CN105026142A - 挤出的石膏基材料 - Google Patents

挤出的石膏基材料 Download PDF

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CN105026142A
CN105026142A CN201480012711.9A CN201480012711A CN105026142A CN 105026142 A CN105026142 A CN 105026142A CN 201480012711 A CN201480012711 A CN 201480012711A CN 105026142 A CN105026142 A CN 105026142A
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CN105026142B (zh
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埃文·R·丹尼尔斯
P·J·安德森
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INTELLECTUAL GORILLA BV
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Abstract

由混合物形成的可挤出的石膏基材料，所述混合物包含：以干重百分比计约40至90％的石膏、以干重百分比计约0.1至50％的第二材料、以干重百分比计约1至20％的增强纤维、以干重百分比计约0.5至10％的流变改性剂、以干重百分比计约0.1至8％的缓凝剂、占总的湿材料重量10至50％的水。

Description

挤出的石膏基材料
发明领域
本发明一般涉及石膏基材料的生产，以及更特别地涉及通过挤出石膏基材料制备的产品(例如，屋面瓦、墙板等)。
背景技术
石膏产品一般是使用大量的水形成浆料来生产的，所述浆料太湿而不能挤出。因此，已经开发了各种减水要素来降低含水量，使得可以使用挤出方法生产石膏基材料。例如，参见第7,172,403号美国专利，将其整体引入本文作为参考。
然而，仍然需要可以被挤出的流变学改性的石膏基材料(例如，屋面瓦、墙板等)。
发明概述
本发明提供了可以被挤出的流变学改性的石膏基材料(例如，屋面瓦、墙板等)。
更具体地，本发明提供了可挤出的石膏基材料，所述石膏基材料是由包含以干重百分比计约40至90％的石膏、以干重百分比计约0.1至50％的第二材料、以干重百分比计约1至20％的增强纤维、以干重百分比计约0.5至10％的流变改性剂、以干重百分比计约0.1至8％的缓凝剂、占总的湿材料重量10至50％的水的混合物形成的。
另外，本发明提供了通过以下步骤制造可挤出的石膏基材料的方法：将石膏、第二材料、增强纤维、流变改性剂和缓凝剂与水混合；使用挤出机将混合物通过模具挤出；以及使挤出的混合物凝固。
附图的简要说明
为了更充分理解本发明的特征和优点，现在请参考本发明的详细说明以及附图，其中：
不适用。
发明详述
虽然以下详细地讨论了本发明的各种实施方案的形成和使用，然而应该理解的是，本发明提供了多种适用的发明构思，所述发明构思可以在各种各样的具体上下文中体现。本文中讨论的具体实施方案仅说明了形成和使用本发明的具体方式，而不是界定本发明的范围。
如以下将描述的，本发明提供了可挤出的石膏基材料，所述石膏基材料是由包含以干重百分比计约40至90％的石膏、以干重百分比计约0.1至50％的第二材料、以干重百分比计约1至20％的增强纤维、以干重百分比计约0.5至10％的流变改性剂、以干重百分比计约0.1至8％的缓凝剂、占总的湿材料重量10至50％的水的混合物形成的。
凝固之前，湿状态的石膏(熟石膏(Plaster of Paris)，半水合硫酸钙)可以从流变学上被改性为粘土样材料，这样能够使用被称为挤出的常规粘土制备方法。
为了挤出，制备感觉和行为与可塑粘土相似的、具有大约10-50wt.％的水和适当的流变改性掺和剂(admixture)的石膏材料。所述材料的触摸感觉是可塑的/可变形的，并且可以使用粘土挤出机与粘土类似地被挤出，在粘土挤出机中，所述材料被螺旋钻向前传送通过筒并连续地通过模具成形为具有形状稳定性的最终形状。
根据含水量和流变改性掺和剂的量，挤出的材料可以具有更高或更低的形状稳定性。
为了在凝固(硬化)之前允许有足够的时间挤出石膏基材料，在使用微量添加的合适缓凝剂例如SodateTM(USG产品)或柠檬酸钠的情况下，凝固时间可以被延迟达数小时。SodateTM是熟石膏、柠檬酸钠和结晶二氧化硅的混合物。挤出之后，所述材料将在数小时内达到成品的最终强度。
石膏可以用作与诸如沙、水泥、飞灰、炉渣、岩石、玻璃纤维、塑料纤维、聚乙烯醇(PVA)纤维、膨胀的轻质骨料等或其组合的多种材料结合的、复合材料组合物中的含水的粘合剂，当在流变学上改性时，其可以如上所述地被挤出。
所述流变改性剂落入以下类别：(1)多糖及其衍生物；(2)蛋白质及其衍生物；以及(3)合成的有机材料。多糖流变改性剂可以进一步被细分为：(a)纤维素基材料及其衍生物，(b)淀粉基材料及其衍生物和(c)其它多糖。
合适的纤维素基流变改性剂包括，例如甲基羟乙基纤维素(MHEC)、羟甲基乙基纤维素(HMEC)、羧甲基纤维素(CMC)、甲基纤维素(MC)、乙基纤维素(EC)、羟乙基纤维素(HEC)、羟乙基丙基纤维素(HEPC)或羟丙基甲基纤维素(HPMC)等。
合适的淀粉基材料包括，例如，小麦淀粉、预胶凝的小麦淀粉、马铃薯淀粉、预胶凝的马铃薯淀粉、支链淀粉、直链淀粉、海凝胶(seagel)、淀粉醋酸酯、淀粉羟乙基醚、离子淀粉、长链烷基淀粉、糊精、氨基淀粉、磷酸酯淀粉和双醛淀粉。
普遍优选的流变改性剂为甲基羟丙基纤维素，其实例为MethocelTM240和MethocelTM 240S，两者购自美国的DOW化学。
在本发明的一个实施方案中，石膏基材料的组成范围可以为：
所述石膏可以为以重量计40％、41％、42％、43％、44％、45％、44％、47％、48％、49％、50％、51％、52％、53％、54％、55％、55％、57％、58％、59％、60％、61％、62％、63％、64％、65％、66％、67％、68％、69％、70％、71％、72％、73％、74％、75％、76％、77％、78％、79％、80％、81％、82％、83％、84％、85％、86％、87％、88％、89％或90％或其之间的其它的增量百分比(incremental percentage)。
水可以为以重量计10％、11％、12％、13％、14％、15％、16％、17％、18％、19％、20％、21％、22％、23％、24％、25％、26％、27％、28％、29％、30％、31％、32％、33％、34％、35％、36％、37％、38％、39％、40％、41％、42％、43％、44％、45％、44％、47％、48％、49％或50％或其之间的其它的增量百分比。
第二材料可以为以重量计0.1％、1％、2％、3％、4％、5％、6％、7％、8％、9％、10％、11％、12％、13％、14％、15％、16％、17％、18％、19％、20％、21％、22％、23％、24％、25％、26％、27％、28％、29％、30％、31％、32％、33％、34％、35％、36％、37％、38％、39％、40％、41％、42％、43％、44％、45％、44％、47％、48％、49％或50％或其之间的其它的增量百分比。
增强纤维可以为以重量计1％、2％、3％、4％、5％、6％、7％、8％、9％、10％、11％、12％、13％、14％、15％、16％、17％、18％、19％或20％或其之间的其它的增量百分比。
流变改性剂可以为以重量计0.5％、0.6％、0.7％、0.8％、0.9％、1.0％、1.1％、1.2％、1.3％、1.4％、1.5％、1.6％、1.7％、1.8％、1.9％、2.0％、2.1％、2.2％、2.3％、2.4％、2.5％、2.6％、2.7％、2.8％、2.9％、3.0％、3.1％、3.2％、3.3％、3.4％、3.5％、3.6％、3.7％、3.8％、3.9％、4.0％、4.1％、4.2％、4.3％、4.4％、4.5％、4.6％、4.7％、4.8％、4.9％、5.0％、5.1％、5.2％、5.3％、5.4％、5.5％、5.6％、5.7％、5.8％、5.9％、6.0％、6.1％、6.2％、6.3％、6.4％、6.5％、6.6％、6.7％、6.8％、6.9％、7.0％、7.1％、7.2％、7.3％、7.4％、7.5％、7.6％、7.7％、7.8％、7.9％、8.0％、8.1％、8.2％、8.3％、8.4％、8.5％、8.6％、8.7％、8.8％、8.9％、9.0％、9.1％、9.2％、9.3％、9.4％、9.5％、9.6％、9.7％、9.8％、9.9％、10.0％或其之间的其它的增量百分比。
缓凝剂可以为以重量计0.1％、0.2％、0.3％、0.4％、0.5％、0.6％、0.7％、0.8％、0.9％、1.0％、1.1％、1.2％、1.3％、1.4％、1.5％、1.6％、1.7％、1.8％、1.9％、2.0％、2.1％、2.2％、2.3％、2.4％、2.5％、2.6％、2.7％、2.8％、2.9％、3.0％、3.1％、3.2％、3.3％、3.4％、3.5％、3.6％、3.7％、3.8％、3.9％、4.0％、4.1％、4.2％、4.3％、4.4％、4.5％、4.6％、4.7％、4.8％、4.9％、5.0％、5.1％、5.2％、5.3％、5.4％、5.5％、5.6％、5.7％、5.8％、5.9％、6.0％、6.1％、6.2％、6.3％、6.4％、6.5％、6.6％、6.7％、6.8％、6.9％、7.0％、7.1％、7.2％、7.3％、7.4％、7.5％、7.6％、7.7％、7.8％、7.9％或8.0％或其之间的其它的增量百分比。
另外，本发明提供了通过以下步骤制造可挤出的石膏基材料的方法：将石膏、第二材料、增强纤维、流变改性剂和缓凝剂与水混合；使用挤出机将所述混合物通过模具挤出；以及使挤出的混合物凝固(例如，最长2至3小时等)。
另外的步骤可以包括：(1)干燥挤出的混合物；(2)固化挤出的混合物；(3)将挤出的混合物模塑、切割、修剪、砂磨或镂铣成规定的形状(例如，屋面瓦、墙板等)；(4)使用防水剂喷涂挤出的混合物；和/或(5)通过在一个或多个表面上印刷至少一种图像、在一个或多个表面上层压饰面、或者在一个或多个表面上刻蚀至少一种图像来装饰挤出的混合物的一个或多个表面。
屋面瓦
石膏基屋面瓦可以由含水(16-25wt.％)的湿状态下的、已经在流变学上改性从而具有粘土样性质的熟石膏(半水合硫酸钙)生产。
屋面瓦可以以粘土和混凝土技术领域中已知的多种方式生产：
1)使用粘土挤出机通过模具挤出而成为屋面瓦的最终形状。
2)使用粘土挤出机通过模具挤出而成为厚度等于或大于瓦片的最终厚度以及宽度允许为一个或多个瓦片宽度的片。通过将所述片在垂直压力下置于下半模之上，或者运行所述片通过成形压延机来将所述片成形为最终瓦片的形状。
3)在垂直压力或类似方式下在下模和上模之间挤出随后成形为最终瓦片形状的材料的圆柱形块。
4)通过混合流变改性的材料和将随后成形为最终瓦片形状的精确计量的材料块在垂直压力或类似方式下置于下模和上模之间。
在数小时内凝固之后，在炉中干燥屋面瓦。通常地，屋面瓦将具有5mm至40mm的厚度。
通过添加纤维增强物，例如，纤维素纤维、玻璃纤维、聚丙烯纤维、聚乙烯醇(PVA)纤维、德兰尼特纤维(Dolanit fiber)或类似物或其组合，来改变机械性能，从而产生延展性(非脆性)材料。
通过使用目前技术水平中已知的防水硅烷或抗水表面涂层处理产品的表面，从而将瓦片制成抗水的。可以通过在复合材料组合物中加入微球囊来实现抗冻融性(Freeze-Thaw resistance)。
与目前技术水平的屋面瓦相比，本发明的屋面瓦更轻、更薄、更加易延展、更耐用并且更便宜。
墙板
石膏基墙板可以由含水(16-25wt.％)的湿状态下的、已经在流变学上改性从而具有粘土样性质的熟石膏(半水合硫酸钙)生产。
用于卫生间隔间内部通道走廊的墙壁是由使用石膏(熟石膏，半水合硫酸钙)作为粘合剂的复合材料制成的。
石膏凝固之前的湿状态下的复合材料被在流变学上改性成粘土样材料，这样能够使用称为被挤出的常规粘土制备方法来形成墙壁的形状。
可以调配复合材料的组成，使得墙壁：重量轻、密实、耐火、耐噪音、耐用和无脆性。通常地，墙板将具有5mm至250mm的厚度。
在制成品凝固和干燥之后，可以使用硅烷或表面涂层将墙元件表面制成抗水的。进一步地，可以通过在表面上印刷、通过将饰面层压到表面上或者在表面上印刷"Nerewood"来装饰表面。例如，名称为“生产在至少一个表面上具有图像的木质基底的方法(Method for Producing a WoodSubstrate Having an Image on at Least One Surface)”的第6,964,722号美国专利或者第61/713,240号美国专利申请和名称为“生产在至少一个表面上具有图像的木质基底的方法”的第PCT/US2013/064435号PCT专利申请，将它们整体引入本文作为参考。
可以理解的是，本文描述的具体实施方案是通过说明的方式显示的，并不作为对本发明的限制。在不脱离本发明范围的情况下，可以在各种实施方案中采用本发明的主要特征。本领域技术人员将认识到或仅仅使用常规实验就能够确定本文描述的具体过程的多种等同方式。这样的等同方式被认为在本发明的范围内，并为权利要求所涵盖。
在说明书中提及的所有出版物、专利和专利申请显示本发明所涉及的领域中的技术人员的技术水平。将所有出版物、专利和专利申请引入本文作为参考，其程度如同具体地和单独地表明将每个单独的出版物、专利或专利申请引入本文作为参考。
词语“一个(a)”或“一个(an)”当在权利要求和/或说明书中与术语“包括”联合使用时，可以指“一个(one)”，但其也与“一个或多个”、“至少一个”和“一个或多于一个”的含义一致。在权利要求中，术语“或”的使用是用于指“和/或”，除非明确表明仅指代供选择的方案，或供选择的方案是互相排斥的，但是本发明支持仅指代供选择的方案和“和/或”的定义。在本申请中，术语“约”用来指这样的值，其包括针对装置、用于测定该值的方法或研究受试者中存在的变化的误差的固有变化。
如在本说明书和权利要求(或多个权利要求)中所使用的，词语“包含(comprising)”(和包含的任何形式，如“包含(comprise)”和“包含(comprises)”)、“具有(having)”(和具有的任何形式，如“具有(have)”和“具有(has)”)、“包括(including)”(和包括的任何形式，如“包括(includes)”和“包括(include)”)或“含有(containing)”(和含有的任何形式，如“含有(contains)”和“含有(contain)”)是包括性的或开放式的，不排除另外的未列举的元素或方法步骤。
如本文所使用的术语“或其组合”是指在该术语前所列项目的所有排列和组合。例如，“A、B、C或其组合”旨在包括以下中的至少一个：A、B、C、AB、AC、BC或ABC，并且如果在具体上下文中顺序是重要的，还包括BA、CA、CB、CBA、BCA、ACB、BAC或CAB。继续该实例，明确包括的是包含一个或多个项目或条款的重复的组合，如BB、AAA、AB、BBC、AAABCCCC、CBBAAA、CABABB等。技术人员将理解通常任意组合的项目或条款的数量没有限制，除非从上下文中明显可见。
根据本发明，本文公开和要求保护的所有组合物和/或方法可以在不进行过度实验的情况下形成或实施。虽然以优选的实施方案描述了本发明的组合物和方法，但对于本领域技术人员明显的是，在不脱离本发明的构思、精神和范围的情况下，变化可以适用于本文所描述的组合物和/或方法以及方法的步骤或步骤的顺序中。对本领域技术人员明显的是所有这些类似的替代和改变被视为在所附权利要求所限定的本发明的精神、范围和构思内。

Claims (27)

1.由混合物形成的可挤出的石膏基材料，所述混合物包含：
以干重百分比计约40至90％的石膏；
以干重百分比计约0.1至50％的第二材料；
以干重百分比计约1至20％的增强纤维；
以干重百分比计约0.5至10％的流变改性剂；
以干重百分比计约0.1至8％的缓凝剂；
占总的湿材料重量10至50％的水；以及
所述混合物是可挤出的。
2.根据权利要求1所述的可挤出的石膏基材料，所述第二材料包括沙、水泥、飞灰、炉渣、岩石、玻璃纤维、塑料纤维、聚乙烯醇(PVA)纤维、膨胀的轻质骨料或其组合。
3.根据权利要求1所述的可挤出的石膏基材料，所述增强纤维包括纤维素纤维、玻璃纤维、聚丙烯纤维、聚乙烯醇(PVA)纤维、德兰尼特纤维(Dolanit fiber)或其组合。
4.根据权利要求1所述的可挤出的石膏基材料，所述流变改性剂包括多糖、多糖衍生物、蛋白质、蛋白质衍生物、合成的有机材料、合成的有机材料衍生物或其组合。
5.根据权利要求4所述的可挤出的石膏基材料，所述多糖包括纤维素基材料、纤维素基材料衍生物、淀粉基材料、淀粉基材料衍生物或其组合。
6.根据权利要求5所述的可挤出的石膏基材料，所述纤维素基材料选自基本上由甲基羟乙基纤维素(MHEC)、羟甲基乙基纤维素(HMEC)、羧甲基纤维素(CMC)、甲基纤维素(MC)、乙基纤维素(EC)、羟乙基纤维素(HEC)、羟乙基丙基纤维素(HEPC)和羟丙基甲基纤维素(HPMC)组成的群组。
7.根据权利要求5所述的可挤出的石膏基材料，所述淀粉基材料选自基本上由小麦淀粉、预胶凝的小麦淀粉、马铃薯淀粉、预胶凝的马铃薯淀粉、支链淀粉、直链淀粉、海凝胶(seagel)、淀粉醋酸酯、淀粉羟乙基醚、离子淀粉、长链烷基淀粉、糊精、氨基淀粉、磷酸酯淀粉和双醛淀粉组成的群组。
8.根据权利要求1所述的可挤出的石膏基材料，所述缓凝剂包括柠檬酸钠，或熟石膏、柠檬酸钠和结晶二氧化硅的混合物。
9.根据权利要求1所述的可挤出的石膏基材料，其中，水的范围为总的湿材料重量的16至25％。
10.一种制备可挤出的石膏基材料的方法，所述方法包括步骤：
将石膏、第二材料、增强纤维、流变改性剂和缓凝剂与水混合；
使用挤出机将混合物通过模具挤出；以及
使挤出的混合物凝固。
11.根据权利要求10所述的方法，所述混合物包括：
以干重百分比计约40至90％的石膏；
以干重百分比计约0.1至50％的第二材料；
以干重百分比计约1至20％的增强纤维；
以干重百分比计约0.5至10％的流变改性剂；
以干重百分比计约0.1至8％的缓凝剂；和
占总的湿材料重量10至50％的水。
12.根据权利要求10所述的方法，所述第二材料包括沙、水泥、飞灰、炉渣、岩石、玻璃纤维、塑料纤维、聚乙烯醇(PVA)纤维、膨胀的轻质骨料等或其组合。
13.根据权利要求10所述的方法，所述增强纤维包括纤维素纤维、玻璃纤维、聚丙烯纤维、聚乙烯醇(PVA)纤维、德兰尼特纤维或其组合。
14.根据权利要求10所述的方法，所述流变改性剂包括多糖、多糖衍生物、蛋白质、蛋白质衍生物、合成的有机材料、合成的有机材料衍生物或其组合。
15.根据权利要求14所述的方法，所述多糖包括纤维素基材料、纤维素基材料衍生物、淀粉基材料、淀粉基材料衍生物或其组合。
16.根据权利要求15所述的方法，所述纤维素基材料选自基本上由甲基羟乙基纤维素(MHEC)、羟甲基乙基纤维素(HMEC)、羧甲基纤维素(CMC)、甲基纤维素(MC)、乙基纤维素(EC)、羟乙基纤维素(HEC)、羟乙基丙基纤维素(HEPC)和羟丙基甲基纤维素(HPMC)组成的群组。
17.根据权利要求15所述的方法，所述淀粉基材料选自基本上由小麦淀粉、预胶凝的小麦淀粉、马铃薯淀粉、预胶凝的马铃薯淀粉、支链淀粉、直链淀粉、海凝胶、淀粉醋酸酯、淀粉羟乙基醚、离子淀粉、长链烷基淀粉、糊精、氨基淀粉、磷酸酯淀粉和双醛淀粉组成的群组。
18.根据权利要求10所述的方法，所述缓凝剂包括柠檬酸钠，或熟石膏、柠檬酸钠和结晶二氧化硅的混合物。
19.根据权利要求10所述的方法，其中，水的范围为总的湿材料重量的16至25％。
20.根据权利要求10所述的方法，其中，使所述挤出的混合物凝固最长2至3小时。
21.根据权利要求10所述的方法，还包括固化所述挤出的混合物的步骤。
22.根据权利要求10所述的方法，还包括干燥所述挤出的混合物的步骤。
23.根据权利要求10所述的方法，还包括将所述挤出的混合物模塑、切割、修剪、砂磨或镂铣成规定的形状的步骤。
24.根据权利要求23所述的方法，其中，所述规定的形状包括屋面瓦或墙板。
25.根据权利要求24所述的方法，其中：
所述屋面瓦的厚度为约5mm至250mm；以及
所述墙板的厚度为约5mm至40mm。
26.根据权利要求10所述的方法，还包括使用防水剂喷涂所述挤出的混合物的步骤。
27.根据权利要求10所述的方法，还包括通过在一个或多个表面上印刷至少一种图像、或者在一个或多个表面上层压饰面或者在一个或多个表面上刻蚀至少一种图像来装饰所述挤出的混合物的一个或多个表面的步骤。
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