JP2016521243A - 石膏含有建材の製造方法及びそれによって疎水化剤としてケテンダイマーを用いて製造される建材 - Google Patents
石膏含有建材の製造方法及びそれによって疎水化剤としてケテンダイマーを用いて製造される建材 Download PDFInfo
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- JP2016521243A JP2016521243A JP2016509491A JP2016509491A JP2016521243A JP 2016521243 A JP2016521243 A JP 2016521243A JP 2016509491 A JP2016509491 A JP 2016509491A JP 2016509491 A JP2016509491 A JP 2016509491A JP 2016521243 A JP2016521243 A JP 2016521243A
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- Prior art keywords
- gypsum
- building material
- ketene dimer
- dispersion
- hemihydrate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000003960 organic solvent Substances 0.000 description 1
- 239000003346 palm kernel oil Substances 0.000 description 1
- 235000019865 palm kernel oil Nutrition 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 229920001277 pectin Polymers 0.000 description 1
- 239000001814 pectin Substances 0.000 description 1
- 235000010987 pectin Nutrition 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- CMPQUABWPXYYSH-UHFFFAOYSA-N phenyl phosphate Chemical class OP(O)(=O)OC1=CC=CC=C1 CMPQUABWPXYYSH-UHFFFAOYSA-N 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- UEZVMMHDMIWARA-UHFFFAOYSA-M phosphonate Chemical compound [O-]P(=O)=O UEZVMMHDMIWARA-UHFFFAOYSA-M 0.000 description 1
- 229910052615 phyllosilicate Inorganic materials 0.000 description 1
- 229920000371 poly(diallyldimethylammonium chloride) polymer Polymers 0.000 description 1
- 229920002401 polyacrylamide Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000001205 polyphosphate Substances 0.000 description 1
- 235000011176 polyphosphates Nutrition 0.000 description 1
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 1
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 1
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 230000001007 puffing effect Effects 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- 229940100486 rice starch Drugs 0.000 description 1
- 229910000275 saponite Inorganic materials 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 229910021647 smectite Inorganic materials 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229940014800 succinic anhydride Drugs 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 239000003784 tall oil Substances 0.000 description 1
- 239000003760 tallow Substances 0.000 description 1
- PUVAFTRIIUSGLK-UHFFFAOYSA-M trimethyl(oxiran-2-ylmethyl)azanium;chloride Chemical compound [Cl-].C[N+](C)(C)CC1CO1 PUVAFTRIIUSGLK-UHFFFAOYSA-M 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
- 229940100445 wheat starch Drugs 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- LTVDFSLWFKLJDQ-UHFFFAOYSA-N α-tocopherolquinone Chemical compound CC(C)CCCC(C)CCCC(C)CCCC(C)(O)CCC1=C(C)C(=O)C(C)=C(C)C1=O LTVDFSLWFKLJDQ-UHFFFAOYSA-N 0.000 description 1
Classifications
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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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
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- C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
- C04B22/08—Acids or salts thereof
- C04B22/14—Acids or salts thereof containing sulfur in the anion, e.g. sulfides
- C04B22/142—Sulfates
- C04B22/143—Calcium-sulfate
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- C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
- C04B22/08—Acids or salts thereof
- C04B22/14—Acids or salts thereof containing sulfur in the anion, e.g. sulfides
- C04B22/142—Sulfates
- C04B22/143—Calcium-sulfate
- C04B22/145—Gypsum from the desulfuration of flue gases
-
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- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/008—Aldehydes, ketones
-
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- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/04—Carboxylic acids; Salts, anhydrides or esters thereof
- C04B24/045—Esters, e.g. lactones
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- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/16—Sulfur-containing compounds
- C04B24/161—Macromolecular compounds comprising sulfonate or sulfate groups
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- 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
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- 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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- 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
- C04B28/16—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 containing anhydrite, e.g. Keene's cement
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
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- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/0028—Aspects relating to the mixing step of the mortar preparation
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- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial 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
Description
1.石膏含有発泡プレハブ建材の製造方法であって、
(a)半水石膏又は無水石膏、以下の式(I)
のケテンダイマーの混合物を調製すること;及び
(b)石膏組成物を形成し、任意に硬化及び乾燥して発泡プレハブ建材を得ること
を含む、前記製造方法。
Aは、任意に1つ以上のヒドロキシル基又はフェニル基によって置換された、分枝鎖状又は非分枝鎖状のC1〜C4−アルキレンであるか、又は
Aは、任意に1つ以上のヒドロキシル基によって置換された、C1〜C3−アルキレン−フェニレン、フェニレン−C1〜C3−アルキレン、又はC1〜C3−アルキレン−フェニレン−C1〜C3−アルキレンであり;且つ
R3、R4、及びR5は、互いに独立して、分枝鎖状又は非分枝鎖状のC1〜C4−アルキル又はC2〜C4−ヒドロキシアルキルであり、これはまたR5の場合にHであることが可能である)
に従う、実施態様9から12までのいずれか1つに記載の方法。
Aが−CH2−CHOH−CH2−、−CH2−CH(CH2OH)−、又は−CH2−CH2−であり;且つ
R3、R4、及びR5が、互いに独立してメチル又はエチルである、実施態様13に記載の方法。
S=NAm/NSac (A)
(式中、
NAmは、多糖類分子当たりのアミノ構造単位の平均数を多糖類分子当たりのアンモニウム構造単位の平均数に添加することによって形成される合計を表し;且つ
NSacは、多糖類分子当たりの単糖構造単位の平均数を表す)
に従って計算される、置換Sの平均程度が、0.01〜0.5、好ましくは0.1〜0.4、更に特に0.2〜0.3である、実施態様9から15までのいずれか1つに記載の方法。
(a)半水石膏又は無水石膏、式(I)
のケテンダイマー、及び水性発泡体の混合物を調製して、石膏組成物を得る工程、及び
(b)石膏組成物を形成し、任意に硬化及び乾燥して、発泡プレハブ建材を得る工程
を含む、前記製造方法に関する。
Aは、任意に1つ以上のヒドロキシル基又はフェニル基によって置換される、分枝鎖状又は非分枝鎖状のC1〜C4−アルキレンであるか;又は
Aは、任意に1つ以上のヒドロキシル基によって置換される、C1〜C3−アルキレン−フェニレン、フェニレン−C1〜C3−アルキレン又はC1〜C3−アルキレン−フェニレン−C1〜C3−アルキレンであり;且つ
R3、R4、及びR5は互いに独立して分枝鎖状又は非分枝鎖状のC1〜C4−アルキル又はC2〜C4−ヒドロキシアルキルであり、これはまたR5がHであることも可能にする)
によるアンモニウム構造単位を有する。
Aが−CH2−CHOH−CH2−、−CH2−CH(CH2OH)−、又は−CH2−CH2−であり;且つ
R3、R4、及びR5が互いに独立してメチル又はエチルである、前記式(IIIb)によるアンモニウム構造単位を有するものである。
S=NAm/NSac (A)
(式中、
NAmは、多糖類分子当たりのアミノ構造単位の平均数を、多糖類分子当たりのアンモニウム構造単位の平均数に加えることによって形成される合計を表し;且つ
NSacは、多糖類分子当たりの単糖構造単位の平均数を表す)
によって計算される。
(a)0.1〜10質量%の硫酸アルミニウム、及び/又は
(b)1〜15質量%の少なくとも1種の水溶性カチオン性デンプン、及び/又は
(c)0.1〜5質量%のナフタレンスルホン酸とホルムアルデヒドとの少なくとも1種の縮合生成物又はナフタレンスルホン酸の塩とホルムアルデヒドとの少なくとも1種の縮合生成物及び/又はリグノスルホン酸又はリグノスルホン酸の塩との少なくとも1種の縮合生成物、及び/又は
(d)0.5〜5質量%の、1〜10個の炭素原子を有する少なくとも1種の飽和カルボン酸、ベンゼンスルホン酸、p−トルエンスルホン酸及び/又は鉱酸(H2SO4、H3PO4)
を含む。
脂肪アルキル硫酸塩系発泡体を以下のように製造した:
0.3%濃度の界面活性剤溶液(ラウリル硫酸塩に基づく)を、圧縮空気を添加して、ステータ−ロータシステムの回転によって発泡体発生器内において発泡体に変換した。達成した発泡体の密度は75g/Lであった。
サソールHydrowax 170(比較分散液):
サソール社製のHydrowax 170は、石膏ボードパネルの疎水化のための市販の特別な分散液(固形分約37%)であり、相互に整列したワックス(パラフィンワックスを含む)及び乳化剤を含み、且つシリコーンを含まない。
C16/C18(50:50)アルキルケテンダイマーの水性分散液を、3質量%のカチオン変性したデンプン(式I及びIIにおいて:R1及びR2は、それぞれ、C14及びC16アルキルである)を用いて分散した。平均粒径は約1000nmである。合計固体含有率は約24%である。
C16/C18(20:80)アルキルケテンダイマーの水性分散液を、3質量%のカチオン変性したデンプン(式I及びIIにおいて:R1及びR2は、それぞれ、C14及びC16アルキルである)を用いて分散した。平均粒径は約1000nmである。合計固体含有率は約18%である。
W=100%×((Mw−MD)/MD)
比較実験2.1:
3.0gの可塑剤Melflux PCE1493L(BASF社製)(水/石膏比を低下させるための40%濃度のポリカルボキシレートエーテル溶液)、600gの石膏(排煙脱硫から得られたβ半水和物)、及び1.3gの促進剤(約2.5分の凝固時間を設定するための微粉砕した硫酸カルシウム二水和物)を、367.5gの水中に導入し、混合物を15秒間静置した。ホバートミキサーを設定II(毎分285回転)で30秒間使用し、この撹拌時間の間に、脂肪アルキル硫酸塩系発泡体(75g/Lの密度で38.6g)を、得られる石膏スラリーの密度が955+/−10kg/m3になるまで混合した。
希釈ワックスエマルションを、347gの水中に32.4gの37%のワックスエマルション(サソールHydrowax 170)を計量することによって調製した。これは、石膏を基準として2質量%のワックス固形分に相当する。次に、3.0gのMelflux PCE1493L(BASF社製)、600gの石膏(排煙脱硫から得られたβ半水和物)、及び1.3gの促進剤(約2.5分の凝固時間を設定するための微粉砕した硫酸カルシウム二水和物)を、希釈したワックスエマルション中に導入し、混合物を15秒間静置した。ホバートミキサーを設定II(毎分285回転)で30秒間使用し、この撹拌時間の間に、脂肪アルキル硫酸塩系発泡体(75g/Lの密度で38.6g)を、得られる石膏スラリーの密度が955+/−10kg/m3になるまで混合した。
希釈AKD分散液を、340.1gの水中に33.3gの18%のAKD分散系Iを計量することによって調製した。これは、石膏を基準として1質量%のAKD固形分に相当する。次に、3.0gのMelflux PCE1493L(BASF社製)、600gの石膏(排煙脱硫から得られたβ半水和物)、及び1.3gの促進剤(約2.5分の凝固時間を設定するための微粉砕した硫酸カルシウム二水和物)を、水性AKD分散液中に導入し、混合物を15秒間静置した。ホバートミキサーを設定II(毎分285回転)で30秒間使用し、この撹拌時間の間に、脂肪アルキル硫酸塩系発泡体(75g/Lの密度で38.6g)を、得られる石膏スラリーの密度が955+/−10kg/m3になるまで混合した。石膏スラリーからの試験片の製造、水吸収の調査、及び水吸収量の計算は、実施例1に記載された方法で、実施例2の実験及び比較実験において行った。
脂肪アルキルエーテル硫酸塩系発泡体を、実施例1に記載される通り調製した。
3.0gのMelflux PCE1493L(BASF社製)、600gの石膏(排煙脱硫から得られたβ半水和物)、及び1.0gの促進剤(約2.5分の凝固時間を設定するための微粉砕した硫酸カルシウム二水和物)を、354.7gの水中に導入し、混合物を15秒間静置した。ホバートミキサーを設定II(毎分285回転)で30秒間使用し、この撹拌時間の間に、脂肪アルキルエーテル硫酸塩系発泡体(75g/Lの密度で36.5g)を、得られる石膏スラリーの密度が970+/−20kg/m3になるまで混合した。
希釈AKD分散液IIを、336.7gの水中に24.0gの25%のAKD分散液IIを計量することによって調製した。次に、3.0gのMelflux PCE1493L(BASF社製)、600gの石膏(排煙脱硫から得られたβ半水和物)、及び0.9gの促進剤(約2.5分の凝固時間を設定するための微粉砕した硫酸カルシウム二水和物)を、希釈したAKD分散液IIに導入し、混合物を15秒間静置した。ホバートミキサーを設定II(毎分285回転)で30秒間使用し、この撹拌時間の間に、脂肪アルキルエーテル硫酸塩系発泡体(75g/Lの密度で36.5g)を、得られる石膏スラリーの密度が970+/−20kg/m3になるまで混合した。
Claims (16)
- ケテンダイマーを、水性分散液の形で使用する、請求項1に記載の方法。
- 半水石膏又は無水石膏を、固体の形で又は水性分散液の形で使用する、請求項2に記載の方法。
- 水性ケテン分散液を、保護コロイドによって安定化する、請求項2又は3に記載の方法。
- 保護コロイドが、デンプン、セルロース又はアンモニウム構造単位によって変性したセルロースである、請求項4に記載の方法。
- 水性ケテン分散液が、分散液の全質量を基準として、1〜60質量%のケテンダイマーを含む、請求項2から5までのいずれか1項に記載の方法。
- 水性ケテン分散液の分散相が、10μm未満、更に好ましくは5μm未満の平均直径を有する、請求項2から6までのいずれか1項に記載の方法。
- 半水石膏又は無水石膏の質量を基準として、0.02〜8.0質量%、特に0.1〜5質量%のケテンダイマーを使用する、請求項1から7までのいずれか1項に記載の方法。
- 半水石膏又は無水石膏が、α半水石膏、α/β−半水石膏、β−半水石膏、天然無水石膏、合成無水石膏、排煙脱硫から得られる無水石膏、及び/又はそれらの2つ以上の混合物から選択される、請求項1から8までのいずれか1項に記載の方法。
- 脂肪アルキル硫酸塩又は脂肪アルキルエーテル硫酸塩を、発泡体を製造するための界面活性剤として使用する、請求項1から9までのいずれか1項に記載の方法。
- 約50〜300g/l、特に60〜250g/lの密度を有する発泡体を使用する、請求項1から10までのいずれか1項に記載の方法。
- 1kgの半水石膏又は無水石膏当たり0.01〜2gの界面活性剤を使用する、請求項1から11までのいずれか1項に記載の方法。
- 請求項1から12までのいずれか1項に記載の方法によって得られた石膏含有発泡プレハブ建材。
- 石膏体が、0.4〜1.1kg/dm3、好ましくは0.4〜0.9kg/dm3、更に好ましくは0.5〜0.8kg/dm3のコア密度を有する、請求項13又は14に記載の建材。
- 石膏ボードパネル、石膏ファイバーボードパネル、石膏含有壁材パネル、及び石膏含有モールディングから選択される、請求項13から15までのいずれか1項に記載の建材。
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PCT/EP2014/058474 WO2014174086A1 (en) | 2013-04-26 | 2014-04-25 | A method for producing a gypsum-containing building material and building material prepared thereby with ketene dimers as hydrophobing agent |
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JP2017537863A (ja) * | 2014-10-23 | 2017-12-21 | ビーエーエスエフ ソシエタス・ヨーロピアBasf Se | コンクリートを疎水化するための方法 |
JP2021500307A (ja) * | 2017-10-24 | 2021-01-07 | ビーエイエスエフ・ソシエタス・エウロパエアBasf Se | 再生石膏含有硫酸カルシウム混合物のための堅牢な一次界面活性剤としての二塩 |
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US11891336B2 (en) | 2019-11-22 | 2024-02-06 | United States Gypsum Company | Gypsum board containing high absorption paper and related methods |
CN114735962A (zh) * | 2022-04-21 | 2022-07-12 | 苏州市兴邦化学建材有限公司 | 一种过烧石膏用改性添加剂及其制备方法 |
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WO2014174086A1 (en) | 2014-10-30 |
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