CN101432240B - 石膏产品用的蜡乳液 - Google Patents

石膏产品用的蜡乳液 Download PDF

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CN101432240B
CN101432240B CN2007800148007A CN200780014800A CN101432240B CN 101432240 B CN101432240 B CN 101432240B CN 2007800148007 A CN2007800148007 A CN 2007800148007A CN 200780014800 A CN200780014800 A CN 200780014800A CN 101432240 B CN101432240 B CN 101432240B
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S·J·万特林
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Abstract

公开了用来赋予石膏产品耐水性的乳液。本发明的乳液包括至少一种蜡、烷基酚和亲水性金属盐，优选硫酸镁。本发明的乳液不需要加入淀粉化合物，和因此甚至在固含量高于现有技术乳液时仍能呈现出增强的稳定性。

Description

石膏产品用的蜡乳液
相关申请资料
本申请要求2006年4月25日提交的美国申请序列号11/410,738的权益，将其全文通过引用并入本文。
发明领域
本发明涉及用来赋予石膏产品耐水性的乳液。具体地说，本发明涉及包括至少一种蜡、烷基酚和亲水性金属盐(优选硫酸镁)的蜡乳液。本发明的乳液不需要加入淀粉化合物并因此甚至在固含量高于现有技术乳液时仍能呈现出增强的稳定性。此外，本发明涉及所述蜡乳液的制备方法和由其所制成的制品。
发明背景
石膏(二水硫酸钙)的某些性能使其普遍用于制造工业和建筑产品，特别是石膏板。它是丰富且普通的廉价原料，其可通过脱水和再水合过程进行浇铸、模制或以其它方式形成有用的形状。生产石膏板的基础原料是硫酸钙的半水合物形式(石膏)，通常称为灰泥，它是通过将已除去水相的二水合物加热转化来生产的。
在制造石膏板的过程中，石膏浆液必须流到纸基材上。在连续方法中，然后是使浆液/基材复合物在辊间通过来使此复合物尺寸定型。在此尺寸定型步骤中的同时，将纸衬背放到尺寸定型的石膏浆液上。因此石膏浆液必须具有足够的流动性以便能制成适当尺寸的石膏板。流动性是指石膏浆液的流动能力。
石膏浆液能够被发泡到有限程度在石膏板的制造中也很重要。发泡能力是指能够发泡的能力。当石膏浆液和纸基材通过尺寸定型辊时，必须要有一定量的石膏浆液回流且累积在辊隙中，以使稳定的石膏流被输送到尺寸定型辊。发泡能力对石膏浆液在辊隙处回流的这一能力很重要。虽然可使用成型板，省去使用主辊，但发泡能力对控制最终产品的密度很重要。
由于其中石膏浆液流到基材上然后通过尺寸定型辊的石膏板生产过程的连续性，尺寸定型后石膏浆液流延程度对维持石膏板的最终产品尺寸很关键。石膏浆液停止流动的时间称为预凝固时间。因此，预凝固时间是石膏浆液的重要性质。石膏浆液的凝固时间也是一个重要性质。凝固时间是指石膏浆液在加热下干燥成最终固体石膏板所花费的时间。如本领域众所周知的，在连续制造石膏板的过程中，石膏浆液具有恒定的凝固时间很重要。
石膏板吸水，这降低墙板的强度。现有技术产品，象普通石膏板、石膏砖、石膏块、石膏铸件等具有相对差的耐水性。例如，当将普通石膏板浸入水中时，石膏板很快吸收大量水，损失其大部分强度。实际测试显示，当将2×4英寸的石膏板芯材料的圆柱体浸入约70℉(21.1℃)的水中时，浸入40分钟后显示圆柱体的吸水率为36％。
先前进行的为石膏板提供防水性的尝试包括在含水石膏浆液中掺入沥青、金属皂、树脂和蜡添加剂。得到的材料难以使用且芯性质难以控制。聚硅氧烷基体系也曾用于赋予石膏板耐水性的尝试中。但是，聚硅氧烷基体系价格高且难以使用。还曾用耐水膜或涂层来涂覆石膏成品。先前为提供耐水石膏产品所做尝试的一个具体实例是向含水石膏浆液中喷入熔融的石蜡、蜡或沥青。
先前为提供耐水石膏产品所做尝试的另一个具体实例是把蜡(例如石蜡)和沥青的乳液，按每份蜡约1-约10份沥青的相对比例加入到含水石膏浆液中。由于沥青在常温下是对于石蜡和类似的蜡的相对差的溶剂，在高温下形成的该溶液在冷却时往往在沥青-蜡表面沉积微小的蜡晶体。
在提供用于给石膏增加耐水性的室温体系的尝试中也曾使用了聚乙烯醇。但是，聚乙烯醇体系往往迅速分离并因而通常需要在使用前连续混合。聚乙烯醇体系固有的不稳定性往往使配方中的化合物产生分层。因此，聚乙烯醇体系会有组分不相容的倾向。此外，由于失稳而分成不同的相，还有细菌生长的可能性。
因此，需要能用于赋予石膏产品耐水性且经济实用的添加剂。需要无需使用昂贵组分且不影响流动性、发泡能力、预凝固时间或凝固时间的耐水性添加剂。
发明概述
本发明的为石膏产品提供耐水性的乳液包括至少一种蜡、烷基酚和硫酸镁。在一个实施方案中，按乳液总重量计，硫酸镁的量为约0.05-约5wt％。在另一个实施方案中，乳液中未加淀粉组分。在另一个实施方案中，本发明包括为石膏产品提供耐水性的本发明的乳液的制备方法。在又一个实施方案中，本发明包括采用本发明的乳液所制备的石膏产品。
发明详述
本发明提供了用来赋予石膏产品耐水性的乳液。所述乳液包括至少一种蜡、烷基酚和亲水性金属盐，优选硫酸镁。本发明的乳液可加入到石膏与水的混合物中，不会对为制造石膏产品例如石膏板所必需的混合物的性质性能产生不利影响。
各种来源的石膏都可用于本发明的组合物。但是石膏样品水合所需的水量将会随样品的纯度而变动。
用于本发明的乳液中的蜡可选自熔点为约120℉(48.9℃)-约150℉(65.6℃)且优选约135℉(57.2℃)-约145℉(62.8℃)的任何市售已知蜡。这类蜡一般是低挥发性的，标准热重分析显示失重率少于约10％。另外，这些蜡的油含量一般低于约1wt％。这些蜡的分子量相对高，平均链长为约36或更多个碳原子(C36或更高)。所述烃蜡组分可包括石膏浆乳液领域已知的任何蜡。
在某些实施方案中，对一种或多种所述蜡进行皂化是有用的。以此方式，皂化的蜡起到额外的表面活性剂的作用。用于此方面的蜡限于具有酸值或皂化值且熔点大于约180℉(82.2℃)的蜡。这些蜡的皂化反应可通过将蜡与强碱性物质例如氢氧化钠或氢氧化钾进行混合来实施。在本发明的乳液中可皂化的蜡包括褐煤蜡、巴西棕榈蜡、蜂蜡、杨梅-桃金娘蜡、小烛树蜡、白蜡棕蜡、蓖麻子蜡、茅草蜡、日本蜡、小冠椰子蜡、retamo-ceri mimibi蜡、虫漆、鲸油蜡、甘蔗蜡、羊毛脂蜡等。皂化蜡所需的强碱性物质的量可根据蜡的皂化值来计算。例如，皂化值除以1000等于每克蜡中加入的氢氧化钾的克数。
已发现将烷基酚掺入乳液中对石膏成品达到低吸水率很重要。本文所用术语“烷基酚”是指具有长链烷基的酚类化合物。所述长链烷基可以是直链或支化的。所述长链烷基可以有24-34个碳原子(C24-C34)。这类烷基酚包括长链C24-C34聚合的亚甲基偶联的烷基酚、酚盐、酚钙、长支链烷基酚钙、长直链烷基酚钙和带或不带胺基取代基的马来酸的络合物类高分子。用于本发明组合物的市售烷基酚的合适实例是C24-C34聚合的亚甲基偶联的烷基酚FLOZOL140、不带胺基取代基的马来酸的络合物类高分子FLOZOL145、带胺基取代基的马来酸的络合物类高分子，它们都可从Lubrizol ChemicalCorp.，Wycliffe，Ohio获得。
本发明的乳液包括硫酸镁(MgSO4)，以省去使用不那么稳定的七钼酸铵作为蜡分散剂且与各种各样的可得蜡(即低价格/低熔点蜡)相容，而七钼酸铵还需要淀粉作为悬浮/凝胶化助剂。使用淀粉的实例描述于美国专利申请公开号2005/0250858A1和美国专利号6,663,707中，引入这两个专利作为参考。不希望为任何理论所束缚，本发明人相信七钼酸铵通过破碎蜡发挥作用，需要加入悬浮/凝胶化助剂(淀粉)来分散蜡。但是，凝胶化状态会导致稳定性和性能方面不可预知。相反，MgSO4水溶性更好，因而提供了使以乳液状悬浮的蜡更均匀地分散于整个灰泥/芯层基材中的机会，且与各种各样的低价格/低熔点的可得蜡相容。本发明的含MgSO4的乳液还允许减少在现有体系中用作分散剂的烷基化的酚的使用。结果是，本发明的蜡乳液要比以前体系或竞争体系显著更稳定，且可在更高的固含量下储存，而不损害乳液的性能或稳定性。
本发明的乳液稳定至少1个星期、优选稳定至少1个月，且更优选稳定至少6个月。本发明的乳液的平均固含量一般为至少35wt％、优选至少40wt％、更优选至少45wt％、更优选至少50wt％、更优选至少55wt％且甚至更优选至少60wt％。更高固含量的乳液的稳定性在可能减少运输费用方面有好处。
用于为石膏产品提供耐水性的本发明的乳液的典型组成范围包括以下任意组合。按乳液总重量计，约25-约40wt％量的至少一种蜡。按乳液总重量计，约2.5-约4.5wt％量的可皂化的蜡。按乳液总重量计，本发明的乳液任选地含有约0.1-约10.0wt％、优选约0.1-约5.0wt％、甚至更优选约0.1-约2.0wt％和最优选在约0.1-约1.0wt％之间量的烷基酚。所需烷基酚的量比现有技术的配方通常所需的量有所减少，在本发明的乳液的制备过程中费用降低。在本发明一个实施方案中，乳液不含有烷基酚。按乳液总重量计，约0.25-约5.0wt％量的聚萘磺酸；按乳液总重量计，约55-约65wt％量的水；按乳液总重量计，约0.5-约1.5wt％量的碱金属氢氧化物。按乳液总重量计，约0.05-约5wt％、优选约0.05-约3.0wt％、甚至更优选约0.1-约2.5wt％和最优选约0.1-约1.0wt％量的MgSO4。
本发明的乳液稳定至少1个星期、优选稳定至少1个月和更优选稳定至少6个月。本发明的乳液的平均固含量一般为至少35wt％、优选至少40wt％、更优选至少45wt％、更优选至少50wt％、更优选至少55wt％和甚至更优选至少60wt％。
为更好地理解包括其代表性的优点在内的本发明，提供以下实施例。
实施例
表1列出了实施例中所用乳液配方的组分和某些特性。在制备乳液的过程中，将水和水溶性组分混合成第一混合物，然后加热到约185℉(85℃)-约205℉(96.1℃)间的温度。蜡化合物与烷基酚掺合成第二混合物并也加热到约185℉(85℃)-约205℉(96.1℃)间的温度。然后将水溶液和蜡混合物合并，然后将得到的混合物放入均化器。通过均质化，优选实现约0.6-约1.8微米的胶束直径分布。但是，胶束直径分布可为约0.5-约2.5微米。例如可通过操作在约2000-约4000psig下的双孔均化器来达到该均化水平。
表1乳液配方1
 
4B 4C 6B 6C 16A 16B 16C 17A 17B 17C 17D
石蜡 33.00 33.00 33.00 33.00 33.00 33.00 33.00 33.00 33.00 33.00 33.00
褐煤蜡 3.30 3.30 3.30 3.30 3.30 3.30 3.30 3.30 3.30 3.30 3.30
烷基酚 0.50 0.50 0.50 0.50 0.00 0.00 0.00 0.00 0.25 0.25 0.25
DISAL2 2.50 2.50 2.50 2.50 2.50 2.50 2.50 0.50 0.50 0.50 0.50
Polyfon H3 0.50 0.50 0.50 0.50
45％KOH水溶液 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
MgSO4 0.50 0.50 0.50 0.15 0.15 0.50 0.15 0.50 0.15 0.50 0.15
水 59.45 59.45 59.45 59.80 60.30 59.95 60.30 61.45 61.55 61.20 61.55
总量 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00
固体 38.69 38.62 39.72 39.23 37.29 38.98 39.19 38.35 38.90 38.65 39.75
pH 11.32 11.37 11.25 12.35 12.59 16.0 12.58 11.27 12.39 11.27 12.38
粘度，厘泊 16.50 23.50 17.00 18.00 12.0 11.46 17.0 12.5 11.0 15.0 15.5
1.所有组分和固体值都是wt％。
2.DISAL是可从Montreal Quebec，Canada的Handy Chemical获得的聚萘磺酸分散剂。
3.Polyfon H是可从Stamford，Connecticut的Mead WestvacoCorporation获得的木素磺酸盐分散剂。
表2、3、4和5列出了由用表1中的乳液制备的测试样品获得的流动性和吸收率数据。表3包括还包括0.25wt％Thiobendizole作为抗菌剂的乳液4B、4C、6B和6C的数据。所有测试样品都是通过将50g灰泥与列表2、3和4所示克数的水和乳液混合来制备的。作为对照(空白)，不加乳液。将石膏、水和乳液(若加的话)混合到一起并静置1分钟。然后将此混合物再混合30秒。第二次混合后，将样品倾倒到平坦表面并测定所得饼状物的直径。饼状物的直径是样品流动性的指标。直径越大，则样品的流动性越大。将流动性试验中制成的饼状物在110℉(43.3℃)下干燥至少24小时。此时间结束时，称重饼状物并记下重量。然后将干燥的饼状物浸入水中2小时。2小时浸泡结束后，称重饼状物并记下此湿重量。根据这两次记录的重量的差来计算水存留百分数。
表2乳液4B、4C、6B和6C的吸水率和流动性数据
 
灰泥(50g) 水/乳液(g/g) 乳液 直径(英寸) 吸水率，wt％
Savannah 31/0 空白 3 3/4 31.42
Savannah 28.65/3.85 4B 3 1/4 1.26
Savannah 28.65/3.85 4B 3 1/4 0.41
Savannah 28.65/3.85 4B 3 5/16 5.20
Savannah 28.65/3.85 4C 3 1/2 无数据
Savannah 28.65/3.85 4C 3 1/2 0.3
Savannah 28.65/3.85 4C 3 1/4 0.29
Savannah 28.75/3.75 6B 3 5/16 0.16
Savannah 28.75/3.75 6B 3 1/4 0.47
Savannah 28.75/3.75 6B 3 1/4 0.05
Savannah 28.65/3.85 6C 3 5/16 0.53
Savannah 28.65/3.85 6C 3 1/2 0.27
Savannah 28.65/3.85 6C 3 1/4 0.44
表3包括0.25wt％Thiobendizole的乳液4B、4C、6B和6C吸水率和流动性数据
 
灰泥(50g) 水/乳液(g/g) 乳液 直径(英寸) 吸水率，wt％
Savannah 31/0 空白 3 7/8 28.99
Savannah 28.65/3.85 4B 3 1/4 0.9
Savannah 28.65/3.85 4B 3 1/4 0.5
Savannah 28.65/3.85 4B 3 1/2 -0.89
Savannah 28.65/3.85 4C 3 1/2 0.37
Savannah 28.65/3.85 4C 3 1/4 0.42
Savannah 28.65/3.85 4C 3 1/2 0.52
Savannah 28.75/3.75 6B 3 1/2 0.42
Savannah 28.75/3.75 6B 3 1/2 0.13
Savannah 28.75/3.75 6B 3 1/4 0.17
Savannah 28.65/3.85 6C 3 1/2 0.84
Savannah 28.65/3.85 6C 3 1/2 0.98
Savannah 28.65/3.85 6C 3 1/2 0.80
表4乳液16A、16B和16C的吸水率和流动性数据
 
灰泥(50g) 水/乳液(g/g) 样品 直径(英寸) 吸水率％
Savannah 31/0 空白 3 3/4 31.97
Savannah 28.45/4.05 16A 1 1/4 0
Savannah 28.45/4.05 16A 2 1/2plop 3.68
Savannah 28.45/4.05 16A 2 1/2plop 0.64
Savannah 28.65/3.85 16B 2 1/2 2.13
Savannah 28.65/3.85 16B 2 1/2plop 0.16
Savannah 28.65/3.85 16B 2 3/4 0.41
Savannah 28.65/3.85 16C 2 3/4plop 5.77
Savannah 28.65/3.85 16C 2plop 0.35
Savannah 28.65/3.85 16C 2 1/2plop 0.4
表5乳液17A、17B、17C和17D的吸水率和流动性数据
 
Savannah 31/0 空白 3 3/4 30.51
Savannah 28.55/3.95 17A 3 1/4 2.81
Savannah 28.55/3.95 17A 3 1/4 2.97
Savannah 28.55/3.95 17A 3 1/4 2.66
Savannah 28.65/3.85 17B 3 1/8 1.14
Savannah 28.65/3.85 17B 3 1/8 2.06
Savannah 28.65/3.85 17B 3 1/8 0.42
Savannah 28.65/3.85 17C 3 5/8 0.18
Savannah 28.65/3.85 17C 3 5/8 1.04
Savannah 28.65/3.85 17C 3 5/8 0.53
Savannah 28.75/3.75 17D 3 0.80
Savannah 28.75/3.75 17D 3 1/4 0.75
Savannah 28.75/3.75 17D 3 1/8 0.58
表7列出了本发明的乳液的最优选的实施方案，和表8提供了该优选的实施方案的吸水率数据。
表7乳液配方1
 
石蜡 43
褐煤蜡 4.3
烷基酚 0.65
DISAL2 3.25
45％KOH水溶液 0.98
MgSO4 0.65
水 47.14
固体 51.85/T
1.所有组分和固体值都是wt％。
2.DISAL是可从Montreal Quebec，Canada的Handy Chemical获得的聚萘磺酸分散剂。
表8表7中的乳液配方的吸水率数据
Figure G2007800148007D00091
尽管已参照详细的实施方案和实施例对本发明进行了描述和说明，但本领域技术人员会意识到本发明本身有许多无需在此例示的变化。为此原因，要确定本发明的真实范围，只能参考所附的权利要求。

Claims (16)

1.为石膏产品提供耐水性的乳液，其包含25wt％-40wt％的熔点为48.9℃-65.6℃的至少一种蜡、0.1wt％-10wt％的烷基酚和0.05wt％-5wt％的硫酸镁，其中所述的烷基酚是具有长链烷基的酚类化合物，所述长链烷基有24-34个碳原子，其中wt％按乳液总重量计。
2.权利要求1的乳液，其中按乳液总重量计，硫酸镁的量为0.1wt％-2.5wt％。
3.权利要求1的乳液，其中按乳液总重量计，硫酸镁的量为0.1wt％-1.0wt％。
4.权利要求1的乳液，但条件是不加淀粉组分。
5.权利要求1的乳液，还包含按乳液总重量计2.5wt％-4.5wt％的熔点大于82.2℃的可皂化的蜡。
6.权利要求5的乳液，还包含按乳液总重量计0.25-5.0wt％量的聚萘磺酸；按乳液总重量计55-65wt％量的水；按乳液总重量计0.5-1.5wt％量的碱金属氢氧化物。
7.权利要求1的乳液，其中所述乳液稳定至少1个月。
8.权利要求1的乳液，其固含量大于乳液总重量的45wt％。
9.制备权利要求1的的乳液的方法，包括以下步骤：
(a)将包含所述熔点为48.9℃-65.6℃的至少一种蜡和所述烷基酚的第一混合物与包含所述硫酸镁和水的第二混合物合并；和
(b)将所得的混合物均质化。
10.权利要求9的方法，但条件是所述乳液不含有淀粉化合物。
11.权利要求9的方法，其中所述第一混合物还包含按乳液总重量计2.5wt％-4.5wt％量的熔点大于82.2℃的可皂化的蜡。
12.权利要求11的方法，其中所述第一混合物包含按乳液总重量计0.1wt％-1.0wt％量的烷基酚。
13.包含石膏和权利要求1的乳液的石膏产品。
14.权利要求13的石膏产品，其中按乳液总重量计，硫酸镁的量为0.1wt％-2.5wt％。
15.权利要求13的石膏产品，其中按乳液总重量计，硫酸镁的量为0.1wt％-1.0wt％。
16.权利要求13的石膏产品，但条件是所述乳液不含淀粉组分。
CN2007800148007A 2006-04-25 2007-04-05 石膏产品用的蜡乳液 Expired - Fee Related CN101432240B (zh)

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