CN1069573C - 制备泡沫石膏产品的方法 - Google Patents

制备泡沫石膏产品的方法 Download PDF

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CN1069573C
CN1069573C CN96192104A CN96192104A CN1069573C CN 1069573 C CN1069573 C CN 1069573C CN 96192104 A CN96192104 A CN 96192104A CN 96192104 A CN96192104 A CN 96192104A CN 1069573 C CN1069573 C CN 1069573C
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斯蒂文·W·萨克奇
布拉德利·S·内梅斯
斯图尔特·E·欣肖
基普·R·布斯特
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28CPREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/02Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions without using driven mechanical means effecting the mixing
    • B28C5/06Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions without using driven mechanical means effecting the mixing the mixing being effected by the action of a fluid
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28CPREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/08Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions using driven mechanical means affecting the mixing
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    • B28C5/1269Mixing in containers not actuated to effect the mixing with stirrers sweeping through the materials, e.g. with incorporated feeding or discharging means or with oscillating stirrers for materials flowing continuously through the mixing device and with incorporated feeding or discharging devices for making cellular concrete
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28CPREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C7/00Controlling the operation of apparatus for producing mixtures of clay or cement with other substances; Supplying or proportioning the ingredients for mixing clay or cement with other substances; Discharging the mixture
    • B28C7/16Discharge means, e.g. with intermediate storage of fresh concrete
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, 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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    • C04B28/14Compositions 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
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
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Abstract

本发明提供一种改进型的制备泡沫石膏产品的方法与装置。本发明采用单个混合室(10)。在本发明的方法与装置中,把含水泡沫引入烧石膏稀浆中的那个点是定位的,以便泡沫比烧石膏所受搅拌少,从而使泡沫破坏得最少,同时还使泡沫在烧石膏稀浆中均匀散布。这是例如把泡沫所用入口(32)比烧石膏所用入口(20)位置定得更靠近稀浆混合室的排放出口(40)来实现,或把泡沫入口(32、34、36),定位于与稀浆混合室的排放出口相连接的排放管道(42、46、48)中来实现的。

Description

制备泡沫石膏产品的方法
本发明涉及用烧石膏(即硫酸钙半水合物或硬石膏)与水组成的原料制备石膏产品(即硫酸钙二水合物构成的产品)的方法与装置。具体地说,本发明涉及制备泡沫石膏产品(即由于在原料中混有含水泡沫而使其中均匀地分布着空洞的轻质石膏产品)的改进型方法与装置。
众所周知,生产石膏产品,其方法是把烧石膏均匀地散布在水中以形成稀浆,然后把稀浆浇注在合要求的型模上或某一表面上,并通过烧石膏(硫酸钙半水合物或硬石膏)与水发生反应形成水合石膏(硫酸钙二水合物)而使稀浆定形成硬结的石膏。另外还众所周知的是,生产轻质石膏产品,其方法是把含水泡沫均匀地混入稀浆中以在其中产生气泡。如果在硬结的石膏形成之前气泡不逸出稀浆之外,定形的石膏产品中就会均匀地分布着空洞。这些空洞减小最终产品的密度,这种产品通常被称为“泡沫石膏”。
在这种方法中所用的含水泡沫,通常是在刚刚要将它介入烧石膏稀浆之前来制备。典型的配法,是把一种合适的发泡剂(有许多发泡剂都是众所周知的)混上水,然后使混合物经过一个把混合物与空气加以搅拌以产生含水泡沫的装置。完成这个过程的装置是众所周知的,它通常被称为“起泡器”。
合成的泡沫,由于其气泡开始破灭,或由于气泡彼此聚结成更大的气泡继而地破灭,仅能较短时地存在。相应地,最好使泡沫以持续方式产生,在这种方式下,发泡剂与水的混合流被导向起泡器,而且离开起泡器的合成含水泡沫流,被导向烧石膏稀浆并与其混合。
稀浆本身通常也是以持续方式产生的,即把烧石膏与水(合乎要求时还有含水泡沫),引入其中有把内装物体搅拌成均匀的水化分散体(稀浆)的装置这样一个混合室中。分散体被导向并穿过该混合室的排放出口,并进入一条与排放出口相连的排放管道中。稀浆流穿过排放管道,从那儿被持续地浇注进一个模子中或浇注在一个表面上。模子或表面也是持续地穿过稀浆从排放管道中被浇注出来的那个位置而移动。稀浆在移动的模子中或在移动的表面上时,由于水合作用而被定形为硬结的石膏产品。该产品随即通常被引导穿过一个轻度加热区(例如一个干燥器),以便把水合作用没有吸收的任何多余水份加速烘干。
在这种方法中,存在着一些与混合含水泡沫相关的问题,其中有些牵涉到有争议的见解。
如前所述,当含水泡沫的气泡形成不久之后,尤其是当它们开始与烧石膏稀浆接触时,这些气泡就要开始破灭,或聚结起来并破灭。即使在上述发泡剂已产生了泡沫而形成所谓“坚韧”泡沫或“稳定”泡沫时,也是如此。因此,使产生泡沫与形成硬结石膏之间的时间周期(它持久地使泡沫在石膏中产生的空洞存留)最短,看来是有益的。
人们也都知道,产生较高剪切力的搅拌情形,能加速被引入水化烧石膏稀浆中的含水泡沫的气泡的聚结与逸散,且聚结本身能导致气泡及合成空洞的形状与分布都不均匀。所以,限制泡沫在稀浆中所遇剪切力的程度,看来可能是有益的。
另一方面,与上述见解相抗争,有人认为在配有典型搅拌装置的典型混合室里,必须有相当大程度的搅拌,才足以使含水泡沫在烧石膏稀浆里均匀分布。但是,这种相当大程度的搅拌,会导致以上提到的问题。(此处所用的“搅拌”这个词。总的来说指的是在被“搅拌”的原料经历剪切力的作用下这种剪切力与时间耗用的结合;例如,说一种原料经受“较高程度”或“较大量”的“搅拌”,是指该原料正经受较高强度的剪切力和/或正经受某种强度的剪切力一个较长的时间周期。)
因此,在带有烧石膏稀浆的混合室里相当大程度地搅拌泡沫,已被认为对于避免非均匀分布的问题是必须的,但是,这种相当大的搅拌,也会引起泡沫丧失、气泡与空洞的大小不均匀这些问题。
试图达到某一程度的搅拌以平衡这些有争议的见解的一个方法,就是建立一个接连有两个混合室的系统。也就是说,要把石膏和水加到提供较高程度搅拌的第一混合室中,以达到使烧石膏与水充分均匀的散布,然后,把室内物体排放给加了含水泡沫的第二混合室。第二混合室向混合物提供较低程度的搅拌,可望足以使泡沫在稀浆中比较均匀地散布,同时,又不更多损坏泡沫,或不产生比起不可避免的气泡大小变化更大的任何变化。这种方法,在1994年9月7日公开的欧洲专利申请公开文本第0613764 A1号中,说明了一个例子。然而,这种方法还是有问题。它依然会产生比较不均匀的泡沫散布和/或比较大的泡沫丧失及空洞大小不均匀。它还要求额外增加经费,并加大复杂性,而且难以提供两个混合室并维修它们,也难以保持它们正常地且充分平衡得达到比较可接受的妥协效果地运行。
对有争议的见解提出的另一个方法,就是增大发泡剂及加入一个由单混合室构成的系统中的合成泡沫这二者的份量。然后,以达到均匀散布所必需的任何程度的搅拌来运行该系统。由于加入了过量的泡沫,可望使石膏产品会有合乎要求的空洞体积及减够了量的重量。然而,比较高度的搅拌,依然会引起不可预料的聚结及随之而来的空洞大小不均匀,而且过量消耗发泡剂花费相当昂贵。在稀浆中高浓度的发泡剂化学物品。对石膏产品的其他特性也会产生负面影响。这样,又反过来会限制所能利用的发泡剂的数量,在有些情况下就不可能达到产品所要求的空洞体积数量。
另外,当要求使用含水泡沫以使重量较轻时,某些特殊的石膏产品及其制造就出现另外一些问题。
例如,当借助泡沫来减小石膏板产品的密度时,长久以来人们都关心石膏的强度是否相应降低。长久以来人们认为,要使石膏中空洞的尺寸尽可能小,泡沫石膏板的强度会被降到最低。最近人们发现,在石膏中含有较大尺寸的空洞,实际上泡沫石膏的强度保持得最好。例子可见美国专利第5085929号及1994年9月23日提出的共同未决的美国专利申请第08/311687号。
在泡沫石膏中产生较大空洞的一种方式,是利用一种发泡剂,它产生的气泡在与烧石膏稀浆接触时是“不稳定”的,即这些气泡在稀浆中很快开始聚结成较大的气泡。然而,这种不稳定的泡沫,在经受人们认为在稀浆中均匀散布泡沫所必需的典型混合室搅拌时,却遇到更厉害的上述泡沫丧失问题。这样,就导致需用更加过量的泡沫,花费更加昂贵,而且在有些情况下,致使不能用足够的发泡剂,以产生不会负面影响石膏产品其他特性的足够的残存泡沫。这个问题,可在使用产生“不稳定”泡沫的发泡剂时合用少量产生“稳定”泡沫的发泡剂来多少缓解一下(例如共同未决的美国专利申请08/311687号所述那样),但是,发泡剂的总用量,比起合乎要求的来依然较大。
生产石膏板尤其会遇到的另一个问题,是生产硬边板的方法。例如美国专利第2985219号与第4279673号所述,由于各种原因,按要求要生产的板的边缘比中部(通常称为“芯”部)更紧密也更硬。这两件专利说明了这种生产的各种方法。例如,使一部分起了泡的稀浆从主要的“芯”稀浆混合室中转向,然后,在一个或几个高度搅拌并/或带有除泡剂的附属混合器中分别处理转了向的这部分,以将所有或大多数泡沫去除,从而,产生要在两条液流中与被浇注的“芯”稀浆流的侧面接触而被浇注的更硬、更紧密的“边”稀浆。这样就制成有更硬更紧密的理想边缘的石膏板产品,但是却要求外加成本,并因多加混合器及化学物品而复杂了。实际上,这样还浪费从边缘稀浆中去除的泡沫,并浪费用于产生泡沫的发泡剂及其效果。
因此,持续需要有新颖而改进的方法与装置来制备泡沫石膏产品,以解决、避免或最大程度消除上述所有问题。本发明符合这种需要。
本发明出人意料地发现,在应用带有搅拌稀浆的典型装置的典型石膏稀浆混合室这样的石膏制备方法中,泡沫丧失及气泡大小不均匀这种问题可以大大缓解,同时仍可达到泡沫在稀浆中均匀散布,办法是把泡沫入口定位于室中,从而在泡沫穿过排放出口排放之前,泡沫比起其他稀浆来经受较少的搅拌。本发明完全避免了涉及两个混合室的那种先前工艺方法所带来的花费昂贵、复杂性及其他困难。同时,又可达到相似或更好的结果。本发明也避免了先前工艺方法添加过量发泡剂以弥补由于高度搅拌所丧失的泡沫而带来的问题。本发明不用(浪费)更多发泡剂就减少泡沫丧失,因此就避免了额外追加费用,并避免了发泡剂浓度高产生的负作用。另外,由于泡沫所受搅拌较少,产生气泡大小不均匀的机会也减少了。而且,这些有益的效果,在使用“不稳定”泡沫产生合要求的更大尺寸气泡的情况下,更加显著。
所以,在本发明的一些实施例中,提供一种制备泡沫石膏产品的方法,它连续而同时地包括:把烧石膏与水通过混合室的一个或几个入口引入混合室;搅拌混合室内容物以形成烧石膏的水化分散体;把含水泡沫通过一个相对于石膏与水的入口吸相对于混合室排放出口而定位的入口引入混合室,以便泡沫比烧石膏所受搅拌小,从而使泡沫破坏得最少,同时使泡沫在石膏的水分散体中均匀散布;通过排放出口排放混合室内容物,使烧石膏形成其中均匀散布着空洞的凝固石膏。
在典型的稀浆混合室中,本发明显著的有益效果,是通常仅需把泡沫入口位置定得比烧石膏与水的入口“更靠近”排放出口,就能达到。我们用“更靠近”,指的是由混合室的形状与结构以及由室中所设典型的搅拌装置所形成的混合室内容物的路径,从泡沫入口至排放出口,比烧石膏稀浆其他部分的入口至排放出口,要短一些。当然,各种入口精确的相对定位,都必须按任何专门的混合装置与稀浆配方的要求来定制,以达到最优结果,不过,一旦本行业专业人员得知本发明公开的基本原理与优点,定制就是他们的事了。
根据本发明,适宜施行上述本发明的方法的装置,包括一个通常为筒形的混合室,它有一根通常为垂直的轴线,有径向的上壁和下壁以及环形周边壁,在一个或两个径向壁上贴近垂直轴线处有烧石膏与水所用的一个或几个入口,在环形周边壁上或贴近该壁处有含水泡沫所用的一个入口,在环形周边壁或贴近该壁处有排放室内物体所用的一个出口,还包括用于搅拌室内物体并使这些物体离心运动且通过排放出口而排出的装置。除了石膏、水、泡沫所用的各入口的相对定位之外,此种装置在业界众所周知。
本发明的发明者们还出乎意料且相当惊喜地发现,把泡沫入口再进一步重新定位,即把泡沫入口完全移离混合室而将其位置定得把泡沫直接引入与混合室的排放出口相连的排放管道,能更加有益地施行本发明。排放管道接纳从混合室排出来的烧石膏稀浆(不含泡沫),并进一步把稀浆运送得浇注在模具中或浇注在一个移动的表面上。当泡沫入口连接着排放管道,且泡沫被直接引入排放管道而不是引入稀浆混合室时,泡沫所受搅拌较小。因此,泡沫丧失及气泡大小不均匀这些问题,会进一步得到缓解。非常令人惊喜的是,泡沫这样被直接引入排放管道,会产生足够的混合作用,从而在排放管道运送的所有石膏稀浆里均匀地散布泡沫。
因此,在本发明的一些更推崇的实施例里,提供一种制备泡沫石膏产品的方法,它连续而同时地包括:通过一个或几个入口把烧石膏与水引入混合室;搅拌混合室内容物以形成烧石膏的水分散体;通过一个排放出口把混合室内容物排入排放管道中;通过一个入口把含水泡沫引入排放管道,以便泡沫被微微搅拌,从而使泡沫破坏得最少,同时在水化烧石膏分散体中均匀地散布泡沫,把得到的分散体从排放管道中排出,以使烧石膏形成其中均匀散布着空洞的凝固石膏。
根据本发明,适宜施行本发明更推崇实施例方法的装置,包括一个通常为筒形的混合室,它有一根通常为垂直的轴线,有径向的上壁和下壁以及环形周边壁,在一个或两个径向壁上贴近垂直轴线处有烧石膏与水所用的一个或几个入口,在环形周边壁上或贴近该壁处有排放室内物体所用的一个出口;还包括一条连接着排放出口以供接纳和运送所排放的室内物体之用的排放管道;还有用于搅拌室内物体并使这些物体离心运动且通过排放出口排放排放管道的装置;以及在排放管道中供含水泡沫所用的入口。除了泡沫入口的定位外,此种装置在业界众所周知。
另外,本发明的发明者们已发现,本发明在制备有硬边的泡沫石膏板时用起来能更有益。发明者们已认识到,在施行本发明时,在稀浆混合室中,要有些区域包含混合良好的烧石膏稀浆,但不怎么包含或不包含泡沫(依泡沫入口是否已在混合室中或在排放管道中定了位而决定)。因此,除了获得上述本发明的所有益处之外,从混合室的低泡或无泡区,能转换出一条或多条“边”流,并能把它们浇注得与从混合室的正常或主要排放出口排放出的“芯”稀浆流的侧边接触。如果合乎要求,一些泡沫也能加给边流,以限制边缘的硬度,但是,这些泡沫的浓度比芯流中的泡沫浓度更低。
因此,在本发明的一些实施例中,提供一种制备有硬边的泡沫石膏板的方法,它连续并同时地包括:混合并搅拌烧石膏与水以形成烧石膏的水分散体;把水分散体分为一条水分散体芯流与一条或几条水分散体边流;把含水泡沫混入芯流中,以便泡沫被微微搅拌,从而使泡沫破坏得最少,同时在水分散体中均匀地散布泡沫;把芯流沉淀在一块移动的盖板上;把那条或那几条边流沉淀在与所沉淀的芯流的一边或两边相邻接的盖板上;用第二块盖板盖住沉淀了的液流;让得到的组件凝固并干燥。
适宜施行所发明的制备硬边泡沫石膏板的方法的发明装置,包括一个通常为筒形的混合室,它有通常为垂直的轴线,还有径向的上壁和下壁以及环形周边壁,在一个或两个径向壁上贴近垂直轴线处有一个或几个烧石膏与水所用的入口,在环形周边壁上或贴近该壁处有至少两个排放室内容物所用的出口;还包括连接着排放出口用以接纳并运送被排放的室内物体的排放管道;还有搅拌室内容物并使这些物体离心运动且通过排放出口排入排放管道的装置;以及在至少一条排放管道中供含水泡沫所用的入口。除了泡沫的入口之外,此种装置在业界众所周知。
以下,参照附图,说明本发明的推荐实施例。在这些图中:
图1是可用以执行本发明方法实施例的、符合本发明装置的片断剖面顶视略图;
图2是沿图1中线段2-2截取绘制成的部分装置的片断剖面侧视略图;
图3是可用以执行本发明方法又一实施例的、符合本发明一个可选用装置的片断剖面顶视略图;
图4是沿图3中线段4-4截取绘制成的部分装置的片断剖面侧视略图。
如前所述,本发明的施行,可采用与先前工艺所用那种制备烧石膏稀浆并排放稀浆以形成凝固石膏产品的装置,相似的装置。本发明的方法与装置,与先前工艺所用那些制备泡沫石膏产品的方法与装置,根本的区别在于把含水泡沫混入烧石膏稀浆的方式与手段。
本发明的方法不同于先前工艺之处是,在比起烧石膏所受搅拌较少搅拌的条件下,把含水泡沫在烧石膏稀浆中均匀地散布,以便避免泡沫丧失、空洞大小不均匀、过度耗费发泡剂。这是在不求助于使用多个混合器的情况下,把含水泡沫引入稀浆中,使之比起此前设想或认为可能的更为告近稀浆排放点,同时依然达到均匀散布而实现的。
本发明提供的装置,与采用先前工艺的装置,根本的区别在于,在稀浆混合室中配置的含水泡沫所用入口,比烧石膏所用入口,更加靠近排放出口,或者,最好使泡沫入口完全定位于混合室外面,即定位于与混合室的排放出口相连接的排放管道中。
本发明的方法与装置二者中,把泡沫最优引入稀浆中的确切点,可以根据所用专门类型的混合装置及稀浆与泡沫的配方而有所不同。该最优点,是泡沫经受刚刚足够的混合作用以均匀地在稀浆中散布的这么一个点。在这个点上,泡沫丧失与气泡大小不均匀这些问题,会被减至最小。
在本发明的一些实施例中,例如采用“不稳定”泡沫的实施例中,本发明的发明者们已发现,泡沫丧失的程度,减至了使发泡剂的耗费可以减少80%。在有些情况下,更大地减少这种耗费都可以。
现在参考图1与图2,说明本发明的一个推荐实施例。这两幅图,稍微精略地分别显示符合本发明的装置的片断剖面顶视图与侧视图。
这两幅图画出一个通常为筒形的混合室10,它有一根通常为垂直的轴线12,还有径向上壁14、径向下壁16及环形周边壁18。
烧石膏所用入口20与水所用入口22,均定位于径向上壁14上的贴近垂直轴线12处。应当明白,这些入口,连接着未显示的石膏与水的供应容器,以便以简单的自重进料方式,能把石膏与水供给混合室10。另外,除了石膏与水之外,制备石膏产品通常在稀浆中所用的其他原料(例如催化剂、缓凝剂、填充剂、粘合剂等等),也能通过这些入口或相似定位的其他入口而供应。
混合室10还包含一个由附接在通常为垂直的轴52上的环形盘54构成的搅拌器50。轴52位置定得与垂直轴线12同心,并穿通径向上壁14而延伸。搅拌器连接着一个未显示的、用以把轴52及所连盘子54沿箭头A所指的逆时针方向旋转的常规装置(例如电机),转速为适宜搅拌并混合混合室内容物并将合成的水化分散体(稀浆)沿通常为离心的方向(大多为逆时针向外盘旋)导引的任何速度。应当明白,此处对搅拌器的绘画相对比较简单,意图仅是标明业界普遍采用于石膏稀浆混合室中的搅拌器的基本原理。也可采用许多有差异的、通常更为复杂的搅拌器设计方案(带有垂直延伸的枢轴或叶片,具有各种不同形状,等等)。
混合室10还有一个与径向壁14相连并向下延伸的圆环圈60。该圈与轴线12同心,它是一个常规零件,有时被称作“聚集圈”。它在室内推助混合作用,并防止原料(例如烧石膏)在被精细地分开并良好散布之前成较大块状地逸出室外。
在周边壁18中,有一个主要排放出口40,用以把良好混合的稀浆的主要部分(“芯流”)排入排放管道42中。在其他可替换实施例中,这个出口可定在不同的位置(例如在径向下壁16上),但通常至少要贴近周边壁18。排放管道42,是配置来把石膏稀浆传送到一个使其被浇注到模具中或浇注到一个移动的表面上以便定形与干燥之用的。如图1所示,排放管道往外就扩宽,这样做适宜把中心(“芯”)部份浇注成例如石膏板产品,当然,它也可以是适宜其他最终产品的其他构形。
在周边壁18中,还有一个辅助排放出口44,用以把良好混合的稀浆的次要部份(“边流”)排入所连接的支岔排放管道46与48中。在某些实施例中,出口44用于把边流分开,但在不需要把稀浆分开为单独的稀浆流的那些实施例中,就没有这个出口。也可把这个出口定在一个不同的位置(例如在径向下壁16上),但通常至少要贴近周边壁18,以便确保仅是良好混合的稀浆才会通过它而排出。排放管道46与48,是配置来把分别不同的石膏稀浆运送了去浇注继而定形与干燥的。如图1所示,这些管道把要被沉淀的稀浆,导引得与众管道42中沉淀出来的芯稀浆流的边缘邻近,以便形成例如泡沫石膏板产品的硬边。当然,在不要求运送任何此种边流的实施例中,就不会有这些管道。
由于图1与图2所示装置中的上述所有零件,对制备石膏产品的业内专业人员显然是一种普通技术,所以,这些零件是众所周知的常规零件。然而,下述零件,就是根据本发明所做的改进了。
在排放管42中,装有一个含水泡沫所用的入口32。这个入口是装配来把常规起泡器(未显示)以常规方式提供和运送的含水泡沫,直接引入排放管42中的。它通常应是符合本发明的装置的推荐构造。如前所述,在排放管中的这个入口的确切定位,应该根据所采用的专门类型的混合装置及稀浆与泡沫的配方来决定。
应当明白,没有把含水泡沫入口定位来直接把泡沫引入混合室10中。因此,从辅助排放出口44排出的稀浆中不会含有泡沫。虽然这样做合乎所提供稀浆能用于生产石膏板的较硬边缘的要求,但是据知,完全不起泡沫的石膏,事实上可以硬得不能优化地用作泡沫芯石膏板的边缘材料(例见美国专利第2985219号)。因此,如图所示,在排放管46与48中,分别安置了入口34与36。这些入口,是配置来把常规起泡器(未显示)以常规方式提供和运送的相对低浓度的含水泡沫,直接引入排入管46与48中的。另外,分别在两个排放管中的这些入口的确切定位,要根据所采用的专门的混合参数及稀浆与泡沫的配方来决定。
尽管图1与图2所示构造,通常是符合本发明的装置的推荐构造,但在某些情况下(例如某些混合装置、混合参数、稀浆配方和/或泡沫配方),直接把含水泡沫引入排放管42,却可能并不提供使泡沫在稀浆中均匀散布的充足混合。在这种情况下,最好采用如图3与图4所示的构造。
图3与图4所示装置,分别具有图1与图2中所有的同样零件与构造,不过,在图3与图4中,含水泡沫所用的入口30,不是安置在排放管42中,而是安在径向上壁14上贴近环形周边壁18处,比起入口20与22(分别为石膏与水所用的入口)来,更加靠近排放出口40得多。有了这种构造,含水泡沫比起烧石膏稀浆的其余部分来,就也会经受明显少的搅拌,这样,泡沫丧失与气泡大小不均匀也都会大大避免,但是这样会使泡沫比起在图1与图2的构造中受到更多的搅拌,以便确保在图1与图2构造中那种可能不足以达到目的的情况下,使泡沫在稀浆中均匀散布。也可选用其他位置的入口30,例如把它安置在环形周边壁上和/或更“上游”(就混合室内容物的行经路径而言),在那里,泡沫也会比起烧石膏稀浆的其余部分来经受明显少的搅拌。
还应当明白,由于泡沫入口30贴近排放出口40,且由于混合室内容物行经路径的缘故,只有极少的泡沫会行进到混合室的其他区域,例如贴近辅助排放出口44的区域。因此,在通过出口44排放的稀浆流中,泡沫的浓度也是极低的。
就适宜产生本发明方法的推荐实施例中可用的含水泡沫的发泡剂而言,已知用于制备泡沫石膏产品的任何常规发泡剂,均可采用。许多这样的发泡剂是众所周知的,并便于从宾夕法尼亚州Ambler的HenkelCorporation买到。对可用的发泡剂的说明,例子可见美国专利第4678835号、第5158612号及第5240639号,还有1994年9月23日提出的共同未决的美国专利申请第08/311687号,以及1995年6月22日公布的PCT国际申请公开文本WO 95/16515号。
如前所述,在许多情况下,最好在石膏产品中形成较大的空洞,以便最佳地保持产品的强度。可以采用在与烧石膏稀浆接触时起泡相对不稳定的发泡剂,来做到这一点。要做到这一点,最好在大量已知起泡相对不稳定的发泡剂中,掺入少量已知起泡相对稳定的发泡剂来用。
这种发泡剂混合物,可以“脱机”预先混掺,即与制备泡沫石膏产品的工序分开。然而,最好同时而连续地混掺这种发泡剂,作为工序的一个“联机”组成部分。例如,实现这部分工序,可以把不同发泡剂的单独各条液流抽吸并带到起泡器上或刚刚带到起泡器之前,该起泡器是用来产生随后被引入烧石膏稀浆中与之混合的含水泡沫流的。通过以此方式掺混,发泡剂的掺混比率就可简单而有效地调节(例如,改变一条或两条单独液流的流率),以达到泡沫石膏产品中所要求的空洞特性。这种调节要与最终产品的检验相对应,以决定这种调节是否需要。关于这种“联机”掺混与调节的进一步说明,可见于1994年9月23日提出的共同未决的美国专利申请第08/311687号。
一种可用于产生不稳定泡沫的发泡剂的一个例子,其分子式为:
ROSO3○M  (Q)
上式中,R为含有2至20个碳原子的烷基化合物,M为阳离子。R最好为含有8至12个碳原子的烷基化合物。
一种可用于产生稳定泡沫的发泡剂的一个例子,其分子式为:
CH3(CH2)xCH2(OCH2CH2)YOSO3M    (J)
上式中,X为一个2至20的数字,Y为0至10且在至少为50wt%的发泡剂中为大于0的数字,M为阳离子。
在本发明的一些推荐实施例中,分子式为上述(Q)式与(J)式的发泡剂掺混在一起,使(Q)分子式发泡剂与其中Y为0的那部分(J)分子式发泡剂掺在一起,构成86wt%至99wt%的混掺发泡剂。
在本发明的一些推荐实施例中,用预先混掺的发泡剂产生出了一种含水泡沫,它的分子式为:
CH3(CH2)xCH2(OCH2CH2)YOSO3M    (Z)
上式中,X为一个2至20的数字,Y为0至10的数字,且在至少50wt%的发泡剂中为0,M为阳离子。在86wt%至99wt%的分子式(Z)发泡剂中,Y最好为0。
在本发明的方法中用作原料的烧石膏,可以是天然的或人工合成的α硫酸钙半水合物、β硫酸钙半水合物、水溶硫酸钙硬石膏,以及它们的混合物。如前所述,除了含水泡沫之外,可以按通行的份量,在烧石膏稀浆中加入其他添加剂,例如凝固催化剂、定形缓凝剂、粘合剂、胶水、助散剂、填充剂以及它们的混合物,以便于赋予合乎要求的各种特性,并促进制造。
在本发明的一个推荐方法中,即在制备带有硬边的泡沫石膏板的方法中,连续而同时地执行下列工序(参见图1与图2)。
通过入口20与22,往混合室10中加入烧石膏(通常为干粒状)与水,以及任何其他合要求的添加剂(含水泡沫除外),它们因搅拌器50的作用而被搅拌并混合成烧石膏稀浆。搅拌器也使稀浆做通常为离心的运动(大多数逆时针的外向盘旋),并使稀浆的主要部分(芯流)从出口40流出并穿过管道42,还使稀浆的次要部分(边流)从出口44流出并穿过管道46与48。
一条由起泡器以空气、水以及如上所述选用的发泡剂而产生的含水泡沫流,被以适宜在稀浆芯流中产生合要求浓度泡沫的流率,通过入口32而抽吸进管道42中。由泡沫流与芯流一起穿过管道42而产生的混合作用(搅拌),刚好足够把泡沫在芯流中均匀地散布,同时还把泡沫的破坏减至最少。含水泡沫被以相似的方式,分别通过入口34与36,抽吸进管道46与48中,但其流率却是适宜使边流中产生的泡沫,浓度明显低于在芯流中产生的泡沫的浓度。
芯流从管道42中被沉淀在一块移动的常规盖板例如一块多层纸板(图中未显示)上。边流则从管道46与48中被沉淀在与芯流的边缘邻近的移动盖板上。在进一步的常规工序(未显示)中,接着把另一块盖板置于芯流与边流合成的稀浆顶部,以便把稀浆夹在两块成为合成石膏板盖面的移动盖板之间。该合成板的厚度由一根成形辊控制,板的侧边被用适宜的机械装置盖住,以便把纸盖板的交错边缘刻痕、折合并胶粘上。当凝结的稀浆在传动带上行进时,另一些导向件保持着板的厚度与宽度。然后,板材就被切割、修边并传给烘干机去烘烤那被定形的但还微微潮湿的板子。
以上专门参考某些推荐实施例,详细说明了本发明,但应当明白,在本发明的宗旨与范围内,可做变动与修改。
关于混合与制备泡沫石膏产品的常规型先前工艺的方法与装置的进一步说明,例子可见美国专利第2639901号、第2762738号、第2985219号、第3343818号和第4279673号,以及1994年9月7日公布的欧洲专利申请公开文本第0613764A1号。

Claims (10)

1.制备泡沫石膏板的方法,连续且并存地包括:
通过混合室的一个或几个入口把烧石膏与水引入一个混合室;
搅拌混合室内容物以形成烧石膏的水分散体;
通过一个相对于石膏与水的入口并相对于混合室的排放出口而定位的入口,把含水泡沫引入混合室,以便泡沫比烧石膏少受搅拌,从而使泡沫破坏得最少,同时在石膏水分散体中均匀地散布泡沫;以及
通过排放出口排放混合室内容物;
把所排放的内容物沉淀在一块移动盖板上;
用第二块盖板盖住所沉淀的物体;以及
使烧石膏成为其中均匀散布着空洞的凝固石膏。
2.根据权利要求1所述的方法,其特征在于:存在于烧石膏分散体中的含水泡沫是不稳定的,形成于凝固石膏中的空洞相对较大。
3.根据权利要求1所述的方法,其中,用下列分子式的发泡剂形成了含水泡沫:
CH3(CH2)xCH2(OCH2CH2)YOSO3M
此式中,X为一个2至20的数字,Y为0至10的数字且在86wt%至99wt%的发泡剂中为0,M为阳离子。
4.制备泡沫石膏板的方法,连续而共存地包括:
通过一个或几个入口把烧石膏与水引入一个混合室;
搅拌混合室内容物以形成烧石膏的水分散体;
通过一个排放出口把混合室内容物排入一条排放管道;
通过一个入口把含水泡沫引入该排放管道,以便泡沫被微微搅拌,从而使泡沫破坏得最少,同时在石膏的水分散体中均匀地散布泡沫;
把得到的分散体从排放管道中排放;
把所排放的分散体沉淀在一块移动盖板上;
用第二块盖板盖住所沉淀的分散体;以及
使烧石膏形成其中均匀散布着空洞的凝固石膏。
5.根据权利要求4所述的方法,其特征在于:存在于烧石膏分散体中的含水泡沫是不稳定的,形成于凝固石膏中的空洞相对较大。
6.根据权利要求4所述的方法,其特征在于:用下列分子式的发泡剂形成了含水泡沫:
CH3(CH2)xCH2(OCH2CH2)YOSO3M
此式中,X为一个2至20的数字,Y为0至10的数字,且在86wt%至99wt%的发泡剂中为0,M为阳离子。
7.制备有硬边的泡沫石膏板的方法,连续而共存地包括:
混合并搅拌烧石膏与水以形成烧石膏的水分散体;
把水分散体分成水分散体的一条芯流与一条或几条边流;
把含水泡沫引入芯流中,以便泡沫被微微搅拌,从而使泡沫破坏得最少,同时在水分散体中均匀地散布泡沫;
把芯流沉淀在一块移动盖板上;
把边流沉淀在与所沉淀芯流的一边或两边相邻近的盖板上;
用第二块盖板盖住所沉淀的液流;以及
使得到的组件凝固并干燥,从而使烧石膏成为凝固石膏,并使由芯流形成的凝固石膏中均匀地散布着空洞。
8.根据权利要求7所述的方法,其特征在于:还连续而并存地包括:
把含水泡沫引入边流中,以便泡沫被微微搅拌,从而使泡沫破坏得最少,同时在水分散体中均匀地散布泡沫;在边流中的泡沫浓度比在芯流中的泡沫浓度低;由边流形成的凝固石膏中均匀分布的空洞,浓度比由芯流形成的凝固石膏中的空洞浓度小。
9.根据权利要求7所述的方法,其特征在于:存在于烧石膏分散体中的含水泡沫是不稳定的,形成于凝固石膏中的空洞相对较大。
10.根据权利要求7所述的方法,其特征在于:用下列分子式的发泡剂形成了含水泡沫:
CH3(CH2)xCH2(OCH2CH2)YOSO3M
此式中,X为一个2至20的数字,Y为0至10的数字且在86wt%至99wt%的发泡剂中为0,M为阳离子。
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