CN102015929B - 非水合灰泥组合物和方法 - Google Patents
非水合灰泥组合物和方法 Download PDFInfo
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- CN102015929B CN102015929B CN200980114406XA CN200980114406A CN102015929B CN 102015929 B CN102015929 B CN 102015929B CN 200980114406X A CN200980114406X A CN 200980114406XA CN 200980114406 A CN200980114406 A CN 200980114406A CN 102015929 B CN102015929 B CN 102015929B
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- 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 abstract description 31
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- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical class O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 4
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- 238000001354 calcination Methods 0.000 description 3
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Inorganic materials [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 3
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- HKIOYBQGHSTUDB-UHFFFAOYSA-N folpet Chemical compound C1=CC=C2C(=O)N(SC(Cl)(Cl)Cl)C(=O)C2=C1 HKIOYBQGHSTUDB-UHFFFAOYSA-N 0.000 description 1
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- ACVYVLVWPXVTIT-UHFFFAOYSA-N phosphinic acid Chemical class O[PH2]=O ACVYVLVWPXVTIT-UHFFFAOYSA-N 0.000 description 1
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- 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 1
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- HRXKRNGNAMMEHJ-UHFFFAOYSA-K trisodium citrate Chemical compound [Na+].[Na+].[Na+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O HRXKRNGNAMMEHJ-UHFFFAOYSA-K 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/02—Emulsion paints including aerosols
- C09D5/024—Emulsion paints including aerosols characterised by the additives
- C09D5/028—Pigments; Filters
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D121/00—Coating compositions based on unspecified rubbers
- C09D121/02—Latex
-
- 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
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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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5076—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with masses bonded by inorganic cements
- C04B41/5085—Calcium sulfate cements
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
- C04B41/61—Coating or impregnation
- C04B41/65—Coating or impregnation with inorganic materials
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- 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
- E04C2/043—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 of plaster
-
- 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
- C04B2111/00482—Coating or impregnation 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
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- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/3188—Next to cellulosic
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- 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
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- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/3188—Next to cellulosic
- Y10T428/31895—Paper or wood
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- 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
- Y10T428/00—Stock material or miscellaneous articles
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- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/31935—Ester, halide or nitrile of addition polymer
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- 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
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- Inorganic Chemistry (AREA)
- Architecture (AREA)
- Wood Science & Technology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Civil Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Crystallography & Structural Chemistry (AREA)
- Dispersion Chemistry (AREA)
- Paints Or Removers (AREA)
- Building Environments (AREA)
- Laminated Bodies (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Panels For Use In Building Construction (AREA)
Abstract
一种修整内墙的方法,包括步骤:制备包含石膏、水泥或其结合的建筑板的基板,所述基板具有一表面;随后在基板上涂上涂层,所述涂层包括5-20%重量的乳胶乳液粘合剂,40-80%重量的半水合硫酸钙,0.05-2%重量的防凝固剂和20-60%重量的水。
Description
技术领域
本发明涉及含有半水合硫酸钙的物品,例如涂层建筑板。更具体地,本发明涉及一种用在涂层和物品中的灰泥样物质,其在应用时具有灰泥感觉但不水合。
背景技术
石膏是一种在建筑行业中广泛用于多种用途的常见材料。该材料的应用至少一定程度上是因为它价格合理且基本上能够形成任何形状。半水合硫酸钙,也称作灰泥或煅烧石膏,与水混合形成糊状或浆体。该浆体可通过任意已知的方式定型,例如但限于,铸造成模具、喷射、倒在某一表面上或者用泥刀涂布。半水合硫酸钙在水合反应中与水反应形成固化的二水合硫酸钙(石膏)晶体的连接体。虽然常常发生一些收缩,但石膏在凝固反应完成之前通常保持其形成时的形状。
板的修整通常是一个耗时的过程。当安装板后,将一层接合剂涂在接缝和钉头处。接合剂在干燥时收缩,在最后干燥的接缝区域留下凹陷。接合剂可以过夜干燥,然后在完全干燥时被打磨。用沾布或湿海绵去除打磨产生的粉尘。在表面的打磨及除尘后,再涂上第二层接合剂并使其过夜干燥。为了保证工作质量,以第三层接合剂重复该工序。即便在安装了板后,表面的修整也要至少三天时间。该过程也可以用于修复受损的墙壁。
尽管这个过程花费时间,但它以相对低的成本产生平滑的整体无缝表面。这是一个相对简单的过程,并且常常可以在没有专业协助下由房主完成。但是,在完成这项工作所需的时间量方面存在不足。在新建工程中,等待完成修整工作时,橱柜、地毯、灯具及其他装饰项目的安装就被延迟。工匠不得不连续数天不停返回同一工作地点。对于进行修复或重新装修的房主来说,家的打乱被延长。表面的反复打磨产生细小的粉尘渗入壁橱和橱柜,需要对整个家进行彻底除尘。承建商和房主都需要一种更快速和更清洁的修整墙壁的方法。
修整内墙和天花板的一种替代方法是在整个石膏板表面涂上一饰面或“表面层”的灰泥涂层。这项技术比起使用接合剂修整产生更牢固的表面,其不太可能裂碎、凹陷、划伤或者出现钉子损伤。该表面不需要另外的准备。有色灰泥的使用甚至可以消除给灰泥表面刷涂料的需要。如果考虑干燥时间的话,在整个墙面上抹单层灰泥要比涂多层接合剂更快。
调和型灰泥组合物的可用性在在许多应用中都是期望的。例如,这种组合物可用于修整墙、牙科应用、铸件、模制品、可加工的物品、可喷射的灰泥以及所属领域技术人员知晓的其他应用。
在美国专利No.4,661,161中,用半水合硫酸钙作为粘合剂配制了一种调和、凝固型接合剂。将缓凝剂添加到湿糊状物中以阻止半水合物水化成二水合物形式。旨在在使用接合剂之前,通过添加促凝剂引发水合作用。然而,发现缓凝剂随时间降解,使水合作用发生在产品的保质期内。
美国专利No.5,746,822公开了一种调和、凝固型接合剂。该组合物使用磷酸盐,如焦磷酸四钾,用于长期持久的凝固延迟并相应伴随长的保质期。然而,发现这些接合剂在许多应用中并不令人满意,因为它们具有相对低的强度。
美国专利No.5,779,786揭示了一种使用丙烯酸和丙烯酰胺重复单元的调和、凝固型接合剂。这些配方比其他接合剂具有降低的水流失和沉降,但它们强度也很低,并且仅用于某些用途。
旨在将以上组合物用作接合剂并专为该用途而配制它们。然而,典型的接合剂在涂抹时并不具有与灰泥组合物相同的“感觉”。当向墙上涂抹一表面涂层或饰面涂层灰泥时,熟练的泥水匠确切地知晓向泥刀施加多大压力以得到合适的厚度。为正确应用,泥水匠使用常规调和接合剂,需要了解接合剂的感觉,以便正确地涂抹。更重要地,接合剂表面涂层耗费劳动和时间,需要涂抹接合剂、干燥时间以及整个表面的打磨,这还产生了大量的灰尘。另一方面,涂饰面灰泥仅需要灰泥的涂抹和致密化,以获得良好的平滑的整体无缝表面。
因此,本领域需要一种组合物,其具有像灰泥一样便于施用到墙上的工作性质,例如灰泥的感觉、无需打磨以及较少的施用步骤。
发明内容
修整内墙的方法包括步骤:制备建筑板基板,以及向基板施用涂层混合物,其中涂层混合物包括5-30%重量的乳胶乳液粘合剂、40-80%重量的半水合硫酸钙、多至约8%重量的防凝固剂和20-60%重量的水。建筑板由石膏、水泥或其混合物制成。
本发明的涂层混合物是一种应用于建筑板的调和组合物。调和组合物比起传统的灰泥有优势,因为不需要将混合灰泥或水的容器运输到工作现场来辅助制备灰浆。用于混合该组合物的水是质量稳定的,使涂层组合物不太可能参与不想要的副反应。而且,现场的泥水匠不需要花时间准备一批批的灰泥备用。调和组合物在重建或者修补工作中也是有利的,因为它们不需要倒出袋装的灰泥并混合。倒出并混合产生灰尘,会污染正使用的生活或工作空间。
由于混合物是由半水合硫酸钙制成,它在施用时具有与常规灰泥一样的感觉。因此,泥水匠不必了解这种新型组合物的感觉,也能够施用该混合物的表面涂层达到与常规灰泥基本相同的精确性。也不必再了解产生特定厚度的混合物所需的压力大小。
这种修整墙的方法比贴胶带、涂接合剂和打磨更快速。常规的方法需要在涂层期间等待长达24小时,以便接合剂足够干燥来施用下一涂层。当使用本发明的方法时,可以施用该混合物的表面涂层,接着在同一天内涂布第二涂层。该方法至少可以节约一天时间,通常是两天。
具体实施方式
本发明满足这些和其他的需要,其涉及涂层建筑板和含有煅烧石膏的物品。涂层板包括建筑板和涂层混合物。半水合硫酸钙分散在作为混合物基础的乳胶聚合物基质中。聚合物基质基本上是无水的,并且进一步包括分布在整个基质中的防凝固剂。半水合硫酸钙和乳胶聚合物的类似共混物也可以形成一种物品。本发明的这两种实施方式中都存在防凝固剂。杀菌剂、保水剂、抗沉降添加剂、防裂剂和流变改性剂是聚合物基质的任选的添加剂。
本发明的实施方式可以使用任何建筑板,包括但不限于:石膏、水泥及其共混物。在一些实施方式中,板是由石膏制成,例如美国石膏公司(Chicago,IL)的牌石膏板。该板是以连续、高速的工艺制备,其中纸饰面铺设在传送带上。将半水合硫酸钙或煅烧石膏、水和添加剂的浆体倒在所述纸上,并且上覆第二饰面以形成“夹心物”。石膏浆沿着夹心物的宽度分布,并形成恒定的厚度,然后使其凝固及硬化。当浆体约50%被水合后,将板切割成适宜的长度,并移至干燥炉中完成干燥。本发明的至少一些实施方式使用美国石膏公司(Chicago,IL)的石膏板。
用于制造板的半水合硫酸钙可以是任何类型。α形式可通过在压力下煅烧石膏获得,使得它相对于β形式较为昂贵。在大气压力下煅烧的石膏是β-煅烧形式。与α形式相比,β-煅烧石膏具有更多的无定形或板状晶体形态。因为α形式较少为针状,当分散于浆体中时,它更容易流动,与β形式相比需要较少的水达到相同的流动性。
水泥板,如牌水泥板,是通过将水泥、水和添加剂的浆体倒在布或网式材料上制得。在充分凝固之前,将板切割成一定大小,并移至干燥炉中以加快干燥过程。水泥板在地下室、浴室或者可能存在水的任何地方都是有用的。还可以考虑使用由水泥和煅烧石膏的混合物制成的板。
基板表面是通过将建筑板贴附到壁骨的框架上制得,壁骨的框架形成对墙壁或天花板的支撑。邻近的板相互毗连,使板之间的接头尽可能小。板可以经切割以适应具体墙壁或天花板的尺寸或形状,并通过任意已知的方法贴附。一般,通过钉子或者螺丝钉贴附板。在贴附板时,应将钉子或螺丝钉打入板足够深,使得在基板表面上看不到头部。每个钉子或螺丝钉在表面上留下一个凹陷,其由该混合物进行填充。
施用到基板上的混合物包括乳胶乳液聚合物作为粘合剂。乳胶乳液聚合物形成该混合物的连续相,无论在湿状态还是涂层干燥后都能将其保持在一起。添加的乳胶乳液聚合物的确切类型和量取决于其所施用的表面。较大浓度的乳胶乳液聚合物更适合与较少孔的基板一起使用。
所述混合物的一些实施方式使用由单体制成的乳胶乳液聚合物,包括丙烯酸乙烯酯、醋酸乙烯酯、氯乙烯、乙烯属烃和取代乙烯。聚氨酯和聚酯乳液也是有用的。聚醋酸乙烯酯适合用于涂布在石膏板上的混合物,但也可能还适用于其他基板。优选地,乳胶乳液聚合物具有大于10,000道尔顿的分子量。乳胶乳液的量是基于混合物组成重量的约5%至约20%。合适的乳胶乳液的实例包括购自Halltech公司(Ontario,Canada)的AC 1265聚醋酸乙烯酯均聚物乳液、HP 19-176聚醋酸乙烯酯共聚物乳液和HP 41-830醋酸乙烯酯乳液,以及购自Engineered Polymer Solutions(Marengo,IL)的VF-812甲基丙烯酸乳胶聚合物。乳胶乳液的煅烧量是基于乳液的40-60%固体。如果选择含有不同固体含量的乳胶,则应该改变乳胶乳液的总量以产生同等重量的乳胶固体。
该混合物的另一种组分是半水合硫酸钙。任何类型的半水合硫酸钙都可用在如上关于建筑板所述的这种混合物中。当该混合物应用于石膏基建筑板时,使用的半水合硫酸钙可选地与用于建筑板的半水合硫酸钙相同,或者它也可能是一种不同的类型。该混合物的许多实施方式使用β-煅烧半水合硫酸钙。优选地,半水合硫酸钙是以该混合物重量的约40%至约80%的量存在。
将防凝固剂添加到该混合物中,以防止半水合硫酸钙的水合作用和凝固。半水合形式的使用保留了传统灰泥的“感觉”。防凝固剂的添加可以使灰泥制备为调和产品,无需在工作现场添加水和/或另外的化学品。可以使用已知的延缓半水合硫酸钙凝固的任何防凝固剂,例如调和、凝固型接合剂中使用的那些。
除了延长混合物的保质期外,该防凝固剂使得涂层在半水合硫酸钙水合为二水合物形式之前干燥。一旦将该混合物施用在建筑板上,水就随着它的干燥而蒸发。没有长效的防凝固剂,半水合物也会水合,吸水而形成二水合晶体。然而,在本发明的涂层中防止形成二水合物。当涂层在建筑板上干燥时,半水合硫酸钙晶体分散在整个连续的聚合物基质中。涂层干燥后,硫酸钙仍在涂层中保持半水合物的形式。
本发明的至少一些实施方式使用低分子量聚合物和聚膦酸化合物的结合作为双-组分防凝固剂。双-组分防凝固剂的两部分都具有对钙离子和硫酸钙晶格的亲和力。这两种添加剂共同作用,以使硫酸钙浆体的凝固机制长期失效。这为包装的灰泥产品提供很长的保质期,而它在作业时不需添加额外组分(例如水或促凝剂)即可使用。
低分子量聚合物优选具有约2,000道尔顿至约6,000道尔顿的分子量。低分子量聚合物的一些实施方式是由单体制成,包括丙烯酸乙烯酯、醋酸乙烯酯、氯乙烯、乙烯属烃、苯乙烯类、取代苯乙烯、取代乙烯及其混合物。具有聚酰胺骨架或羧酸酯官能团的聚合物也是有用的。低分子量聚合物的量是基于该组合物重量的多至约8%,或者约0.05%至约2%。ALCOQUEST 408和ALCOQUEST 747(Alco Chemical,Chattanooga,TN)分别是具有约3000的分子量的聚丙烯酸脂和改性聚羧酸酯聚合物的液态溶液。这些聚合物尤其适合用在该混合物中。
小分子,作为优选的防凝固剂的一部分,是许多小分子中的任何一种。一些有用的小分子包括聚膦酸化合物,包括但不限于:焦磷酸四钠、焦磷酸四钾、氨基(三亚甲基膦酸)、二乙烯三胺五(亚甲基膦酸)三钠盐、己二胺四(亚甲基膦酸)、焦磷酸四钾及其混合物。膦酸化合物的酯也是有用的。美国专利No.6,409,824和No.5,788,857披露了聚膦酸酯化合物的其他实例,在此将它们整体引用引入本文。该混合物中使用的小分子的量是基于全部组合物总重量的多至约8%,或者约0.1%至约2%。一种合适的小分子的实例是焦磷酸四钾(Astaris,Cateret,NJ)。
在生产期间向混合物中添加水,使得该混合物在工作现场可以立即投入使用。确切的加水量取决于想要的混合物粘度,通常为90-180布拉班德单位(BU)。可以制备混合物,使其具有传统的灰泥、涂料或接合剂的稠度。优选地,水是以全部组合物重量的至少20%的量添加。对于较稀的配方,可以添加高达组合物重量的60%,以减少不必要的化学反应、与配方中的组分相互作用或者导致酸败的微生物污染的机会。
有涂层的建筑板供内部或外部使用。在应用于建筑板之前,可选地向该混合物中添加一种或多种添加剂,以赋予该混合物特定的物理特性。合适的添加剂的实例包括但不限于那些便于获得特定粘度、抗弯强度、抗机械损伤(AbuseResistance)、耐水性、耐火性、润湿剂、流动改进剂、防裂剂、分散剂、抗霉性、干燥时间、表面硬度等,以及它们的结合。已知的与石膏一起使用的任何添加剂均可适用于该混合物中,只要它不与本发明的乳胶聚合物乳液或防凝固剂发生负面相互作用。
可选地,添加抗微生物剂以防止该组合物在保质期中的霉菌和细菌生长。如果该组合物在混合后不久就被使用,则不需要抗微生物剂。不过,抗微生物剂的添加对于维持有用的保质期是必要的。抗微生物剂的量在一定程度上取决于选择的确切的抗微生物剂。如果有的话,一些抗微生物剂是以基于该混合物的组分重量的0.08%至约0.5%的量存在。在一些实施方式中,抗微生物剂是以约0.08%至约0.3%的量存在。适当的杀真菌剂和杀细菌剂的实例是本领域熟知的,包括但不限于174杀细菌剂(Troy Chemical Company,Floram Park,NJ)和FungitrolTM 158杀真菌剂(Fritz Chemical Company,Houston,TX)。
可选地向该混合物中添加润湿剂或保水剂,以便保持水分。优选的润湿剂包括丙二醇、聚乙二醇和甲氧基聚乙二醇。两种或全部三种二醇类的结合也认为是可用的。如果有的话,润湿剂是以基于调和组合物重量的约1-10%的量使用。它减少了产品保质期期间的水分离和释放。在施用该产品时,聚亚烷基二醇也能保持水分,使其有更长的凝固时间。已知的任何与石膏或水泥浆或建筑涂料一起使用的保水剂也可用于该混合物中。该混合物的一些实施方式包括淀粉或聚丙烯酰胺作为保水剂。
可选地还添加乙二醇用于冻融稳定性。当用于该目的时,乙二醇是以基于组合物重量的约1%至约5%的量添加,并且与存在的任意保水剂无关。
降裂剂是以基于混合物组分重量的约0.1至约7%的量添加。在该混合物中,添加的淀粉,如淀粉(A.E.Staley Manufacturing Co.,Decatur,IL)发挥作用以减少成品涂层中表面裂纹的数目。
该涂层的另一种可选的组分是抗沉降添加剂。该添加剂是以基于混合物组分总重量的约0.05%至约1%使用。抗沉降添加剂减少了液体的排放以及固体的沉降。优选的抗沉降添加剂包括淀粉、改性淀粉、改性粘土,如改性蒙脱石粘土,硅酸盐,如改性含水钠锂镁硅酸盐及其混合物。
可选择地,以调和型组合物重量的约0.05%至约10%的量向该调和型灰泥复合物中添加增稠剂。增稠剂改变混合物组分的流变性以便有更好的施工性能,并且使该材料抗塌陷性更强。增稠剂的实例包括改性纤维素,如产品(Akzo Nobel,Stenungsund,Sweden),悬浮微粒聚合物,如MicrospersionTM(Micropowders,Inc.,Tarrytown,NY)和聚合物微粉,如产品(Wacker Chemicals,Munich,Germany)。
几种制备实施方式说明了合并这些组分的方法。单个化合物不需要以任意特定的顺序结合。
本发明的至少一种实施方式首先从将双组分防凝固剂溶解在水中开始。将含有低分子量聚丙烯酸脂的聚合物(0.05-2.0%)、聚膦酸化合物(0.1-2.0%)和抗微生物剂/杀真菌剂包(0.08-0.5%)添加到水(20-60%)中,并在约60rpm下搅拌充分溶解。将半水合硫酸钙(40-80%)与改性淀粉(0.1-7.0%)干混合5分钟形成干混合物。可选地,干蜡/PTFE微粉(0.5-10%)、改性蒙脱石粘土或层状硅酸盐粘土(0.05-1%)的任何结合也可以包含在该干混合物中。将干混合物缓慢添加到水性组分中,同时在60rpm或更低速度下混合。最后,添加聚丙二醇(1-10%)和乳胶乳液(5-20%),以60rpm混合。可选择地,还在该阶段添加蜡/PTFE分散剂(0.5-10%)。当不再有视觉可分辨的块状物时,即完成混合,通常为15-20分钟。
为了保质期长,其他实施方式含有杀菌剂。将含有低分子量聚丙烯酸脂的聚合物(0.05-2.0%)、聚膦酸化合物(0.1-2.0%)和抗微生物剂/杀真菌剂包(0.08-0.5%)添加到水(20-60%)中,并在约60rpm下搅拌充分溶解。然后添加聚丙二醇(1-10%)和乳胶乳液((5-20%),在60rpm下混合1-2分钟。可选择地,还在该阶段添加蜡/PTFE分散剂(0.5-10%)。最后,将半水合硫酸钙(40-80%)与改性淀粉(0.1-7.0%),可选地还有干蜡/PTFE微粉(0.5-10%)或改性蒙脱石粘土或层状硅酸盐粘土(0.05-1%)的任何结合,干混合5分钟。将干混合的物料缓慢地添加到水性组分中,同时在60rpm或更低速度下混合。当不再有视觉可分辨的块状物时,即完成混合,通常为15-20分钟。
本发明还有其他实施方式是通过以下制成:将聚膦酸化合物(0.1-2.0%)与抗微生物剂/杀真菌剂包(0.08-0.5%)结合,将其添加到水(20-60%)中并在约60rpm下搅拌充分溶解。将半水合硫酸钙(40-80%)与改性淀粉(0.1-7.0%)、含有低分子量聚丙烯酸酯的聚合物(0.05-2.0%),可选地还有干蜡/PTFE微粉(0.5-10%)、改性蒙脱石粘土或酥皮层状硅酸盐粘土(0.05-1%)的任何结合,干混合5分钟。将干混合物缓慢地添加到水性组分中,同时在60rpm或更低速度下混合。最后,在60rpm搅拌下添加丙二醇(1-10%)和乳胶乳液(5-20%)。可选择地,还在该阶段添加蜡/PTFE分散剂(0.5-10%)。当不再有视觉可分辨的块状物时,即完成混合,通常为15-20分钟。此时,可向混合物中添加额外的水,以获得所需要的粘度。
实施例1
用表I的组分制备涂层混合物。将408(National Starch andChemical Co.,Bridgewater,NJ)聚合物溶液、焦磷酸四钾和抗微生物剂/杀真菌剂包添加到水中,并在60rpm下搅拌充分溶解。然后添加丙二醇和乳胶乳液,在60rpm下混合和搅拌1-2分钟。最后,将半水合硫酸钙与136淀粉干混合5分钟。将干混合的物料缓慢地添加到水性组分中,同时在60rpm或更低速度下混合。混合在80rpm下继续进行,当不再有视觉可分辨的块状物时,即完成混合。
表I
由精通的工匠用托灰板和泥刀以及常规的双涂层饰面抹灰技术将该材料施用到垂直安装的牌石膏板基板上。该实施方式具有较厚和较粘的涂布感觉并且需要水抹压。一旦该材料凝固,表面就变硬、平滑并且具有增强的耐磨性能。
实施例2
用表II的组分制备涂层混合物。将45%的ALCOQUEST 747溶液、焦磷酸四钾、抗微生物剂/杀真菌剂包和301s消泡剂(Lubrizal Corp.,Wickliffe,OH)添加到水中,并在约60rpm下搅拌充分溶解。然后添加丙二醇和HP 41-830,在60rpm下混合和搅拌1-2分钟。最后,将半水合硫酸钙与STAPROL 136(2.0%)以及LAPOINTE合成蒙托石粘土(Rockwood AdditivesLtd.,UK)干混合5分钟。将干混合的物料缓慢地添加到水性组分中,同时在60rpm或更低速度下混合。混合在80rpm下继续进行,直到不再有视觉可分辨的块状物。
表II
由精通的工匠用托灰板和泥刀以及常规的双涂层饰面抹灰技术将该材料施用到垂直安装的牌石膏板基板上。该材料贮存时对渗出水具有更强的抵抗作用,不过该材料的感觉有所变化。一旦该材料凝固,表面就变平滑,并且具有与灰泥差不多的耐磨性能。
实施例3
用表I的组分制备调和型灰泥组合物。将ALCOQUEST 408聚丙烯酸酯聚合物和焦磷酸四钾化合物(TKPP)添加到水中,并在约60rpm下搅拌充分溶解。将半水合硫酸钙与STAPROL 136预凝胶淀粉干混合5分钟形成干混合物。将干混合物缓慢地添加到水性组分中,同时在60rpm或更低速度下混合。将丙二醇和HP 41-803醋酸乙烯酯乳胶乳液添加到该组合物中,同时在60rpm下混合。混合在80rpm下继续进行,直到不再有视觉可分辨的块状物。
表III
由精通的工匠用托灰板和泥刀以及常规的双涂层饰面抹灰技术将该材料施用到垂直安装的牌石膏板基板上。该材料比接合剂的粘性小,更易于控制和抹平,不会留下痕迹或需要打磨。这些性质使该材料比用于表面涂层涂布的接合剂更好。该材料在泥刀下感觉并不完全像混合粉末的灰泥,但在应用性能和便利性之间提供了很好的协调。一旦该材料凝固,表面就变平滑、无裂纹,并且具有与灰泥差不多的耐磨性能。
实施利4
将45%的ALCOQUEST 747溶液(1.6%)、焦磷酸四钾(0.4%)、抗微生物剂/杀真菌剂包(0.1%)和301s消泡剂(0.6%)添加到水(20.2%)中,并在60rpm下搅拌充分溶解。然后,在60rpm下添加丙二醇(3.1%)和HP 19-176(12.8%)以及250-50微粉蜡(T.H.HilsonCo.,Wheaton,IL)(3.6%),并混合1-2分钟。最后,将半水合硫酸钙(56.6%)与STAPROL 136(1.0%)干混合5分钟。将干混合的物料缓慢地添加到水性组分中,同时在60rpm或更低速度下混合。混合在80rpm下继续进行,直到不再有视觉可分辨的块状物。
尽管本发明已经显示和描述了非水合灰泥组合物及方法的具体实施方式,然而本领域技术人员可以理解,在不背离本发明的情况下可以在更广范围对其做出变化和修改,正如以下权利要求所述。
Claims (12)
1.一种涂层板,包括:
建筑板;和
涂层,包括在乳胶聚合物基质中的半水合硫酸钙,其中所述聚合物基质是无水的并进一步包括分布在整个所述基质中的防凝固剂。
2.如权利要求1所述的涂层板,其中所述防凝固剂包括分子量小于6000道尔顿的低分子量聚合物、聚膦酸或其酯的化合物、及其混合物中的至少一种。
3.如权利要求1所述的涂层板,进一步包括抗沉降添加剂。
4.如权利要求3所述的涂层板,其中所述抗沉降添加剂包括改性粘土、硅酸盐及其混合物中的一种。
5.如权利要求1所述的涂层板,其中所述乳胶聚合物由单体制成,该单体包括乙烯属烃。
6.如权利要求1所述的涂层板,其中所述乳胶聚合物由单体制成,该单体包括取代乙烯。
7.如权利要求1所述的涂层板,其中所述乳胶聚合物由单体制成,该单体包括丙烯酸乙烯酯、醋酸乙烯酯、氯乙烯。
8.如权利要求1所述的涂层板,进一步包括非乳液聚合防裂剂,其以基于组合物总重量的0.1%至7%的量存在。
9.如权利要求2所述的涂层板,其中所述聚膦酸化合物是以基于组合物总重量的0.1%至2.0%的量存在。
10.如权利要求1所述的涂层板,其中所述低分子量聚合物是以基于组合物总重量的0.05至2.0%的量存在。
11.一种含有半水合硫酸钙的涂层混合物,包括:
乳胶聚合物;
半水合硫酸钙;和
双组分防凝固剂;
其中所述聚合物基质是无水的,并且所述防凝固剂包括分子量小于6000道尔顿的低分子量聚合物、聚膦酸化合物及其混合物中的至少一种。
12.如权利要求11所述的涂层混合物,进一步包括有机保水剂。
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EP2274387B1 (en) | 2013-08-21 |
US8563139B2 (en) | 2013-10-22 |
MX2010011030A (es) | 2010-11-05 |
RU2497854C2 (ru) | 2013-11-10 |
EP2274387A1 (en) | 2011-01-19 |
BRPI0907329A2 (pt) | 2018-01-09 |
ZA201008261B (en) | 2011-07-27 |
AU2009238509A1 (en) | 2009-10-29 |
BRPI0907329B1 (pt) | 2018-10-30 |
PL2274387T3 (pl) | 2014-10-31 |
CN102015929A (zh) | 2011-04-13 |
EP2274387A4 (en) | 2011-05-25 |
JP5505888B2 (ja) | 2014-05-28 |
WO2009131790A1 (en) | 2009-10-29 |
NZ588429A (en) | 2012-03-30 |
AU2009238509B2 (en) | 2014-01-16 |
KR20110005281A (ko) | 2011-01-17 |
US20090264556A1 (en) | 2009-10-22 |
CA2721379C (en) | 2016-08-16 |
CO6331353A2 (es) | 2011-10-20 |
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