KR20190127292A - Foaming agent composition for gypsum board and manufacturing method for gypsum board using the same - Google Patents

Abstract

The present invention provides a foaming agent composition for gypsum boards having a foaming structure optimized for improving the strength of gypsum boards, and a method for manufacturing gypsum boards using the same. The foaming agent composition for gypsum boards comprises alkyl sulfate represented by chemical formula 1: H(CH_2)_nOSO_3^(-)M^(+), and alkyl polyglucoside having 10 to 20 carbon atoms.

Description

FOAMING AGENT COMPOSITION FOR GYPSUM BOARD AND MANUFACTURING METHOD FOR GYPSUM BOARD USING THE SAME}

The present invention relates to a foaming agent composition for gypsum board and a method for producing gypsum board using the same.

Calcium sulfate dehydrate is commonly used as a major component in building wall products. For example, gypsum board with hardened gypsum as its main component and paper-treated surface is widely used for dry works on walls and ceilings. At this time, it is necessary to manufacture a gypsum board having a light weight and a certain strength or more so as to be easily applied to the field process. Such a gypsum board may be manufactured to uniformly distribute a plurality of bubbles in the gypsum slurry by uniformly mixing a predetermined amount of bubbles with the gypsum slurry.

As above, the gypsum board should be light and easy to work with, while having a certain level of strength so that it can be bonded to the wall or ceiling of the building. The structure of the bubbles, which occupy a large part of the volume of the gypsum core in the gypsum board, affects the strength of the gypsum board. These bubbles are injected into the gypsum slurry and solidified in the gypsum slurry without being released to the outside. It will exist. In this case, the bubbles are present in the gypsum slurry only for a relatively short period of time before the bubbles in the bubbles burst or, in combination with other bubbles, are present in the gypsum slurry in the form of large bubbles. In particular, if the stability of the bubble is not good, there is a disadvantage that the bubble is bubbled before the hardening of the gypsum is formed to form a gypsum board of the proper density.

In addition, in order to facilitate product formation in the manufacturing process of gypsum board, in general, extra water is added to the gypsum slurry to give fluidity, and after the forming process, the excess water is dried at a high temperature to form a complete gypsum. Manufactures products. In this case, the bubbles in the gypsum board during the drying process has a significant effect on the properties of the final gypsum board. Therefore, in order for the gypsum board to be efficiently dried within a short time at an appropriate temperature which is not subjected to thermal shock, it is important to form bubbles of appropriate shape in the gypsum board.

In the gypsum board, the strength has a great influence on the shear force and the bending strength. Generally, small bubbles are not suitable for drying excess water, resulting in uneven drying, which may lower the strength of the gypsum board. The fact is confirmed in US 5,085,929 and the like.

Therefore, while maintaining the size of the bubbles in the gypsum board large, various studies have been conducted to prevent the side effects that the bubbles are unstable due to the instability of the gypsum slurry hardening in the mixing process, without being deflected.

Korean Laid-Open Patent Publication No. 2004-0012664

The present invention provides a foaming agent composition for gypsum board having a bubble structure optimized for improving the strength of the gypsum board.

In another aspect, the present invention provides a method for producing a gypsum board comprising air bubbles optimized for weight reduction and strength improvement of the gypsum board by using a foaming agent composition comprising a specific blowing agent.

The present invention provides a foaming agent composition for gypsum board comprising an alkyl sulfate and an alkyl polyglucoside.

In addition, there is provided a gypsum board manufacturing method comprising preparing a gypsum slurry comprising a hemihydrate gypsum, and mixing the gypsum slurry with a foaming solution prepared from the above-mentioned gypsum board foaming agent composition.

The foaming agent composition for gypsum board according to the present invention can increase the size of the bubbles present in the gypsum slurry while increasing the dispersibility, thereby improving the strength of the gypsum board.

In addition, in the present invention, by using a single mixing chamber, the foaming solution capable of foaming in a stable form and the foaming solution capable of foaming in an unstable form are independently supplied to the gypsum slurry to improve the stability of bubbles. By maintaining appropriately, the strength of the gypsum board can be improved.

1 is a view schematically showing a process for producing a gypsum slurry using a foaming agent composition for gypsum board of an embodiment of the present invention.
2 is a view schematically showing a process of manufacturing a gypsum slurry using a foaming agent composition for gypsum board of another embodiment of the present invention.
3 is a view showing a bubble distribution in the gypsum board according to the sixth embodiment.
4 is a view showing a bubble distribution in the gypsum board according to the third embodiment.

Hereinafter, the present invention will be described in detail.

The present invention provides a foaming agent composition for gypsum board.

<Gypsum board foaming agent composition>

The foaming agent composition for gypsum board of the present invention includes alkyl sulfate and alkyl polyglucoside. The alkyl sulfate and the alkyl polyglucoside are blowing agents, and the blowing agents can reduce the density of the gypsum board by forming bubbles in the gypsum slurry. Furthermore, the bubbles introduced into the gypsum slurry may be present in a stable form without defoaming in the drying process, thereby enabling uniform drying of the gypsum board, thereby improving the strength of the final manufactured gypsum board.

The foaming agent is used in a state in which a foaming agent for producing a stable foam (foam) and a foaming agent for generating a foam of an unstable form is mixed, thereby increasing the size dispersion of the bubbles present in the gypsum board while optimizing the bubbles It can be formed in the state of.

The blowing agent that produces the foam of the unstable form may be an alkyl sulfate, for example an anionic alkyl sulfate.

The alkyl sulfate may be represented by the following formula (1).

[Formula 1]

H (CH ₂ ) _n OSO ₃ ^- M ⁺

N may be 1 to 20, and another example may be 6 to 14.

The M may be an alkali metal or a polyatomic cation capable of forming a monovalent cation, for example lithium, sodium, potassium, ammonium, phosphonium, oxonium, and the like.

The blowing agent that produces the foam in stable form may be an alkyl polyglucoside, for example a nonionic alkyl polyglucoside.

The alkyl polyglucoside may have 10 to 20 carbon atoms, and another example may have 10 to 12 carbon atoms.

The total weight of the alkyl sulfate and the alkyl polyglucoside present in the gypsum board foaming agent composition may be 0.05 part by weight to 0.25 part by weight based on 100 parts by weight of gypsum in the gypsum slurry.

The foaming agent composition for gypsum board may include the alkyl sulfate and the alkyl polyglucoside in a weight ratio of 20: 1 to 2: 1, for example, in a weight ratio of 10: 1 to 2: 1, and Other examples may include a weight ratio of 9: 1 to 2.3: 1. When the weight ratio of the alkyl sulfate to the alkyl polyglucoside exceeds 20: 1, the ratio of the alkyl sulfate to form an unstable foam may increase, thereby causing bubbles to bubble in the gypsum slurry. When the weight ratio of the alkyl sulfate and the alkyl polyglucoside is less than 2: 1, the average diameter of the bubbles may be small, and thus, the strength of the gypsum board may finally be poor.

The foaming agent composition for gypsum board may be prepared as a foaming solution in which bubbles are formed therein by foaming for 10 seconds to 10 minutes through a commonly used foaming machine such as a dispenser.

The average diameter of the bubbles contained in the foaming solution may be 0.8 mm to 1.5 mm. If the average diameter of the bubbles is less than 0.8 mm, non-uniform drying may occur in the drying process for manufacturing gypsum board, the adhesive force between the gypsum surface and the paper may be lowered, if the average diameter of the bubbles is more than 1.5 mm gypsum slurry The density of can become so low that the strength of the gypsum board can be poor.

In addition, the present invention provides a gypsum board manufacturing method.

<Gypsum Board Manufacturing Method>

The gypsum board manufacturing method of the present invention includes preparing a gypsum slurry containing a hemihydrate gypsum, and mixing the gypsum slurry with a foaming solution prepared from the above-mentioned gypsum board foaming agent composition.

The gypsum slurry containing the hemihydrate gypsum may be prepared by mixing a solid material and a liquid material containing the hemihydrate gypsum. The solid raw material containing the semi-hydrated gypsum is mixed with the liquid raw material containing the water, and the semi-hydrated gypsum is uniformly distributed in water to make a gypsum slurry, and the gypsum slurry is cast into a desired shape. As it is transformed into a solid form, gypsum board is produced.

Most of the solid raw material is made of hemihydrate gypsum, a small amount of functional additives such as starch or antibacterial agent may be mixed. For example, the hemihydrate gypsum may be included in an amount of 90% by weight to 99.9% by weight based on the total weight of the solid raw material.

The hemihydrate gypsum represents a calcium sulfate hemihydrate salt, and the chemical formula may be represented by CaSO ₄ .1 / 2H ₂ O.

Functional additives such as starch or antimicrobial agent are not limited thereto as long as they can be used in the process of manufacturing gypsum board.

The liquid raw material may further include additives such as process water, waterproofing, water reducing agent, and the like.

The process water (water) may be included in an amount of 10 parts by weight to 50 parts by weight based on 100 parts by weight of the hemihydrate gypsum, and the remaining additives except for the process water are 0.001 parts by weight to 10 parts by weight based on 100 parts by weight of the hemihydrate gypsum. It may be included in the amount of parts.

When the content of the process water in the liquid raw material is less than 10 parts by weight based on 100 parts by weight of the hemihydrate gypsum, the water content in the gypsum slurry is too small to reduce the fluidity of the gypsum slurry and difficult to form outside the mixing chamber (mixer) Symptoms may occur. When the content of the process water in the liquid raw material is more than 50 parts by weight based on 100 parts by weight of the hemihydrate gypsum, the drying cost may increase in a later step in the manufacture of gypsum board may cause a rise in manufacturing cost.

The waterproofing or water reducing agent can be used without limitation as long as it can be used in the gypsum board. The sensitizer may be a sensitizer such as Lignosulfonates, polymer naphthalene sulfonate (PNS), or carboxylate ether polymer (Polycarboxylate ether).

The foaming solution may include 15 parts by weight to 50 parts by weight of process water, 0.03 parts by weight to 0.24 parts by weight of alkyl sulfate, and 0.002 parts by weight to 0.09 parts by weight of alkyl polyglucoside based on 100 parts by weight of the hemihydrate gypsum.

Another gypsum board manufacturing method of the present invention is to prepare a gypsum slurry containing a hemihydrate gypsum, 190: 1 to the gypsum slurry, the alkyl sulfate represented by the formula (1) and alkyl polyglucoside having 10 to 20 carbon atoms Mixing a first foaming solution containing a content of from 23 to 23: 1, and mixing a second foaming solution prepared from a foaming agent composition containing an alkyl polyglucoside to a gypsum slurry to which the first foaming solution is added. It includes more.

In this case, the second blowing solution may include only alkyl polyglucoside as an active ingredient of the blowing agent.

In addition, the gypsum board manufacturing method of the present invention has a process efficiency and economical efficiency using a single mixing chamber, and in order to increase the dispersibility of the bubble size, bubble input piping so that various sizes of bubbles can be introduced into the gypsum slurry. By connecting two or more, foaming solutions with different characteristics (for example, the average diameter of bubbles, etc.) can be prepared and added. That is, the first foamed solution and the second foamed solution may be separated from each other and introduced independently into the gypsum slurry.

According to Fig. 1, in the input line 1, the foam prepared from the mixed foam solution is added to the mixing chamber 3 by adding a foaming agent that produces a foam of stable form to a foaming agent that produces a foam of unstable form. Is committed. At this time, the first foaming machine 1 is introduced into the input line 1 so that the porous disk can be injected at high pressure and foamed. The solid and liquid raw materials are also introduced into the mixing chamber 3 to produce a gypsum slurry. At this time, the input line 1, the solid phase raw material, the input of the liquid raw material can be carried out at the same time, can be added in any order.

According to FIG. 2, in the input line 1, a foam having a large average diameter prepared from the first foaming solution mixed by adding a small amount of the foaming agent to form a stable foam to the foaming agent to form an unstable foam. Is fed into the mixing chamber (3). In the input line 2, only the second foam solution prepared from the foaming agent to generate a foam of a stable form can be injected into the mixing chamber 3 only the bubbles having a small average diameter. At this time, the first foaming machine 1 is introduced into the input line 1 so that the foam can be injected by blowing air at high pressure into the porous disk, and the second foamer 2 is similarly introduced into the input line 2, respectively. Foaming solution can be added to the mixing chamber (3). In this case, in order to optimize the bubbles present in the gypsum slurry, bubbles having a large average diameter should be larger than bubbles having a small average diameter, so that the first foam solution may be added at a higher weight than the second foam solution.

The first foaming solution may include alkyl sulfate and alkyl polyglucoside as an active ingredient of the blowing agent, and the first foaming solution is based on 100 parts by weight of the hemihydrate gypsum, 10 parts by weight to 40 parts by weight of process water, 0.01 weight Parts to 0.5 parts by weight of alkyl sulfate, 0.0001 parts to 0.02 parts by weight of alkyl polyglucoside. For example, it may include 0.03 parts by weight to 0.24 parts by weight of alkyl sulfate, 0.0002 parts by weight to 0.009 parts by weight of alkyl polyglucoside.

The second foaming solution may include alkyl polyglucoside as an active ingredient of the blowing agent, and the second foaming solution may be 5 to 10 parts by weight of process water, 0.0001 to 0.1 parts by weight, based on 100 parts by weight of the hemihydrate gypsum. Parts by weight of alkyl polyglucoside. For example, it may comprise 0.002 parts by weight to 0.075 parts by weight of alkyl polyglucoside.

The first foaming solution and the second foaming solution may be mixed in a weight ratio of 2: 1 to 5: 1. When the weight ratio of the first foamed solution and the second foamed solution is less than 2: 1, the ratio of the foamed solution to produce a stable foam is increased, so that the average diameter of the bubbles is small, drying may be uneven when manufacturing gypsum board, When the weight ratio of the first foamed solution and the second foamed solution exceeds 5: 1, bubbles may be bubbled in the gypsum slurry, resulting in poor strength of the gypsum board.

Hereinafter, the present invention will be described in detail with reference to Examples. However, embodiments according to the present invention can be modified in many different forms, and the scope of the present invention should not be construed as being limited to the embodiments described below. The embodiments of the present invention are provided to more completely explain the present invention to those skilled in the art.

<Example 1>

0.8 g of a blowing agent mixed with Basf's Texapon 842 UP alkyl sulfate and Basf's Glucopon 215UP alkyl polyglucoside at a weight ratio of 95: 5 was mixed with 350 g of water, followed by foaming with a dispenser for 1 minute. The solution was prepared.

1,000 g hemihydrate gypsum, 10 g polymer naphthalene sulfonate (PNS) type water reducing agent, 2 g ball milled dihydrate, 2 g potassium sulfate (K ₂ SO ₄ ), 350 g Immediately after mixing the water, the prepared foaming solution was mixed and mixed to prepare a gypsum slurry.

<Example 2>

In Example 1, a gypsum slurry was prepared in the same manner as in Example 1, except that the alkyl sulfate and the alkyl polyglucoside were mixed in a weight ratio of 90:10, instead of mixing in a weight ratio of 95: 5.

<Example 3>

In Example 1, the gypsum slurry was prepared in the same manner as in Example 1, except that the alkyl sulfate and the alkyl polyglucoside were mixed in a weight ratio of 70:30, instead of mixing in a weight ratio of 95: 5.

Comparative Example 1

In Example 1, a gypsum slurry was prepared in the same manner as in Example 1, except that the alkyl sulfate and the alkyl polyglucoside were mixed at a weight ratio of 50:50 instead of mixing at a weight ratio of 95: 5.

Comparative Example 2

In Example 1, a gypsum slurry was prepared in the same manner as in Example 1, except that the alkyl sulfate and the alkyl polyglucoside were mixed at a weight ratio of 30:70 instead of mixing at a weight ratio of 95: 5.

Comparative Example 3

In Example 1, a gypsum slurry was prepared in the same manner as in Example 1, except that only alkyl sulfate was used instead of mixing alkyl sulfate and alkyl polyglucoside in a weight ratio of 95: 5.

<Comparative Example 4>

In Example 1, gypsum slurry was prepared in the same manner as in Example 1, except that only alkyl polyglucoside was used instead of mixing alkyl sulfate and alkyl polyglucoside in a weight ratio of 95: 5.

The dispersion of the average diameter and the average diameter of the bubbles present in the gypsum slurry prepared in Examples 1 to 3 and Comparative Examples 1 to 4 was measured. The plaster gypsum slurry was placed in a layer between sheets of paper to prepare a miniboard specimen having an area of 0.1 m ² and a thickness of 12.5 mm, and then measured the strength of the specimen. The evaluation results are shown in Table 1 below. The average diameter of the bubbles was measured by an optical microscope to measure the size of each bubble, and the average and dispersion of bubble sizes were measured.

division Alkyl sulfate: weight ratio of alkyl polyglucoside Gypsum density
(g / cm ³ ) Bubble average diameter
(mm) Variance of Bubble Average Diameter Specimen strength
(N) Peeling Experiment
(%) Example 1 95: 5 0.64 1.15 0.0039 259 100 Example 2 90: 10 0.64 1.17 0.0026 250 100 Example 3 70: 30 0.64 0.88 0.0012 244 80 Comparative Example 1 50: 50 0.64 0.24 0.0007 237 5 Comparative Example 2 30: 70 0.64 0.21 0.0001 229 0 Comparative Example 3 100: 0 0.88 0.77 0.0018 280 70 Comparative Example 4 0: 100 0.64 0.11 0.0001 208 0

According to Table 1, as the ratio of the alkyl sulfate increases, the dispersibility of the bubble average diameter increases, it was confirmed that the size of the bubble average diameter also increases.

In addition, according to Table 1, in order to increase the specimen strength, it was confirmed that the average diameter of the bubbles should be increased, and the dispersibility of the average diameter of the bubbles should also be increased. Furthermore, the larger the average diameter of the bubbles, the better the gypsum core and the paper were attached.

In general, the higher the content of the alkyl sulfate, the larger the diameter and the larger the dispersion.However, as shown in the results of Comparative Example 3, if no alkyl polyglucoside is added, bubbles are not maintained during slurry mixing, and thus the average diameter of the bubbles is increased as the gypsum density increases. It is confirmed that it does not grow.

In addition, when the alkyl sulfate was not added at all as in Comparative Example 4, it was confirmed that the specimen strength was poor because the average diameter of the bubbles could not be increased.

<Example 4>

0.76 g of alkyl sulfate and 0.004 g of alkyl polyglucoside were mixed in 270 g of water and foamed for 1 minute to prepare a first foamed solution, and 0.036 g of alkyl polyglucoside was mixed in 80 g of water and foamed for 1 minute. A second foaming solution was prepared.

1,000 g of hemihydrate gypsum, 10 g of polymer naphthalene sulfonate (PNS) type water reducing agent, 2 g of ball milled dihydrate, 2 g of potassium sulfate (K ₂ SO ₄ ), 350 g of water Immediately after, the first foamed solution and the second foamed solution were mixed and mixed to prepare a gypsum slurry.

<Example 5>

In Example 4, 0.72 g of alkyl sulfate and 0.008 g of alkyl polyglucoside were mixed in 270 g of water and foamed for 1 minute to prepare a first foamed solution, and 0.072 g of alkyl polyglucoside was added to 80 g of water. A gypsum slurry was prepared in the same manner as in Example 4, except that the second foaming solution was prepared by mixing and foaming for 1 minute.

<Example 6>

In Example 4, 0.56 g alkyl sulfate and 0.024 g alkyl polyglucoside were mixed in 270 g of water and foamed for 1 minute to prepare a first foamed solution, and 0.216 g of alkyl polyglucoside was added to 80 g of water. A gypsum slurry was prepared in the same manner as in Example 4, except that the second foaming solution was prepared by mixing and foaming for 1 minute.

Comparative Example 5

In Example 4, a first foamed solution was prepared by mixing 0.4 g of alkyl sulfate and 0.04 g of alkyl polyglucoside in 270 g of water and foaming for 1 minute to prepare 0.36 g of alkyl polyglucoside in 80 g of water. A gypsum slurry was prepared in the same manner as in Example 4, except that the second foaming solution was prepared by mixing and foaming for 1 minute.

Comparative Example 6

In Example 4, 0.24 g of alkyl sulfate and 0.056 g of alkyl polyglucoside were mixed in 270 g of water and foamed for 1 minute to prepare a first foamed solution, and 0.504 g of alkyl polyglucoside was added to 80 g of water. A gypsum slurry was prepared in the same manner as in Example 4, except that the second foaming solution was prepared by mixing and foaming for 1 minute.

Dispersion of the average diameter and diameter average of the bubbles present in the gypsum slurry prepared in Examples 4 to 6 and Comparative Examples 5 to 6 was measured. The plaster gypsum slurry was placed in a layer between sheets of paper to prepare a miniboard specimen having an area of 0.1 m ² and a thickness of 12.5 mm, and then measured the strength of the specimen. The evaluation results are shown in Table 2 below.

The bubble distribution of the gypsum specimen according to Example 6 is shown in FIG. 3, and the bubble distribution of the gypsum specimen according to Example 3 is shown in FIG. 4.

division Alkyl sulfate: weight ratio of alkyl polyglucoside Gypsum density
(g / cm ³ ) Bubble average diameter
(mm) Variance of Bubble Average Diameter Specimen strength
(N) Peeling Experiment
(%) Example 4 95: 5 0.65 1.24 0.0043 270 100 Example 5 90: 10 0.64 1.21 0.0034 257 100 Example 6 70: 30 0.64 0.98 0.0024 249 90 Comparative Example 5 50: 50 0.64 0.33 0.0009 241 30 Comparative Example 6 30: 70 0.64 0.29 0.0004 235 10

According to Table 1 and Table 2, the effect of the foaming solution to the gypsum slurry can be confirmed.

Comparing Example 4, Example 1, Example 5, Example 2, Example 6, and Example 3, the foamed solution containing alkyl sulfate and alkyl polyglucoside in the same weight and the same weight ratio is first foamed. In the case of Examples 4 to 6 separated and introduced into the solution and the second foamed solution, the average diameter and average of the bubbles in the gypsum slurry were compared with those of Examples 1 to 3 foamed at once without separation of the foamed solution. It can be seen that the dispersion value of the diameter is larger. This means that the strength of the gypsum board is improved, it can be seen that the strength of the specimen is greater than the case of Examples 1 to 3 in the case of Examples 4 to 6.

Although the present invention has been described in detail only with respect to the embodiments described, it will be apparent to those skilled in the art that various modifications and variations are possible within the technical scope of the present invention, and such modifications and modifications belong to the appended claims.

1: first foaming machine
2: second foamer
3: mixing chamber

Claims (4)

To include an alkyl sulfate represented by the formula (1) and an alkyl polyglucoside having 10 to 20 carbon atoms,
[Formula 1]
H (CH ₂ ) _n OSO ₃ ^- M ⁺
(n is 1 to 20, M is an alkali metal or a monovalent polyatomic cation)
A foaming agent composition for gypsum board, wherein the alkyl sulfate and the alkyl polyglucoside are included in a weight ratio of 20: 1 to 2: 1. Preparing a gypsum slurry comprising hemihydrate gypsum, and
Mixing the foaming solution prepared from the foaming agent composition for gypsum board of claim 1 with the gypsum slurry
Plasterboard manufacturing method comprising a. Preparing gypsum slurry comprising hemihydrate gypsum,
Mixing the first foaming solution with the gypsum slurry containing an alkyl sulfate represented by the following Chemical Formula 1 and an alkyl polyglucoside having 10 to 20 carbon atoms in an amount of 190: 1 to 23: 1, and
[Formula 1]
H (CH ₂ ) _n OSO ₃ ^- M ⁺
(n is 1 to 20, M is an alkali metal or a monovalent polyatomic cation)
And a second foaming solution prepared from a foaming agent composition comprising an alkyl polyglucoside, to the gypsum slurry to which the first foaming solution is added. The method according to claim 3,
The first foamed solution and the second foamed solution is a gypsum board manufacturing method is mixed in a weight ratio of 2: 1 to 5: 1.

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