JP6659768B2 - ボード及びその作成方法 - Google Patents
ボード及びその作成方法 Download PDFInfo
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- JP6659768B2 JP6659768B2 JP2018099285A JP2018099285A JP6659768B2 JP 6659768 B2 JP6659768 B2 JP 6659768B2 JP 2018099285 A JP2018099285 A JP 2018099285A JP 2018099285 A JP2018099285 A JP 2018099285A JP 6659768 B2 JP6659768 B2 JP 6659768B2
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- starch
- slurry
- board
- viscosity
- water
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
- B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing layered articles
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/24—Macromolecular compounds
- C04B24/38—Polysaccharides or derivatives thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08B—POLYSACCHARIDES; DERIVATIVES THEREOF
- C08B30/00—Preparation of starch, degraded or non-chemically modified starch, amylose, or amylopectin
- C08B30/12—Degraded, destructured or non-chemically modified starch, e.g. mechanically, enzymatically or by irradiation; Bleaching of starch
- C08B30/14—Cold water dispersible or pregelatinised starch
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L3/00—Compositions of starch, amylose or amylopectin or of their derivatives or degradation products
- C08L3/02—Starch; Degradation products thereof, e.g. dextrin
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- C—CHEMISTRY; METALLURGY
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Description
本出願は、2012年10月23日出願の米国仮特許出願第61/717,588号、2013年3月15日出願の米国非仮特許出願第13/835,002号および2013年10月2日出願の米国部分継続出願第14/044,582号の利益を主張し、これらの先行する全ての特許出願の全体が参照により本明細書に組み込まれる。
本実施例は、本明細書で「VMA法」と呼ぶ、粘度測定アッセイ法を説明する。本明細書で粘度と呼ぶ場合、別段の指示が無い限り、それはVMA法に従うものである。粘度は、同心性のシリンダーを備えるDiscovery HR−2ハイブリッドレオメーター(TA Instruments Ltd)、羽形形状(直径28および長さ42.05mm)を有する標準カップ(直径30mm)を用いて測定する。
測定する。粘度は、30秒から60秒の測定の平均である。
本実施例は、異なる状態における(15%の水溶液中の)デンプンの粘度を例示する。試験した代表的なデンプンは、ヒドロキシエチルトウモロコシデンプン(ADMから入手可能なClineo 706)であった。図1を参照すると、X軸は時間を示し、一方Y軸はトルクおよび温度を重ねたものである。グラフは、デンプンが煮沸されて最終的に糊化されるにつれて粘度がどのように変化するかを実証する。トルクは、ローターを回転する力を測定し、したがって粘度の測定である。トルクは、ブラベンダー単位である。
本実施例は、2インチ(5.08センチメートル)の立方体を用いる立方体圧縮試験を記述する。一部の実施形態において、立方体圧縮試験は、デンプンおよびその量が本明細書に述べるように多様でありうる場合の石膏配合物を測定する。配合物は、別段の指示が無い限りスタッコの2重量%に設定されたデンプンの量で、水/スタッコ比1.0のための投入量に設定された石膏スラリーから形成される。
本実施例は、粒状デンプン(すなわち、非糊化)をスタッコスラリーに加えることと糊化されたデンプンをスタッコスラリーに加えることとの石膏配合物の圧縮強度へのそれぞれの影響を比較する。それぞれのデンプンを、実施例3に記載の通りの立方体試験のための石膏スラリー内に入れた。
本実施例は、VMA法に従って測定される粘度の範囲を示す、種々の糊化されたデンプンを例示する。実施例3に記述されている配合物および立方体試験に従って、デンプンのそれぞれの石膏配合物における圧縮強度への影響を評価した。糊化されたデンプンの粘度およびデンプンを含むスラリーから形成された石膏立方体の圧縮強度を示す結果を、下表5に記述する。
本実施例は、糊化後の粘度の範囲を示すエチル化デンプンを比較する。粒状(未糊化デンプン)および糊化されたデンプンを、それぞれ、スタッコスラリーに加えることを考慮して、石膏配合物の強度への影響も、実施例3に記述されている配合物および立方体試験に従って評価した。糊化されたデンプンの粘度およびデンプンを含むスラリーから形成された石膏立方体の圧縮強度を示す結果を、下表6に記述する。それぞれ示した粘度は、デンプンの糊化後であるが、粒状デンプン(未糊化デンプン)をスタッコスラリーに加えることを考慮して強度もデータに含められる。
本実施例は、石膏スラリーに入れられるデンプンの量の範囲にわたって、石膏配合物の強度への糊化されたデンプンの影響を比較する。デンプンの量が多様であることを除いて、実施例3に記述されている配合物および立方体試験を用いた。表7に結果を記述する。
本実施例は、種々の糊化されたデンプンによる石膏スラリーの流動性への影響を例示する。それぞれのデンプンを、水/スタッコ比およびデンプンの量が多様であることを除いて、実施例3による石膏配合物に入れる。スランプ試験を用いて以下のように流動性を測定した。スランプを、高さ4インチ(10.2cm)である(それぞれの端部において開放でありかつ平坦な滑面上に直立して置かれた)2インチ(5.08cm)直径のシリンダー内にスラリーを注いで、スラリーの上部を均すことにより測定した。これは、全ての試験のためのスラリーの硬化体積を提供する。次いで、直ちにシリンダーを持ち上げて、スラリーをシリンダーの開放底端部から勢いよく出した。このパテの直径を、センチメートルで測定して、記録する。より流動性のスラリーは、典型的にはより大きい直径のパテを生じるであろう。表8に結果を記述する。
本実施例は、乾燥状態酸修飾によるアルファ化トウモロコシ粉の粘度減少を実証する。アルファ化トウモロコシ粉(125g、Bunge Milling)を、ホバートミキサーの混合ボウルへ量り入れた。スピード2で混合しながらトウモロコシ粉の上部に1M 硫酸(6.2から18g)を噴霧した。試料を、さらに10分間混合した。試料を、蓋を備えたプラスチック瓶に移し、次いで80℃で3時間加熱した。等モルの水酸化カルシウムを加えて、試料を2分間混合した。試料を、室温で一晩乾燥した。
本実施例は、様々な量の酸を用いて酸修飾したデンプンを用いる立方体圧縮強度およびスランプを記述する。使用した石膏スラリー配合物を表3に示す。水スタッコ比(WSR)は、1.0であった。石膏立方体試料は、実施例3の方法に従って調製した。実施例8に記載のようにスランプ試験を後に続けた。圧縮強度試験およびスランプ試験の結果を、表10に示す。
本実施例は、酸への様々な暴露時間を用いて酸修飾したデンプンを用いる立方体圧縮強度およびスランプを記述する。アルファ化トウモロコシ粉(31g)を、混合しながら水(200g)を含むWarrenブレンダーへ量り入れた。デンプン溶液を、フラスコ内へ移した。ブレンダーを水(77g)ですすいで、水をフラスコへ移した。濃硫酸(1.94ml、95〜98%)を、撹拌しながらデンプン溶液に加えた。溶液を、70℃で60から100分間保温した。次いで等モルの水酸化カルシウム(2.58g)を、デンプン溶液に加えて10分間撹拌した。使用した石膏スラリー配合物を表3に示す。石膏立方体試料は、実施例3の方法に従って調製した。実施例8に記載のようにスランプ試験を後に続けた。圧縮強度試験およびスランプ試験の結果を、表11に示す。
本実施例は、アルファ化トウモロコシ粉の酸修飾による石膏スラリーの流動性への影響を例示する。スランプ試験を、実施例8に記載のように流動性測定するために用いた。WSRに従って水量を調整したことを除いて、使用した石膏スラリー配合物は表3に示すものである。表12にスランプ試験の結果を示す。
本実施例は、実験室で煮沸した酸修飾デンプンを含む立方体の立方体圧縮強度試験を記述する。配合物は、デンプンの量をスタッコの2重量%に設定して、対照アルファ化トウモロコシデンプンについては1.0の水/スタッコ比を有する石膏スラリーおよび実験室で煮沸した酸修飾トウモロコシデンプン(Clinton 277)については0.9を有する石膏スラリーから形成する。対照および実験室で煮沸した酸修飾トウモロコシデンプンのために使用した配合物を、表13に開示する。立方体の密度は、様々な速度で泡を加えることにより25から45ポンド立方フィート(400kg/m3から721kg/m3)の間に設定した。
本実施例は、パイロット規模の押出しを用いて冷水可溶性アルファ化デンプン(Clinton 277)を形成する方法、および押出しされたアルファ化デンプンを含む立方体の圧縮強度を記述する。
本実施例は、種々の条件下でベンチ規模の押出しによって作成されたアルファ化酸修飾デンプン(Clinton 277)の冷水溶解度を例示する。
本実施例は、本明細書で「CWVA法」と呼ぶ、冷水粘度測定アッセイ法を説明する。本明細書で冷水粘度と呼ぶ場合、別段の指示が無い限り、それはCWVA法に従う。
[付記1]
2つのカバーシートの間に配置される硬化石膏芯を備えるボードであって、前記芯が、スタッコ、水および少なくとも1種のアルファ化デンプンを含むスラリーから形成され、前記デンプンは、前記デンプンがVMA法に従う条件を受ける間に粘度が測定される場合に約20センチポイズから約700センチポイズの前記粘度の特性を有する、ボード。
前記デンプンの前記粘度の特性は、VMA法に従って約30センチポイズから約200センチポイズである、付記1に記載のボード。
前記デンプンは、前記デンプンを含まない前記硬化石膏芯と比較して前記硬化石膏芯の前記芯硬度を増加するために効果的である、付記1または2に記載のボード。
前記デンプンが、VMA法に従って700センチポイズより大きい粘度特性(例えば、773センチポイズ)を有するデンプンによって必要とされる過剰な水の量の増加よりも少ない、前記デンプン無しであるレベルと同レベルに前記スラリー流動性を維持するために前記スラリーに加えることが必要とされる過剰な水の量の増加を必要とする、付記1〜3のいずれか一つに記載のボード。
前記デンプンは、前記スタッコの約0.5重量%から約3重量%の量である、付記1〜4のいずれか一つに記載のボード。
前記デンプンは、酸修飾デンプンである、付記1〜5のいずれか一つに記載のボード。
前記水/スタッコ比は、約0.55から約0.8である、付記1〜6のいずれか一つに記載のボード。
前記ボードは、約24pcf(384kg/m3)から約35pcf(561kg/m3)の密度を有する、付記1〜7のいずれか一つに記載のボード。
前記スラリーは、(a)糊化されていない、(b)VMA法に従って20センチポイズ未満の前記粘度の特性を有するアルファ化デンプンである、または(c)VMA法に従って700センチポイズを超える前記粘度の特性を有するアルファ化デンプンである、第2の種類のデンプンを含む、付記1〜8のいずれか一つに記載のボード。
前記第2の種類のデンプンは、アルキル化デンプンを含む、付記9に記載のボード。
前記スラリーは、重量の大きい部分の不安定成分および重量の小さい部分の安定成分を含む少なくとも発泡剤をさらに含み、発泡剤の量および前記不安定な成分の安定成分に対する重量比が、前記硬化石膏芯の内部に間隙分布を形成するために効果的である、付記1〜10のいずれか一つに記載のボード。
前記スラリーは、ナフタレンスルホン酸塩分散剤をさらに含む、付記1〜11のいずれか一つに記載のボード。
前記スラリーは、トリメタリン酸ナトリウムをさらに含む、付記1〜12のいずれか一つに記載のボード。
前記ボードが約1/2インチ(1.3cm)の厚さで鋳造される場合、前記ボードは、ASTM標準C473に従って測定されるような、少なくとも約65ポンド(29.5kg)の釘引抜き耐性を有しかつ少なくとも約11ポンド(5kg)の芯硬度を有する、付記1〜13のいずれか一つに記載のボード。
水、スタッコおよび少なくとも1種のアルファ化デンプンを含むスラリーであって、前記デンプンがVMA法に従う条件を受ける時に粘度が測定される場合に前記デンプンは約20センチポイズから約700センチポイズの前記粘度の特性を有する、スラリー。
(a)少なくとも水、スタッコおよび少なくとも1種のアルファ化デンプンを混合してスラリーを形成するステップであって、前記デンプンは、粘度がVMA法に従って測定される場合に約20センチポイズから約700センチポイズの前記粘度の特性を有するステップと、
(b)前記スラリーを第1のカバーシートと第2のカバーシートとの間に配置して湿性アセンブリを形成するステップと、
(c)前記湿性アセンブリをボードに裁断するステップと、
(d)前記ボードを乾燥するステップと
を含むボードを作成する方法。
(a)炭酸カルシウムと、
(b)少なくとも1種のアルファ化デンプンであって、前記デンプンは約20センチポイズから約700センチポイズの粘度を有し、かつ前記粘度はVMA法に従って測定される、デンプンと
を含むジョイントコンパウンド。
繊維および少なくとも1種のアルファ化デンプンを含む吸音成分を含む吸音パネルであって、前記デンプンは、約20センチポイズから約700センチポイズの粘度を有し、前記粘度はVMA法に従って測定され、かつ前記パネルは、ASTM C 423−02に従って少なくとも約0.5の騒音減少率を有する、吸音パネル。
デンプンは、約30%より大きい冷水溶解度を有し、
硬化石膏芯は、約30%未満の冷水溶解度を有するデンプンで作成された硬化石膏芯より大きい圧縮強度を有する、
2つのカバーシートの間に配置される前記硬化石膏芯を備えるボードであって、前記芯が、スタッコ、水および少なくとも1種のアルファ化デンプンを含むスラリーから形成される、ボード。
前記デンプンは、約30%から約75%の冷水溶解度を有する、付記19に記載のボード。
前記デンプンは、スタッコの重量に基づいて約0.1重量%から約5重量%の量である、付記19または20に記載のボード。
前記ボードは、約24pcf(384kg/m3)から約35pcf.(561kg/m3)の密度を有する、付記19〜21のいずれか一つに記載のボード。
デンプンは、約30%より大きい冷水溶解度を有し、
硬化石膏芯は、約30%未満の冷水溶解度を有するデンプンで作成された硬化石膏芯より大きい圧縮強度を有する、
(a)少なくとも水、スタッコおよび少なくとも1種のアルファ化デンプンを混合してスラリーを形成するステップと、
(b)前記スラリーを第1のカバーシートと第2のカバーシートとの間に配置して湿性アセンブリを形成するステップと、
(c)前記湿性アセンブリをボードに裁断するステップと、
(d)前記ボードを乾燥するステップと
を含むボードを作成する方法。
アルファ化デンプンは、約30%より大きい冷水溶解度を有する、
(a)少なくとも水および非アルファ化デンプンを混合して湿性デンプンを作成するステップと、
(b)前記湿性デンプンを約90℃以上の温度のダイを有する押出機内に配置するステップと、
(c)前記デンプンを乾燥するステップと
を含むアルファ化デンプンを作成する方法。
前記アルファ化デンプンは、約30%から約75%の冷水溶解度を有する、付記24に記載の方法。
前記押出機ダイは、温度が約150℃以上である、付記24または25に記載の方法。
前記湿性デンプンは、デンプンの約25重量%未満の含水量を有する、付記24〜26のいずれか一つに記載の方法。
Claims (9)
- 2つのカバーシートの間に配置される硬化石膏芯を備えるボードであって、
前記芯が、スタッコ、水および少なくとも1種の押出しされたアルファ化デンプンを含むスラリーから形成され、
前記押出しされたアルファ化デンプンは、湿性デンプンを押出しすることにより形成され、
前記押出しされたアルファ化デンプンは、25℃で測定した場合に30%より大きい冷水溶解度を有し、
前記押出しされたアルファ化デンプンは、25℃及びせん断速度100s−1で1分間測定したときの前記押出しされたアルファ化デンプンを水に溶かした10重量%のスラリーの冷水粘度が120センチポイズから300センチポイズであり、
前記芯は、前記押出しされたアルファ化デンプンの代わりに25℃で測定した場合の冷水溶解度が30%未満であるデンプンの1つを用いて作成された硬化石膏芯より大きい圧縮強度を有する、
ボード。 - 前記押出しされたアルファ化デンプンは、30%から95%の冷水溶解度を有する、
請求項1に記載のボード。 - 前記押出しされたアルファ化デンプンは、スタッコの重量に基づいて0.1重量%から5重量%の量である、
請求項1又は2に記載のボード。 - 前記ボードは、24pcf(約384kg/m3)から35pcf(約561kg/m3)の密度を有する、
請求項1から3のいずれか1項に記載のボード。 - 前記ボードは、ASTM標準C473−10に従って測定して、少なくとも11ポンド(約5kg)の芯硬度を有する、
請求項1から4のいずれか1項に記載のボード。 - 前記押出しされたアルファ化デンプンは、100ミクロンから400ミクロンの粒径を有する、
請求項1から5のいずれか1項に記載のボード。 - (a)少なくとも水、スタッコおよび少なくとも1種の押出しされたアルファ化デンプンを混合してスラリーを形成するステップであって、
前記押出しされたアルファ化デンプンは、湿性デンプンを押出しすることにより形成され、
前記押出しされたアルファ化デンプンは、25℃で測定した場合に30%より大きい冷水溶解度を有し、
前記押出しされたアルファ化デンプンは、25℃及びせん断速度100s−1で1分間測定したときの前記押出しされたアルファ化デンプンを水に溶かした10重量%のスラリーの冷水粘度が120センチポイズから300センチポイズである、
ステップと、
(b)前記スラリーを第1のカバーシートと第2のカバーシートとの間に配置して湿性アセンブリを形成するステップと、
(c)前記湿性アセンブリをボードに裁断するステップと、
(d)前記ボードを乾燥するステップと
を含み、
前記ボードの硬化石膏芯は、前記押出しされたアルファ化デンプンの代わりに25℃で測定した場合の冷水溶解度が30%未満であるデンプンの1つを用いて作成された硬化石膏芯より大きい圧縮強度を有する、
ボードを作成する方法。 - 前記ボードは、ASTM標準C473−10に従って測定して、少なくとも11ポンド(約5kg)の芯硬度を有する、
請求項7に記載の方法。 - 前記押出しされたアルファ化デンプンは、100ミクロンから400ミクロンの粒径を有する、
請求項7又は8に記載の方法。
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