CN113286768A - 制备石膏基产品的方法 - Google Patents
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Abstract
一种制备石膏基产品的方法，包括将煅烧石膏与聚合物颗粒和水混合以提供浆料的步骤。聚合物颗粒主要包括聚乙酸乙烯酯，并且具有使用激光衍射法测量的粒径分布，使得直径为4.5μm或更小的颗粒提供至少90％的总颗粒体积。
Description
技术领域
本发明涉及制备包含聚合物添加剂的石膏基产品的方法，特别是涉及制备包含聚乙酸乙烯酯的石膏基产品的方法。
背景技术
轻质面板，例如石膏板(例如石膏板)、聚苯乙烯板和纤维板通常用于提供建筑物内的隔板(分隔物)。它们在这种应用中的优势包括其重量轻、安装快。
然而，在某些情况下，这种轻质面板可能在将固定装置(例如，螺钉)直接插入面板中时，也就是说，不存在诸如墙壁插头或锚定物的插入物的情况下，具有不够坚固不足以支撑附着物的缺点(例如，水槽、电视、散热器、灭火器、架子和任何其他需要连接到面板的物品)。在这种情况下，附着物的重量可能导致固定装置(例如，螺钉)从面板中拉出，使得附着物从隔板上脱落。
典型地，这个问题已经通过提供胶合板来提高面板的固定强度来解决。在这种情况下，胶合板提供在面板上与附着物所处位置相对的一侧。胶合板可以提供增加的强度以保持一个或多个用于将附着物固定到面板上的固定装置(例如，螺钉)。通常，胶合板放置在隔板框架内，石膏板固定在胶合板上，因此它位于隔板框架的外面。
作为替代，可以提供金属支撑装置。这些可以包括固定板、通道、带子或金属紧固件。与胶合板的情况一样，金属支撑装置通常位于板的与附着物要固定的一侧相对的一侧上，并用于对用于将附着物附接到面板上的固定装置进行接收和固定，例如固定螺钉。
这两种布置的缺点是，它们需要面板和附加支撑部件在现场相互固定。此外，当使用金属支撑装置时，可能需要多个这样的支撑装置来支撑将附着物固定到面板所需的全套固定装置。因此，安装过程可能既耗时又昂贵。
此外，添加金属支撑装置或胶合板增加了隔板的重量和厚度，和/或导致空腔壁空间的减少。一般来说，胶合板本身必须在现场切割成所需尺寸，因此增加了安装所需的时间，并可能导致灰尘和潜在有害成分的释放。
因此，需要提供改进的面板，其能够保持固定装置和支撑附着物，并且不需要耗时的安装过程。
以前，已经发现将聚合物和/或纤维并入纸面石膏板(gypsum plasterboard)的石膏基质中可以有助于增加板的固定强度。通常，将聚合物和/或纤维组分混合到用于形成石膏板的石膏浆料中。
令人惊讶的是，现已发现，在聚乙酸乙烯酯并入石膏基产品的石膏基质中的情况下，如果聚乙酸乙烯酯以细颗粒分布的形式提供，则石膏基产品的固定强度可以进一步提高。
发明内容
因此，在第一方面，本发明可以提供一种制备石膏基产品的方法，包括将煅烧石膏与聚合物颗粒和水混合以提供浆料的步骤，所述聚合物颗粒主要包含聚乙酸乙烯酯，其中
聚合物颗粒具有使用激光衍射法测量的粒径分布，使得直径为4.5μm或更小的颗粒提供至少90％的总颗粒体积。
通常，聚合物颗粒以水基乳液的形式并入浆料中。在这种情况下，除了水基乳液之外，该方法还可以包括将另外量的水并入到浆料中的步骤。
在一个不太优选的替代方案中，可以将聚合物颗粒以干的形式掺入浆料中，并且可以单独提供水以形成浆料。
当颗粒悬浮在水基乳液中时，使用粒径的激光衍射测量法测定聚合物颗粒的粒径分布。
优选地，聚合物颗粒具有使用激光衍射法测量的粒径分布，使得直径为4μm或更小的颗粒提供至少90％的总颗粒体积。
更优选地，聚合物颗粒具有使用激光衍射法测量的粒径分布，使得直径为3.5μm或更小的颗粒提供至少90％的总颗粒体积。
在某些情况下，聚合物颗粒的粒度分布是单峰的(也称为单式)。
通常，颗粒的平均聚乙酸乙烯酯含量为至少80体积％，优选85体积％，更优选90体积％。
在某些情况下，颗粒另外包含聚乙烯醇，其可以作为部分或全部地围绕颗粒外部延伸的表面层存在。聚乙烯醇的存在被认为通常是由于聚乙酸乙烯酯的部分水解。认为聚乙烯醇的存在可有助于使聚合物颗粒稳定化。
通常，聚合物颗粒以相对于煅烧石膏至少1重量％、优选至少3重量％、最优选至少4重量％的量存在于浆料中。
通常，聚合物颗粒在浆料中的存在量相对于煅烧石膏为25重量％或更少，优选20重量％或更少，最优选15重量％或更少。
煅烧石膏通常包含硫酸钙半水合物和/或硬石膏硫酸钙(硫酸钙无水石膏)。硫酸钙半水合物可以以α和/或β形式存在。
通常，浆料的水位(水位计)(包括作为聚合物颗粒乳液的一部分提供的任何水和单独提供的任何水)相对于煅烧石膏为至少40重量％，优选至少50重量％，最优选至少60重量％。一般而言，当硫酸钙半水合物全部或主要以α形式存在时，例如当至少50重量％的硫酸钙半水合物以α形式存在时，可实现较低的水位(例如，低至40重量％)。通常，当硫酸钙半水合物全部或主要以β形式存在时，例如当至少50重量％的硫酸钙半水合物以β形式存在时，需要更高的水位(例如，至少60重量％)。
通常，浆料的水位相对于煅烧石膏小于120重量％，优选小于100重量％。
典型地，该方法还包括将纤维增强材料例如玻璃纤维并入浆料中的步骤。在某些情况下，纤维增强材料的纤维的平均长度范围在2-20毫米，通常为5-15毫米。通常，纤维增强材料在浆料中的存在的量相对于煅烧石膏为至少1重量％，优选至少1.5重量％，更优选至少2重量％。
通常，相对于煅烧石膏，纤维增强材料在浆料中的存在的量为15重量％或更少，优选10重量％或更少，最优选5重量％或更少。
通常，该方法用于生产芯部具有石膏基质的板。通常，板在至少一个面上设置有衬垫，例如纸衬垫或玻璃纤维垫。衬垫通常部分或全部嵌入板中。也就是说，在凝固石膏浆料以形成板期间，石膏浆料通常部分或全部渗透衬里。
通常，板的螺钉拔出强度至少为550N，优选至少为600N。
在适当的情况下，其他无害材料、辅料和成分也可包含在浆料中。此类无害材料可包括任选的其它成分，例如除聚乙酸乙烯酯或聚乙烯醇之外的聚合物(包括其它合成聚合物和/或淀粉)；凝固加速剂和迟缓剂；变形抑制剂(如抗流挂剂)；防缩添加剂；再煅烧抑制剂；泡沫稳定剂；杀菌剂；杀真菌剂；pH调节剂；着色剂；阻燃剂；疏水添加剂；和填料(例如粒状矿物材料或塑料，其在一些实施方案中可以是膨胀形式)。
附图说明
现在将参考以下附图通过例子来描述本发明，其中:
图1(a)至1(h)分别显示了实施例1-8的粒度分布的图形表示；
图1(i)至1(k)分别显示了比较例9-11的粒度分布的图形表示；
图2显示了实施例1-8和比较例9-11的螺钉拔出数据。
实施例
测定了11份水基聚乙酸乙烯酯乳液样本的体积粒径分布，并用其计算每份样本的D90值。
随后，以足以提供相对于煅烧石膏为4.5重量％的聚乙酸乙烯酯含量(以聚乙酸乙烯酯的干重测量)的量将各乳液并入各自的石膏基浆料中。该浆料还含有相对于煅烧石膏为2.3重量％的量的纤维，并且具有足以提供相对于煅烧石膏为80重量％的水位的总含水量。然后将各浆料制成各自的石膏板。测定了各板的螺钉拔出强度。
结果如表1所示。此外，图1(a)-(k)中显示了各聚乙酸乙烯酯样本的体积粒度分布图形，图2中以图形方式显示了螺钉拉出结果。
表1
D90值的测量
使用Malvern Mastersizer 3000激光衍射粒度分析仪，使用激光衍射法测量聚乙酸乙烯酯水分散体的体积粒度分布。
将聚乙酸乙烯酯样品在水中稀释，以制备含有4.5重量％固体含量聚乙酸乙烯酯的乳液。手动摇晃乳液一分钟，以确保聚合物均匀分散，然后将其移液至分析仪的分散单元。聚合物乳液的加入量使的产生在1％至4％之间的减光率(obscuration)。以3000±50rpm搅拌分散单元。
分析仪在球形粒子模式下运行。
对于每个实施例和比较例测试三个样品，并且对于每个样品取六个粒度分布行迹(traces)。因此，对每个实施例和比较例进行18次测试。表1中的D90值代表这18项测试的平均值。图1(a)至图1(k)中所示的粒度分布图形表示显示了从其中一个样本中提取的六个行迹的平均值。
石膏板样品的生产
在石膏板样品的生产中，由灰泥(煅烧石膏)、平均长度为6mm的玻璃纤维、水基聚乙酸乙烯酯乳液和附加水制备石膏浆料。
浆料的纤维含量相对于灰泥为2.3重量％。将聚乙酸乙烯酯乳液以提供相对于灰泥为4.5重量％的聚乙酸乙烯酯含量(不包括乳液中存在的水)的量加入到浆料中。浆料的水位(包括来自聚乙酸乙烯酯乳液的水和额外的水)相对于灰泥为80重量％。
通过将所需量的水基聚乙酸乙烯酯乳液与额外的水手工混合来制备浆料。随后，将纤维加入到稀释的乳液中，并使用Kenwood混合器混合30s。之后，在Kenwood混合器中将灰泥添加到含水聚乙酸乙烯酯/纤维混合物中，并混合30s。
将浆料倒入模具中，该模具限定了具有相对面的平面型腔。腔的相对面衬有用水饱和了的纸。模具得到支撑，使得腔处于垂直方向。轻敲模具的外表面以去除浆料中的任何气穴，并根据需要将浆料进一步倒入型腔中，直至其充满。
将浆料静置15-20分钟，然后打开模具，取出石膏板。从板边缘修剪掉任何多余的纸张，并用遮蔽胶带包裹板的边缘。
从将浆料倒入模具开始25分钟后，将板置于160℃的烘箱中1小时。随后，将板从烘箱中取出，将遮蔽胶带从板的边缘移除，并将板置于另一个在40℃下的烘箱中约24小时，直至其达到恒定质量。
此后，将板在23℃和50％相对湿度下调节约24小时，直至达到恒定质量。
螺钉拔出强度的测量
螺钉拔出测试涉及使用万能试验机对嵌入板中的螺钉施加拉力，直到螺钉脱离板。
使用长度为50mm、轴直径为5mm的Unifix单螺纹螺钉，对经过调节的板进行螺钉拔出试验。在开始拔出测试之前，将螺钉插入板中，使螺钉的10毫米(1毫米)从板的后部伸出。施加10N的预载荷，然后以10mm/s的十字头速度增加载荷，直至失效。记录峰值失效载荷以提供拔出强度。
Claims (14)
1.一种制备石膏基产品的方法，包括将煅烧石膏与聚合物颗粒和水混合以提供浆料的步骤，所述聚合物颗粒主要包含聚乙酸乙烯酯，其中
聚合物颗粒具有使用激光衍射法测量的粒径分布，使得直径为4.5μm或更小的颗粒提供至少90％的总颗粒体积。
2.根据权利要求1所述的方法，其中所述聚合物颗粒具有使用激光衍射法测量的粒径分布，使得直径为4μm或更小的颗粒提供至少90％的总颗粒体积。
3.根据权利要求2所述的方法，其中所述聚合物颗粒具有使用激光衍射法测量的粒径分布，使得直径为3.5μm或更小的颗粒提供至少90％的总颗粒体积。
4.根据前述权利要求中任一项的方法，其中所述颗粒的平均聚乙酸乙烯酯含量为至少90体积％。
5.根据前述权利要求中任一项的方法，其中所述颗粒另外包含聚乙烯醇。
6.根据权利要求5所述的方法，其中所述聚乙烯醇相作为部分或全部地围绕所述颗粒外部延伸的表面层存在。
7.根据前述权利要求中任一项的方法，其中所述聚合物颗粒以水基乳液的形式提供。
8.根据权利要求7所述的方法，除了所述水基乳液之外，其还包括向所述浆料中并入另外量的水的步骤。
9.根据前述权利要求中任一项的方法，其中聚合物颗粒以相对于煅烧石膏至少1重量％的量存在于浆料中。
10.根据前述权利要求中任一项的方法，其进一步包括将纤维如玻璃纤维并入浆料中的步骤。
11.根据权利要求10所述的方法，其中所述纤维以相对于所述煅烧石膏至少1重量％的量存在于所述浆料中。
12.根据前述权利要求中任一项所述的方法，其中所述石膏基产品是板。
13.根据权利要求12所述的方法，其中所述板在至少一个面上设置有衬垫，所述衬垫例如是纸衬垫或玻璃纤维垫。
14.根据前述权利要求中任一项所述的方法，其还包括将所述浆料成型并使其凝固以提供纸面石膏板的步骤。
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| GB2579043A (en) | 2020-06-10 |
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| AU2019382061A1 (en) | 2021-05-13 |
| SG11202103386RA (en) | 2021-04-29 |
| CA3115192A1 (en) | 2020-05-22 |
| PH12021550935A1 (en) | 2021-11-22 |
| WO2020099243A1 (en) | 2020-05-22 |
| GB201818653D0 (en) | 2019-01-02 |
| BR112021007474A2 (pt) | 2021-07-27 |
| MX2021004227A (es) | 2021-08-05 |
| GB2579043B (en) | 2021-04-14 |
| US20220009832A1 (en) | 2022-01-13 |
| KR20210090245A (ko) | 2021-07-19 |
| CA3115192C (en) | 2024-04-23 |
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