CN101563220A - 低尘石膏墙板 - Google Patents

低尘石膏墙板 Download PDF

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CN101563220A
CN101563220A CNA2007800467731A CN200780046773A CN101563220A CN 101563220 A CN101563220 A CN 101563220A CN A2007800467731 A CNA2007800467731 A CN A2007800467731A CN 200780046773 A CN200780046773 A CN 200780046773A CN 101563220 A CN101563220 A CN 101563220A
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wallboard
low dust
gypsum
gypsum wallboard
weight
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CN101563220B (zh
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于强
卫新·戴维·宋
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United States Gypsum Co
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United States Gypsum Co
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    • 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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    • C04B38/0061—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity closed porosity
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    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
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    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
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Abstract

本发明提供具有高空隙体积的低尘低密度石膏墙板产品，其对应于约10－30pcf的低密度。该墙板具有一形成于两个大体平行的板层之间的凝固石膏芯，该凝固石膏芯优选总空隙体积为约80％－92％，并由包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的浆体制成。预凝胶淀粉和萘磺酸盐分散剂的组合还为凝固石膏晶体粘结在一起时提供一种胶状作用。该墙板配方，和小气泡空隙(以及水隙)一起，在切割、锯、掘、折、钉或拧紧、或钻孔该含石膏产品时提供粉尘控制。本发明还提供一种制造所述低尘低密度石膏产品的方法，包括在凝固石膏芯中引入足够量的肥皂泡沫以形成包含气隙、优选约80％－92％的总空隙体积，对应于凝固石膏芯密度为约10pcf－30pcf。按照本方法生产的墙板大大减少在加工期间产生的粉尘。

Description

低尘石膏墙板
本申请是2006年6月7日提交的美国专利申请No.11/449,177的部分继续申请，也是2006年6月2日提交的美国专利申请No.11/445,906的部分继续申请，各项申请都要求2005年6月9日提交的美国临时申请No.60/688,839的权益。在此引入上述各项专利申请的全部内容作为参考。
技术领域
本发明涉及一种生产石膏墙板的方法，其中加工墙板期间粉尘的产生大大降低。更具体地，该方法包括引入足够量的肥皂泡沫以在凝固石膏芯中形成约80％-90％的总空隙体积，对应于凝固石膏芯密度为约10pcf-30pcf，该方法在加工期间提供明显降低的粉尘形成。本发明还涉及一种利用该方法制造的低尘石膏墙板。
背景技术
石膏(二水合硫酸钙)的某些性能使其在制造工业和建筑产品如石膏墙板的应用中很受欢迎。石膏是一种丰富和廉价的原料，其通过脱水和再水合过程，可以铸造、模塑或以其它方式形成有用的形状。作为石膏墙板和其它石膏产品制造来源的基底材料是硫酸钙的半水合物形式(CaSO4·1/2H2O)，通常称作“灰泥”，它是由硫酸钙的二水合物形式(CaSO4·2H2O)加热转化，从中除去1-1/2分子水产生。
传统的含石膏产品如石膏墙板具有很多优点，例如低成本和易于加工，然而当这些产品被切割或钻孔时会产生大量的石膏粉尘。利用淀粉作为制造含石膏产品的浆体成分已经在制造这些产品方面实现了各种改进。预凝胶淀粉，像胶水一样，可增强包括石膏墙板在内的含石膏产品的抗弯强度和耐压强度。已知的石膏墙板包含小于约10lbs/MSF水平的淀粉。
为了保证浆体有适当的流动性，在含预凝胶淀粉的石膏浆中还有必要使用大量的水。但是，大部分水最终必须通过干燥去除，而干燥费用昂贵，因为干燥过程使用高成本的燃料。干燥步骤也很费时。研究发现使用萘磺酸盐分散剂能增强浆体的流动性，由此克服对水的需求问题。此外，研究还发现如果使用水平(量)够高，萘磺酸盐分散剂能交联到预凝胶淀粉上，以便在干燥后将石膏晶体粘合到一起，由此增强石膏复合品的干强度。因此，预凝胶淀粉和萘磺酸盐分散剂的结合在粘合凝固石膏晶体中提供了类似胶水的作用。在过去，人们没有认识到三偏磷酸盐影响石膏浆的水需求。然而，本发明人发现在特定分散剂的存在下，将三偏磷酸盐的水平增加到目前未知的水平上可能以出人意料地减少的水量，甚至在高水平淀粉存在下，实现浆体适当的流动性。这当然是非常可取的，因为它反过来减少了干燥的燃料用量以及与后来水去除处理步骤相关的处理时间。因此，本发明人还发现石膏墙板的干强度可通过在用于制造墙板的浆体中使用萘磺酸盐分散剂结合预凝胶淀粉来增强。
本发明的石膏板应区别于不具有夹层(face sheet)的吸声板或砖。并且，本发明的石膏板应区别于包含聚苯乙烯作为轻量骨料的吸声板或砖。重要的是，上述吸声板或砖不符合适用于石膏墙板的很多ASTM标准。例如，已知的吸声板不具有包括本发明在内的石膏墙板所需的抗弯强度。相反，为了使吸声板或砖符合ASTM标准，吸声板或砖的暴露表面需要具有中空空洞或凹陷，这在石膏墙板中是不合需要的，并且会对钉拉阻力性质产生不利影响。
粉尘产生是所有墙板安装时的潜在问题。例如，当石膏墙板通过切割、锯、掘、折、钉或拧紧、或钻孔被加工时会产生大量的石膏粉尘。对于本发明揭露内容而言，“粉尘”和“粉尘产生”指在含石膏产品加工期间，例如通过切割、锯、掘、刻/折、钉或拧紧、或钻孔该板，粉尘释放进入周围工作空间。加工通常还可包括正常板处理，包括在运输、携带和安装期间意外地刮或刨削该板时产生的粉尘。如果找到一种粉尘产生大大降低的生产低密度墙板的方法，将是对本领域特别有用的贡献。
发明内容
本发明通常包括一种低尘石膏墙板，其包括在两个大体平行的板层之间形成的一凝固石膏芯，该凝固石膏芯具有约75％-95％的总空隙体积，该石膏芯是由包含水、灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成，其中预凝胶淀粉是以基于灰泥重量约0.5-10％重量的量存在。优选地，萘磺酸盐分散剂是以基于干灰泥重量约0.1-3.0％重量的量存在。可选地，三偏磷酸钠是以基于灰泥重量至少约0.12％重量的量存在。在一种优选的实施方式中，三偏磷酸钠是以基于干灰泥重量约0.12-0.4％重量的量存在。
在一种优选的实施方式中，本发明包括一种低尘石膏墙板，其包括在两个大体平行的板层之间形成的含有预凝胶淀粉和萘磺酸盐分散剂的一凝固石膏芯，该凝固石膏芯具有约80％-92％的总空隙体积，其中总空隙体积的至少60％包含平均直径小于约100微米的气隙(air void)，且凝固石膏芯的密度为约10pcf-30pcf。术语“pcf”定义为磅每立方英尺(lb/ft3)。该凝固石膏芯由包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成，其中预凝胶淀粉是以基于灰泥重量约0.5-10％重量的量存在。优选地，萘磺酸盐分散剂是以基于干灰泥重量约0.1-3.0％重量的量存在。
根据本发明制造的石膏墙板具有高强度，但重量比传统墙板低的多。此外，研究发现通过确保凝固石膏芯的总芯空隙体积为约70％-95％，并优选为约80％-92％，在切割、锯、掘、折、钉或拧紧、或钻孔根据本发明制造的墙板时，产生的粉尘也减少很多。
在另一种实施方式中，本发明建立一种制造高强度、低粉尘的石膏墙板的方法，即通过混合包含水、灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆，其中萘磺酸盐分散剂是以基于干灰泥重量约0.1-3.0％重量的量存在，预凝胶淀粉是以基于灰泥重量，至少约0.5％高至约10％重量的量存在，并且添加足够的肥皂泡沫至含石膏浆，以在成品墙板中形成约75％-95％的包含气隙的总空隙体积。将产生的含石膏浆沉积在第一纸的或其它适当板层上，然后将第二纸或其它适当板层置于该沉积浆体上以形成石膏墙板。当含石膏浆硬化到足以用于切割时，切割该石膏墙板，并干燥由此产生的石膏墙板，以在成品墙板中提供具有约75％-95％的包含气隙的总空隙体积的凝固石膏芯。所述含石膏浆可选择地包含三偏磷酸盐，例如三偏磷酸钠。其它常规成分也可用于该浆体中，视情况包含促进剂、粘结剂、防水剂、纸纤维、玻璃纤维、粘土、杀菌剂和其它已知成分。
在另一种实施方式中，本发明建立一种使用低尘石膏墙板的方法，即通过提供具有一总空隙体积为约75％-95％的凝固石膏芯的低尘石膏墙板，其中总空隙体积的至少60％包含平均直径小于约100微米的气隙以及包含平均直径小于约5微米的水隙(water void)，以产生石膏粉尘的方式(如切割、锯、掘、刻/折、钉或拧紧、或钻孔)加工该墙板；以及在空隙中捕获相当大一部分石膏粉尘。
附图简要说明
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具体实施方式
研究结果意外地发现，用含有灰泥、预凝胶淀粉和萘磺酸盐分散剂以及适量泡沫的含石膏浆制成的石膏墙板，当凝固石膏芯的总空隙体积为约80％-92％时，不仅具有非常低的约10-30pcf的板芯密度(因此有轻的板重量)，而且在正常板处理和加工，例如切割、锯、掘、刻/折、钉或拧紧、或钻孔时具有低份尘。因此这种墙板比其它已知产品更易于切割。肥皂泡沫的引入产生小气(泡)隙，其直径平均可小于约100微米，但通常直径都大于约10微米，且优选直径大于约20微米。本发明要求这些小气泡，与蒸发的水隙(通常直径约5微米或更小，正常情况下直径小于约2微米)一起，通常均匀地分布在成品墙板产品的整个凝固石膏芯中。例如，凝固石膏芯的总空隙体积可以为约80％-92％，其中总空隙体积的至少60％包含平均直径大于约10微米的气隙，且总空隙体积的至少10％包含平均直径小于约5微米的水隙。可以认为以这种方式制备的低密度板芯，其具有的凝固石膏芯的总空隙体积作为气隙和水隙(总芯空隙体积)为约80％-92％，当切割、锯、掘、折、钉或拧紧、或钻孔该板时，在暴露的空隙中捕获了相当大量的小粉尘和其它碎片，使得粉尘产生大大减少且不会浮在空中。
半水合硫酸钙(灰泥)的再水合以及随之发生的硬化需要具体的、理论量的水(1-1/2摩尔水/摩尔灰泥)以形成二水合硫酸钙晶体。然而，工业化过程通常需要过量的水。这种过量的工艺水在石膏晶体基质中产生蒸发水隙，通常其形状相当不规则，并且还与其它水隙相连，在凝固石膏晶体之间以通常连续的网状形成不规则通道。相反，气(泡)隙是利用肥皂泡沫引至石膏浆中。气隙通常为球形/圆形形状，且通常与其它气隙分开，因此一般是不连续的。水隙可以分布于气隙的壁内(参见如图8-10)。
粉尘捕获的效力取决于石膏芯的组分。研究发现萘磺酸盐分散剂如果用量足够高，能交联到预凝胶淀粉以将石膏晶体干燥后结合在一起，由此增强石膏复合物的干强度。此外，研究意外地发现预凝胶淀粉和萘磺酸盐分散剂(有机相)的结合在将凝固石膏晶体结合到一起时提供了一种胶样(glue-like)作用，且当该配方与特定的空隙体积和空隙分布相结合时，刻/折成品墙板时会产生较大尺寸的碎片。较大的石膏碎片通常产生较少扬尘。相反，如果使用传统墙板配方，就会产生较小碎片并因此有更多粉尘。例如，传统墙板能在锯切时产生平均直径约20-30微米、最小直径约1微米的粉尘碎片。相反，本发明的石膏墙板在锯切时产生平均直径约30-50微米、最小直径约2微米的粉尘碎片；刻/折时可产生甚至更大的碎片。
在较软墙板中，粉尘可以在水隙和气隙中被捕获(如捕获作为单晶粉尘的小石膏针体)。较硬的墙板有利于粉尘在气隙中的捕获，因为凝固石膏芯的较大块或碎片是在加工这些板时产生。在这种情况下，粉尘碎片对于水隙来说太大，但可在气隙中被捕获。根据本发明的一种实施方式，通过在凝固石膏芯中引入优选的空隙/孔径分布，有可能实现增强的粉尘捕获。优选的是具有小的和大的空隙尺寸的分布，作为气隙和水隙的分布。在一种实施方式中，优选的气隙分布可用肥皂泡沫制备。参见以下实施例6和7。
凝固石膏芯中气隙(大于约10微米)和水隙(小于约5微米)的比率可以为约1.8∶1至约9∶1。凝固石膏芯中气隙(大于约10微米)和水隙(小于约5微米)的优选比率可以为约2∶1至约3∶1。在一种实施方式中，凝固石膏芯中空隙/孔尺寸分布应为测得的总空隙的百分比的约10-30％的空隙小于5微米并且约70-90％的空隙大于约10微米。换个方式说，凝固石膏芯中气隙(大于10微米)和水隙(小于5微米)的比率为约2.3∶1至约9∶1。在一种优选实施方式中，凝固石膏芯中空隙/孔尺寸分布应为30-35％的空隙小于5微米以及约65-70％的空隙大于约10微米，占测定的总空隙的百分比。换个方式说，凝固石膏芯中气隙(大于10微米)和水隙(小于5微米)的比率为约1.8∶1至约2.3∶1。
优选的是平均气(泡)隙尺寸的直径小于约100微米。在优选的实施方式中，凝固石膏芯中空隙/孔尺寸分布为：大于100微米(20％)，约50微米-100微米(30％)和小于约50微米(50％)。也就是说，优选的中值空隙/孔尺寸为约50微米。
在凝固石膏芯中优选将肥皂泡沫引入并控制气(泡)隙尺寸和分布，以及控制该凝固石膏芯的密度。肥皂的优选范围为约0.2lb/MSF-0.6lb/MSF；肥皂的更优选水平为约0.45lb/MS。
肥皂泡沫必须以有效地产生所需密度的量，并以控制的方式加入。为了控制该过程，操作者必须监测板成型线的源头，并保持封袋充满。如果封袋未保持充满，会产生带有中空边缘的墙板，因为浆体不能充满所需要的体积。封袋体积是通过增加肥皂用量以避免板生产期间气泡的破裂(为了更好地保留气泡)，或通过增加空气爆炸率保持充满。因此，通常封袋体积是通过增加或降低肥皂用量，或通过增加或降低气体爆炸率来控制和调节的。控制源头的技术包括通过添加肥皂泡沫以增加浆体体积，或通过减少泡沫用量以减少浆体体积来调整台上的“动态浆”。
根据本发明的一种实施方式，提供了用包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成的成品含石膏产品。萘磺酸盐分散剂是以基于干灰泥重量的约0.1％-3.0％重量的量存在。预凝胶淀粉是以基于配方中干灰泥重量的至少约0.5％、高至10％重量的量存在。浆体中可能使用的其它成分包括粘合剂、防水剂、纸纤维、玻璃纤维、粘土、杀菌剂和促进剂。本发明需要添加肥皂泡沫至新配制的含石膏浆中以降低成品含石膏产品(例如石膏墙板)的密度，并通过在凝固石膏芯中以小气(泡)隙和水隙的形式引入约75％-95％，优选约80％-92％的总空隙体积以控制粉尘。优选地，平均孔径分布将为约1微米(水隙)-约40-50微米(气隙)。
可选择地，约0.5％重量-约10％重量的预凝胶淀粉、约0.1％重量-约3.0％重量的萘磺酸盐以及至少约0.2％重量-约0.4％重量的三偏磷酸盐(全部基于石膏浆中使用的干灰泥重量)的组合，出人意料且大大地增加了该石膏浆的流动性。这大大降低了需要的水量以生产用于制造含石膏产品如石膏墙板的有足够流动性的石膏浆。三偏磷酸盐的水平至少为标准配方中(为三偏磷酸钠)的约两倍，被认为可以提高萘磺酸盐分散剂的分散活性。
萘磺酸盐分散剂必须用于根据本发明制备的含石膏浆中。用于本发明的萘磺酸盐分散剂包括聚萘磺酸及其盐(聚萘磺酸盐)和衍生物，其为萘磺酸和甲醛的缩合产物。尤其可取的聚萘磺酸盐包括萘磺酸钠和萘磺酸钙。萘磺酸盐的平均分子量可以为约3000-27000，但优选的是该分子量为约8000-22000，更优选的是该分子量为约12000-17000。作为商业产品，较高分子量的分散剂比较低分子量的分散剂具有更高的粘性和更低的固体内容物。有用的萘磺酸盐包括购自GEO特种化学品公司(俄亥俄州，克里夫兰)的DILOFLO；购自罕布什尔化学公司(马萨诸塞州，列克星敦)的DAXAD；购自GEO特种化学品公司(印第安纳州，拉斐特)的LOMAR D。萘磺酸盐优选作为固体内容物35-55％重量的水溶液使用，例如固体内容物约40-45％重量。或者，在适当情况下，萘磺酸盐可以干燥固体或粉末形式使用，例如LOMARD。
本发明有用的聚萘磺酸盐具有结构通式(I)：
Figure A20078004677300141
其中n＞2，M为钠、钾、钙等。
萘磺酸盐分散剂，优选作为约45％重量的水溶液，以基于石膏复合配方中干灰泥重量的约0.5％-3.0％重量使用。萘磺酸盐分散剂更优选的范围为基于干灰泥重量的约0.5％-2.0％重量，且最优选的范围为基于干灰泥重量的约0.7％-2.0％重量。相反，已知的石膏墙板包含该分散剂的水平为基于干灰泥重量的约0.4％重量或更低。
换个方式说，萘磺酸盐分散剂，在干重基础上，以基于石膏复合配方中干灰泥重量的约0.1％-1.5％重量使用。萘磺酸盐分散剂更优选的范围，在干燥固体基础上，是基于干灰泥重量的约0.25％-0.7％重量，最优选的范围(在干燥固体基础上)是基于干灰泥重量的约0.3％-0.7％重量。
该含石膏浆可选择地包含三偏磷酸盐，例如三偏磷酸钠。根据本发明任何合适的水溶性偏磷酸盐或聚磷酸盐均可使用。优选的是使用三偏磷酸盐，包括复盐，即具有两个阳离子的三偏磷酸盐。尤其有用的三偏磷酸盐包括三偏磷酸钠、三偏磷酸钾、三偏磷酸钙、三偏磷酸钠钙、三偏磷酸锂、三偏磷酸铵等，或其结合。优选的三偏磷酸盐为三偏磷酸钠。优选的是三偏磷酸盐作为水溶液使用，例如固体内容物约10-15％重量。还可使用其它的环或非环聚磷酸盐，如Yu等的美国专利No.6,409,825中所述，在此纳入作为参考。
三偏磷酸钠是含石膏组合物中已知的添加剂，但它通常以基于石膏浆中所用干灰泥重量的约0.05％-0.08％重量使用。在本发明的实施方式中，三偏磷酸钠(或其它水溶性偏磷酸盐或聚磷酸盐)可以以基于石膏复合配方中所用干灰泥重量的约0.12％-0.4％重量存在。三偏磷酸钠(或其它水溶性偏磷酸盐或聚磷酸盐)的优选范围是基于石膏复合配方中所用干灰泥重量的约0.12％-0.3％重量。
灰泥有两种形式，α和β。灰泥的这两种类型是由不同的煅烧手段产生。本发明中灰泥的α或β形式均可使用。
淀粉，尤其包括预凝胶淀粉，必须用在根据本发明制备的石膏浆中。优选的预凝胶淀粉是预凝胶玉米淀粉，例如购自Bunge Milling(密苏里州，圣路易斯)公司的预凝胶玉米粉，具有如下典型分析：水分7.5％，蛋白质8.0％，油0.5％，粗纤维0.5％，灰分0.3％；生强度0.48psi；和松密度35.0lb/ft3。预凝胶玉米淀粉应以基于含石膏浆中所用干灰泥重量的至少约0.5％重量、高至约10％的重量使用。
本发明人进一步发现，在约0.1％-3％重量的萘磺酸盐分散剂存在下，通过使用至少约0.5％重量，高至约10％重量的预凝胶淀粉(优选预凝胶玉米淀粉)可获得(尤其在墙板中)干强度的意外增强(淀粉和萘磺酸盐水平均基于配方中干灰泥的重量)。不管水溶性偏磷酸盐或聚磷酸盐是否存在，都可获得这一出人意料的结果。
此外，发明人意外地发现，预凝胶淀粉可以至少约10lb/MSF或更高水平用于根据本发明制备的干石膏墙板中，还能实现高强度和低重量。石膏墙板中预凝胶淀粉高达35-45lb/MSF的水平已经被证明是有效的。例如，如下表1和表2所示的配方B包括45lb/MSF，还产生了具有优良强度的1042lb/MSF的板重量。在该实例(配方B)中，作为45％重量水溶液的萘磺酸盐是以1.28％重量的水平使用。
当萘磺酸盐分散剂-三偏磷酸盐组合与预凝胶玉米淀粉、并可选地与纸纤维或玻璃纤维相结合时，本发明还得到更加意外的结果。由包含这三种成分的配方制成的石膏墙板具有增强的强度和降低的重量，并且由于在其制造时减少了水需求而更加经济可行。纸纤维的有用水平可以是基于干灰泥重量的约2％重量。玻璃纤维的有用水平可以是基于干灰泥重量的约2％重量。
本发明的含石膏组合物中可使用如Yu等的美国专利No.6,409,825所述的促进剂，在此纳入作为参考。一种可取的耐热促进剂(HRA)可由干研磨的建筑石膏(二水合硫酸钙)制成。少量添加剂(通常约5％重量)如糖、右旋糖、硼酸和淀粉可用于制备该HRA。一般优选糖或右旋糖。其它有用的促进剂是美国专利No.3,573,947所述的“气候稳定型促进剂”，在此纳入作为参考。
水/灰泥(w/s)比率是一个重要的参数，因为过量的水最后必须通过加热除去。在本发明的实施方式中，通常优选的w/s比率为约0.7-1.3。
其它石膏浆添加剂可包括促进剂、粘结剂、防水剂、纸或玻璃纤维以及其它已知组分。
板层可以像传统石膏墙板一样用纸制成，但也可使用其它本领域已知的有用的板层材料(如玻璃纤维垫)。纸板层在石膏墙板中提供强度特性。有用的板层纸包括美国石膏公司(伊利诺斯州，芝加哥)的马尼拉7层纸(Manila 7-ply)和News-Line5层纸(News-Line 5-ply)；和购自Caraustar公司(印第安纳，新港)的灰底白板3层纸(Grey-Back 3-ply)和马尼拉白3层纸(Manila Ivory 3-ply)。纸板层包括顶部板层或面纸、和底部板层或背纸。优选的背板层纸为5层News-Line纸。优选的面板层纸为马尼拉7层纸。
纤维垫也可以用作一个或两个板层。一种有用的纤维垫是玻璃纤维垫，其中玻璃纤维丝通过粘合剂粘结在一起。最优选地，无纺玻璃纤维垫将具有重的树脂涂层。例如，可使用购自约翰-曼维尔公司的重量约1.2-2.0lb/100ft2的Duraglass无纺玻璃纤维垫，该垫重量的约40-50％来自树脂涂层。其它有用的纤维垫包括但不限于纺织玻璃垫和非纤维素织物。
以下实施例进一步阐明本发明。它们不应被视为以任何形式限制本发明的范围。
实施例1样品石膏浆配方
石膏浆配方如下表1所示。表1中所有值均以基于干灰泥重量的重量百分比表示。括号中的值为以磅计的干重(lb/MSF)。
表1
Figure A20078004677300161
Figure A20078004677300171
*用于预产生泡沫
1 1.28％的45％水溶液
实施例2墙板的制备
根据Yu等的美国专利No.6,342,284和No.6,632,550制备样品石膏墙板，在此纳入作为参考。该方法包括单独产生泡沫，并把该泡沫引入到这些专利实施例5中所述的所有其它成分的浆体中。
用实施例1的配方A和配方B制备的石膏墙板以及普通对照板的测试结果如下表2所示。在该实施例和以下其它实施例中，钉拉阻力、芯硬度和抗弯强度测试均按照ASTM C-473执行。此外，应注意，通常的石膏墙板约1/2英寸厚，且重量为约1600-1800磅每1000平方英尺材料，或lb/MSF。(“MSF”在本领域为1000平方英尺的标准缩写；它可用于盒子、瓦楞纸媒介和墙板的面积测量)
表2
  实验室测试结果   对照板   配方A板   配方B板
  板重量(lb/MSF)   1587   1066   1042
  钉拉阻力(lb)   81.7   50.2   72.8
  芯硬度(lb)   16.3   5.2   11.6
  增湿粘结负荷(lb)   17.3   20.3   15.1
  增湿粘结破坏(％)   0.6   5   11.1
  抗弯强度，面朝上(MD)(lb) 47 47.2 52.6
  抗弯强度，面朝下(MD)(lb) 51.5 66.7 78.8
  抗弯强度，面朝上(XMD)(lb) 150 135.9 173.1
  抗弯强度，面朝下(XMD)(lb) 144.4 125.5 165.4
MD：纵向(机器方向)
XMD：横向(跨机器方向)
如表2所示，用配方A和B制备的石膏墙板与对照板相比重量大大降低。再参见表1，配方A板和配方B板的对比非常明显。配方A和配方B中水/灰泥(w/s)比率相似。配方B还使用了明显较高水平的萘磺酸盐分散剂。而且，配方B使用了明显较多的预凝胶淀粉，约6％重量，比配方A增加100％多，并伴随着显著的强度增加。即便如此，配方B浆体中产生所需流动性的需水量仍然很低，与配方A相比约为10％的差异。在这两个配方中低需水量是因为石膏浆体中萘磺酸盐分散剂和三偏磷酸钠组合的协调效应，其即使在大量较高水平的预凝胶淀粉存在下，也能增强石膏浆的流动性。
如表2所示，与用配方A浆体制备的墙板相比，用配方B浆体制备的墙板具有大大增加的强度。通过合并加量的预凝胶淀粉和加量的萘磺酸盐分散剂和三偏磷酸钠，配方B板的钉拉阻力比配方A板提高了45％。还观察到配方B板中抗弯强度与配方A板相比大大增加。
实施例31/2英寸石膏墙板重量降低试验
进一步的石膏墙板实施例(板C、D和E)，包括浆体配方和测试结果，如下表3所示。表3的浆体配方包括浆体的主要组分。括号中的值表示基于干灰泥重量的重量百分比。
表3
Figure A20078004677300191
Figure A20078004677300192
ASTM标准：77lb
1DILOFLO为45％的萘磺酸盐水溶液
如表3所示，与对照板相比，板C、D和E是由大量增加的淀粉、DILOFLO分散剂和三偏磷酸钠制成(淀粉和分散剂百分比为约两倍增加，三偏磷酸盐为两到三倍增加)，同时保持w/s比率不变。然而，板重量显著降低，且通过钉拉阻力测得的强度没有受到明显影响。因此，在本发明实施方式的该实施例中，新配方(如板D)可以在可用的、易流动的浆体中提供增加的淀粉，同时保持相同的w/s比率和足够的强度。
实施例4湿石膏立方体强度测试
利用购自美国石膏公司(伊利诺斯州，芝加哥)的Southard CKS板灰泥和实验室的自来水进行湿立方体强度测试，以测定它们的湿抗压强度。使用了以下实验室测试程序。
将灰泥(1000g)，CAS(2g)和约70°F的自来水(1200cc)用于各个湿石膏立方体铸造。预凝胶玉米淀粉(20g，基于灰泥重量的2.0％)和CAS(2g，基于灰泥重量的0.2％)在与含萘磺酸盐分散剂和三偏磷酸钠的自来水溶液混合之前，首先在塑料袋中与灰泥彻底干混合。使用的分散剂为DILOFLO分散剂(1.0-2.0％，如表4所示)。使用了不同用量的三偏磷酸钠，同样如表4所示。
干成分和水溶液先在实验室告警搅拌器中混合，产生的混合物浸泡10s，然后该混合物在低速下混合10s以便制成浆体。由此形成的浆体被铸入三个2”X2”X2”的立方体模子。然后将铸造的立方体从模子中移出，称重，并密封在塑料袋中以防止在进行抗压强度测试前的水分损失。用ATS机器测量该湿立方体的抗压强度，并以磅每平方英寸(psi)记录平均数。所得结果如下：
表4
  测试样品编号   三偏磷酸钠，克(基于干灰泥的wt％)   DILOFLO1(基于干灰泥的wt％)  湿立方体重量(2”X2”X2”)，g   湿立方体抗压强度，psi
  1   0   1.5   183.57   321
  2   0.5(0.05)   1.5   183.11   357
  3   1(0.1)   1.5   183.19   360
  4   2(0.2)   1.5   183.51   361
  5   4(0.4)   1.5   183.65   381
  6   10(1.0)   1.5   183.47   369
  7   0   1.0   184.02   345
  8   0.5(0.05)   1.0   183.66   349
  9   1(0.1)   1.0   183.93   356
  10   2(0.2)   1.0   182.67   366
  11   4(0.4)   1.0   183.53   365
  12   10(1.0)   1.0   183.48   341
  13   0   2.0   183.33   345
  14   0.5(0.05)   2.0   184.06   356
  15   1(0.1)   2.0   184.3   363
  16   2(0.2)   2.0   184.02   363
  17   4(0.4)   2.0   183.5   368
  18   10(1.0)   2.0   182.68   339
1DILOFLO为45％的萘磺酸盐水溶液
如图4所示，本发明的三偏磷酸钠水平约0.12-0.4％的样品4-5，10-11和17，与三偏磷酸钠水平超出该范围的样品相比，普遍提供更好的湿立方体抗压强度。
实施例51/2英寸轻量石膏墙板厂产品试验
对试验板1和2进行了进一步的试验，包括浆体配方和测试结果如下表5所示。表5的浆体配方包括浆体的主要组分。括号中的值表示基于干灰泥重量的重量百分比。
表5
Figure A20078004677300221
Figure A20078004677300222
ASTM标准：77lb
MD：纵同
XMD：横向
1DILOFLO为45％的萘磺酸盐水溶液
290°F/90％相对湿度
3应清楚地理解，在这些测试条件下，破坏率百分比＜50％都是可以接受的。
如表5所示，与对照板相比，试验板1和2由含大量增加的淀粉、DILOFLO分散剂和三偏磷酸钠的浆体制成，同时w/s比率略有下降。然而，通过钉拉阻力和弯曲测试测得的强度都得到保持或改善，且板重量明显下降。因此，在本发明实施方式的该实施例中，新配方(如，试验板1和2)能在可用的、易流动的浆体中提供增加的三偏磷酸盐和淀粉，同时保持大体相同的w/s比率和足够的强度。
实施例61/2英寸超轻量石膏板厂产品试验
同实施例2一样，用配方B(实施例1)进行进一步的试验(试验板3和4)，不同的是该预凝胶玉米淀粉是以10％浓度用水制备(湿淀粉制备)，并使用HYONIC 25AS和PFM 33肥皂(购自GEO特种化学品公司，印第安纳州，拉斐特)的混合物。例如，试验板3用HYONIC 25AS和25AS的混合物制备，其中65-70％重量为25AS，而剩余的为PFM33。例如，试验板4用HYONIC 25AS/HYONIC PFM 33的70/30wt./wt.的混合物制备。试验结果如下表6所示。
表6
实验室测试结果   试验板3(配方B+HYONIC肥皂混合物65/35)(n＝12)   试验板4(配方B+HYONIC肥皂混合物70/30)(n＝34)*
  板重量(lb/MSF)   1106   1013
  钉拉阻力(lb)   85.5   80.3
  芯硬度b(lb)   ＞15   12.4
  抗弯强度，平均值c(MD)(lb) 55.6 60.31
  抗弯强度，平均值d(XMD)(lb) 140.1 142.31
除标明的以外
1n＝4
MD：纵向
XMD：横向
aASTM标准：77lb
bASTM标准：11lb
cASTM标准：36lb
dASTM标准：107lb
如表6所示，通过钉拉阻力和芯硬度测得的强度特征均高于ASTM标准。测得的抗弯强度也高于ASTM标准。此外，在本发明实施方式的该实施例中，新配方(例如试验板3和4)能在可用的、易流动的浆体中提供增加的三偏磷酸盐和淀粉，同时保持足够的强度。
实施例71/2英寸厚石膏墙板芯空隙体积百分比计算结果对板重量和锯切结果的函数关系
同实施例2一样，用配方B(实施例1)进行进一步的试验以便测定空隙体积和密度(试验板5-13)，不同的是该预凝胶玉米淀粉是以10％浓度用水制备(湿淀粉制备)，使用了0.5％的玻璃纤维，并且以45％的水溶液形式使用了1.2％重量的萘磺酸盐(DILOFLO)。肥皂泡沫是用肥皂泡沫发生器制造，并以有效地提供所需密度的量被引入石膏浆体。在本发明的实施例中，肥皂是以0.25lb/MSF-0.45lb/MSF的水平使用。也就是说，肥皂泡沫的用量可酌情增加或减少。在各个样品中，墙板厚度为1/2英寸，且芯体积假定统一为39.1ft3/MSF。空隙体积是跨4英尺宽的墙板样品测量，该墙板样品上的正面和背面纸被除去。正面和背面纸的厚度为11-18密尔(每一侧)。通过扫描电子显微镜(见以下实施例8)和X射线CT扫描技术(XTT)测定空隙体积/孔尺寸和孔径分布。
表7
Figure A20078004677300241
1＞10微米气(泡)隙
2＜5微米水隙
3基于统一的芯体积＝39.1ft3/MSF；即总芯空隙体积＝泡沫空隙体积+蒸发空隙体积/39.1Xl00
4基于统一的芯体积＝39.1ft3/MSF；即板芯密度(pcf)＝板重量(lb/MSF)-纸板层的重量(lb/MSF)/39.1ft3/MSF＝板重量(lb/MSF)-90lb/MSF/39.1ft3/MSF
Figure A20078004677300251
测量的总空隙的百分比
如表7所示，制成总芯空隙体积为79.0％-92.1％的试验板样品，其分别对应于板芯密度28pcf下低至10pcf。举个例子，锯切总空隙体积为81.8％、板密度为23pcf的试验板10，产生的粉尘比对照板少30％。举另一个例子，如果传统配方的含有较少粘合剂(淀粉作为粘合剂，有或没有分散剂)的墙板，其具有明显较少的约75％-80％的总芯空隙体积，那么在切割、锯、掘、折、钉或拧紧、或钻孔时预计会产生明显较多的粉尘。例如，传统墙板在锯切时会产生平均直径约20-30微米、最小直径约1微米的粉尘碎片。相反，本发明的石膏墙板在锯切时将产生平均直径约30-50微米、最小直径约2微米的粉尘碎片；刻/折时将产生甚至更大的碎片。
研究发现用于制造含石膏浆的几种关成分，即灰泥、萘磺酸盐分散剂、预凝胶玉米淀粉、三偏磷酸钠，以及玻璃和/或纸纤维的组合，与足够的有效量的肥皂泡沫相结合，在生产有用的低密度石膏墙板中可具有协同效应，这种效应在刀切、锯切、刻/折、钻孔以及正常板处理时也显著减少石膏粉尘形成。
实施例8试验板10中气泡空隙尺寸和水隙尺寸、以及石膏晶体形态的测定
通过扫描电子显微镜(SEM)分析工厂试验下制备试验板10的铸造石膏立方体(2英寸X 2英寸X 2英寸)。观察到并测量了气泡空隙和蒸发的水隙，以及石膏晶体尺寸和形状。
制成三个样品立方体并分别标记为11:08，11:30和11:50。图1-3说明了各个样品在15X放大时的气泡空隙尺寸和分布。图4-6说明了各个样品在50X放大时的气泡空隙尺寸和分布。
在较高放大倍数时，例如在通常较大的气泡空隙壁中，可观察到水隙，如图7-10中样品立方体11:50高达10000X放大时所示。几乎所有的石膏晶体均为针状物；极少观察到小片状。这些针状物的密度和填充在气泡空隙的表面上是不同的。在气泡空隙壁的水隙中也能观察到石膏针状物。
该SEM结果证明在根据本发明制备的含石膏产品中，气隙和水隙通常均匀分布在整个凝固石膏芯。观察到得空隙尺寸和空隙分布也证明足够的自由空间随着气隙和水隙(总芯空隙体积)形成，这样很大部分的产生的石膏粉尘将在正常板处理和在切割、锯、掘、折、钉或拧紧、或钻孔时暴露的周围的空隙中被捕获，并且不会浮在空中。
实施例9低尘石膏墙板中的粉尘捕获
如果墙板是根据本发明如实施例7中的教导制成，可以预见在加工该墙板时产生的石膏粉尘包括至少50％重量的直径大于约10微米的石膏碎片。通过切割、锯、掘、刻/折、钉或拧紧、以及钻孔加工该墙板时，产生的总粉尘的至少约30％或更多将被捕获。
在描述本发明的上下文(特别是权利要求书上下文)中所用的术语“一”、“一个”，“这个/该”(a，an，the)及类似指称应理解为包括单数和复数，除非本文另有说明或者明确地否认。此处数值范围的列举仅作为一种逐个指出落入该范围的每个独立值的速记方法，除非本文另有说明，并且每个独立的值被纳入说明书中，犹如其被本文单独列出。本文描述的所有方法可以任何适合的顺序完成，除非本文另有说明或明确地否认。本文提供的任何和所有实施例，或示范性语言(如“例如”)，仅为了更好地解释说明本发明，并不限制本发明的范围，除非另有声明。说明书中的语言不应解释为将任何未要求的元素作为本发明实践的要素。
在此描述了本发明的优选实施方式，包括发明人知道的用于实施本发明的最佳实施方式。应理解的是，阐明的实施方式仅是示范性的，不应视为对本发明范围的限制。

Claims (54)

1、一种低尘石膏墙板，包括：
在两个大体平行的板层之间形成的一凝固石膏芯，该凝固石膏芯具有约75％至约95％的总空隙体积。
2、如权利要求1所述的低尘石膏墙板，其中所述凝固石膏芯具有约80％至约92％的总空隙体积。
3、如权利要求1所述的低尘石膏墙板，其中所述凝固石膏芯具有约10pcf至约30pcf的密度。
4、如权利要求1所述的低尘石膏墙板，其中所述凝固石膏芯是由包含水、灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成，其中预凝胶淀粉是以基于灰泥重量的约0.5％至约10％重量存在。
5、如权利要求4所述的低尘石膏墙板，其中所述萘磺酸盐分散剂是以基于灰泥重量的约0.1％至约3.0％重量存在。
6、如权利要求4所述的低尘石膏墙板，其中所述萘磺酸盐分散剂是以基于灰泥重量的约0.3％至约0.7％重量存在。
7、如权利要求4所述的低尘石膏墙板，其中所述萘磺酸盐分散剂是含有约40％至约45％重量的萘磺酸盐的水溶液形式，且该水溶液是以基于灰泥重量的约0.5％至约2.5％重量存在。
8、如权利要求4所述的低尘石膏墙板，其中所述含石膏浆进一步包含以基于灰泥重量约0.12％至约0.4％重量存在的三偏磷酸钠。
9、如权利要求1所述的低尘石膏墙板，其中该墙板的干重为约1200lb/MSF至约1400lb/MSF。
10、如权利要求2所述的低尘石膏墙板，其中该墙板的干重为约500lb/MSF至约1200lb/MSF。
11、如权利要求2所述的低尘石膏墙板，其中所述总空隙体积的至少60％包括平均直径小于约100微米的气隙。
12、如权利要求2所述的低尘石膏墙板，其中所述总空隙体积的至少10％包括平均直径小于约5微米的水隙。
13、如权利要求2所述的低尘石膏墙板，其中所述总空隙体积的至少65％包括平均直径大于约10微米的气隙。
14、如权利要求2所述的低尘石膏墙板，其中所述总空隙体积的至少60％包括平均直径大于约20微米的气隙。
15、如权利要求2所述的低尘石膏墙板，其中所述总空隙体积的至少60％包括平均直径大于约10微米的气隙，且所述总空隙体积的至少10％包括平均直径小于约5微米的水隙，并且其中气隙和水隙通常均匀分布在整个凝固石膏芯中。
16、如权利要求2所述的低尘石膏墙板，其中所述总空隙体积的至少60％包括平均直径小于约100微米的气隙，其中所述气隙通常为球形，且所述气隙通常互相分离。
17、如权利要求2所述的低尘石膏墙板，其中所述凝固石膏芯包括平均直径大于约10微米的气隙和平均直径小于约5微米的水隙，且其中气隙∶水隙的比率为约2.3∶1至约1.8∶1。
18、如权利要求2所述的低尘石膏墙板，其中所述凝固石膏芯包括平均孔径分布为约1微米至约50微米的空隙。
19、如权利要求2所述的低尘石膏墙板，其中所述凝固石膏芯包含的气隙的孔径分布包括：空隙大于约100微米的占总空隙的约20％，空隙为约50微米至约100微米的占总空隙的约30％，以及空隙小于约50微米的占总空隙的约50％。
20、如权利要求4所述的低尘石膏墙板，其中所述含石膏浆进一步包含以约0.25lb/MSF至约0.48lb/MSF的量存在的肥皂。
21、如权利要求4所述的低尘石膏墙板，其中所述含石膏浆进一步包含以基于灰泥重量高至约2％重量存在的纸纤维，以及以基于灰泥重量高至约2％重量存在的玻璃纤维。
22、如权利要求4所述的低尘石膏墙板，其中水/灰泥比率为约0.7至约1.3。
23、如权利要求1所述的低尘石膏墙板，其中所述板层包括纸。
24、如权利要求1所述的低尘石膏墙板，其中所述板层的至少一层选自纤维垫、无纺玻璃纤维垫、纺织玻璃垫和非纤维素织物。
25、一种低尘石膏墙板，包括：
一凝固石膏芯，其在两个大体平行的板层之间形成，包含预凝胶淀粉和萘磺酸盐分散剂，该凝固石膏芯具有约80％至约92％的总空隙体积，其中总空隙体积的至少60％包括平均直径小于约100微米的气隙，且该凝固石膏芯具有约10pcf至约30pcf的密度。
26、如权利要求25所述的低尘石膏墙板，其中该凝固石膏芯是由包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成，其中预凝胶淀粉是以基于灰泥重量的约0.5％重量至约10％重量存在。
27、如权利要求26所述的低尘石膏墙板，其中所述萘磺酸盐分散剂是以基于灰泥重量的约0.1％至约3.0％重量存在。
28、如权利要求26所述的低尘石膏墙板，其中所述萘磺酸盐分散剂是以基于灰泥重量的约0.3％至约0.7％重量存在。
29、如权利要求26所述的低尘石膏墙板，其中所述含石膏浆进一步包含以基于灰泥重量的约0.12％至约0.4％重量存在的三偏磷酸钠。
30、如权利要求29所述的低尘石膏墙板，其中所述墙板的干重为约500lb/MSF-至约1200lb/MSF。
31、如权利要求25所述的低尘石膏墙板，其中该板层包含纸。
32、一种制备高强度、低尘石膏墙板的方法，包括以下步骤：
(a)混合包含水、灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆，其中所述预凝胶淀粉以基于灰泥重量的约0.5％重量至约10％重量存在，且其中所述萘磺酸盐分散剂以基于灰泥重量的约0.1％至约3.0％重量存在；
(b)将足够的肥皂泡沫添加至该含石膏浆，以在成品墙板中形成约75％至约95％的总空隙体积；
(c)将所述含石膏浆沉积在第一板层上；
(d)将第二板层置于所述沉积的浆体上，以形成石膏墙板；
(e)待含石膏浆硬化至足以切割后进行切割；以及
(f)干燥所述石膏墙板，以提供在成品墙板中的凝固石膏芯。
33、如权利要求32所述的方法，其中在步骤(b)加入足够的肥皂泡沫以在凝固石膏芯中形成约80％至约92％的总空隙体积。
34、如权利要求32所述的方法，其中总空隙体积的至少60％包括平均直径小于约100微米的气隙。
35、如权利要求32所述的方法，其中所述第一板层和第二板层是由纸制成。
36、如权利要求32所述的方法，其中所述板层的至少一层选自纤维垫、无纺玻璃纤维垫、纺织玻璃垫和非纤维素织物。
37、如权利要求32所述的方法，其中所述浆体进一步包含以基于灰泥重量的约0.12％至约0.4％重量存在的三偏磷酸钠。
38、如权利要求32所述的方法，其中所述墙板的干重为约1200lb/MSF至约1400lb/MSF。
39、如权利要求33所述的方法，其中所述浆体进一步包含以基于灰泥重量的约0.12％至约0.4％重量存在的三偏磷酸钠。
40、如权利要求39所述的方法，其中所述墙板的干重为约500lb/MSF至约1200lb/MSF。
41、一种加工石膏墙板中低粉尘的方法，包括以下步骤：
(a)提供带有凝固石膏芯的低尘石膏墙板，所述凝固石膏芯具有约75％至约95％的总空隙体积，其中总空隙体积的至少60％包括平均直径大于约10微米的气隙，且总空隙体积的至少10％包括平均直径小于约5微米的水隙；
(b)加工该墙板以产生石膏粉尘；和
(c)将大部分石膏粉尘捕获在空隙中。
42、如权利要求41所述的方法，其中所述加工是选自切割、锯、掘、刻/折、钉、钉紧、拧紧和钻孔。
43、如权利要求41所述的方法，其中所述凝固石膏芯的总空隙体积为约80％至约92％。
44、如权利要求41所述的方法，其中所述被捕获的石膏粉尘部分至少为产生的石膏粉尘的约20％重量。
45、一种低尘石膏墙板，包括：
一凝固石膏芯，其在两个大体平行的板层之间形成，包含预凝胶淀粉和萘磺酸盐分散剂；
预凝胶淀粉和萘磺酸盐分散剂是以足够的量存在，以产生大于约2微米直径的石膏碎片；
该凝固石膏芯具有约80％至约92％的总空隙体积，其中总空隙体积的至少60％包括平均直径大于约10微米的气隙，且密度为约10pcf至约30pcf。
46、如权利要求45所述的低尘石膏墙板，其中所述凝固石膏芯是由包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成，其中预凝胶淀粉是以基于灰泥重量的约0.5％至约10％重量存在。
47、如权利要求46所述的低尘石膏墙板，其中所述萘磺酸盐分散剂是以基于灰泥重量的约0.1％至约3.0％重量存在。
48、如权利要求47所述的低尘石膏墙板，其中所述含石膏浆进一步包含以基于灰泥重量的约0.12％至约0.4％重量存在的三偏磷酸钠。
49、如权利要求48所述的低尘石膏墙板，其中所述墙板的干重为约500lb/MSF至约1200lb/MSF。
50、一种低尘石膏墙板，包括：
一凝固石膏芯，其在两个大体平行的板层之间形成，包含预凝胶淀粉和萘磺酸盐分散剂，该凝固石膏芯具有约75％至约95％的总空隙体积；
包含至少一个选自纤维垫、无纺玻璃纤维垫、纺织玻璃垫和非纤维素织物的板层。
51、如权利要求50所述的低尘石膏墙板，其中所述凝固石膏芯是由包含灰泥、预凝胶淀粉和萘磺酸盐分散剂的含石膏浆制成，其中预凝胶淀粉是以基于灰泥重量的约0.5％重量至约10％重量存在。
52、如权利要求51所述的低尘石膏墙板，其中所述萘磺酸盐分散剂是以基于灰泥重量的约0.1％至约3.0％重量存在。
53、如权利要求51所述的低尘石膏墙板，其中所述含石膏浆进一步包括以基于灰泥重量的约0.12％至约0.4％重量存在的三偏磷酸钠。
54、如权利要求50所述的低尘石膏墙板，其中所述板层的至少一个为无纺玻璃纤维垫。
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CN109721661B (zh) * 2013-10-02 2022-04-15 美国石膏公司 制备预糊化部分水解淀粉的方法及相关方法和产品

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