifiers andDispersants”的共同待决的美国专利第11/152,323号中更详细地揭示一种用于将分散剂和改性剂添加到灰泥组合物中的方法。
在石膏浆液将要应用于的特殊应用中,通常也将其他添加剂添加到浆液中。添加凝固延迟剂(高至约2lb./MSF(9.8g/m2))或干燥促进剂(高至约35lb./MSF(170g/m2))以改变水合反应发生速率。″CSA″是一种凝固促进剂,其包含与5%糖共同研磨并加热到250(121℃)以使糖焦糖化的95%二水合硫酸钙。CSA可从USG公司(Southard,OKplant)购得,及根据美国专利第3,573,947号加以制备,该专利以引用方式并入本文中。硫酸钾是另一优选促进剂。HRA是以约5至25磅糖/100磅二水合硫酸钙的比率与糖共同新鲜研磨的二水合硫酸钙。其进一步阐述于美国专利第2,078,199号中,该专利以引用方式并入本文中。这两者均是优选促进剂。
另一称为湿石膏促进剂或WGA的促进剂也是优选促进剂。湿石膏促进剂的用途和制备方法的阐述揭示于美国专利第6,409,825号中,其以引用方式并入本文中。此促进剂包括至少一种选自包括有机膦化合物、含磷酸基化合物或其混合物的群中的添加剂。此特定促进剂表现出实质上很长的寿命并且随着时间的过去可保持其有效性使得可在使用前制备、储存且甚至长途运输湿石膏促进剂。以约5至约80磅/千平方英尺(24.3至390g/m2)板产品的含量使用湿石膏促进剂。
在本发明某些实施例中,将添加剂引入石膏浆液中以改变终产品的一或多个特性。以业内习知方式和含量使用添加剂。以每1000平方英尺已完成板(″MSF″)中的数量报告浓度。以约3至约20lbs./MSF(14.6至97.6g/m2)的含量使用淀粉以增强纸结合并强化产品。视需要以至少11lb./MSF(54g/m2)的含量向浆液中添加玻璃纤维。将最多15lb./MSF(73.2g/m2)的纸纤维也添加到浆液中。以高至90lb./MSF(0.4kg/m2)的含量向石膏浆液中添加蜡乳液以改良已完成石膏板的耐水性。
在采用起泡剂于凝固含石膏产品中产生空隙以减轻重量的本发明实施例中,可采用任何已知可用于制备发泡凝固石膏产品的习用起泡剂。这些起泡剂许多为人所熟知而且可从市场上容易地购得,例如来自GEO Specialty Chemicals(Ambler,PA)的HYONIC系列皂产品。发泡和用于制备发泡石膏产品的优选方法揭示于美国专利第5,683,635号中,其以引用方式并入本文中。如果将泡沫添加到产品中,视需要在计量水与泡沫水之间分配聚羧酸系物分散剂,或在向半水合硫酸钙添加分散剂前在计量水和泡沫水中使用两种不同分散剂。此方法揭示于标题为”Effective Use of Dispersants inWallboard Containing Foam”的共同待决的申请案美国专利第11/152,404号中,其在上文中以引用方式并入本文中。
在某些实施例中将三偏磷酸盐化合物添加到石膏浆液中以增强产品强度并改良凝固石膏的弛垂抗性。优选地,三偏磷酸盐化合物的浓度为经煅烧石膏重量的约0.07%至约2.0%。包含三偏磷酸盐化合物的石膏组合物揭示于美国专利第6,342,284号和第6,632,550号中,两者均以引用方式并入本文中。实例性三偏磷酸盐包括三偏磷酸钠盐、钾盐或锂盐,例如可从Astaris、LLC、St.Louis、MO购得的那些。当三偏磷酸盐与石灰或可提高浆液pH的其他改性剂共同使用时必须小心行事。在pH约9.5以上,三偏磷酸盐会失去其强化产品强度的能力而浆液变得延迟性极高。
其他可能添加到壁板的添加剂是可降低霉菌、霉病或真菌生长的杀生物剂。端视所选择杀生物剂和壁板的拟定用途,可将杀生物剂添加到覆盖层、石膏核心或同时添加到二者中。杀生物剂的实例包括硼酸、巯氧吡啶和铜盐。可将杀生物剂添加到覆盖层或石膏核心中。使用时,在覆盖层中以小于500ppm的含量使用杀生物剂。
另外,石膏组合物视需要可包含淀粉,例如预胶凝淀粉或酸改性淀粉。预胶凝淀粉的引入增强凝固干燥石膏模型的强度并最小化或避免在高湿度条件下(例如涉及升高的水与经煅烧石膏的比率)纸脱层的风险。熟习此项技术者应了解预胶凝粗淀粉的方法,例如在至少约185(85℃)温度下的水中蒸煮粗淀粉或其他方法。预胶凝淀粉的适宜实例包括(但不限于)可购自Lauhoff Grain公司的PCF 1000淀粉和均可购自Archer Daniels Midland公司的AMERIKOR 818与HQM PREGEL淀粉两者。如果包含预胶凝淀粉,其以任何适宜含量存在。举例而言,如果包含预胶凝淀粉,可将其添加到用来形成凝固石膏组合物的混合物中,使得其以占凝固石膏组合物约0.5重量%至约10重量%的含量存在。视需要也可添加诸如USG95(United States Gypsum公司,Chicago,IL)等淀粉以增强核心强度。
在作业中,使石膏在输送机上向混合机移动。在进入混合机前,将诸如干凝固促进剂等干添加剂添加到粉末化石膏中。某些添加剂可通过独立管线直接添加到混合机中。在下述实例中使用此方法添加三偏磷酸盐。也可将其他添加剂添加到水中。若添加剂为液态形式此方法尤其便利。对大多数添加剂来说,将添加剂置于浆液时无严格要求,并且可使用任何便利的装置或方法添加。
然而,在使用本发明分散剂时,重要的是在添加灰泥前将分散剂添加到水中。如果考虑到来自其他来源的水分,以满足水与灰泥的目标比率所需量在混合机中添加计量水或补给水。
若需要可使用其他已知添加剂来改变产品的特定性质。可使用诸如右旋糖等糖类来改良板末端的纸结合。蜡乳液或聚硅氧烷可用于增强耐水性。如果需要刚性,通常添加硼酸。可通过添加蛭石来改良阻燃性。这些和其他已知添加剂可用于本发明浆液和壁板调配物中。
实例1
实施测试以测定添加碳酸钾对两种不同分散剂的影响。在下述各样品中,自400克来自Southard,OK的灰泥、180克水和占灰泥干重0.2%的分散剂制备石膏浆液。根据2005年6月14日申请的美国专利第11/152,678号和美国专利第11/xxx,xxx号(代理文号DCP 3)中的制备实例3来制备211分散剂,二专利标题均为”Polyether-Containing Copolymer”且均以引用方式并入本文中。分散剂类型和碳酸钾含量,以及圆饼尺寸和硬化速率测试的结果共同展示于下表I中。
表I
分散剂 | 碳酸钾,g | 圆饼尺寸,cm | 硬化时间 |
211 | 0.6 | 30.3 | 6:00 |
211 | 0.0 | 19.8 | 2:05 |
MELFLUX 2500L | 0.6 | 26.0 | 10:30 |
MELFLUX 2500L | 0.0 | 15.5 | 2:35 |
从上表I中数据可看出,与先前技术分散剂MELFLUX 2500L相比,本发明的二重复单元分散剂211在添加和不添加碳酸钾改性剂情况下均显示可缩短硬化时间。此实例也显示碳酸钾改性剂对所述两种分散剂各自的效应。应注意相同浓度的211分散剂对改性剂响应更佳,其形成更大圆饼尺寸而表明分散作用更佳,但硬化时间减少。
实例2
用各种改性剂测试优选211分散剂以测定效力的改良。测试试剂级焦磷酸钠(TSP),焦磷酸四钠(TSPP)和碳酸钠(苏打灰)。同样测试可从Solutia公司(St.Louis,MO)购得的DEQUEST 2006(一种胺基三(亚甲基膦酸)的五钠盐)。
对所有测试样品而言,水与灰泥比率为0.5而且添加占灰泥干重0.66重量%的湿石膏促进剂(WGA)。对照样品仅含有0.5重量%的WGA。所添加各改性剂含量,与凝固时间和以各样品制造的圆饼尺寸一起展示于表II中。
将改性剂和分散剂添加到水中,然后添加灰泥和WGA。搅拌浆液直至其为均质。
表II
改性剂 | 对照 | DEQUEST 2006 | TSP | TSPP | 苏打灰 |
含量 | 0 | 0.05% | 0.05% | 0.05% | 0.15% |
圆饼尺寸 | 20cm | 23.7cm | 21.5cm | 25.5cm | 27.5cm |
硬化时间 | 2:15 | 2:35 | 2:15 | 2:55 | 2:30 |
即使使用更多苏打灰来获得所述结果,也将其视为有效因为其只消费其他改性剂价格的三分之一。此外,苏打灰可使圆饼尺寸增加37%同时仅使凝固时间延长11%。DEQUEST 2006产生的圆饼小得多且凝固时间大致相同,而TSPP形成的圆饼尺寸更小但凝固时间更长。
实例3
实施车间试验以测试在生产线上制备的壁板中分散剂减少水分的能力。经由输送机将灰泥输送到高切应力混合机中。在运送灰泥时将诸如淀粉等干添加剂添加到输送机中。以达成已考虑液态添加剂中水分的水与灰泥目标比率的必需量将计量水添加到混合机中。通过独立管线将三偏磷酸盐直接添加到混合机中。在混合机中掺合所有组份直至获得均质浆液。浆液的基本组成展示于表III中。
表III
基本组成,lbs./1000ft2(308m2)
灰泥 1714lbs.(779kg)
湿石膏促进剂 45lbs.(20.5kg)
皂 0.42lbs.(19g)
在将分散剂以展示于表IV中的剂量引入混合机之前将其掺合入计量水中。所显示剂量是基于作为干灰泥百分比的干分散剂的重量。调节促进剂含量以在刀具处达成凝固50%至60%。由于水合为放热反应,使用温度升高来估计反应程度并相应改变促进剂含量。随着使用更多PCE211,凝固延迟导致表明凝固低于50%的刀具处温度,从而使过程控制器增加促进剂剂量。各数据点的促进剂含量也展示于表IV中。在此表中,比较本发明分散剂PCE211与基准实例0.14%萘磺酸酯和具有至少三种重复单元的聚羧酸系物分散剂。
掺合所有组份后,将浆液排出到载有面板纸的输送机上。将第二层面板纸置于浆液上面并输送经过一组滚筒以形成4英尺(1.2m)宽,5/8”(15mm)厚的连续板。然后用切割刀具将板切割成8英尺(2.4m)长。
表IV
分散剂 | 0.14% | 0.21% | 0.10%. | 0.10% | 0.125% | 0.15% | 0.20% |
类型 | NS | NS | MELFLUX 2500L | PCE211 | PCE211 | PCE211 | PCE211 |
ΔWSR | 基准 | -0.03 | -0.01 | -0.01 | -0.07 | -0.09 | -0.15 |
Δ水, | 基准 | -45 | -11 | -21 | -122 | -161 | -273 |
lbs.(kg) | (-21) | (-5) | (-9.5) | (-56) | (-73) | (-124) | |
ΔWGA, | 基准 | 0 | * | 2 | 6 | 6 | 12 |
lbs.(kg) | (0.9) | (2.7) | (2.7) | (5.5) |
*无法获得数据
与包含0.14%萘磺酸酯(″NS″)(DAXAD分散剂,Dow Chemicals,Midland,M1)的基线数据相比,变为0.1%的MELFLUX 2500L(购自Degussa)节省约11磅水/1000ft2(16kg/1000m2)。在相同剂量下,PCE211节省约21磅水/1000ft2(31kg/1000m2)。将剂量增加到0.20%使得可节省273磅水/1000ft2(886kg/m2)板长度。然而,在最高分散剂剂量下,促进剂含量必须增加12磅(5.5kg)以满足在刀具处凝固50%的需求。0.5WSR下的已完成板的特性满足所有技术规格,尽管核心和边缘硬度结果低于对照样品。来自包含PCE211的特定样品的结合结果较差,但这是由于在标明炉温前过度干燥。
虽然本文已展示并阐述石膏浆液壁板的组合物的具体实施例,但熟习此项技术者应理解,在不背离本发明更宽广态样和下文权利要求书所列述范畴的情况下,可对其进行修改和改变。
Claims (20)
1.一种石膏浆液,其包含:
水;
水硬组份,以所述水硬组份干重计其包含至少50重量%的半水合硫酸钙;和
聚羧酸系物分散剂,其基本由第一和第二重复单元组成,其中所述第一重复单元是烯烃不饱和单羧酸重复单元或其酯或盐、或烯烃不饱和硫酸重复单元或其盐,而所述第二重复单元具有以下通式(I):
其中R1由下式表示:
且其中R2为氢或脂肪族C1至C5烃基团,R3为未经取代或经取代芳基并优选为苯基,而R4为氢或脂肪族C1至C20烃基团、环脂族C5至C8烃基团、经取代C6至C14芳基或符合下式的基团:
其中R5和R7各自独立地代表烷基、芳基、芳烷基或烷芳基而R6是二价烷基、芳基、芳烷基或烷芳基,p为0至3且包括0和3,m和n独立地为2至4且包括2和4的整数;x和y独立地为55至350且包括55和350的整数,而z为0至200且包括0和200。
2.如权利要求1所述的石膏浆液,其中m和n至少一个为2。
3.如权利要求1所述的石膏浆液,其中p为0或1。
4.如权利要求1所述的石膏浆液,其另外包含改性剂,其以化学方法构造成可提高所述聚羧酸系物分散剂效力。
5.如权利要求4所述的石膏浆液,其中所述改性剂选自下述各项组成的群组:石灰、苏打灰、碳酸盐、硅酸盐、磷酸盐、膦酸盐、水泥和其组合。
6.如权利要求1所述的石膏浆液,其另外包含至少一种选自下述各项组成的群组的添加剂:凝固延迟剂、凝固促进剂、起泡剂、三偏磷酸盐、杀生物剂、淀粉、糖类、硅氧烷和蜡乳液。
7.如权利要求6所述的石膏浆液,其中所述凝固促进剂包括至少一种湿石膏促进剂、HRA和CSA。
8.如权利要求1所述的石膏浆液,其中所述第一重复单元包括由丙烯酸和甲基丙烯酸组成的群组中的至少一种。
9.如权利要求1所述的石膏浆液,其中所述水硬组份包含至少80重量%的半水合硫酸钙。
10.如权利要求1所述的石膏浆液,其中所述半水合硫酸钙包含少于600ppm的可溶盐。
11.如权利要求1所述的石膏浆液,其中所述分散剂的电荷密度为约600至约2000微当量电荷/克共聚物。
12.如权利要求1所述的石膏浆液,其中所述分散剂以计算为干石膏百分比的干分散剂重量计以约0.01%至约2%的量存在于所述浆液中。
13.如权利要求12所述的石膏浆液,其中所述分散剂以计算为干石膏百分比的干分散剂重量计以约0.05%至约0.3%的量存在。
14.一种石膏板,其包含:
石膏核心材料,所述石膏核心材料包含二水合硫酸钙和基本由第一和第二重复单元组成的分散剂,其中所述第一重复单元是烯烃不饱和单羧酸重复单元或其酯或盐、或烯烃不饱和硫酸重复单元或其盐,而所述第二重复单元具有以下通式(I):
其中R1由下式表示:
且其中R2为氢或脂肪族C1至C5烃基团,R3为未经取代或经取代芳基并优选为苯基,而R4为氢或脂肪族C1至C20烃基团、环脂族C5至C8烃基团、经取代C6至C14芳基或符合下式的基团:
其中R5和R7各自独立地代表烷基、芳基、芳烷基或烷芳基,而R6是二价烷基、芳基、芳烷基或烷芳基,p为0至3且包括0和3,m和n独立地为2至4且包括2和4的整数;x和y独立地为55至350且包括55和350的整数,而z为0至200且包括0和200。
15.如权利要求14所述的石膏板,其中所述核心材料另外包含由下述各项组成的群组中的至少一种:凝固促进剂、起泡剂、凝固延迟剂、强化剂、淀粉、三偏磷酸盐和改性剂。
16.如权利要求14所述的石膏板,其中所述板在5分钟内至少凝固50%。
17.如权利要求14所述的石膏板,其另外包含由泡沫形成的空隙。
18.如权利要求14所述的石膏板,其中在无促进剂存在的情况下所述板在10分钟内至少凝固50%。
19.如权利要求14所述的石膏板,其中水与经煅烧石膏的重量比小于0.6。
20.如权利要求19所述的石膏板,其中水与经煅烧石膏的重量比小于0.5。
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CN103443048B (zh) * | 2011-02-23 | 2015-11-25 | 巴斯夫欧洲公司 | 石膏基淤浆、发泡石膏板以及生产发泡石膏板的方法 |
US10125049B2 (en) | 2011-02-23 | 2018-11-13 | Basf Se | Gypsum slurries and boards and methods of making the same |
CN103958436A (zh) * | 2011-12-19 | 2014-07-30 | Sika技术股份公司 | 用于基于硫酸钙的粘结剂的促凝剂 |
US9255032B2 (en) | 2011-12-19 | 2016-02-09 | Sika Technology Ag | Setting accelerator for binders based on calcium sulfate |
CN108698929A (zh) * | 2016-02-19 | 2018-10-23 | 埃特克斯建筑性能国际联合股份公司 | 石膏板 |
Also Published As
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WO2006138000A2 (en) | 2006-12-28 |
US20100056655A1 (en) | 2010-03-04 |
US7767019B2 (en) | 2010-08-03 |
US20060278130A1 (en) | 2006-12-14 |
UA91862C2 (ru) | 2010-09-10 |
NZ562971A (en) | 2010-12-24 |
JP2008543716A (ja) | 2008-12-04 |
US20060278127A1 (en) | 2006-12-14 |
TW200704619A (en) | 2007-02-01 |
US8142915B2 (en) | 2012-03-27 |
ES2714805T3 (es) | 2019-05-30 |
US20110213043A1 (en) | 2011-09-01 |
MX2007015523A (es) | 2008-02-25 |
PT1896374T (pt) | 2019-04-02 |
IL187018A0 (en) | 2008-02-09 |
US7776462B2 (en) | 2010-08-17 |
DK1896374T3 (en) | 2019-04-15 |
RU2420471C2 (ru) | 2011-06-10 |
HUE043562T2 (hu) | 2019-08-28 |
BRPI0612040A2 (pt) | 2010-10-13 |
RU2008101459A (ru) | 2009-07-20 |
WO2006138000A3 (en) | 2007-12-13 |
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