TW200920712A - Microstructure features of gypsum wallboard made with high starch and high dispersant level - Google Patents
Microstructure features of gypsum wallboard made with high starch and high dispersant level Download PDFInfo
- Publication number
- TW200920712A TW200920712A TW97137701A TW97137701A TW200920712A TW 200920712 A TW200920712 A TW 200920712A TW 97137701 A TW97137701 A TW 97137701A TW 97137701 A TW97137701 A TW 97137701A TW 200920712 A TW200920712 A TW 200920712A
- Authority
- TW
- Taiwan
- Prior art keywords
- weight
- gypsum
- stucco
- amount
- wallboard
- Prior art date
Links
- 239000010440 gypsum Substances 0.000 title claims abstract description 204
- 229910052602 gypsum Inorganic materials 0.000 title claims abstract description 204
- 239000002270 dispersing agent Substances 0.000 title claims description 42
- 229920002472 Starch Polymers 0.000 title description 17
- 235000019698 starch Nutrition 0.000 title description 17
- 239000008107 starch Substances 0.000 title description 17
- 239000011800 void material Substances 0.000 claims description 72
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 62
- 239000002002 slurry Substances 0.000 claims description 56
- PSZYNBSKGUBXEH-UHFFFAOYSA-M naphthalene-1-sulfonate Chemical compound C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-M 0.000 claims description 27
- 239000000344 soap Substances 0.000 claims description 25
- 229920000881 Modified starch Polymers 0.000 claims description 22
- UGTZMIPZNRIWHX-UHFFFAOYSA-K sodium trimetaphosphate Chemical compound [Na+].[Na+].[Na+].[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 UGTZMIPZNRIWHX-UHFFFAOYSA-K 0.000 claims description 21
- 239000003365 glass fiber Substances 0.000 claims description 18
- 239000007864 aqueous solution Substances 0.000 claims description 13
- 239000011505 plaster Substances 0.000 claims description 12
- 239000000843 powder Substances 0.000 claims description 11
- 239000000835 fiber Substances 0.000 claims description 9
- 239000004575 stone Substances 0.000 claims description 7
- 239000000126 substance Substances 0.000 claims description 7
- 239000011521 glass Substances 0.000 claims description 5
- 239000006185 dispersion Substances 0.000 claims description 4
- 239000004744 fabric Substances 0.000 claims description 4
- 239000011152 fibreglass Substances 0.000 claims description 4
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 claims 2
- 230000002787 reinforcement Effects 0.000 claims 1
- 239000001509 sodium citrate Substances 0.000 claims 1
- NLJMYIDDQXHKNR-UHFFFAOYSA-K sodium citrate Chemical compound O.O.[Na+].[Na+].[Na+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O NLJMYIDDQXHKNR-UHFFFAOYSA-K 0.000 claims 1
- 229910052938 sodium sulfate Inorganic materials 0.000 claims 1
- 235000011152 sodium sulphate Nutrition 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 14
- 239000000203 mixture Substances 0.000 description 78
- 238000012360 testing method Methods 0.000 description 72
- 238000009472 formulation Methods 0.000 description 64
- 239000000428 dust Substances 0.000 description 39
- 238000009826 distribution Methods 0.000 description 20
- 239000006260 foam Substances 0.000 description 17
- 239000000123 paper Substances 0.000 description 17
- 238000001878 scanning electron micrograph Methods 0.000 description 16
- 239000013078 crystal Substances 0.000 description 15
- 238000000034 method Methods 0.000 description 14
- 239000000047 product Substances 0.000 description 14
- AZSFNUJOCKMOGB-UHFFFAOYSA-K cyclotriphosphate(3-) Chemical compound [O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 AZSFNUJOCKMOGB-UHFFFAOYSA-K 0.000 description 11
- 238000005553 drilling Methods 0.000 description 10
- 238000012545 processing Methods 0.000 description 10
- 229920002261 Corn starch Polymers 0.000 description 9
- 239000008120 corn starch Substances 0.000 description 9
- 238000005520 cutting process Methods 0.000 description 9
- 150000003839 salts Chemical class 0.000 description 8
- 238000004626 scanning electron microscopy Methods 0.000 description 8
- 238000001035 drying Methods 0.000 description 7
- 239000012634 fragment Substances 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- 239000002253 acid Substances 0.000 description 6
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 6
- 239000004615 ingredient Substances 0.000 description 6
- 229920000388 Polyphosphate Polymers 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 238000001704 evaporation Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- UFWIBTONFRDIAS-UHFFFAOYSA-N naphthalene-acid Natural products C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 5
- 239000001205 polyphosphate Substances 0.000 description 5
- 235000011176 polyphosphates Nutrition 0.000 description 5
- 238000005452 bending Methods 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical group C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 3
- 240000008042 Zea mays Species 0.000 description 3
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 3
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 239000011324 bead Substances 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 235000005822 corn Nutrition 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 230000008020 evaporation Effects 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 125000005341 metaphosphate group Chemical group 0.000 description 3
- 239000004570 mortar (masonry) Substances 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 239000011734 sodium Substances 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- LNETULKMXZVUST-UHFFFAOYSA-N 1-naphthoic acid Chemical class C1=CC=C2C(C(=O)O)=CC=CC2=C1 LNETULKMXZVUST-UHFFFAOYSA-N 0.000 description 2
- 241000196324 Embryophyta Species 0.000 description 2
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 description 2
- XYFCBTPGUUZFHI-UHFFFAOYSA-N Phosphine Chemical compound P XYFCBTPGUUZFHI-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 239000003139 biocide Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 125000004122 cyclic group Chemical group 0.000 description 2
- 150000004683 dihydrates Chemical class 0.000 description 2
- 238000010410 dusting Methods 0.000 description 2
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 239000003337 fertilizer Substances 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- 239000013022 formulation composition Substances 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 239000008103 glucose Substances 0.000 description 2
- 239000003292 glue Substances 0.000 description 2
- 238000009533 lab test Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000001000 micrograph Methods 0.000 description 2
- 150000002790 naphthalenes Chemical class 0.000 description 2
- 125000005608 naphthenic acid group Chemical class 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920000417 polynaphthalene Polymers 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000005871 repellent Substances 0.000 description 2
- 230000002940 repellent Effects 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 2
- 230000002195 synergetic effect Effects 0.000 description 2
- 239000008399 tap water Substances 0.000 description 2
- 235000020679 tap water Nutrition 0.000 description 2
- HMUNWXXNJPVALC-UHFFFAOYSA-N 1-[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]piperazin-1-yl]-2-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)ethanone Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)N1CCN(CC1)C(CN1CC2=C(CC1)NN=N2)=O HMUNWXXNJPVALC-UHFFFAOYSA-N 0.000 description 1
- LDXJRKWFNNFDSA-UHFFFAOYSA-N 2-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)-1-[4-[2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidin-5-yl]piperazin-1-yl]ethanone Chemical compound C1CN(CC2=NNN=C21)CC(=O)N3CCN(CC3)C4=CN=C(N=C4)NCC5=CC(=CC=C5)OC(F)(F)F LDXJRKWFNNFDSA-UHFFFAOYSA-N 0.000 description 1
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical group [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 108010010803 Gelatin Proteins 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical group [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 241000612118 Samolus valerandi Species 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- WQZGKKKJIJFFOK-VFUOTHLCSA-N beta-D-glucose Chemical compound OC[C@H]1O[C@@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-VFUOTHLCSA-N 0.000 description 1
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 1
- 239000004327 boric acid Substances 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 239000011575 calcium Chemical group 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 210000000078 claw Anatomy 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- -1 clays Substances 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000002591 computed tomography Methods 0.000 description 1
- 239000007859 condensation product Substances 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000007676 flexural strength test Methods 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 238000013467 fragmentation Methods 0.000 description 1
- 238000006062 fragmentation reaction Methods 0.000 description 1
- 229920000159 gelatin Polymers 0.000 description 1
- 239000008273 gelatin Substances 0.000 description 1
- 235000019322 gelatine Nutrition 0.000 description 1
- 235000011852 gelatine desserts Nutrition 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 150000002429 hydrazines Chemical class 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 210000003127 knee Anatomy 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000003020 moisturizing effect Effects 0.000 description 1
- PSZYNBSKGUBXEH-UHFFFAOYSA-N naphthalene-1-sulfonic acid Chemical group C1=CC=C2C(S(=O)(=O)O)=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-N 0.000 description 1
- URXNVXOMQQCBHS-UHFFFAOYSA-N naphthalene;sodium Chemical compound [Na].C1=CC=CC2=CC=CC=C21 URXNVXOMQQCBHS-UHFFFAOYSA-N 0.000 description 1
- RWYGQIQKHRMKFH-UHFFFAOYSA-N naphthalene;sulfuric acid Chemical class OS(O)(=O)=O.C1=CC=CC2=CC=CC=C21 RWYGQIQKHRMKFH-UHFFFAOYSA-N 0.000 description 1
- 125000005609 naphthenate group Chemical group 0.000 description 1
- 150000005209 naphthoic acids Chemical class 0.000 description 1
- 125000001624 naphthyl group Chemical group 0.000 description 1
- 239000012074 organic phase Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 229910000073 phosphorus hydride Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 239000011591 potassium Chemical group 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 238000007790 scraping Methods 0.000 description 1
- 230000011218 segmentation Effects 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 229940074404 sodium succinate Drugs 0.000 description 1
- ZDQYSKICYIVCPN-UHFFFAOYSA-L sodium succinate (anhydrous) Chemical compound [Na+].[Na+].[O-]C(=O)CCC([O-])=O ZDQYSKICYIVCPN-UHFFFAOYSA-L 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- QPLUUBGVWZCEER-UHFFFAOYSA-H tricalcium 2,4,6-trioxido-1,3,5,2lambda5,4lambda5,6lambda5-trioxatriphosphinane 2,4,6-trioxide Chemical compound [Ca++].[Ca++].[Ca++].[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1.[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 QPLUUBGVWZCEER-UHFFFAOYSA-H 0.000 description 1
- SUZJDLRVEPUNJG-UHFFFAOYSA-K tripotassium 2,4,6-trioxido-1,3,5,2lambda5,4lambda5,6lambda5-trioxatriphosphinane 2,4,6-trioxide Chemical compound [K+].[K+].[K+].[O-]P1(=O)OP([O-])(=O)OP([O-])(=O)O1 SUZJDLRVEPUNJG-UHFFFAOYSA-K 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
-
- 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
-
- 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
- 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
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
- C04B2111/0062—Gypsum-paper board like materials
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/40—Porous or lightweight materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249967—Inorganic matrix in void-containing component
- Y10T428/249968—Of hydraulic-setting material
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Structural Engineering (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Laminated Bodies (AREA)
- Building Environments (AREA)
- Panels For Use In Building Construction (AREA)
- Finishing Walls (AREA)
Description
200920712 九、發明說明: 【發明所屬之技術領域】 本發明係關於一種具有一微結構之輕重量石膏牆板,該微結構 包含大的空氣空隙,該等空隙之顯著的厚壁具有強化的緻密表面 (reinforced densified surfaces )。本發明亦關於一種製造具有此微 結構之輕重量牆板之方法。 【先前技術】 '石膏(硫酸鈣二水合物)的某些特性使其非常普遍地用於製造 工業及建築產品中,例如石膏牆板。石膏係豐饒且普遍低價位之 原料,透過脫水及再水合之處理,石膏可經澆鑄、鑄型或以其他 方式塑型成可用的形狀。用以製造石膏牆板及其他石膏產品之基 本原料係半水合物形式的硫酸鈣(CaS04· 1/2H20),通常稱為「灰 泥」,其係藉由二水合物形式的硫酸鈣(CaS04.2H20)之熱轉換 所產生的,其中的水分子已被移除。 儘管產品裁切或鑽孔時會產生大量的石膏塵埃,傳統的含石膏 4 產品(例如石膏牆板)仍具有許多優點,例如低成本及易於加工 性。使用澱粉作為製造含石膏產品所用漿料之成分已達到多方面 的改良。預膠化澱粉,例如膠(glue),可增加含石膏產品(包含 石膏牆板)的撓曲強度及壓縮強度。已知的石膏牆板含有低於約 10磅/MSF (千平方英呎)之澱粉含量。 為了確保漿料的適當流動性,亦必須於含有預膠化澱粉之石膏 漿料中使用大量的水。不幸的是,大部分此類的水最終必須藉由 乾燥而除去,由於乾燥過程所用燃料的高成本而使花費提高,且 200920712 乾燥步驟亦是費時的。已發現使用萘磺酸鹽分散劑可增加漿料的 流動性,進而可克服水需求量的問題。此外,亦已發現若萘績酸 鹽分散劑之用量夠高,其可在乾燥之後與預膠化澱粉交聯,進而 使石膏晶體結合在一起而可增加石膏複合體的乾強度。因此,預 膠化澱粉與萘磺酸鹽分散劑之組合可提供一類膠效果,而將凝固 石膏晶體結合在一起。三偏磷酸鹽在過往並未被認定為會對石膏 漿料的水需求量產生影響。然而,本案發明人已發現於一特定分 散劑的存在下,增加三偏麟酸鹽的含量至迄今仍未知的含量,可 達到適當之漿料流動性,且同時出乎意料地可減少水量(即便有 高含量之澱粉存在)。當然,此係高度所欲者,因其可減少用於乾 燥的燃料用量,以及減少與後續水除去步驟相關之處理時間。因 此本案發明人亦已發現藉由在用於製造牆板之漿料中,將一萘磺 酸鹽分散劑與預膠化澱粉併用可增加石膏板的乾強度。 本發明之石膏牆板應與不具有飾面薄片之吸音板或磚瓦區隔。 再者,本發明牆板亦應與含有聚苯乙烯作為輕質附聚物之吸音板 或磚瓦區隔。重要的是,前述之吸音板及磚瓦並未達到多數適用 於石膏牆板之ASTM標準。舉例言之,已知的吸音板並未具有包 含本發明石膏牆板在内的石膏牆板所需之撓曲強度。相反地,為 使吸音板或磚瓦達到ASTM標準,需要使吸音板或磚瓦的曝露面 具有空洞空隙或凹陷,此對於石膏牆板而言並非所欲者,且會對 抗拔釘力特性以及表面硬度特性產生不利的影響。 在所有牆板的安裝過程中,塵埃的產生係一個潛在的問題。當 對石膏牆板進行例如裁切、鋸開、挖槽、刨痕、釘釘子或鎖螺絲、 200920712 或鑽孔等加工時,會產生大量的石膏塵埃。為了本發明揭露之目 的,「落塵(dusting )」及「塵埃產生(dust generation )」係代表當 對含石膏產品加工時,例如對牆板進行裁切、鋸開、挖槽、刻痕/ 刨痕、釘釘子或鎖螺絲、或鑽孔等工作時,釋放經空氣傳播的塵 埃至周圍的工作空間中。加工亦可廣泛地包含一般的板處理,包 含於運送、運載及安裝過程中意外地敲碎及刮到板所製造的塵 埃。若能發現一種製造可明顯地減少塵埃產生之低密度牆板之方 法,此方法將可於本領域提供特別有用的貢獻。 此外,若能發現一種能增加石膏牆板強度且同時減少板重量之 方法,此將可於本領域提供有用的貢獻。現有牆板產品中之空氣 空隙具有相對較薄之壁,其中空隙間的平均壁厚度為約20至30 微米。若能提供一種新類型的石膏牆板,具有增加的厚度及強化 的緻密表面之壁的空氣空隙的微結構並因此增加的牆強度,將可 達成本領域中之一重要且有用的貢獻。又,若能發現一種增加空 隙尺寸且同時增加空隙之間之壁的厚度及表面密度,以製造具有 增加的強度及處理特性之低密度牆板之方法,此方法將可於本領 域提供另一個重要的貢獻。 【發明内容】 本發明廣泛而言係包含一輕重量石膏牆板,包含一凝固石膏 芯,其係形成於實質上平行之二覆蓋薄片之間,該凝固石膏芯具 有廣泛地分散遍佈於該凝固石膏芯之空隙,且該空隙具有平均厚 度為至少約30微米至約200微米與強化的緻密表面之壁。該凝固 石膏芯係由一含石膏漿料所製得,該漿料包含水、灰泥、以約〇_5 200920712 重量%至約ίο重量%(以灰泥之重量計)之量存在之預膠化澱粉、 以約〇,2重量%至約2重量% (以灰泥之重量計)之量存在之萘磺 酸鹽分散劑、以約〇,1重量%至約〇·4重量% (以灰泥之重量計) 之量存在之三偏磷酸鈉、以及以最高約〇 2重量%(以灰泥之重量 計)之量存在之視需要的玻璃纖維。最後,肥皂泡沫係以能提供 約27 pcf至約30 pCf之凝固石膏芯密度之有效量存在。「pcf」係 定義為多少碎/立方英叹(lb/ft3 )。 根據本發明所製得之石膏牆板具有高強度,卻具有比傳統牆板 更輕的重量。此外,已發現根據本發明實施態樣所製得之輕重量 之石膏牆板’其具有大的空氣空隙,該等空隙之顯著的厚壁具有 強化的表面,可同時加強牆板芯之微結構,製造具有優異的強度 及加工特性之牆板。又,本文亦描述製造此類輕重量之具有優異 的強度及加工特性之石膏牆板之方法。 【實施方式】 出乎意料地,已發現使用含石膏漿料(含有灰泥、預膠化澱粉、 奈~酸鹽分散劑、三偏磷酸鈉、視需要的玻璃纖維、以及適當量 之肥皂泡沫)所製得之石膏牆板可提供增加的空氣空隙體積,其 中該等空氣空隙周圍(即因此亦為空隙之間)的壁係實質上較厚 且具有強化的表面,並因而比傳統牆板中所發現的空氣空隙要來 的更堅固。該增加的空氣空隙體積可減少板密度與重量,且該較 厚之強化的壁可藉由強化凝固石膏芯之微結構而使牆板更堅固。 因此,根據本發明所製得之最終輕重量之牆板,具有優異的拔釘 力、撓曲強度、芯/邊緣硬度、以及其他的高度所欲之特性。此外, 200920712 於一較佳實施態樣中’根據本發明所製得之1/2英吋的最終輕重量 之石膏牆板’其乾重量為約1150碎/MSF至約1260磅/MSF,並具 有約27pcf至約3〇pcf之低板芯密度。 引入肥皂泡沫會產生小的空氣(泡泡)空隙,平均直徑可小於 約100微米,但其直徑通常大於約10微米,較佳大於約2〇微米, 更佳大於約50微米。本發明需要這些小的空氣泡泡,連同蒸發水 的空隙(直徑通常為約5微米或更小,一般係小於約2微米)一 差 起,廣泛且均勻地分散遍佈於最終牆板產品中之凝固石膏芯。舉 例言之,凝固石膏芯具有一約75%至約95%,較佳為約8〇%至約 92%之總空隙體積,其中至少60%之總空隙體積包含平均直徑大於 約10微米之空氣空隙’且至少10%之總空隙體積包含平均直徑小 於約5微米之水空隙。咸信以此方式所製造之低密度的板芯,凝 固石膏芯之約80%至約92%的總空隙體積係空氣及水空隙(總芯 空隙體積),可抓取大量的細小塵埃及其他碎屑留在因對板進行裁 切、鋸開、挖槽、刨痕、釘釘子或鎖嫘絲、或鑽孔等工作而曝露 之空隙中,以使塵埃之產生顯著地減少並使塵埃不會隨空氣傳 播。更佳地’本發明牆板之凝固石膏芯可具有平均直徑為約5〇微 米至約300微米之空氣空隙。 於一實施態樣中,平均而言,空氣空隙之壁具有大於約3〇微米, 最高約200微米之平均厚度。較佳地,空隙之壁厚平均為至少約 50微米。更佳地,空隙之壁厚平均為約70微米至約ι2〇微米。此 外,如第15圖至第19圖所示,較小的晶體尺寸(尤其是非常小、 非常細微的針狀物)與晶體之較緻密的堆積某裎度可賦予較厚的 200920712 空氣空隙壁。 咸信該等壁表面的強化係由於在板的初始乾燥期間,預膝化殿 粉/分散劑/三料咖移至空氣空隙表面,填補壁表面的針狀空隙 並因此緻密化該表面。此強化了凝固石f芯之微結構製造具有 增加的強度及提高的加卫特質之牆板。所得之經強化的緻密表面 可由例如第15圖中之「A」處看出,其中所指出之緻密區域係沿 者壁表面延伸。儘管咸信此強化的表面包含經移動之預膠化殿 粉、分㈣、以及三糾義,本⑽a狀並料謂本發明係被 此說明所限制,且係認同該強化的表面可包含比所有這三種材料 還要少的材料並確實可衍生自不同的來源或機制。 於一較佳實施態樣中,輕重量之石膏膽板包含一凝固石膏芯, 其係形成於實質上平行之二覆蓋薄片之間,該凝固石膏芯具有廣 泛地分散遍佈於該凝固石膏怎之空隙,該等空隙係由具有強化的 緻密表面之增厚的壁所界—較佳凝固石膏芯係由—含石膏衆 料所製得’該漿料包含水、灰泥、以約〇 5重量%至約ι〇重量% (乂人泥之重里计)之量存在之預膠化澱粉、以約重量%至約
2重$%(以灰泥之重量計)之量存在之萘績酸鹽分散劑、以約(M 重量%至約0.4重量%(以灰泥之重量計)之量存在之三偏攝酸納、 以及以最高為約〇·2重量% (以灰泥之重量計)之量存在之視需要 的玻璃纖維。 石每半水合物(灰泥)之再水合及隨後的硬化需要一特定理 論的水量f 1丄Ή· , , u 2冥耳水/莫耳灰泥)’以形成硫酸約二水合物晶體。 然而,商業處理通常需要過量的水。此過量之處理水會於石膏晶 200920712 體基質内產生蒸發水的空隙,其形狀實質上常為不規則的且與其 他水空隙互相連接,形成凝固石f晶體間之廣泛連續網絡中^不 規則的通道。與此相反’使用肥4泡泳將空氣(泡泡)空隙引入 至石膏漿料中。空氣㈣通常為球狀/圓球狀,且—般係與其他的 空氣空隙分開,因而普遍呈不連續的形式。水空隙可散佈於空氣 空隙之壁的内部(請參照例如第8圖至第1〇圖)。 ;; 塵埃抓取的效果係取決於凝固石膏芯之組成而定。已發現若蔡 石黃酸鹽分散劑之用量夠高,其可在乾燥之後與預膠化㈣交聯了 進而使石膏晶體結合在-起,因而可增加石膏複合體的乾強度。 此外’出乎意㈣’目前已發卿膠储粉與萘魏鹽分散劑之 組合(有機相)可提供-類膠效果而將凝固石膏晶體結合在—起, 且當此調配物結合-特殊的空隙體積及空隙分佈時,對最終牆板 刻痕/㈣時會產生較大尺寸的碎片。本發明之增加的壁厚度:強 化的緻密牆表面微結構可進一步加強此結果。較大的石膏碎片通 常會產生較少經空氣傳播之塵埃。與此相反,若使用傳統的牆板 調配物時,會產生較小的碎片並因此而產生較多的塵埃。舉;言 之,傳統牆板因鋸切所產生的塵埃碎片具有約2〇至3〇微米之平 均直徑,且最小的直徑約為丨微^相反地,本發明之石膏牆板 因鋸切所產生的塵埃碎片具有約35至50微米之平均直徑,且最 小的直徑約為2微米;刻痕/刨痕甚至可產生更大的碎片。 於較軟的牆板中,水空隙及空氣空隙兩者皆可抓取塵埃(例如 抓取如單-晶體塵埃之微小石膏針狀物)。較硬牆板傾向抓取塵埃 留在空氣空隙中,因為對這些板進行加工時會產生較大的凝固石 11 200920712 膏芯之碎誠碎片。在此情況下,塵埃碎片對於水 :但可困於空氣空隙中。根據本發明之-實施態樣;: 在凝固二芯内引人-較佳空隙/孔洞尺寸分佈而實現增加的㈣ 爪取。^及水空隙之分佈較佳係具有小空隙及大空隙尺寸之八 佈。於-實施態樣中’可使用肥息泡殊來製備一較佳空氣空隙: 佈。請參照後述之實施例6及實施例7。 刀 凝固石膏芯内之线㈣(大於約1()微米)對水空隙(小於約 5微米)之比例為約L8: i至約9:丨。凝固石膏芯内之空氣 (大於約Π)微米)對水空隙(小於約5微米)之較佳比例為約2:、 1至約3:丨。於—實施祕巾,凝固石膏如之空隙/孔洞尺寸分 佈應為約10至30%之空隙係小於約5微米,且約7〇至9〇%之空 隙係大於約10微米,以所測量之總空隙百分比來計算。於另一方 法中’凝固石膏芯内之空氣空隙(大於1〇微米)對水空隙(小於 5微米)之比例為約2.3: !至約9: i。於一較佳實施態樣中凝 固石膏芯内之空隙/孔洞尺寸分佈應為約3〇至35%之空隙係小於 約5微米,且約65至70%之空隙係大於約1〇微米,以所測量之 總空隙百分比來計算。於另一方法中,凝固石膏芯内之空氣空隙 (大於10微米)對水空隙(小於5微米)之比例為約18 : 1至約 2.3 : 1 〇 空氣(泡泡)空隙尺寸之平均直徑較佳係低於約1〇()微米。於 一較佳實施態樣中,凝固石膏芯内之空隙/孔洞尺寸分佈為:大於 約100微米(20%)、約50微米至約1〇〇微米(30%)、以及小於 約50微米(50% )。換言之’較佳的中間空隙/孔洞尺寸係約5〇微 12 200920712 米。 空氣空隙會減弱經起泡之低密度凝固石膏怒與覆蓋薄片之間的 接口強度。因為泡珠的關係,複合體石膏板超過—半的體積係由 工氣工隙所構成’因此泡殊會干擾經起泡之低密度凝固石膏芯與 紙覆蓋薄片之間的接合。此可藉由在放置覆蓋薄片至芯之前,視 ,要提供-未經起泡(或經降低起泡)之接合高密度層於頂部覆 盍薄片、或底部覆蓋薄片、或頂部覆蓋薄片以及底部覆蓋薄片兩 者之接觸石膏芯的表面上而解決。此未經起泡、或者經降低起泡 之接合高密度層調配物一般係與石膏漿料芯調配物相同,除了未 添加肥皂或添加大幅減少用量之肥息(泡殊)之外。視需要,為 了幵> 成此接&層’可以機械方式將泡殊從s調配物中移除,或可 於經起泡之低密度凝固石膏芯/覆蓋薄片介面塗敷—不同的無泡沐 調配物。 較佳係引入肥皂泡沫以控制凝固石膏芯内之空氣(泡泡)空隙 尺寸及分佈’並控制凝固石膏芯之密度。較佳肥皂範圍為約〇2 碎/MSF至約0.7磅婀卯;更佳肥矣含量為約〇 45磅/msf至約〇 5 磅/MSF。 肥皂泡沫必須以能製造所欲密度之有效量來添加,並且係以受 控制的方式來添加。為控制該程序,操作員必須監控板成型線 (b〇ardformingline)的前端,並使殼模保持填滿。若殼模未保持 填滿’由於⑽紐填滿必㈣體積而會得_有空洞邊緣之牆 板。藉由增加肥皂的用量來避免空氣泡泡在板生產過程中破裂(以 更佳地保留空氣泡泡)、或藉由增加空氣泡料而使殼模體積保持 13 200920712 填滿的。因此,一般而言,殼模體積係藉由增加或降低肥皂用量、 或藉由增加或降低空氣泡珠率來控制及調整的。控制前端的技術 包含藉由添加肥皂泡沫以增加漿料體積、或藉由降低肥皂泡沫用 量以減少漿料體積來對檯面上之「動態漿料」進行調整。 根據本發明之一實施態樣係提供最終之含石膏產品,其係由含 有灰泥、預膠化澱粉、以及萘磺酸鹽分散劑之含石膏漿料而製得。 該萘磺酸鹽分散劑係以約O.i重量%至約3 〇重量% (以灰泥之乾 重計)之量存在。該預膠化殿粉係以至少約0 5重量%至最高約i 〇 重量% (以調配物内之灰泥之乾重計)之量存在。可於漿料中使用 其他成分,包含黏合劑、防水劑、紙纖維、玻璃纖維、黏土、殺 生物劑、以及加速劑。本發明需要添加肥皂泡沫至剛調配之含石 膏漿料中,以降低例如石膏牆板之最終之含石膏產品的密度,並 藉由於凝固石膏芯内,引入約75%至約%%,較佳為約8〇%至約 92%之總空隙體積(呈小的空氣(泡泡)空隙及水空隙形式),以 控制落塵。較佳地,平均孔洞尺寸分佈為約丨微米(水空隙)至 約40至50微米(空氣空隙)。 視需要’皆以石膏浆料内所用之灰泥之乾重計,約〇 5重量0/〇灵 最高約10重量%之預膠化澱粉、約〇1重量%至最高約3 〇重量0/〇 之萘磺酸鹽分散劑、以及至少約0.12重量%至最高約〇 4重量%之 最少量的三偏磷酸鹽的組合,出乎意料且明顯地增加石膏漿料的 動性。此實質上減少製造具足夠流動性之石膏漿料所需之水 量’該石膏聚料係用以製造含石膏產品,例如石膏牆板。咸信楳 準調配物(如三偏磷酸鈉)含量之至少約兩倍之三偏磷酸鹽的含 200920712 量’可促進萘績酸鹽分散劑之分散劑活性。 於根據本發明所製備之含石膏锻姐士 ^ w «聚枓令,必須使用萘磺酸鹽分散 劑。本發明所使用之萘績酸鹽分 刀政劑包含聚萘磧酸及其鹽類(聚 萘磺酸鹽)及其衍生物,該此化入私 —冗σ物為萘磺酸與甲醛的縮合產物 (c〇ndensati〇n pr〇ducts )。特別所欲之聚萘續酸鹽包含萘績酸鈉及 萘石《妈。萘賴鹽之平均分子量為約3,刪至約27,刪,儘管其 較佳分子量為約8,_至約22,_,且更佳分子量為約i2 〇〇〇至 約17,000。作為-商業產品,與較低分子量之分散劑相比,較高 分子星之仝政劑具有較尚的黏性及較低的固體含量。可用的萘續 酸鹽包含可付自 GEO Specialty Chemicals, Cleveland, Ohio 之 DILOFLO ;可得自 Hampshire Chemical Corp·,Lexington, Massachusetts 之 DAXAD ;以及可得自 GEO Specialty Chemicals,
Lafayette, Indiana之LOMAR D。舉例言之,較佳係使用呈3 5至 55重量%固體含量之水溶液形式的萘項酸鹽。更佳使用例如呈約 40至45重量%固體含量之水溶液形式的萘磺酸鹽。或者,若適當 時,可使用呈乾燥之固體或粉末形式的萘磺酸鹽’例如LOMARD。 可用於本發明之聚萘磺酸鹽具有結構(I):
15 200920712 其中n> 2,且其中M為鈉、鉀、鈣等。 萘績酸鹽分散劑(較佳係呈約45重量%水溶液形式)之使用範 圍係約G.5重夏%至約3 Q重量% (以用於石膏複合體調配物内之 灰泥之乾重计)。更佳的萘磺酸鹽分散劑範圍係約〇 5重量%至約 2.0重量%(以灰泥之乾重計);且最佳的萘續酸鹽分散劑範圍係約 〇.7重量%至約2.0重量% (以灰泥之乾重計)。與此相反,已知的 石s牆板含有此分散劑的含量係約〇4重量%或更低(以灰泥之乾 重計)。 於另一方法中,萘磺酸鹽分散劑(以乾重計)之使用範圍係約 0.1重里/〇至約1.5重量% (以用於石膏複合體調配物内之灰泥之 乾重計)。較佳的萘磺酸鹽分散劑(以乾固體計)範圍係約〇 25 重量%至約0.7重量% (以灰泥之乾重計);且最佳的萘磺酸鹽分 政劑(以乾固體計)範圍係約0 3重量%至約〇 7重量% (以灰泥 之乾重計)。 含石膏漿料可視需要包含三偏磷酸鹽,例如三偏磷酸鈉。可根 據本發明使用任何適宜的水溶性偏磷酸鹽或聚磷酸鹽。較佳係使 用三偏磷酸鹽,其包含複鹽,亦即具有兩個陽離子之三偏磷酸鹽。 特別適用的三偏磷酸鹽包含三偏磷酸鈉、三偏磷酸鉀、三偏磷酸 鈣、三偏磷酸鈣鈉、三偏磷酸鋰、三偏磷酸銨等或其組合。較佳 的二偏碟酸鹽為三偏填酸鈉。較佳係使用呈水溶液形式之三偏填 酸鹽,例如約10至15重量%固體含量之範圍。亦可使用其他環狀 或非環狀之聚磷酸鹽,如由Yu等人所著之美國專利第6,4〇9,825 號中所述,該篇專利内容併於本文以供參考。 16 200920712 三偏磷酸鈉在含石膏組成物中係一已知的添加劑,儘管其通常 係以約0.05重直%至約〇.〇8重量。/。(以用於石膏聚料内之灰泥之 乾重計)之範圍來使用。於本發明之實施態樣中,三偏磷酸鈉(或 其他水溶性偏磷酸鹽或聚磷酸鹽)係以約〇1〇重量%至約〇·4重 量。/〇(以用於石膏複合體調配物内之灰泥之乾重計)之範圍存在。 三偏磷酸鈉(或其他水溶性偏磷酸鹽或聚磷酸鹽)之較佳範圍係 約0.12重量%至約0.3重量%(以用於石膏複合體調配物内之灰泥 之乾重計)。 f ' 灰泥具有兩種形式,α及β。此兩種灰泥類型係藉由不同煅燒方 法所製造的。本發明可使用α或β形式之灰泥。 於根據本發明所製備之含石膏漿料中,必須使用澱粉,尤其是 包含預膠化澱粉。較佳的預膠化澱粉係預膠化玉米澱粉,例如可 知自Bunge Milling,St. Louis,Missouri之預膠化玉米粉,具有以 下的典型分析:水分為7.5%,蛋白質為8 〇% ,油為〇 5%,天然 纖維為0·5%’粉塵(ash)為〇.3%;具有〇.48psi之生述強度(呂職 C. strength);以及具有35.0磅/立方英呎之疏鬆的體密度(bulk density)。預膠化玉米澱粉應以至少約〇 5重量%至最高約ι〇重量 %(以用於含石膏漿料中之灰泥之乾重計)之量使用。於—更佳實 施態樣中,預膠化澱粉係以約〇.5重量%至約4重量% (以用於含 石膏漿料中之灰泥之乾重計)之量存在。 本案發明人更進-步發現藉由於約重量%至約3()重量%之 蔡雜鹽分散劑的存在下,使用至少約〇 5重量%至最高約1〇重 量%之預膠化殿粉(較佳係預谬化玉米殿粉),(尤其是於牆板中) 17 200920712 可獲得無法預期之乾強度的增加(澱粉及萘磺酸鹽含量係以存在 於調配物中之灰泥之乾重計)。無論是否存在水溶性三偏磷酸鹽或 聚磷酸鹽皆可獲得此無法預期的結果。 此外,出乎意料的,已發現可於根據本發明所製得之經乾燥的 石膏牆板中,以至少約10磅/MSF或更高之含量來使用預膠化澱 粉,且仍可達到高強度及低重量。已顯示石膏牆板中具有高達35 至45磅/MSF含量之預膠化澱粉係有效的。以調配物B作為例子, 如下表1及表2所示,包含45磅/MSF之預膠化澱粉,所製得之 板重量為1042磅/MSF,且該板具有優異的強度。於此例(調配物 B)中,係以1,28重量%之含量使用萘磺酸鹽分散劑(呈45重量 %水溶液形式)。 當本發明使用萘磺酸鹽分散劑及三偏磷酸鹽之組合與預膠化玉 米澱粉、以及視需要的紙纖維或玻璃纖維併用時,可達到另一個 無法預期的結果。由含有此三種成分之調配物所製得之石膏牆板 具有增強的強度及減輕的重量,且由於在石膏牆板的生產過程中 之水需求量的降低,更為經濟效益上所欲者。紙纖維的用量最高 為約2重量% (以灰泥之乾重計)。玻璃纖維的用量最高為約2重 量%(以灰泥之乾重計)。 可於本發明之含石膏組成物中使用加速劑,如由Yu等人所著之 美國專利第6,409,825號中所述,該篇專利内容併於本文以供參 考。可自土石膏(硫酸鈣二水合物)的乾研磨而製得一所欲之抗 熱加速劑(HRA)。可使用少量添加劑(通常為約5重量%),例如 糖、葡萄糖、硼酸、以及澱粉來製造此HRA。目前較佳的是糖或 18 200920712 葡萄糖。另一可用之加速劑為「頃向(climate)穩定化加速劑」 或「頃向穩定加速劑」(CSA),如美國專利第3,573,947或中' ’ 該篇專利内容併於本文以供參考。 水/灰泥(w/s )比率係一重要的參數’因為過I水最終必/員藉 加熱而除去。於本發明之實施態樣中’較佳w/s比率為約〇.7至約 1.3。 其他石膏漿料添加劑可包含加速劑、黏合劑、防水劑、紙或玻 璃纖維、黏土、殺生物劑、以及其他已知的成分。 儘管可使用本領域中已知的其他可用之覆蓋薄片材料(例如纖 維玻璃墊片),覆蓋薄片亦可由紙製得’如同傳統石膏膽板中所用 一般。紙覆蓋薄片可提供石膏牆板内之強度特質。可用的覆蓋薄 片紙包含可得自 United States Gypsum Corporation,Chicago, Illinois 之 Manila 7-ply 及 News-Line 5-ply,可付自 Caraustar, Newport,Indiana 之 Grey-Back 3-ply 及 Manila Ivory 3-ply;以及可 得自 United States Gypsum Corporation, Chicago, Illinois 之 Manila 重紙(heavy paper)及 MH Manila HT ( high tensile ’ 局張力)紙。 紙覆蓋薄片包含頂部覆蓋薄片或正面紙’以及底部覆蓋薄片或背 面紙。較佳背面覆蓋薄片紙係News_Line 5-p】y。較佳正面覆蓋薄 片紙包含MH Manila HT (高張力)紙及Manila 7-ply。 亦可使用纖維墊片作為一覆蓋薄片或該二覆蓋薄片。一種可用 之纖維墊片係玻璃纖維墊片’其中玻璃纖維之細絲係藉由黏著劑 而結合在一起的。較佳纖維墊片係非織造玻璃纖維墊片,其中玻 璃纖維之細絲係藉由黏著劑而結合在一起。最佳地’該非織造玻 19 200920712 璃纖維塾片具有一厚重的樹脂塗層。例如可使用可得自 J〇hnS-Manville之Duraglass非織造破璃纖維塾片,其具有約u 至2.0镑/100平方英叹之重量且約仙至卿的㈣重量係來自於 樹脂塗層。其他可用之纖輕片包含,但不限於,織造玻璃塾片 及非纖維素織物。 以下實施例將進-步闡述本發明,但無論如何不應將其視為限 制本發明之範圍。 實施例1 石貧聚料調配物試樣 石膏漿料調配物係如以下表i所示。表!中的所有數值皆係以 灰泥之乾重St之重量百分比來表示。括弧中之數值係代表乾重, 單位為磅(磅/MSF)。 表1 成分 調配物A 調配物B 灰泥(磅/MSF) ( 732) (704) 三偏磷酸鈉 0.20 ( 1.50) 0.30 (2.14) 分散劑(萘項酸鹽) 0.18 ( 1.35) 0.581 ( 4.05 ) 預膠化澱粉(乾粉) — 2.7 (20) 6.4 (45) 板澱粉 0.41 (3.0) 0 抗熱加速劑(HRA) ---- 1 . (15) (15) 玻璃纖維 0.27 ( 2.0) 0.28 (2.0) 20 200920712 紙纖維 0 0 99 Γ 7 0) 肥皂* 0.03 ( 0.192) Ο.Ολ ( 0 197 s) 總水量(磅) 805 ----------- m 852 水/灰泥比率 l.io 1.21 1 」 氺 m m :2is 也立,ι 、, . *用以預先產生泡珠 呈45%水溶液形式,1.28重量% 實施例2 製備牆板 石膏踏板試樣係根㈣⑪等人所著之美國專利第號 及Yu等人所著之美國專利第6,632,55〇號所製得該二專利内容 併於本文以供參考。如此二專利中之實施例5中所述,其包含獨 立產生泡沫並將泡沫引入所有其他成分之漿料中。 表2所示為使用實施例1中之調配物a及 7 A次調配物B所製得之石 膏牆板、以及常規的控制組板之測試钤罢 & . . . ... . ° 在此實施例及後述實 μ·#㊉* 曲強度測武係根據ASTMC-473 來進仃。此外,需注意典型的石膏 用腸板係大約1/2英吋屋且右约 1600至1800碎/千平方英 央寸厚且具有約 ,「A;rcc产t 斗或镑/msf)的重量。(在本領域 中,「MSF」係千平方英吸 I (在本領域 ( t , , 知竿縮寫;其係用於箱子、瓦楞芯紙 (corrugated media)、以及膝> 膦板的面積測量。)
21 200920712 板重量(磅/MSF) 抗拔釘力(碎) 芯硬度(磅) 增濕(humidified) 接合負載(碌) 增濕接合失敗(%) 挽曲強度,面朝上 (MD)(磅) 撓曲強度,面朝下 (MD)(磅) 挽曲強度,面朝上 (XMD)(磅) — 挽曲強度,面朝下 (XMD)(磅) 1587 81,7 16.3 17.3 0.6 47 51.5 150 144.4 1066 1042 50.2 72.8 5.2 20.3 47.2 66.7 135.9 125.5 11.6 15.1 11 52.6 78.8 173.1 165.4 MD :機器方向 XMD ·與機器方向交又 如表2所不’與控制組板相比,使用調配物A及調配物B之漿 料所製知之石膏牆板在重量方面具有明顯的降低。請再次參照表 1,調配物A板與調配物B板之比較係相當明顯的。水/灰泥(w/s) 比率在調配物A及調配物B中係相似的。亦於調配物B中使用明 顯較高含量之萘磺酸鹽分散劑。再者,於調配物B中使用實質上 22 200920712 較多的預膠化澱粉(約6重量%,比調配物A多超過100%),伴 隨著是明顯的強度增加。即便如此,在調配物B漿料中產生所需 流動性之水需求量較低,與調配物A相比之差約為10%。該二調 配物之低水需求量係歸因於石膏漿料中之萘磺酸鹽分散劑與三偏 磷酸鈉組合之協同效應,使其即便在有實質上較高含量之預膠化 澱粉的存在下,仍可增加石膏漿料的流動性。 如表2所示,與使用調配物A漿料所製得之牆板相比,使用調 配物B漿料所製得之牆板具有實質上增加的強度。藉由併用增加 量的預膠化澱粉與增加量的萘磺酸鹽分散劑及三偏磷酸鈉,調配 物B板之抗拔釘力比調配物A板增加45%。與調配物A板相比, 亦可於調配物B板中觀察到實質上增加的撓曲強度。 實施例3 1 /2英忖石膏牆板重量減輕試驗 其他石膏牆板試樣(板C、板D及板E),包含漿料調配物及測 試結果係如以下表3所示。表3之漿料調配物包含漿料的主要成 分。括弧中之數值係代表以灰泥之乾重計之重量百分比。 表3 試驗調配物 成分/參數 控制組板 調配物C板 調配物D板 調配物E板 乾灰泥 (磅/MSF) 1300 1281 1196 1070 23 200920712 加速劑 (磅/MSF) 9.2 9.2 9.2 9.2 DIL0FL01 (磅/MSF) 4.1(0.32%) 8.1( 0.63%) 8.1(0.68%) 8.1( 0.76%) 普通殿粉 (磅/MSF) 5.6(0.43%) 0 0 0 預膠化玉米 澱粉 (磅/MSF) 0 10 (0.78%) 10 (0.84%) 10 (0.93%) 三偏碟酸鈉 (磅/MSF) 0.7(0.05%) 1.6(0.12%) 1.6(0.13%) 1.6(0.15%) 總水量/ 灰泥比率 (w/s ) 0.82 0.82 0.82 0.84 試驗調配物 測試結果 乾板重量 (磅/MSF) 1611 1570 1451 1320 抗拔釘力 (磅) 77.3f 85.5 77.2 65.2 fASTM標準:77磅 1 DILOFLO係一 45%萘橫酸鹽水溶液 24 200920712 如表3所示’與控制組板相比,板c、板D及板e係由具有實 質上增加量的澱粉、D肋肋分㈣、以及三料咖(救粉與 分散劑,以百分比計,約增加兩倍;三偏磷酸鹽,以百分比計, 約增加兩倍至三倍)的㈣而製得,且同時仍維持w/s㈣不變。 然而,板重量係顯著地減輕,而由抗拔釘力所測得之強度並未劇 幅地受影響。因此,於本發明實施態樣之此實施例中新調配物 (例如板D)可提供調配於一可用的、流動的漿料中之增加的澱 粉用量,且同時仍維持相同的w/s比率及足夠的強度。 實施例4 濕石賞立方體強度測試 濕立方體強度測試係使用得自United States Gypsum Corp., Chicago, Illinois之Southard CKS板灰泥及實驗室之自來水來進 行’以決定其濕壓縮強度。該測試係使用後述實驗室測試步驟。 於約70〇F下’使用灰泥(1000克)、CSA (2克)、以及自來水 (1200cc)來製得各濕石膏立方體鑄件。預膠化玉米澱粉(2〇克, 以灰泥重量計係2.0%)及CSA (2克,以灰泥重量計係0.2%)係 於與含有萘磺酸鹽分散劑及三偏磷酸鈉之自來水溶液混合之前, 先在一塑膠袋中與灰泥徹底地乾混合。所使用的分散劑為 DIL0FL0分散劑(1.0至2.0%,如表4所示)。如表4所示,亦可 使用不同量的三偏磷酸鈉。 首先於實驗室Warning授拌器中將乾成分及水溶液合併,使所 產生之混合物浸濕10秒,且隨後以低速混合該混合物10秒,以 25 200920712 製造漿料。將如此所形成之漿料澆鑄至三個2吋χ2吋以吋立方體 鑄模中。隨後將澆鑄立方體從鑄模移出、秤重、並密封於塑膠袋 中’以避免水分在壓縮強度測試進行之前流失。濕立方體之壓縮 強度係使用ATS機^來測量,並解均每平 的單位來記錄。所獲得之結果如τ : " " (PS〇 表4
26 200920712 13 0 2.0 183.33 345 14 0.5 (0.05) 2.0 184.06 356 15 1 (0.1) 2.0 184.3 363 16 2 (0.2) 2.0 184.02 363 17 4 (0.4) 2.0 183.5 368 18 10 ( 1.0) 2.0 182.68 339 DILOFLO係一 45%萘磺酸鹽水溶液 如表4所示,本發明之具有約0.12至0.4%之三偏磷酸鈉含量的 試樣4、試樣5、試樣10、試樣11、以及試樣17,與具有在此範 圍之外的三偏磷酸鈉之試樣相比,一般而言可提供較佳的濕立方 體壓縮強度。 實施例5 1/2英吋輕重量之石膏牆板的工廠製造試驗 進行其他試驗(試驗板1及試驗板2),包含漿料調配物及測試 結果係如以下表5所示。表5之漿料調配物包含漿料的主要成分。 括弧中之數值係代表以灰泥之乾重計之重量百分比。 表5 試驗調配物 控制組板1 工廠調配物 控制組板2 工廢調配物 成分/參數 試驗板1 試驗板2 乾灰泥 1308 1160 1212 1120 27 200920712 (磅/MSF) DILOFLO' (磅/MSF) 5.98 ( 0.457%) 7.98 ( 0.688%) 7.18 ( 0.592%) 8.99 ( 0.803%) 普通澱粉 (磅/MSF) 5.0(0.38%) 0 4.6(0.38%) 0 預膠化玉米 澱粉 (磅/MSF) 2.0(0.15%) 10 (0.86%) 2.5(0.21%) 9.0(0.80%) 三偏磷酸鈉 (磅/MSF) 0.7(0.05%) 2.0(0.17%) 0.6(0.05%) 1.6(0.14%) 總水量/ 灰泥比率 (w/s ) 0.79 0.77 0.86 0.84 試驗調配物 測試結果 乾板重量 (磅/MSF) 1619 1456 1553 1443 抗拔釘力 (磅) 81.51 82.4 80.7 80.4 撓曲強度, 平均(MD) (磅) 41.7 43.7 44.8 46.9 撓曲強度, 134.1 135.5 146 137.2 28 200920712 平均 (XMD) (磅) 增濕接合2 負載,平均 (磅) 19.2 17.7 20.9 19.1 增濕接合2’3 失敗(%) 1.6 0.1 0.5 0 tASTM標準:77磅 MD :機器方向 XMD :與機器方向交叉 1 DILOFLO係一 45%萘磺酸鹽水溶液 2 90°F/90%相對濕度 3應充分地瞭解,在這些測試條件下,失敗率百分比<50%是可接 受的。 如表5所示,與控制組板相比,試驗板1以及試驗板2係由具 有實質上增加量的澱粉、DILOFLO分散劑、以及三偏磷酸鈉的漿 料而製得,且同時僅少量地減少w/s比率。然而,由抗拔釘力及 撓曲測試所測得之強度係維持不變或增強的,且板重量係明顯地 減輕。因此,於本發明之實施態樣之此實施例中,新調配物(例 如試驗板1及試驗板2)可提供調配於一可用的、流動的漿料中之 增加的三偏磷酸鈉及澱粉用量,且同時仍維持實質上相同的w/s 比率及足夠的強度。 29 200920712 實施例6 1/2英吋超輕重量之石膏牆板的工廠製造試驗 除以水製備10%濃度之預膠化玉米澱粉(濕澱粉製備)及使用 HYONIC 25 AS 與 PFM 33 肥皂(可得自 GEO Specialty Chemicals, Lafayette, Indiana )推混物外,如同實施例2 —般使用調配物B (實 施例1)進行進一步的試驗(試驗板3及試驗板4)。舉例言之, 試驗板3係由65至70重量%之HYONIC 25 AS與剩餘重量%之 PFM33的HYONIC 25 AS與PFM 33摻混物所製得。例如,試驗 板 4 係以 70/30 (重量/重量)之 HYONIC 25 AS/HYONIC PFM 33 摻混物所製得。試驗結果係如表6所示。 表6 實驗室測試結果 試驗板3 (調配物B 試驗板4 (調配物B 加上HYONIC肥皂 加上HYONIC肥皂 摻混物65/35) 摻混物70/30) (n=12) (n=34) * 板重量(磅/MSF) 1106 1013 抗拔釘力a (磅) 85.5 80.3 芯硬度b (磅) >15 12.4 撓曲強度,平均e 55.6 60.31 (MD)(磅) 撓曲強度,平均d 140.1 142.3' 200920712 (XMD )(磅) __ 有註記者除外 1 n=4 MD :機器方向 XMD :與機器方向交叉 a ASTM標準:77磅 b ASTM標準:11磅 。ASTM標準:36磅 d ASTM標準:107磅 應注意於此實施例所述之調配物,其係已公開於2006年11月2 曰所申請之美國專利第11/592,481號母案中,可製造如後述實施 例7至實施例9中所述之石膏牆板,該石膏牆板具有顯著的厚壁 之大的空氣空隙,且該等厚壁具有強化的緻密表面。如表6所示, 由拔釘力及芯硬度測試所測得之強度特質係優於ASTM標準。所 測量之撓曲強度亦係優於ASTM標準。再者,於本發明之實施態 樣之此實施例中,新調配物(例如試驗板3及試驗板4)可提供調 配於一可用的、流動的漿料中之增加的三偏磷酸鹽及澱粉用量, 且同時仍維持足夠的強度。 實施例7 於1/2英吋厚之石膏牆板芯内之空隙體積百分比計算,其係作為板 重量與鋸切結果的函數 31 200920712 除以水製備10%濃度之預膠化玉米澱粉(濕澱粉製備)、使用 0.5%玻璃纖維以及1.2重量%含量之萘確酸鹽(dil〇FL〇X呈45% 水溶液形式)外,如同實施例2 —般使用調配物b (實施例1 )進 行進一步試驗’以決定空隙體積及密度(試驗板第5號至第13 號)。用肥皂泡沫產生器製備肥皂泡沫並以有效的量引入石膏漿料 中,以提供所欲之密度。在此實施例中,肥皂係以0,25磅/MSF 至0.45碎/MSF之含量來使用。意即,可適當的增加或減少肥皂泡 沫的使用。於各試樣中,牆板的厚度為1/2英吋,且假設芯體積係 一致為39.1立方英呎/MSF。測量從正面及背面紙之經移除處橫越 4英呎寬之牆板試樣的空隙體積。正面及背面紙可具有丨1至18毫 英吋(mil)之厚度(每一面空隙體積/孔洞尺寸及孔洞尺寸分 佈係藉由掃描電子顯微術(請參照後述實施例8)與X射線CT掃 描技術(XMT )而測定的。 表7 試 驗 板 編 號 板重 量 (磅 /MSF) 泡沫空 隙體積 1 (立方 英叹 /MSF) 泡沫孔 洞尺寸 分佈 (%) 1 蒸發空 隙體積 2 (立方 英呎 /MSF) 蒸發孔 洞尺寸 分佈 (%) f 總芯 空隙 體積3 (%) 板芯密 度 (pcf) 4 5 1600- 15 54 12.7 46 70.8 39-41 1700 (控 32 200920712 制組) 6 1400 19.6 66 10.3 34 76.5 34 7 1300 21.1 69 9.4 31 78.0 31 8 1200 20.9 68 10.0 32 79.0 28 9 1100 21.1 67 10.4 33 80.6 26 10 1000 20.9 65 11.1 35 81.8 23 11 900 23.4 71 9.5 29 84.1 21 12 800 25.5 76 8.1 24 85.9 18 13 500 31.5 88 4.5 12 92.1 10 > 1 〇微米空氣(泡泡)空隙 < 5微米水空隙 以一致的芯體積(=39.1立方英叹/MSF)計;即總芯空隙體積= 〔(泡沫空隙體積+蒸發空隙體積)mi〕xi〇〇 4以一致的芯體積(=39.1立方英呎/MSF)計;即板过密度(pcf) =(板重量(磅/MSF) —紙覆蓋薄片之重量(磅/MSF)) /39.1立 方英叹/MSF=(板重量(磅/MSF ) - 90磅/MSF )/39.1立方英呎/MSF +所測量之總空隙百分比 如表7所不,所製得之試驗板試樣具有79 〇%至92.1%之總芯空 隙體積,其係個別符合28pcf降至1〇pcf之板芯密度。舉财之二 總芯空隙體積為81.8%及板芯密度為23辦之試驗板ι〇的鑛切, 組板少30%的塵埃。以另一例子為例,若嶋 黏。劑(例如驗,具有或不具有分散劑)之傳統調配 33 200920712 物所製彳于’該等牆板具有明顯少之约75至80%之總芯空隙體積, V十Sx二牆板進行裁切、鑛開、挖槽、刨痕、釘釘子或鎖螺絲、 或鑽孔等工作時’可預期會產生明顯較多的塵埃。例如,傳統牆 板因鑛切所產生的塵埃碎片具有約20至30微米之平均直徑,且 取小的直徑約為1微米。與此相反,本發明之石膏牆板因鑛切所 產生的塵埃碎片具有約3〇至5〇微米之平均直徑,且最小的直徑 約為2微米;刻痕/刨痕甚至可產生更大的碎片。 已發現用以製造含石膏漿料之若干關鍵成分的結合,即:灰泥、 蔡確酸鹽分散劑、預勝化玉米殿粉、三偏填酸納、以及玻璃和域 紙纖維的組合,與一足夠且有效量之肥皂泡沫併用,可在製造可 用之低密度石膏牆板方面提供協同效應,且亦會劇幅地減少在刀 切、鋸切、刻痕/创痕、鑽孔、以及常規板處理過程中所形成的石 膏塵埃。 實施例8 試驗板10内之空氣泡泡空隙尺寸及水空隙尺寸之測定,以及石膏 晶體結構 以掃描電子顯微術(SEM)分析來自工廠試驗用以製備試驗板 10之洗鑄石膏立方體(2忖X2忖X2对)。觀測並測量空氣泡泡空 隙與蒸發水的空隙以及石膏晶體之尺寸與形狀。 製得三個試樣立方體,並分別標記為11 : 08、u : 3〇、以及^ . 50。第1圖至第3圖所示為在15倍放大倍率下,各該試樣中之咖 氣泡泡空隙尺寸及分佈。第4圖至第6圖所示^ , ^ τ马在50倍放大倍率 34 200920712 下,各該試樣中之空氣泡泡空隙尺寸及分佈。 在更尚的放大倍率下,可觀測到水空隙(例如在通常實質上較 大的空隙泡泡空隙壁中)’如試樣立方體11 : 50之第7圖至第1〇 圖所不,最高為1〇,_倍放大倍率。幾乎所有石膏晶體皆為針狀 物;僅觀測到少數小型板狀物。在空氣泡泡空隙表面上之針狀物 的密度及堆積是不同的^亦於空氣泡泡空隙壁中之水空隙内觀測 到石膏針狀物。 該SEM結果指出於根據本發明所製得之含石膏產品中,空氣及 水空隙係廣泛均勻地分散遍佈於㈣石H所觀測到之空隙尺 寸及空隙分佈亦指出會形成足夠的自由空間,以成為空氣及水空 隙(總芯空隙體積),可將於一般之板加工時及對板進行裁切、鑛 開、挖槽、刨痕、釘釘子或鎖螺絲、或鑽孔等工作期間中所產生 之大量的石膏塵埃留在周圍曝露之空隙中,絲其不會隨空氣傳 播。 實施例9 低塵埃產生之石膏牆板之塵埃抓取 若牆板係根據本發明實施例7之教示所製得,可預期在對牆板 加工的過程中,所產生的石膏塵埃會包含至少5〇重量%直徑大於 約10微米之石膏碎片。可抓取至少約3〇%或更多的總塵埃量該 些塵埃係因為對牆板進行裁切、鋸開、挖槽、刻痕/刨痕、釘釘子 或鎖螺絲、或鑽孔等工作而產生的。 35 200920712 實施例ίο 其他1/2英吋輕重量之石膏牆板的工廠生產之試驗調配物 實施例7至實施例9提供一輕重量之牆板,其具有增加的空隙 體積。其他類似於實施例7至實施例9之試樣,亦強調牆板微結 構之增加的壁厚度及強化的緻密空隙壁表面。應注意在此關係 中,試樣8之第5圖及第6圖的顯微照片指出根據本發明之含有 較大的空氣空隙及增加的厚度之壁兩者的微結構。 進一步所製備之漿料調配物(試驗14)係如表8所示。表8之 漿料調配物包含漿料的主要成分。括弧中之數值係代表以灰泥之 乾重計之重量百分比。 表8 試驗調配物 工廠調配物 控制組調配物A 控制組調配物B 成分/參數 試驗14 乾灰泥 902 1145 1236 (磅/MSF) DIL0FL01 14 5.22 1.98 (磅/MSF) (1.6%) (0.456%) (0.160%) 普通澱粉 0 2.0 4.0 (磅/MSF) (0.17%) (0.32%) 預膠化玉米澱粉 26 5.6 0 (磅/MSF) (2.9%) (0.49%) 三偏磷酸鈉 2.78 0.74 0.61 36 200920712 (磅/MSF) (0.308%) (0.06%) (0.05%) 玻璃纖維 2.0 0.34 -- (磅/MSF) (0.22%) (0.03%) 肥皂摻混物2 0.52 N/A N/A (磅/MSF) ( 0.058%) 總水量/ 0.87 0.82 0.78 灰泥比率 (w/s ) 1 DILOFLO係一 45%萘磺酸鹽水溶液 2 95重量/5重量之HY0NIC 25 AS及PFM 33肥皂摻混物。需注意 在動態製造過程中,肥皂比例可從70/30提高至所欲之目標範圍, 例如從70/30至80/20至85/15或最高至90/10。 實施例11 其他1/2英吋輕重量之石膏牆板的工廠生產試驗 使用實施例10之工廠試驗調配物14與控制組調配物A所製得 之石膏牆板、以及兩個傳統比較板之測試結果係如表9所示。牆 板試樣在70°F/50%相對濕度下調節24小時之後,測試該些石膏牆 板之抗拔釘力、邊緣/芯硬度、撓曲強度、以及16小時增濕接合。 抗拔釘力、邊緣/芯硬度、增濕彎曲、以及撓曲強度測試係根據 ASTM C-473來進行。不可燃性係根據ASTM E-136來進行。表面 燃燒特質測試係根據ASTM E-84來進行,以決定其延燒指數 (Flame-Spread Index,FSI)。以掃描電子顯微術(請參照後述實 37 200920712 施例12)及能量分散光譜(EDS)來分析板試樣。亦可以又射線 CT掃描技術(XMT)來分析板試樣。 以鋸切及鑽孔測試來進行塵埃產生的測量。為測定鑽孔所產生 的塵埃,使用鑽床(drill press)在最終牆板試樣上鑽5〇個洞,並 收集所產生的石膏塵埃。為測定以手鋸切所產生的塵埃,裁切五 個Ϊ对長的最終牆板部分,並收集所產生的石膏塵埃。為測定洞 鋸切(hole-sawing)所產生的塵埃,於最終牆板試樣上切出五個 直徑為4英吋之圓,並收集所產生的石膏塵埃。 表9 試驗調配物測 試結果 ----- 工薇調配物 試驗板14 控制組調配 物板A —----- 傳統比較 石膏板1 傳統比較 石膏板2 乾板重量 (磅/MSF) 1232 1439 1655 1652 抗拔釘力 (磅) 80.5 [ —-- 89.2 73.8 72.0 撓曲強度,平 1(MD)(磅) 44.9 43.8 39.3 50.4 撓曲強度,平 均(XMD) (磅) 146.1 130.1 126.7 124.4 硬度,芯(磅) ----- 17.6 20.3 16.7 16.7 硬度,邊緣 33.9 31.2 27.0 22.3 38 200920712 (磅) .......^ 增濕彎曲 (英p寸) 0.22 0.22 4.38 --- 4.1〇 16小時增濕接 合1負載,平均 (FU)(磅) 14.3 13.5 10.7 10.0 16小時增濕接 合1負載,平均 (FD)(磅) 15.8 13.7 14.6 11,2 不可燃性 合格 合格 合格 -- 合格 延燒指數 15 15 N/A N/A 塵埃產生, 鑽孔(克) 1.20 1.35 1.59 ------- 1,53 塵埃產生, 洞鋸切(克) 19.63 20.93 21.83 - 21.87 塵埃產生, 手鑛切(克) 11.82 13.42 14.02 -- 14.54 90°F/90%相對濕度 如表9所示,由抗拔釘力、撓曲強度、以及邊緣/芯硬度所測得 之試驗板I4的強度特質係優於傳統比較板,且超過ASTM標準。 增濕彎曲(下垂)係優於傳統比較板,且超過術河標準。以增 濕接合而言’除了優異的紙對芯接合(無失敗)之外,試驗板14 39 200920712
亦具有最佳的接合強度結果,如表9所示。最後,除了通過ASTM 標準的不可燃性測試之外,試驗板14亦被測定為ASTM的Class-A 材料。 此外,以外觀評估、薄片滑行(sheet slide)、撓曲測試、消防 負荷(fireman’s carry )、角落旋轉(corner rotation )、邊緣拖曳(edge drag )、邊緣掉落(edge drop )、刻痕及刨痕、錘磨(rasping )、洞 裁切、螺絲固定、釘子固定、以及10英呎半徑來評定試驗板14 試樣之處理、分段、及安裝順序。評估的結論是,試驗板14之處 理特性係等同於或超過控制組板A及表9中之其他傳統比較石膏 板。 實施例12 試驗板14内之空氣泡泡表面特徵的測定,以及石膏晶體結構 如同實施例8,以掃描電子顯微術(SEM)分析來自工廠試驗用 以製備試驗板14之澆鑄石膏立方體(2吋x2吋x2吋)。觀測並測 量空氣泡泡空隙與蒸發水的空隙以及石膏晶體之尺寸與形狀。 該SEM結果再次指出於根據本發明所製得之含石膏產品中,空 氣及水空隙係廣泛均勻地分散遍佈於凝固石膏芯。所觀測到之空 隙尺寸及空隙分佈亦指出會形成足夠的自由空間,以成為空氣及 水空隙(總芯空隙體積),可將於一般板加工時及對板進行裁切、 鋸開、挖槽、刨痕、釘釘子或鎖螺絲、或鑽孔等工作期間所產生 之大量的石膏塵埃留在周圍曝露之空隙中,並使其不會隨空氣傳 播。 40 200920712 f 第11圖至第19圖之SEM結果說明,在類似於上述實施例8 SEM顯微照片的增加的放大倍率下之壁厚度。這些SEm結果,2 第13圖及第14圖所示,分別比較試驗板14及控制把板A,顯示 出以下兩個改良:D試驗板中之空氣泡泡空隙實f上係大於控^ 板中之工氣泡/包空隙,以及2 )試驗板中之空隙間的平均壁厚声 係遠大於控制組板中之空隙間的平均壁厚度。一般而言,試:: Η中之空隙間的平均壁厚度係至少約%微米至最高約雇微米。 與此相反’控制組板A中之空關的平均壁厚度通常為約2〇至 3〇微米。此外,第15圖之秦倍的顯微照片顯示出強化的緻密表 面「A」係沿著空隙之壁往顯微照片的右邊延伸。 丄别所述’空氣空隙間之平均壁厚度較大,可對最終牆板提供 门的強度’即較佳的抗拔釘力、車交麵芯/邊緣硬度、以及較佳 的力工特貝,例如鑽孔、裁切、以及鋸開時的塵埃減量。 實施例13 、定平均工隙尺寸、壁厚度、以及緻密強化的壁表面之存在 藉由對n式之牆板試樣刻痕並㈣丨穿過&,以分成適當尺寸 办式樣來製備芯試樣。隨後藉由例如直接以強力的氣流橫越該經 X艮之區域而將鬆散的碎片移除。該芯試樣隨後以傳統掃描電子 顯微照相技術來安裝及塗層。 平均空隙尺寸 式樣内隨機取樣的1〇個位置處拍攝50倍放大倍率的10張 200920712 .、員微…、片。測量橫越該10張顯微照片内之各空隙的最大橫截面距 離。將所測得之距離相加並計算平均最大橫截面距離 。此即為試 樣之平均空隙尺寸。 平均壁厚度 在芯試樣内隨機取樣的10個位置處拍攝5〇倍放大倍率的1〇張 顯微照片。測量沿著顯微照片之水平與垂直邊緣相交的邊緣分佈 各二隙間的距離。將所測得之距離相加並計算平均距離。此即 為試樣之平均壁厚度。 緻密強化的壁表面 在〜忒樣内隨機取樣的10個位置處拍攝5〇倍放大倍率的張 j微,系片。檢測這些顯微照片中所呈現之經放大的空隙是否有沿 f空隙邊緣分佈之厚白線’如同那些在第i5圖中之A特徵一般。 這些厚白線的存在指出試樣中之緻密強化的空隙壁表面的存在。 曰除非在此或上述文中有另外說明,於本發明之說明書中(尤其 是在後述專利中請範圍中)所使用之「_」、「該」及類似詞語應 理解為包含單數及複數形式。除非另外說明,於此文中所列舉之 、值範圍僅作為個別提及落在該範圍内之各個單獨數值的簡記 法’且各個單獨數值係併人說明書中,如同其在本文中所個別列 +除非本中文有另外說明或明顯與說明書抵觸,本文所述之所 有方法可以任何適宜的順序來進行。本文所用之任何或所有實施 42 200920712 例、或例示性文字(像是「例如」)僅是用以較佳的說明本發明, 且除非另外說明,否則不應對本發明範圍設限。不應將說明書中 的文字理解為實施本發明所必需的任何非請求元件。 本文中所述之本發明之較佳實施態樣,包含最佳方法,係發明 人已知可用以實施本發明的。應瞭解所舉例之實施態樣僅係用於 例示性說明,且不應作為本發明範圍之限縮。 【圖式簡單說明】 f 第1圖為本發明之一實施態樣之澆鑄石膏立方體試樣(11 : 08) 在15倍放大倍率下之掃描電子顯微照片; 第2圖為本發明之一實施態樣之澆鑄石膏立方體試樣(11 : 30) 在15倍放大倍率下之掃描電子顯微照片; 第3圖為本發明之一實施態樣之澆鑄石膏立方體試樣(11 : 50) 在15倍放大倍率下之掃描電子顯微照片; 第4圖為本發明之一實施態樣之澆鑄石膏立方體試樣(11 : 08) 在50倍放大倍率下之掃描電子顯微照片; k 第5圖為本發明之一實施態樣之澆鑄石膏立方體試樣(11 : 30) 在50倍放大倍率下之掃描電子顯微照片; 第6圖為本發明之一實施態樣之澆鑄石膏立方體試樣(11 : 50) 在50倍放大倍率下之掃描電子顯微照片; 第7圖為本發明之一實施態樣之澆鑄石膏立方體試樣(11 : 50) 在500倍放大倍率下之掃描電子顯微照片; 第8圖為本發明之一實施態樣之澆鑄石膏立方體試樣(11 : 50) 在2,500倍放大倍率下之掃描電子顯微照片; 43 200920712 第9圖以及第10圖為本發明之一實施態樣之澆鑄石膏立方體試 樣(11 : 50)在10,000倍放大倍率下之掃描電子顯微照片; 第11圖為控制組板試樣在15倍放大倍率下之掃描電子顯微照 片,其係用以說明凝固石膏芯内之空氣空隙分佈、空隙尺寸、空 隙間的壁之平均厚度、以及壁之強化表面; 第12圖為根據本發明所製得之牆板試樣在15倍放大倍率下之 掃描電子顯微照片,其係用以說明根據本發明之一實施態樣之凝 固石膏芯内之空氣空隙分佈、空隙尺寸、空隙間的壁之平均厚度、 以及壁之強化表面; 第13圖為第11圖之控制組板試樣在50倍放大倍率下之掃描電 子顯微照片,其係用以說明凝固石膏心内之空氣空隙分佈、空隙 尺寸、空隙間的壁之平均厚度、以及壁之強化表面; 第14圖為第12圖之牆板試樣在50倍放大倍率下之掃描電子顯 微照片,其係用以說明根據本發明之一實施態樣之凝固石膏芯内 之空氣空隙分佈、空隙尺寸、空隙間的壁之平均厚度、以及壁之 強化表面; 第15圖為第12圖之牆板試樣在500倍放大倍率下之掃描電子 顯微照片,其係用以說明根據本發明之一實施態樣之凝固石膏芯 内之空隙間的壁之平均厚度以及微結構特徵; 第16圖為第12圖之牆板試樣在250倍放大倍率下之掃描電子 顯微照片,其係用以說明根據本發明之一實施態樣之凝固石膏芯 内之空隙間的壁之平均厚度以及微結構特徵; 第17圖為第16圖之牆板試樣在500倍放大倍率下之掃描電子 44 200920712 顯微照片,其係用以說明根據本發明之一實施態樣之凝固石膏芯 内之空隙間的壁之平均厚度以及微結構特徵; 第18圖為第16圖之牆板試樣在1,000倍放大倍率下之掃描電子 顯微照片,其係用以說明根據本發明之一實施態樣之凝固石膏芯 内之空隙間的壁之平均厚度以及微結構特徵;以及 第19圖為第16圖之牆板試樣在2,500倍放大倍率下之掃描電子 顯微照片,其係用以說明根據本發明之一實施態樣之凝固石膏芯 内之空隙間的壁之平均厚度以及微結構特徵。 【主要元件符號說明】 45
Claims (1)
- 200920712 十、申請專利範園: L 一種石膏牆板,包含一凝固石膏芯,其係形成於實質上平行 之二覆蓋薄片之間,該凝固石膏芯具有廣泛地分散遍佈於該 凝固石膏芯之空隙,且該空隙具有平均厚度為約30至約2〇〇 微米之壁(walls)。 2,如請求項1所述之石膏牆板,其中該等空隙之壁具有約至 約200微米之平均厚度。 3·如請求項1所述之石膏牆板’其中該等空隙之壁具有強化的 緻密表面(reinforced densified surfaces )。 4,如請求項3所述之石膏牆板,其中該凝固石膏芯係由一含有 石膏之漿料所製得,該漿料包含水、灰泥(stucc〇)、以約 〇·5重量%至約10重量% (以灰泥之重量計)之量存在之預膠 化澱粉、以約0.2重量%至約2重量% (以灰泥之重量計)之 量存在之萘磺酸鹽分散劑、以約01重量%至約〇 4重量%(以 灰泥之重量計)之量存在之三偏磷酸鈉、以及以約〇至約〇2 重量。/。(以灰泥之重量計)之量存在之玻璃纖維。 5’如明求項4所述之石膏牆板,其中該預膠化殿粉係以約0.5 重量%至約4重量% (以灰泥之重量計)之量存在。 6. 如請求項4所述之石f牆板,其中水/灰泥比率為約〇 7至約 1.3。 7. 如請求項1所述之石膏牆板,其中該等覆蓋薄片包含紙。 8·如請求項7所述之石膏牆板,其中該等覆蓋薄片之至少一者 係高張力紙(high tensile paper )。 46 200920712 V 9 j 士 清求項3所述之石膏牆板,其中該等覆蓋薄片之至少一者 係選自由纖維墊片、非織造玻璃纖維墊片、織造玻璃墊片及 非纖維素織物所組成之群組。 種t重里之石膏牆板,包—凝固石膏芯,其係形成於實 質上平行之二覆蓋薄片之間,該凝固石膏芯具有廣泛地分散 遍佈該凝固石膏芯之空隙,且該空隙具有強化的緻密表面及 平均厚度為約30至約200微米之壁,以及該凝固石膏芯之密 f ' 又為約 27 碎/立方英吸(pounds per cubic foot,pcf)至約 30 磅/立方英呎。 u.如請求項1〇所述之輕重量之石膏牆板,其中該凝固石膏芯係 由3有石膏之漿料所製得,該漿料包含水、灰泥、以約ο.〗 重量0至約10重量% (以灰泥之重量計)之量存在之預勝化 澱粉、以約0.2重量%至約2重量% (以灰泥之重量計)之量 存在之萘磺酸鹽分散劑、以約〇1重量%至約〇 4重量% (以 灰泥之重1计)之量存在之三偏填酸鈉、以及以約〇至約0.2 k 重置%(以灰泥之重量計)之量存在之玻璃纖維。 12. 如明求項u所述之輕重量之石膏牆板,其中該預膠化澱粉係 以約0.5重量%至約4重量% (以灰泥之重量計)之量存在。 13. 如請求項1〇所述之輕重量之石膏牆板,其中該等覆蓋薄片之 至少一者係高張力紙。 14. 如明求項1〇所述之輕重量之石膏牆板,其中該等覆蓋薄片之 至少一者係選自由纖維墊片、非織造玻璃纖維墊片、織造玻 璃墊片及非纖維素織物所組成之群組。 200920712 15. —種輕重量之石膏牆板,包含: 一凝固石膏芯,其係形成於實質上平行之二覆蓋紙薄片 之間’該凝固石膏芯具有廣泛地分散遍佈於該凝固石膏芯之 空隙,且該空隙具有平均厚度為約70至約120微米之壁; 其中該凝固石膏芯係由一含有石膏之漿料所製得,今亥 漿料包含水、灰泥、以約3重量%(以灰泥之重量計)之量存 在之預膠化澱粉、以約1.5重量% (以灰泥之重量計)之量存 在之45重量%的萘磺酸鹽分散劑水溶液、以約〇3重量%(以 灰泥之重量計)之量存在之三偏麟酸鈉、以約〇至約〇 2重量 % (以灰泥之重量計)之量存在之玻璃纖維、以及肥皂泡沐; 其中該等覆蓋薄片之至少一者係高張力紙; 其中該凝固石膏芯之密度為約29磅/立方英呎; 且其中該牆板具有約1200時/MSF之乾重(針對1/2英对 厚之牆板)、至少約77磅/MSF之抗拔釘力及至少約丨丨磅/河卯 之芯硬度。 48 200920712 七、指定代表圖: (一) 本案指定代表圖為:第(1)圖。 (二) 本代表圖之元件符號簡單說明: (無) 八、本案若有化學式時,請揭示最能顯示發明特徵的化學式: (無)
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