CN102776978A - 高淀粉轻质石膏墙板 - Google Patents

高淀粉轻质石膏墙板 Download PDF

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CN102776978A
CN102776978A CN2012102560579A CN201210256057A CN102776978A CN 102776978 A CN102776978 A CN 102776978A CN 2012102560579 A CN2012102560579 A CN 2012102560579A CN 201210256057 A CN201210256057 A CN 201210256057A CN 102776978 A CN102776978 A CN 102776978A
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CN102776978B (zh
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余强
威欣·D·宋
迈克尔·R·林恩
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
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    • 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
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Abstract

本发明大体来说提供含石膏浆液和用所述浆液制得的含石膏产品，具体地，本发明提供高淀粉轻质石膏墙板，并提供制造该石膏墙板的方法。所述浆液包括灰泥、萘磺酸盐分散剂和预胶质化淀粉。以干灰泥的重量计，所述萘磺酸盐分散剂是以约0.1重量%-3.0重量%的量存在。以所述调配物中干灰泥的重量计，所述预胶质化淀粉是以至少约0.5重量%至多达约10重量%预胶质化淀粉的量存在。其它浆液添加剂可包括三偏磷酸盐、加速剂、粘合剂、纸纤维、玻璃纤维和其它已知的成分。

Description

高淀粉轻质石膏墙板
本申请是申请日为2006年6月8日、申请号为200680019824.7、发明名称为“高淀粉轻质石膏墙板”的发明专利申请的分案申请。
技术领域
本发明涉及一种制备含有预胶质化淀粉和萘磺酸盐分散剂的石膏浆液的方法，和由所述石膏浆液制得的产品。本发明还涉及一种增加包括墙板在内的含石膏产品的干强度的方法，其是通过在用于制造所述产品的浆液中使用与预胶质化淀粉组合的萘磺酸盐分散剂来进行。
背景技术
石膏（二水合硫酸钙）的某些特性使其非常适合用于制造工业和建筑产品，诸如石膏墙板。石膏是一种蕴藏丰富并且通常极为廉价的原材料，通过脱水和再水合的过程，能够对其进行浇注、模制或另外使其形成有用的形状。制造石膏墙板和其它石膏产品的基本材料是通常称为“灰泥”的半水合形式的硫酸钙（CaSO4·1/2H2O），它是通过加热转化二水合形式的硫酸钙（CaSO4·2H2O），由去除其1-1/2个水分子得到。
常规的含石膏产品（诸如石膏墙板）具有多种益处，诸如成本低和易于加工，但当切割或钻开所述产品时，会产生大量的石膏粉尘。已使用淀粉作为用于制造所述产品的浆液中的成分来实现对制造含石膏产品的方法的多种改进。淀粉可增加包括石膏墙板在内的含石膏产品的抗弯强度和压缩强度。已知的石膏墙板含有小于约10lbs/MSF含量的纸板淀粉（board starch）。
还需要在含有预胶质化淀粉的石膏浆液中使用大量的水以便确保所述浆液的适当流动性。不幸的是，大部分的水最终都必须通过加热来分离去除，这一步骤因加热过程中所用的燃料具有较高成本而显得代价太大。加热步骤还相当费时。已发现，使用萘磺酸盐分散剂能够增加浆液的流动性，从而克服需水的问题。此外，还发现，如果使用量足够高，那么萘磺酸盐分散剂能够与预胶质化淀粉交联以在干燥后结合石膏晶体，从而增加石膏复合物的干强度。过去，并未认识到三偏磷酸盐能够影响石膏浆液的需水量。然而，本发明的发明者已发现，在特定分散剂的存在下，将三偏磷酸盐的含量增加到目前尚未知的程度甚至在高淀粉含量的存在下仍可能会实现适当的浆液流动性，和出人意料地降低的水量。当然，由于增加三偏磷酸盐含量随之减少了燃料的使用以及与随后去除水的处理步骤相关的处理时间，故而变得特别合乎需要。由此，本发明的发明者还发现，通过在用于制造石膏板的浆液中使用与预胶质化淀粉组合的萘磺酸盐分散剂将能够增加所述墙板的干强度。
发明内容
本发明大体来说包含一种包括灰泥、萘磺酸盐分散剂和预胶质化淀粉的浆液。以干灰泥的重量计，所述萘磺酸盐分散剂是以约0.1重量%-3.0重量%的量存在。以所述调配物中干灰泥的重量计，所述预胶质化淀粉是以至少约0.5重量%多达约10重量%的量存在。其它浆液添加剂可包括加速剂、粘合剂、纸纤维或玻璃纤维和其它已知的组分。本发明还包含用所述浆液制成的含石膏产品。
本发明还包含一种包括灰泥、三偏磷酸盐、萘磺酸盐分散剂和预胶质化淀粉的浆液。以干灰泥的重量计，所述三偏磷酸钠是以至少约0.12重量%的量存在。在优选实施例中，以干灰泥的重量计，所述三偏磷酸盐是以约0.12-0.4重量%的量存在。以干灰泥的重量计，所述萘磺酸盐分散剂是以约0.1重量%-3.0重量%的量存在。以所述调配物中干灰泥的重量计，所述预胶质化淀粉是以至少约0.5重量%多达约10重量%的量存在。其它浆液添加剂可包括加速剂、粘合剂、纸纤维或玻璃纤维和其它已知的组分。本发明还包含用所述浆液制成的含石膏产品。
优选的含石膏产品为石膏墙板。在本实施例中，本发明构造包含形成于两个大体平行的盖板之间的凝固石膏组合物的石膏墙板，所述凝固石膏组合物是使用由水、灰泥、预胶质化淀粉和萘磺酸盐分散剂构成的含石膏浆液制成。含石膏浆液可视情况含有三偏磷酸盐，例如三偏磷酸钠。根据本发明制成的这种石膏墙板具有高强度，但重量比常规板轻得多。此外，当切割、锯开、扳断或钻开根据本发明制成的墙板时，将产生少得多的粉尘。
在另一实施例中，本发明提供一种通过混合包含水、灰泥、预胶质化淀粉和萘磺酸盐分散剂的含石膏浆液来制造石膏墙板的方法，其中以灰泥的重量计，所述预胶质化淀粉是以至少约0.5重量%多达约10重量%的量存在。将所得的含石膏浆液沉积于第一个纸盖板上，并且将第二个纸盖板放到已沉积的浆液上以形成石膏墙板。当含石膏浆液硬化到足以进行切割后，对石膏墙板进行切割，并且干燥所得到的石膏墙板。含石膏浆液可视情况含有三偏磷酸盐，例如三偏磷酸钠。还可将其它常用成分用于浆液中，包括（适当时）加速剂、粘合剂、纸纤维、玻璃纤维和其它已知的成分。通常还加入肥皂泡沫以减小最终的石膏墙板产品的密度。
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具体实施方式
根据本发明的一个实施例，提供由含有灰泥、预胶质化淀粉和萘磺酸盐分散剂的含石膏浆液制成的含石膏成品。以干灰泥的重量计，所述萘磺酸盐分散剂是以约0.1重量%-3.0重量%的量存在。以所述调配物中干灰泥的重量计，所述预胶质化淀粉是以至少约0.5重量%多达约10重量%的量存在。所述浆液中可使用的其它成分包括粘合剂、纸纤维、玻璃纤维和加速剂。通常还将肥皂泡沫加入新调配的含石膏浆液中，以降低最终的含石膏产品（例如，石膏墙板）的密度。
视情况，约0.5重量%多达约10重量%的预胶质化淀粉、约0.1重量%多达约3.0重量%的萘磺酸盐分散剂和最小为至少约0.12重量%多达约0.4重量%的三偏磷酸盐（所有物质都是以石膏浆液中所使用的干灰泥的重量计）的组合将出人意料地明显增加所述石膏浆液的流动性。这将大体上减少制备具有足够的流动性待用于制造含石膏产品（诸如石膏墙板）的石膏浆液所需的水量。相信为标准调配物中含量的至少约2倍的三偏磷酸盐的含量（以三偏磷酸钠的形式）将会增强萘磺酸盐分散剂的分散剂活性。
用于本发明中的萘磺酸盐分散剂包括聚萘磺酸和其盐（聚萘磺酸盐）和衍生物，其为萘磺酸与甲醛的缩合产物。特别合乎需要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在约3,000到27,000的范围内，但所述分子量优选为约8,000到10,000。在给定固体百分比的水溶液中，较高分子量的分散剂具有较高的粘度，并且在调配过程中产生比较低分子量分散剂高的需水量。有用的萘磺酸盐包括购自GEOSpecialty Chemicals,Cleveland,Ohio的DILOFLO；购自Hampshire Chemical Corp.,Lexington,Massachusetts的DAXAD；和购自GEO Specialty Chemicals,Lafayette,Indiana的LOMAR D。萘磺酸盐优选是以（例如）固含量在35-55重量%的范围内的水溶液的形式使用。最优选使用（例如）固含量在约40-45重量%的范围内的水溶液形式的萘磺酸盐。或者，适当时，萘磺酸盐可以干固体或粉末形式使用，诸如LOMAR D。可用于本发明中的聚萘磺酸盐具有通用结构（I）：
Figure BDA00001917518000041
其中n>2，且其中M为钠、钾、钙等。
以石膏复合物调配物中所使用的干灰泥的重量计，优选为约45重量%的水溶液形式的萘磺酸盐分散剂可以在约0.5重量%到约3.0重量%范围内的量使用。以干灰泥的重量计，萘磺酸盐分散剂的更优选范围为约0.5重量%到约2.0重量%，并且以干灰泥的重量计，最优选的范围为约0.7重量%到约2.0重量%。相比之下，已知的石膏墙板含有以干灰泥的重量计约0.4重量%或更低含量的所述分散剂。
换种方式说，以石膏复合物调配物中所使用的干灰泥的重量计，萘磺酸盐分散剂以干重计可以在约0.1重量%到约1.5重量%范围内的量使用。以干灰泥的重量计，萘磺酸盐分散剂更优选范围（以干固体计）为约0.25重量%到约0.7重量%，并且以干灰泥的重量计，最优选的范围（以干固体计）为约0.3重量%到约0.7重量%。
含石膏浆液可视情况含有三偏磷酸盐，例如三偏磷酸钠。任何适当的水溶性偏磷酸盐或聚磷酸盐都可用于本发明中。优选使用三偏磷酸盐，包括复盐，也就是具有两个阳离子的三偏磷酸盐。特别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，或其组合。优选的三偏磷酸盐为三偏磷酸钠。优选使用（例如）固含量在约10-15重量%的范围内的水溶液形式的三偏磷酸盐。如以引用方式并入本文中的Yu等人的美国专利第6,409,825号中所述，还可使用其它环状或无环聚磷酸盐。
三偏磷酸钠是一种含石膏组合物中的已知添加剂，但以石膏浆液中所使用的干灰泥的重量计，其通常是以在约0.05重量%到约0.08重量%范围内的量使用。在本发明的实施例中，以石膏复合物调配物中所使用的干灰泥的重量计，三偏磷酸钠（或其它水溶性偏磷酸盐或聚磷酸盐）可以在约0.12重量%到约0.4重量%范围内的量存在。以石膏复合物调配物中所使用的干灰泥的重量计，三偏磷酸钠（或其它水溶性偏磷酸盐或聚磷酸盐）的优选范围为约0.12重量%到约0.3重量%。
存在两种形式的灰泥，α和β。这两类灰泥是由不同的煅烧方式制得。在本发明中，可使用β或α形式的灰泥。
在根据本发明所制备的含石膏浆液中，必须使用淀粉（尤其包括预胶质化淀粉）。优选预胶质化淀粉为预胶质化玉米淀粉，例如，购自Bunge Milling,St.Louis,Missouri的预胶质化玉米粉，其具有以下典型分析：水分7.5%，蛋白质8.0%，油0.5%，粗纤维0.5%，灰分0.3%；生坯强度为0.48psi；且松装密度为35.0lb/ft3。以含石膏浆液中所使用的干灰泥的重量计，所述预胶质化玉米淀粉应以至少约0.5重量%多达约10重量%的量使用。
本发明的发明者还发现，在约0.1重量%到3.0重量%的萘磺酸盐分散剂的存在下，通过使用至少约0.5重量%至多达约10重量%的预胶质化淀粉（优选为预胶质化玉米淀粉）（淀粉和萘磺酸盐含量都是以调配物中存在的干灰泥的重量计）能够使干强度（尤其在墙板中）获得意外增加。这出人意料的结果能够在存在或不存在水溶性偏磷酸盐或聚磷酸盐的情况下获得。
此外，还意外地发现，预胶质化淀粉可以至少约10lb/MSF或更高的含量用于根据本发明制成的干石膏墙板中，而且仍能够实现高强度和低重量。石膏墙板中高达35-45lb/MSF的预胶质化淀粉含量被证实是有效的。举例来说，如下表1和表2中所示，调配物B包括45lb/MSF，但产生具有优良强度的1042lb/MSF的纸板重量。在本实例（调配物B）中，呈45重量%水溶液形式的萘磺酸盐分散剂是以1.28重量%的含量使用。
其它有用的淀粉包括经酸改性的淀粉，诸如经酸改性的玉米粉，如购自BungeMilling,St.Louis,Missouri的HI-BOND。这种淀粉具有以下典型分析：水分10.0%，油1.4%，可溶物17.0%，碱性流动性98.0%，松装密度30lb/ft3，和产生4.3的pH值的20%浆液。另一种有用淀粉为未预胶质化小麦淀粉，诸如购自ADM/Ogilvie,Montreal,Quebec,Canada的ECOSOL-45。
当将萘磺酸盐分散剂三偏磷酸盐的组合与预胶质化玉米淀粉和视情况纸纤维或玻璃纤维组合时，用本发明可实现另一出人意料的结果。由含有这三种成分的调配物制成的石膏墙板具有增加的强度和减轻的重量，并且因其生产过程中所需的水量减少而在经济上更合乎需要。
如以引用的方式并入本文中的Yu等人的美国专利第6,409,825号中所述，可以将加速剂用于本发明的含石膏组合物中。一种合乎需要的耐热加速剂（HRA）可由干磨的建筑石膏粉（landplaster）（二水合硫酸钙）制得。可使用少量诸如糖、右旋糖、硼酸和淀粉等添加剂（通常约5重量%）制得此HRA。当前优选糖或右旋糖。如以引用的方式并入本文中的美国专利第3,573,947号所述，另一种有用的加速剂为“气候稳定的加速剂（climate stabilized accelerator）”或“气候可稳定加速剂”（CSA）。
以下实例将进一步说明本发明。不应将其解释为以任何方式限制本发明的范围。
实例1
石膏浆液调配物样本
将石膏浆液调配物展示于下表1中。表1中的所有值都是基于干灰泥的重量以重量百分比表示。括号里的值为以磅为单位的干重（lb/MSF）。
表1
Figure BDA00001917518000071
*用于预先产生泡沫。
11.28重量%的45%的水溶液
实例2
墙板的制造
石膏墙板样本是根据以引用的方式并入本文中的Yu等人的美国专利第6,342,284号和Yu等人的第6,632,550号制造。如这些专利的实例5所述，制造方法包括单独产生泡沫，和将所述泡沫引入具有其它成分的浆液中。
使用实例1的调配物A和B所制得的石膏墙板和对照的试验结果都展示于下表2中。在本实例和下文的其它实例中，拔钉抗性、芯部硬度和抗弯强度试验都是根据ASTMC-473进行。此外，应注意，典型的石膏墙板为约1/2英寸厚，并且具有介于每1000平方英尺材料约1600到1800磅（或lb/MSF）的重量。（“MSF”在所属领域中为一千平方英尺的标准缩写；其为对盒子、波状介质和墙板的面积度量。）
表2
MD：纵向
XMD：横向。
如表2中所述，相比对照纸板，使用调配物A和B浆液所制得的石膏墙板的重量明显减轻。再参看表1，调配物A纸板与调配物B纸板相差极大。调配物A与调配物B的水/灰泥（w/s）比类似。调配物B中还使用明显较高含量的萘磺酸盐分散剂。此外，在调配物B中使用约6重量%的实质更多的预胶质化淀粉，这比调配物A增加超过100%，同时伴随明显的强度增加。即使这样，产生所需的流动性的需水量对调配物B浆液而言仍较低，与调配物A相比，差异为约10%。两种调配物的低需水量归因于石膏浆液中萘磺酸盐分散剂和三偏磷酸钠组合的协同作用，这使得甚至在存在实质更高含量的预胶质化淀粉的情况下仍能增加石膏浆液的流动性。
如表2所述，相比使用调配物A浆液所制得的墙板，使用调配物B浆液所制得的墙板具有实质上增加的强度。通过并入与增加量的萘磺酸盐分散剂和三偏磷酸钠组合的增加量的预胶质化淀粉，调配物B纸板的拔钉抗性相比调配物A纸板改进45%。与调配物A纸板相比，在调配物B纸板中还观察到抗弯强度的实质增加。
实例3
1/2英寸石膏墙板的减重实验
包括浆液调配物和试验结果在内的其它石膏墙板实例（纸板C、D和E）都展示于下表3中。表3中的浆液调配物包括所述浆液中的主要组分。括号中的值是基于干灰泥的重量以重量百分比表示。
表3
Figure BDA00001917518000081
+ASTM标准：77lb
1DILOFLO为45%的萘磺酸盐水溶液
如表3中所述，纸板C、D和E都是由与对照纸板相比淀粉、DILOFLO分散剂和三偏磷酸钠的量显著增加（淀粉和分散剂以百分比计约两倍增加；且三偏磷酸盐增加2到3倍）而同时w/s比保持恒定的浆液制成。然而，如通过拔钉抗性测量到的强度未受到明显影响并且纸板重量明显减轻。因此，在本发明实施例的这一实例中，新颖调配物（诸如，纸板D）可将增加的淀粉调配于保持适当强度的同时还便于使用的可流动浆液中。
实例4
湿石膏立方块强度试验
湿立方块强度试验是在实验室中通过使用购自United States Gypsum公司,Chicago,Illinois的Southard CKS纸板灰泥和自来水进行以测定其湿压缩强度。使用以下实验室试验程序。
在约70℉下，将灰泥（1000g）、CSA（2g）和自来水（1200cc）用于各湿石膏立方块浇注。首先，在塑料袋中将预胶质化玉米淀粉（20g，以灰泥重量计为2.0%）和CSA（2g，以灰泥重量计为0.2%）与灰泥彻底干拌混合，随后使其与含有萘磺酸盐分散剂与三偏磷酸钠的自来水溶液混合。所使用的分散剂为DILOFLO分散剂（1.0-2.0%，如表4中所示）。还如表4中所示使用变化量的三偏磷酸钠。
最初，在实验室用Warning混合机组合干成分和水溶液，将所产生的混合物浸泡10秒，且随后以低速混合所述混合物10秒以便制成浆液。将由此形成的浆液浇注到三个2"×2"×2"的立方体模具中。随后将所浇注的立方块从模具中取出，称重并且密封于塑料袋中以防止水分在进行压缩强度试验之前损失。湿立方块的压缩强度是使用ATS机测量，并且记录为以每平方英寸的磅数（psi）表示的平均值。所得结果如下：
表4
Figure BDA00001917518000101
1DILOFLO为45%的萘磺酸盐水溶液
如表4中所述，三偏磷酸钠含量在约0.12-0.4%范围内的本发明的样本4-5、10-11和17相比三偏磷酸钠含量在此范围外的样本通常具有优良的湿立方块压缩强度。
实例5
1/2英寸轻质石膏墙板工厂生产实验
进行其它实验（实验纸板1和2），包括浆液调配物和试验结果都展示于下表5中。表5中的浆液调配物包括所述浆液中的主要组分。括号中的值是基于干灰泥的重量以重量百分比表示。
表5
Figure BDA00001917518000111
+ASTM标准：77lb
MD：纵向
XMD：横向。
1DILOFLO为45%的萘磺酸盐水溶液
290℉/90%相对湿度
3应了解，在这些试验条件下，破坏百分率<50%是可接受的。
如表5中所述，实验纸板1和2都是由相比对照纸板淀粉、DILOFLO分散剂和三偏磷酸钠的量实质增加而同时w/s比略有降低的浆液制成。然而，如通过拔钉抗性和抗弯试验所测量到的强度仍得以保持或得到改进，并且纸板重量明显减轻。因此，在本发明的实施例的这一实例中，新颖调配物（诸如，实验纸板1和2）可将增加的三偏磷酸盐和淀粉调配于便于使用的可流动浆液中，同时还保持适当强度。
实例6
1/2英寸超轻质石膏墙板工厂生产实验
与实例2一样，使用调配物B（实例1）进行其它实验（实验纸板3和4），但预胶质化玉米淀粉是用水以10%的浓度制备（湿淀粉制剂）并且使用HYONIC PFM肥皂（购自GEO Specialty Chemicals,Lafayette,Indiana）的掺合物。举例来说，实验纸板3是用在65-70重量%/35-30重量%范围内的HYONIC PFM10/HYONIC PFM33的掺合物制造。举例来说，实验纸板4是用70/30wt./wt.的HYONIC PFM10/HYONIC PFM33的掺合物制造。实验结果展示于下表6中。
表6
Figure BDA00001917518000121
*所标记的除外。
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中所述，如通过拔钉和芯部硬度所测量到的强度特征都高于ASTM标准。抗弯强度经测量也高于ASTM标准。此外，在本发明的实施例的这一实例中，新颖调配物（诸如，实验纸板3和4）可将增加的三偏磷酸盐和淀粉调配于便于使用的可流动浆液中，同时还保持适当强度。
除非在本文中另作说明或通过文字明确地作相反说明，否则在描述本发明的上下文中（尤其在以下权利要求书的上下文中），术语“一”和“所述”以及类似表述的使用应解释为涵盖单个和多个参考物。除非另作说明，否则对于本文中值的范围的叙述只是想要用作独立地提及在所述范围内的各单独值的简化方法，并且各单独值都将并入本说明书中，就如同在本文中对其独立地进行叙述一般。除非在本文中另作说明或通过文字另外明确地作相反说明，否则本文所述的所有方法可以任何次序进行。除非另作声明，否则本文所提供的任何实例和所有实例或示范性术语（例如，“诸如”）的使用都只是想要用于更好地说明本发明，并且不形成对本发明的范围的限制。不应将本说明书中的术语解释为指示任何非所申请的元素为实践本发明所必需。
本文描述本发明的优选实施例，包括发明者已知的用于进行本发明的最佳模式。应了解，所述实施例只是出于示范说明的目的给出，并且不应将其视作对本发明范围的限制。

Claims (30)

1.一种轻质石膏板，其包含：
置于两个盖板之间的凝固石膏组合物，该石膏组合物由至少以下物质制成：水、灰泥、淀粉和发泡剂；
以灰泥的重量计，所述淀粉的量为约0.5重量%-约10重量%；
所述发泡剂包含较多重量部分的不稳定成分和较少重量部分的稳定成分，发泡剂的量和所述不稳定成分与稳定成分的重量比对于在所述石膏组合物中形成孔隙分布是有效的；
所述淀粉和孔隙分布对于提供约34lb/ft3（约540kg/m3）或更小的板密度和至少约11lb（约5kg）的芯部硬度是有效的，所述芯部硬度根据ASTM标准C473确定。
2.根据权利要求1所述的轻质石膏板，其中发泡剂包含不稳定和稳定成分的掺混物。
3.根据权利要求1所述的轻质石膏板，其中发泡剂包含至少约65重量%的不稳定成分。
4.根据权利要求1所述的轻质石膏板，其中以灰泥的重量计，发泡剂的量为0.1重量%或更少。
5.根据权利要求1所述的轻质石膏板，其中以灰泥的重量计，发泡剂的量为约0.02重量%-约0.03重量%。
6.根据权利要求1所述的轻质石膏板，其中石膏组合物由约0.7-约1.2的水与灰泥的重量比制成。
7.根据权利要求1-6任一项所述的轻质石膏板，其中相对于没有淀粉的石膏组合物，所述淀粉对于提高石膏组合物的芯部硬度是有效的。
8.根据权利要求7所述的轻质石膏板，其中以灰泥的重量计，所述淀粉的量为约0.5重量%-约3重量%。
9.根据权利要求7所述的轻质石膏板，其中所述淀粉包含预胶质化淀粉，且以灰泥的重量计，所述淀粉的量为约0.5重量%-约6重量%。
10.根据权利要求1所述的轻质石膏板，其中所述板在（a）于足以产生90%相对湿度和90℉（约32℃）温度条件的环境中调整约6小时，和（b）干燥至恒定重量后，具有至少约15lb（约6.8kg）的潮湿粘结荷载。
11.根据权利要求1所述的轻质石膏板，其中所述凝固石膏组合物还至少从分散剂制成。
12.根据权利要求1所述的轻质石膏板，其中所述凝固石膏组合物还至少从萘磺酸盐分散剂制成，以灰泥的重量计，萘磺酸盐分散剂的量为约0.2重量%-约3.0重量%。
13.根据权利要求1所述的轻质石膏板，其中所述凝固石膏组合物还至少从聚磷酸盐制成，以灰泥的重量计，聚磷酸盐的量为约0.12重量%-约0.4重量%。
14.根据权利要求1所述的轻质石膏板，其中：
相对于没有淀粉的石膏组合物，所述淀粉对于提高石膏组合物的芯部硬度是有效的；所述板在（a）于足以产生90%相对湿度和90℉（约32℃）温度条件的环境中调整约6小时，和（b）干燥至恒定重量后，具有至少约15lb（约6.8kg）的潮湿粘结荷载；且
在板厚为约1/2英寸（约1.3cm）的情况下，该板具有至少约65lb（约29kg）的拔钉抗性，拔钉抗性根据ASTM标准C473确定。
15.根据权利要求14所述的轻质石膏板，其中：
以灰泥的重量计，发泡剂的量为0.1重量%或更少；且
在板厚为约1/2英寸（约1.3cm）的情况下，该板具有至少约72lb（约33kg）的拔钉抗性，拔钉抗性根据ASTM标准C473确定。
16.根据权利要求1所述的轻质石膏板，其中：
所述板在（a）于足以产生90%相对湿度和90℉（约32℃）温度条件的环境中调整约6小时，和（b）干燥至恒定重量后，具有至少约17lb（约7.7kg）的潮湿粘结荷载；且
在板厚为约1/2英寸（约1.3cm）的情况下，该板具有至少约77lb（约35kg）的拔钉抗性，拔钉抗性根据ASTM标准C473确定。
17.根据权利要求15所述的轻质石膏板，其中在板厚为约1/2英寸（约1.3cm）的情况下，所述板具有至少约36lb（约16kg）的纵向抗弯强度和/或约107lb（约48.5kg）的横向抗弯强度，抗弯强度根据ASTM标准C473确定。
18.根据权利要求17所述的轻质石膏板，其中：
所述凝固石膏组合物还从分散剂制成，以灰泥的重量计，分散剂的量为约0.2重量%-约3.0重量%；
石膏组合物由约0.7-约1.2的水与灰泥的重量比制成；且
所述板在（a）于足以产生90%相对湿度和90℉（约32℃）温度条件的环境中调整约6小时，和（b）干燥至恒定重量后，具有至少约17lb（约7.7kg）的潮湿粘结荷载。
19.根据权利要求18所述的轻质石膏板，其中所述凝固石膏组合物还从三偏磷酸钠制成，以灰泥的重量计，三偏磷酸钠的量为约0.12重量%-约0.4重量%。
20.一种轻质石膏板，其包含：
置于两个盖板之间的凝固石膏组合物，该凝固石膏组合物由至少以下物质制成：水、灰泥、淀粉、分散剂和聚磷酸盐；
灰泥的量至少为700lb/MSF（约3.4kg/SQM）;
以灰泥的重量计，所述淀粉的量为约0.5重量%-约10重量%，且相对于没有淀粉的石膏组合物，所述淀粉对于提高石膏组合物的芯部硬度是有效的；
以灰泥的重量计，分散剂的量为约0.1重量%-约3.0重量%;
以灰泥的重量计，聚磷酸盐的量为约0.12重量%-约0.4重量%;
所述板具有约34lb/ft3（约540kg/m3）或更小的密度；且
所述板具有至少约11lb（约5kg）的芯部硬度，芯部硬度根据ASTM标准C473确定。
21.根据权利要求20所述的轻质石膏板，其中灰泥的量为约700lb/MSF（约3.4kg/SQM）-约1300lb/MSF（约6.3kg/SQM）。
22.根据权利要求20所述的轻质石膏板，以干灰泥的重量计，还包含约0.20%-1.30%的量的纸纤维和/或玻璃纤维。
23.根据权利要求20所述的轻质石膏板，以干灰泥的重量计，还包含约0.2%-约0.9%的量的加速剂。
24.根据权利要求20所述的轻质石膏板，其中所述石膏组合物由约0.7-约1.2的水与灰泥的重量比制成。
25.根据权利要求20所述的轻质石膏板，其中：
所述凝固石膏组合物还至少从发泡剂和加速剂制成；
灰泥的量为约700lb/MSF（约3.4kg/SQM）-约1300lb/MSF（约6.3kg/SQM）;
以灰泥的重量计，所述淀粉的量为约0.5重量%-约6重量%；
以灰泥的重量计，分散剂的量为约0.2重量%-约3.0重量%;
所述发泡剂包含较多重量部分的不稳定成分和较少重量部分的稳定成分，发泡剂的量和所述不稳定成分与稳定成分的重量比对于在所述石膏组合物中形成孔隙分布是有效的，其中以灰泥的重量计，发泡剂的量为0.1重量%或更少；
所述淀粉和孔隙分布对于提供约24lb/ft3（约380kg/m3）-约34lb/ft3（约540kg/m3）的板密度是有效的，且在板厚为约1/2英寸（约1.3cm）的情况下，所述芯部硬度为至少约11lb（约5kg），拔钉抗性为至少约65lb（约29kg），纵向抗弯强度为至少约36lb（约16kg）和/或横向抗弯强度为至少约107lb（约48.5kg），拔钉抗性和抗弯强度根据ASTM标准C473确定；且
所述板在（a）于足以产生90%相对湿度和90℉（约32℃）温度条件的环境中调整约6小时，和（b）干燥至恒定重量后，具有至少约15lb（约6.8kg）的潮湿粘结荷载。
26.根据权利要求25所述的轻质石膏板，其中以灰泥的重量计，发泡剂的量为约0.02重量%-约0.03重量%。
27.根据权利要求25所述的轻质石膏板，其中：
所述凝固石膏组合物还至少从纸纤维和/或玻璃纤维制成；
所述石膏组合物由约0.7-约1.2的水与灰泥的重量比制成；
所述淀粉包含预胶质化淀粉；、
所述分散剂包含萘磺酸盐；
所述磷酸盐包含三偏磷酸钠；
以灰泥重量计，所述纸纤维和/或玻璃纤维以约0.02重量%-1.30重量%的量存在；
所述加速剂包含耐热加速剂，以灰泥重量计，所述加速剂以约0.2重量%-0.9重量%的量存在；且
所述板在（a）于足以产生90%相对湿度和90℉（约32℃）温度条件的环境中调整约6小时，和（b）干燥至恒定重量后，具有至少约17lb（约7.7kg）的潮湿粘结荷载。
28.根据权利要求20-27任一项所述的轻质石膏板，其中所述凝固石膏组合物还至少从发泡剂制成，所述发泡剂包含较多重量部分的不稳定成分和较少重量部分的稳定成分，发泡剂的量和所述不稳定成分与稳定成分的重量比在所述石膏组合物中形成孔隙分布。
29.根据权利要求28所述的轻质石膏板，其中以灰泥的重量计，发泡剂的量为约0.1重量%或更少。
30.根据权利要求28所述的轻质石膏板，其中以灰泥的重量计，发泡剂的量为约0.02重量%-约0.03重量%。
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