SA06270225B1 - Siloxane Polymerization in Wallboard - Google Patents

Abstract

Abstract: The present invention relates to the polymerization of siloxane using a gypsum-based slurry comprising stucco, class C fly ash and magnesium oxide, and an emulsion of siloxane and water. This slurry is used in a method of making waterproof plaster products which involves making an emulsion of siloxane and water, then combining the slurry with a dry mix of stucco, magnesium oxide and Class C fly ash. The slurry is then molded as needed and the grout is left stucco silicone siloxane polymerizes. The resulting product is useful for making a water-resistant gypsum panel having a mold (principal material) comprising grids of calcium sulfate dihydrate crystals and silicone resin, in which catalyst is distributed through the grids, comprising magnesium oxide and components of fly ash Class C.

Description

1 Polymerize siloxane in a wall beam

Siloxane Polymerization in Wallboard Full Description BACKGROUND The present invention relates to a method for making water-resistant gypsum products; and including siloxane in particular.” The present invention relates to the addition of a new catalyst for siloxane curing in a gypsum product. 0 - Gypsum-based building products are usually used in construction. Gypsum wall beam is flame retardant and can be used to create walls of almost any shape. It is mainly used as an interior wall and ceiling product, and gypsum has sound-deadening properties. It can be easily repaired or replaced if damaged. There are a variety of decorative finishes that can be applied to the wall beam; It includes paints 0 and wallpaper. Despite all these advantages, it is still a relatively expensive building material. Gypsum is also known as calcium sulfate dihydrate ¢ ground clay 0 and ground mortar landplaster. Paris dough is also known as roasted gypsum of ¢ calcined gypsum stucco ¢ i.e. calcium sulfate semihydrate » or calcium sulfate half-hydrate. Synthetic gypsum, a by-product of off-gas from desulphurization processes from power plants, can also be used. and when 10 raw gypsum is taken out of the mines; It is found in the form of hemihydrate in general. in this picture; There are about two water molecules associated with each molecule of calcium sulfate. To produce a hemihydrate image, “gypsum can be calcined to get rid of some of the rehydration water by the following equation: YEVY

dm CaS0,402H,0—-CaS04e1/2H,0 + 3/2H,0

A number of useful gypsum products can be made by mixing stucco with water and letting

He has the doubt by letting calcium sulfate half-hydrate interact with water to convert hemihydrate

into a lattice of overlapping calcium sulfate dihydrate crystals. by the formation of reticular tissue; The slurry of the product becomes solid and has a preferred shape. Then » the excess water should be removed from the product by means of

drying.

in the absence of additives that prevent this; Gypsum slump absorbs up to 0.75 of its weight at

Submerge it with water. beams or panels that absorb water swell; It becomes deformed and loses its strength.

This property is not preferred in products that are likely to be exposed to water. 1. in areas such as bathrooms or kitchens; High temperatures and humidity are common; Water is likely to come

to the walls. in these areas; It is preferable to use a gypsum beam that is water resistant.

It maintains strength and dimensional stability.

Many attempts have been made to improve the water resistance of gypsum products. Many have been added

of hydrocarbons; It includes waxes, resins and asphalt to slurry to impart 1_ water resistance to the brittle product. The use of silicone compounds; that form silicone resins in

gypsum products; to impart water resistance; well known.

Although the use of silicone compounds in gypsum mortars is a useful means of imparting strength

Water on the final product » However, there are drawbacks related to it. When silicone is added to gypsum mortar

slurry will be commissioned to make silicone resins on site; Silicone may be slow to set. Silicone 0 constitutes a silanol compound, a reactive intermediate for the production of polymethylsilicic acid; which is related to the composition

Yevy

-¢ - silicone resin. The reaction progresses slowly; It usually persists after the gypsum has set and takes 1-2 weeks to show thorough waterproofing. A wall beam made in this way must be stored for a period of time sufficient for water resistance to appear before the beam is shipped. in some cases; The silicone may not dissuade you within a reasonable period of time or may not completely dissuade you. in these cases; No 0 The water resistance of the gypsum beam appears to be satisfactory. in addition to; Failure to process leads to the use of a larger dose of silicone ¢ which increases the cost of raw materials. It is known that the catalysts are Jie oxides and alkaline earth hydroxides; Jaa from Jeli form silicone in gypsum mortar 8010600 . These catalysts are relatively soluble in water and raise the pH of the slurry. PH 0 can interfere with the rehydration of the stucco Gaal and can react negatively with some preferred wall beam additives. on it; As the polymerization of silicone ¢ improves, other considerations make the use of these catalysts unfavorable. MgO” 4” magnesium oxide is known to catalyze reactions of silicone; however, when the activity of the catalyst is high enough to completely cleavage the silicone, cracking is not favored. For light burning MgO 0, the activity required to cleavage silicone quickly, but this activity leads to unfavorable side reactions alg, these side reactions hydrogen which causes product expansion and cracking of brittle gypsum Hard-burning or solid-burning MgO has low activity but results in a lower product However, when using MgO alone, it is very difficult to balance the activity of the catalyst with the limit required for siloxane polymerization of 1

- oo siloxane There are also special plaster sources where it is very difficult to control polymerization in various forms and salts; calcium sulfate from Alas and gypsum is a mixture of polymerization and obviously; that some. aluminosilicate 5 ¢ silicates 5 « aluminates and a variety of when. silicone resin Gypsum sources include one or more of the formation-suppressing ingredients listed; These catalysts are not able to stucco using known catalysts with gypsum types oo of 705 of water absorption. dll has improved water resistance at an affordable cost. The catalyst must be relatively inexpensive; It has good activity with few unfavorable side reactions. There should be a little silicone copolymerization crosstalk between the catalyst and other gypsum additives; 0 GENERAL DESCRIPTION OF THE INVENTION These requirements, along with others, are met or exceeded by the present invention which required silicone and in some cases reduced the amount of ¢ siloxane polymerization from Jia polymerization

ASTM 1398 to meet specifications; and ash stucco using a mortar that includes a special silicone plaster; Day polymerization improves on yo and water. siloxane and an emulsion of volatile fly ash ¢ magnesium oxides© A method for making water-resistant gypsum products involving the making of a slurry emulsion using this mortar; stucco from Gla and slurry mixture water; Then combine the siloxane slurry from slurry Jal) then; Class C. is machined from fly ash; and magnesium oxide fly ash. siloxane polymerizes to mold and polymerize stucco as needed and leave the gypsum 0

YEVY

= - The resulting product is useful for making water-resistant gypsum panel, 4 mold (main material) that includes overlapping retinal tissues of calcium sulfate dihydrate crystals and silicone Cua «resin catalyst distributed through the retinal tissue nested; Contains magnesium oxide and fly ash Class C components

The mixture of magnesium oxide and fly ash © class catalyses the polymerization of silicone to accelerate the development of water resistance in the slurry product. Waterproof products such as wall beams should not be stored for long periods of time waiting for the siloxane polymerization reactions to complete. The use of this catalyst also increases the range of cdo lil) resulting in good water resistance. A water absorption of less than 75 was achieved using the fly ash blend 0; It was not possible to reach this ratio using either catalyst alone. on oxide siloxane that; In addition to accelerating the polymerization reaction; The catalyst also allows polymerization in some cases. And because silicone is more integrated, allowing a reduction in the amount of polymerization, it is one of the most expensive wall beam additives; Reducing the dose leads to silicone

ye save on the cost of raw materials. There is another advantage of the present invention; It is the dimensional stability of the product. Some of the compounds used to catalyze this reaction lead to noticeable expansion when the product dries. And by expanding the beam from (Jalal), it causes a crack in the outer surface of the beam; it damages it. The use of fly ash results in

fly ash and magnesium oxide results in very little expansion and very little cracking in the final product. Yevy

- A - This combination of fly ash, magnesium oxide 5 fly ash, also allows satisfactory polymerization using a wider range of degrees of Law. magnesium oxide Previous art reveals that only solid-burning magnesium oxide is suitable for acting as a catalyst for siloxane polymerization; when combined with fly ash; Hard-burnt or light-burnt magnesium oxide can also be used. This feature allows manufacturers of gypsum products additional freedom in choosing the sources of magnesium oxide used in slurry. Detailed Description: Cay present invention broadly improves the water resistance of gypsum-0 based materials by adding polymerizable silicone to the slurry used to make gypsum-0 based materials based. It is preferable to add silicone in the form of an emulsion. then; The silicone is molded and dried under fund conditions from the polymerization of the silicone to form a well-bonded silicone resin. A catalyst improving the silicone yay to form a well-bonded silicone resin is added to the gypsum slurry. In the face of cole, it is preferable for the silicone to be a silicone modified with fluid linear hydrogen 0, but it can also be a silicone modified with cyclic hydrogen. Composition of well-bonded silicone resins These fluids are well known to persons of average skill in the art and are commercially available; as described in patent books. Typically, compounds include modified silicone linear B 1130:0860 useful in application The present invention contains those with a repeating unit having the general form: fr R n so 1

m - where R is a saturated or unsaturated monovalent hydrocarbon moiety. in preferred forms; R expresses an alkyl group, and it is more preferable that 18 expresses a methyl group. during polymerization; The terminal groups are removed by condensation and the silicone groups link with each other to form silicone resin as chain cross-linking occurs. The resulting silicone resin© imparts water resistance to the gypsum lattice as it sets. The gypsum-based waterproofing materials of the present invention are preferably made using a solventless methyl hydrogen siloxane fluid sold as SILRES BS 94 from Wacker-Chemie GmbH (Munich, Germany) as silicone. The manufacturer states that this product is a siloxane fluid that does not contain water or solvents. It is believed that 0 can be used between about 807 and 06 of 94 siloxane BS based on the weight of the dry ingredients. It is preferable to use between 0.4 Moa and about 7008 of silicone based on the dry weight of the stucco. After 555) slurry ¢ the silicone turns into an emulsion or stable suspension with water. A number of siloxane emulsions have been considered for use in this slurry. 1_water emulsions are also available. Also for purchase, but they can include emulsifiers that tend to modify the properties of gypsum materials, such as paper binder in wall beam products.This is why emulsions or stable suspensions prepared without the use of emulsifiers are preferred.It is preferable to form a suspension on site by mixing a siloxane fluid with water It is essential that the silicone suspension be stable to reach the mixer and remain well dispersed under slurry conditions The siloxane suspension or emulsion must remain well dispersed in the presence of optional additives; Jie set accelerators ¢ that are present in the slurry.It must also remain suspended or emulsified Yevy silicone

Stable through the steps by which gypsum-based products are also cured. Preferably, the suspension should remain stationary for more than £0 minutes. It is more preferable to remain upright for at least one hour. in the explanation and safeguards described below; The term 'emulsion' is meant to include true emulsions and suspensions which are stable at least until stucco© 0.75 solidifies. In a preferred embodiment, preferably at least a portion of the titration water is fed continuously into a high shear mixer. yay siloxane fluid is specified to a high shear mixer with water to emulsify in a period of 1 to 2 seconds.The ratio of water to silicone is not significant; it is known that a mixture of YO is 1 part water to 1 part silicone This emulsion is stable for several minutes without the addition of an emulsifier for a period of time long enough to mix the slurry, form the material, and leave it to solidify. In an alternative embodiment, the use of da from titration water to form The emulsion. A sliding stream of the titration water is combined with the silicone in a high shear mixer. (Xie) It is preferable to add the silicone emulsion to the titration water prior to slurry formation to provide sufficient time for the silicone emulsion to mix thoroughly with the water used for slurry formation; 1 that it is evenly distributed throughout the resulting material, although not wanting to be bound by a particular theory; However, it is believed that water resistance appears when the silicone hardens within the formed wall beam. The polymerization reaction proceeds slowly on its own; This requires the wall beam to be stored for sufficient time to develop water resistance before shipment. It is known that the blues accelerate the polymerization reaction; It reduces or eliminates the time required to store the vy. wall beam product when water resistance appears. The use of solid-burning magnesium oxide to polymerize silicone is described in a pending US patent; No. 01/919717 7; Entitled “Method of Khala A

- y= which is referred to herein cof Making Water-Resistant Gypsum-Based Article” Solid-burning is insoluble and reacts less with magnesium oxide as a reference. And in some cases; Silicone causes other mortar ingredients to be suspicious. It accelerates hardening and is available commercially in a consistent formulation. A particularly preferred source of ses/m 0.1 silicone is BET with a surface area of .baymag 96 solid burnt; It is magnesium oxide © magnesium at least g. And the loss on ignition is less than 7001 by weight. It is preferable to use dry stucco and about 5 based on the weight of the plaster 0.10 in quantities ranging from about “oxide in the market” based on the temperature of magnesium oxide and there are at least three categories of mm You. "Solid Burnt" when the magnesium oxide ranges from roasting. And roasting

Martin) MagChem P98-PV M with most, if not all, activity excluded. You and 00 solid-burning magnesium oxide are an example (Marietta Magnesia Specialties, Bethesda, MD).

Martin ( MagChem 10 5 «(Baymag, Inc. of Calgary, Alberta, Canada) BayMag 96 ( magnesium oxide) is an example of magnetia (Marietta Magnesia Specialties, Bethesda, MD) "solid burning" at temperatures of Solid-burning magnesium oxide. It is roasting and has a high density; it is used at BL m. It has a narrow band of 70901 between about 1000 m and about 1 m. Application normally when slow decay or chemical activity is required; such as in "Light burning" or "caustic" feed, which is magnesium oxide for animals and fertilizers. The third grade is M. 0001 and about a Ver ranges between about Biba It is produced by roasting at degrees This type of material is used in a wide range of applications including magnesium oxide, plastics, rubber, paper, pulp processing, steel boiler additives, and +0 adhesives.

Yivy

11 - - and acid neutralization. Examples of light burning magnesium oxide include 30 BayMag s < BayMag 40" and BayMag 30 (-* 17 mesh) (BayMag, Inc. of Calgary, Alberta, Canada). It has been found to be de lina The preferred catalyst is a mixture of magnesium oxide and fly ash © class. And when mixed in this way; Any grade of magnesium oxide© is beneficial. however; Solid and solid burning magnesium oxide is preferred due to its low activity. The high activity of magnesium oxide Las ¢ can lead to cracking reactions that can hydrogen adh . by producing hydrogen; The product expands causing cracks in the stucco. Expansion also causes collapse of the molds into which the stucco is cast; which leads to loss in detail; The product is deformed into one or more dimensions. and preferably 0; Magnesium oxide 96 (BayMag, MagChem P98-PV) and <MagChem 10 are the preferred sources. It is preferable to add magnesium oxide and fly ash to the gypsum before adding it to the calibration water. sole Dry ingredients such as these are often dribbled to grout when they are moved along a conveyor to the mixer The preferred fly ash is Class © fly ash Hydraulic fly ash © or similar is the most preferred fly ash component A typical composition of Class © fly ash is shown © In table 1. fly ash with a high onl content greater than 7710 lime by weight is obtained from the processing of some coals.ASTM identifier B 0-618;which is referenced herein describes The patent; Class © fly ash attributes. Preferred Class C fly ash is supplied by Bayou Ash Inc., Big Cajunl, LA Preferred fly ash © is used in amounts from about 7001 to about 75 on a dry grout weight basis. Z is preferred YEVY

17 - - more; Use of fly ash in amounts ranging from about 78.7 to 71.99 on the basis of dry weight of gypsum. Table 1: Typical composition of Class C fly ash. Catalytic decomposition of silicone leads to faster and more complete polymerization and cross-linking of silicone to form silicone resin 0 . The stucco hydration forms an interlocking lattice of hemihydrate crystals

calcium sulfate. While the reticular texture of gypsum is repeated; Silicone molecules also recreate texture

silicone resin plexiglass . As long as these materials are formed simultaneously; Partially on (JA) it becomes

The two retinal tissues are intertwined with each other. The water and additives are dispersed into the slurry

» including magnesium oxide fly ash _and additives to be described

0 below; which were distributed through the slurry through the retinal tissue in the interstitial spaces. Lafla 1

creamy

when used to make plaster beams; A number of additives are useful to improve properties

Final article. Conventional amounts of additives are used. If not decided otherwise; no

There are known catalyst or polysiloxane interactions with additives involved. Quantities have been determined

of multiple additives in 'pounds/pad lf square'; which expresses pounds of the additive per thousand

square feet of the bar.

Some embodiments of the invention use a foaming agent to produce voids in the gypsum-containing product

Rigid to provide lighter weight 0 In these models, any foaming agent can be used

It is known to be useful in the preparation of rigid gypsum foam products. And a lot

Among the foaming agents mentioned are well known and already commercially available; For example (JE) the HYONIC | 0 line for the production of soap from (GEO Specialty Chemicals, Ambler, PA) was revealed.

Foams and a preferred method for preparing foam-permeated gypsum products in American patents

0; used as a reference in this patent.

Dispersants 15 are used to improve slurry flow and reduce the amount of water used

To make slurry. Any known distraction is beneficial; It includes polycarboxylates, or sulfonated melamine compounds, or naphthalene sulfonate. It is naphthalene

sulfonate is the most preferred dispersant and is used in quantities ranging from zero lbs/1,000

square feet and 81 lbs / thousand square feet; Most preferably between about ; lbs/thousand square feet

And about 11 lbs. / thousand add sq. The preferred naphthalene sulfonate dispersion is DAXAD

(Dow Chemical, Midland, MI) Dispersant

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16 0- - water is added to the slurry in any quantity ih flowable slurry. The amount of water used varies greatly according to the application in which it is used; the actual dispersant used; And the properties of the plaster Asal stucco used additive. Preferably, the water-to-grout ratio (“WSR”) for wall beam should be between about 0.7 and about 017 based on the dry weight of the plaster. commonly 0 is preferred WSR is between about 0.4 and about 0.9. The water used for making slurries should be practically pure to obtain the best control of the properties of both the slurry and the solid slurry. It is well known that salts and organic compounds modulate the setting time of mortar and vary widely from accelerators to inhibitors of setting. Some impurities lead to disparities in the structure and the overlapping lattice of dihydrate crystal images; This reduces the strength of the rigid product. on it; 0 product strength and consistency are enhanced by the use of water that is practically free of contaminants. stucco gypsum is present; Also known as calcium sulfate semihydrate or roasted gypsum, calcined gypsum; In quantities of at least 0 759 dry matter. It is preferable that the amount of stucco plaster be at least 2860. in many variations of wall beams; The substance of the dry component is more than 790 or even 0 7495 of calcium sulfate semihydrate. The method of roasting is of little importance; Any baked alpha or beta stucco stucco is suitable. Calcium sulfate anhydrite can also be considered, although it is preferable to use it in smaller quantities than TX. Trimetaphosphate compound is added to gypsum slurry in some embodiments to improve product strength and improve sag resistance ( Subsidence) rigid gypsum. It is preferable that the concentration of trimetaphosphate 0 range between about 70004 and about 77.0 based on the weight of the roasted gypsum YEVY

And 1 - calcined gypsum. Compositions of gypsum containing trimetaphosphate compounds have been disclosed in US Patents 7477784 and 13770060; They are referred to by reference in this patent. Examples of Attam 101612005 salts include the sodium or potassium salts of (Jie ¢ trimetaphosphate) that are available from LLC, St.

Louis, MO, Katahafiz. Caution should be exercised when trimetaphosphate is used with lime or other modifiers that raise the pH of the mortar. At a pH of 1m ¢4.6, trimetaphosphate loses 45.3 to fortify the product; The slurry becomes highly disabling. Other additives are also added to the slurry as is customary in the special application of gypsum slurry. Set retarders (up to approximately ? 0 lb/0001 sq ft SA) g/Yo or dehydration accelerators (up to approximately ? lb/0 vo) are added sq ft (Ye fan 171) to adjust the rate at which the hydration reactions take place. “CSA” is a shake rate comprising 79559 calcium sulfate dihydrate milled with 75 sugar; heated to You 771 F (771 F). m) to turn sugar into caramel. CSA is available from “USG Corporation, Southard, OK plant” and is manufactured lag US Patent No. 549 L ve, which is cited as a reference herein. Potassium sulfate is Another preferred accelerator. HRA is calcium sulfate dihydrate that is milled pure with sugar at a rate of about 0 yo g lb of sugar per 100 lbs of calcium sulfate hemihydrate. This has also been described In US Patent 001748199; which is used as a reference herein. These two compounds are preferred as accelerators. YEVY

- 11 -

Another favorite accelerator; Known as a Wet Gypsum Accelerator or WGA A description of the use and method of making a Wet Gypsum Accelerator is disclosed in US Patent 58 + which is referenced herein. This accelerator includes at least one additive selected from the group consisting of a corganic phosphonic compound or a compound

© contains phosphate or mixtures thereof. This special accelerator exhibits great longevity and maintains its effectiveness over time so that a wet gypsum accelerator can be made; and store it; To transport it over long distances before use 0 wet gypsum accelerator is used in amounts ranging from about 0

and about Ae pounds per thousand square feet (YET) to 798 (Tp fon) of the girder product.

Another possible additive to the wall beam is biocides - to reduce

0 mold growth; or mildew; or fungi. Depending on the biocide chosen and the intended use of the wall beam; biocide can be added to the cap; or plaster cast

gypsum core, or both. Examples of biocides include boric acid biocides and Ismattammia

salts ¢ and salts 7. Biocides can be added to either the cover or the gypsum core. When used, biocides are used in the covers

Baie names include a pyrithione of 9060 ppm. Ji is defined by ve quantities

2-mercaptopyridine-N-oxide; 2-pyridinethiol-1-oxide (CAS Registry No. 1121-31-9); 1-

hydroxypyridine-2-thione and 1 hydroxy-2(1H)-pyridinethione (CAS Registry No. 1121-

30-8).

1 No

117 - - The o(CsSH,NOSNa) sodium derivative known as CAS Registry No. ) pyrithione sodium 2--3811) is one example of this particularly useful salt. In addition, pyrithione salts are commercially available from sodium OMADINE (fie ¢<Arch Chemicals, Inc. of Norwalk, CT) or Zinc OMADINE. The gypsum composition may optionally include starches such as the above. It is gelatinized or modified starch using acid.The starch is used in amounts ranging from ? to about 01 lb / 0 sq ft (from 14.6 to 997.23 g / Ta) to increase the strength of the paper bond and to strengthen the product. Previously gelatinized of hard and dried gypsum mold strength; reduces or avoids the risk of paper jamming in the wall beam under excessively wet conditions (eg for high water to calcined gypsum ratios) a person of skill will appreciate Methods for converting raw starch into gelatin in a preparative manner, for example (Jal cooking raw starch in water at temperatures of at least 08 F NOY C) or other methods Suitable examples include starch that has been gelatinized pre-gelatinized but not limited to commercially available PCF 1000 Lis from Lauhoff Grain Company and two types of starch 818 HQM PREGEL 5 AMERIKOR; Available commercially from Archer Daniels Midland Company 0 if included; The starch that has already been gelatinized is present in any suitable quantity. For example; if pre-gelatinized starch is included; It can be added to the mixture used to form the solid gypsum composition, so that it is present in an amount ranging between about 7009 and about 7010 by weight of the solid gypsum composition. It is also possible to add types of starch (United States Gypsum Company, Chicago, IL) Jie 115095 as an option to strengthen the base material. Other known additives may be used as needed to modify certain product properties. Sugars such as dextrose are used to improve the bonding of the paper to the ends of the beams. YeVY

M81 - Wax emulsions or 5 are used for water resistance. if stiffness is required; It is common to add acid © . The ignition inhibition can be improved by the addition of formulations 4859 These and other additives known to be useful in existing slurry and gypsum board formulations. Optionally, fiberglass is added to mortar 0 in quantities of up to 11 lb / 0001 cu ft (08 g) Ta and up to 11 001 lb / sq ft (7.7 g) / (Tp) of paper fibers to the mortar. Wax emulsions are added to the gypsum slurry in amounts up to 50 lb/ 0001 sq ft (79; kg/a) to improve the water resistance of the finished gypsum keel board. During the process, a slide stream of calibration water is taken and combined with silicone and water in a 0 - high shear mixer to form an emulsion 91116006. The two components are mixed for several minutes until a stable emulsion is formed. From the high shear mixer the emulsion goes directly to the slurry mixer It is mixed with the remainder of the calibration water.At the same time the stucco andl moves towards the mortar mixer.Before entering the mixer dry starch additives or set accelerators are added to the stucco plaster. 1 Powder Some additives are added directly to the mixer via a separate line For most of the additives it is not important to put the additives into the slurry nosnai They can be added using any suitable equipment or methods. after mixing; Optional foam is added to the wall keel to reduce product density. fis lather by mixing soap with water. Then the soap is injected into the mobile gypsum slurry 0 after leaving the mixer through an inclined hose or tube. The foaming ring is a YEVY device

q —_— \ _ multiple ports arranged in a ring perpendicular to the axis of the hose so that foam is forced under pressure into the gypsum slurry as it passes through the foam ring. when combining foam and mortar; The resulting slurry moves forward and is poured onto a conveyor aligned with one piece of interface material 8 . and another piece of facing material is placed on top of the mortar 7; Where the mortar is inserted between the two facing materials 0 and the aforementioned sandwich shape is fed to a forming board » and its lols height determines the crossbar. after that; The continuous sandwich is cut into convenient lengths at the cutting knife; It usually ranges between eight and twelve feet. (dive) The beams move into a drying oven. The temperatures in the oven are typically between 4506°F and a maximum of 9008°F. It is preferable to have three temperature zones or more in the kiln. In the first zone that the beam touches In the last two zones the temperature increases to the maximum while the temperature decreases slowly. The fan of the first zone is placed at the outlet of the zone, so that it blows air against the direction of the movement of the beam. In the second and third zones, the fans are located at the entrance of the zone, and they direct the hot air In the direction of the beam movement Vo. The less intense heating in zone 1 of the latter prevents the roasting of the dry areas of the beam, causing poor bonding of the paper. The typical residence time in the oven is about forty minutes, but the time varies depending on the capacity of the line"; moisture of the bar and other factors EXAMPLE 1 Two grams of solid-burning magnesium oxide BAYMAG 30 and grams of YEVY are added

nor - fly ash Class © to 0 g of stucco from each of the several sources specified in the table? 0 These dry ingredients are placed in a plastic bag and shaken to mix. Sg Prepare an emulsion by mixing ??.? aha of silicone 3894 and .00 g water for 0.¥ min in a high-shear 0 mixer (Silverson Machines, East) (Longmeadow, MA©). Emulsion is poured into a Waring mixer. 1 liter at 6 96 rpm (Waring Products, Inc., Torrington, CT) for 0 sec. Then, the slurry is poured into a 7 * SYN cube mould. After setting, the slurry is emptied. The molds are made from cubes and placed in an oven to dry until a constant weight is reached at 0.11 F. The dry cubes are immersed in water for two hours for a water absorption test as specified in accordance with ASTM C1396 (0) which is cited as a reference in this patent. Weight gain during immersion was used to calculate water absorption Table Y stucco Dryness Dryness Humidity ea | eee er | Yevy

— \ ¥ — To | [wa [en ea] [Sem | Ce | ves wa [owe ee | 7 we wr [wa] an | 7 ee | ev | en | wef ee T° To en [ea ev | This example demonstrates the ability of this catalyst to reduce water absorption to less than 75 in a variety of grouts. example? Experiments were conducted on a commercial scale to test the performance of a mortar containing VY lbs/1,000 sq ft silicone 0; It contains magnesium oxide and fly ash as shown in Table 7. Magnesium oxide 5 fly ash is added to the grout before entering the mixer. The type and brand of the roasted magnesium oxide are also shown in Table 3. Silicone is added to the calibrated ele and mixed in a high shear mixer to form an emulsion. This emulsion is combined with the dry ingredients in a grout mixer until a homogeneous slurry is formed; The slurry 0 is placed on a face paper on a conveyor. The packing paper is placed on top of the slurry and the sandwich is fed to a forming roller which flattens the sandwich to a regular 01 inch (01 cm) half lela. when the mortar has hardened enough to keep its shape; Continuous beams are cut into 8-foot lengths. Table 1 Source of MgO Amount of MgO Amount of fly ash Absorption for two hours fly ash

Baymag 96 hea | ae |e |e] dee | ee |e Te

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except Te |e oe | dea | ee be dey |e |e [oe fee | ae oe Te fev |e oe Te IE > Er EE ger ov Te [fe] den vee pe oer Te fe] rs Te] aaa kaf 1 ee dee | [ox fe den oe x pe] en ve x be dee | vx | ka all ey ev la a le le as en aaa ka rw ae eT eee when adding fly ash to solidly burned magnesium oxide 10 “MagChem water resistance improves to more than AYO and the same comparison is made when the same amount of fly ash is added to ? lbs/thousand square feet of 30 BayMag. The same combination of fly ash with ? lbs/thousand sq ft of BayMag 30 is better than 4 lbs/all sq ft of BayMag 30 on its own. example? 1 5/1

The cubes are made according to Example 1 using Shoals plaster and 0.7 by weight of 94 silicone BS. Either “Baymag 30 magnesium oxide” or fly ash or both shall be added to the slurry as Za ga in table ¢. The target water adsorption was 1/.

schedule ;

Baymag 30 fly ash fly ash water adsorption ash 0 When using magnesium oxide and fly ash ae Flyash the water reduction is improved by equivalent to the amounts shown in the above example. Example ¢ Gypsum cubes are made according to the method in Example 1 using silicone icy and catalyst composition 0 shown in Table 4. Table © Source ual MgO dosage Fly ash Water absorption fly ash silicone stucco YEVY

y $ _ - oe a a l re Len | evr fame aj fee srr | Cte | ene dah ‎fam] Dim | Yes | oa These tests have been carried out on stucco plasters for which it is difficult to obtain a satisfactory water resistance. Neither fly ash nor MgO alone was able to produce the desired standard of less than 75 water absorption. For this, Laie, the two laa catalysts were used. Absorption of the amount of J of the standard was well achieved; Even with a lower dose of silicone m o Judi a factory trial was conducted to test this catalyst in a wall beam on a commercial scale. The composition of the wall girder is shown in Table A, Table + “0 thousand km pe except 1

- Yo-ee | owes LC-211 4 “Daxad 3 and thickener” USGS 5 “trimetaphosphate 5” HRA Add dry silicone 5. stucco water and 1480 are mixed to grout ¢ fly ash and fly ash in silicone in a high speed mixer at high speed for less than one minute to make a stable suspension of and mix it with titration water;catalyst mix/water slurry.Then;the suspension is pumped to the slurry mixer sec. Once the slurry is discharged the VO remains in the grout mixer is less than stucco 0.

YEVY

Y 2 —_ —- Mixer; The foam made of soap is inserted; and foams air and foams water to slurry - to reduce the tell density of a product. Table 1 Water Absorption The cubes are made from a sample of mortar in accordance with ASTM 1396©. The results of the absorption tests are shown in Table 6. These tests confirm that a wall beam with a water absorption of less than 75 can be produced in a commercial mold using a catalyst, mortar and method. present invention. Although a special model of fly ash and a magnesium oxide catalyst for siloxane polymerization has been demonstrated and described; Those skilled in the art will appreciate that modifications and variations may be made to it without deviating from the invention and its broader features and as set forth in the following Claims 0 - . YEVY

Claims (1)

Y Y — — Claims 1-1 mortar containing: stucco in an amount of at least 0 75 by weight of total dry matter in mortar and slurry ¢ ¢ and fly ash class ¢” C magnesium oxide °¢ 1 and an emulsion of siloxane and water. -Y 1 slurry slurry according to claim 0 where the rate of said fly ash to said magnesium oxide ranges between about ?: 1 and about AY 1 *- Gy slurry slury for claim 7; The said fly ash Y presents in the slurry in amounts ranging from about 7001 to about 75 on the basis of dry stucco weight. 01 +- slumy mortar according to claim 10 in which the said fly ash Y is present in amounts ranging from about 7001 to about 75 based on the weight of dry stucco plaster. —o 1 slurry of claim 1 in which said magnesium oxide X is present in amounts ranging from about 7001 to about 70.5 on the basis of dry weight of the stucco. No 1 1>- slurry slurry according to protection Gua) said magnesium oxide Y is solid or solid burnt magnesium oxide. 1 #- slurry according to claim 1 where said emulsion comprises silicone polysiloxane fluid Y and water. —A 1 slurry ai, slurry of claim 1 where Sle HSA silicone is fluid silicone; linear; rate of hydrogen . 1 4- Shury slurry of claim 0 where it also comprises at least one of group 7 consisting of starch and foaming agents; and accelerators 1 doubt set accelerators; set retarders ¢ and biocides ¢ + dispersants + fibers or enhancers) 348 strength enhancers °. -01 1 slurry of claim Gamo) Said emulsion comprises a stable Y suspension. -11-1 Slurry of claim 1, wherein said suspension is free of emulsifying agent Y. 1 No : a method for making water-resistant gypsum products comprising \Y-1 and water; siloxane for preparing an emulsion of class Y© with fly ash plaster and magnesium oxide fly ash and then mixing 1stucco¢ catalyst To form a slurry containing [stucco pan) with a siloxane admixture mix emulsion 2 by weight of at least 0 70 total dry material weight in the slurry to a grout of 1 ¢ slurry l slurry forming slurry A wallboard to form; Forming the wall beam mold, gypsum slurry, leaving gypsum mortar, q. siloxane; and polymerization of core Ya wherein the said preparation step includes mixing OY (method according to claim VF) and water in a high shear mixer. silicone Y wherein said forming step includes intercalation VY (method of claim VF) -1 1 To form a beam facing material between two pieces of slurry facing material Y . wallboard panel and a wall where the aforementioned mixing step takes place before the mixing step VY of the protection element Way 11-1 the aforementioned method. Y LS from the era where it also includes taking the method 01 according to the element Protection 11-1. Determined from the titration water for use as Y YEVY Ars 1-1 water-resistant gypsum panel with molding includes 7 interlocking 3S crystal textures; calcium sulfate hemihydrate 75 wt ¥ at least total dry weight of volatile matter in core and non-sulfate ¢ catalyst dispersed through interwoven mesh tissue aad comprising magnesium oxide °C and fly ash components Class C. Gay panel zs 18 -1 of claim OV which also includes at least one of the groups consisting of starch and foaming agents “Y” and set accelerators Sal; set retarders, biocides, and dispersants; The fibers or strength enhancers ° ¢ are distributed throughout the aforementioned overlapping retinal tissue. <1 01 The Gay panel of the VY protection element, where the said template is sandwiched between two Y pieces of facing material. Yevy