TW201609595A - 輕重量石膏板 - Google Patents

輕重量石膏板 Download PDF

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TW201609595A
TW201609595A TW104138253A TW104138253A TW201609595A TW 201609595 A TW201609595 A TW 201609595A TW 104138253 A TW104138253 A TW 104138253A TW 104138253 A TW104138253 A TW 104138253A TW 201609595 A TW201609595 A TW 201609595A
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gypsum
weight
microns
core
voids
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余勤
威金 大衛 松恩
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美國吉普森公司
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    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
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    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
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    • 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
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    • 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
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    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
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    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/16—Sulfur-containing compounds
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    • C04B24/226—Sulfonated naphtalene-formaldehyde condensation products
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0051—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
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    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
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    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
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    • C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
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Abstract

本發明提供低粉塵、低密度之石膏壁板產品，其具有高總芯部空隙體積，對應於約10pcf至30pcf範圍內之低密度。該等壁板具有一形成於兩塊大體平行之覆蓋片之間的定形石膏芯，該定形石膏芯較佳具有約80%至約92%之總空隙體積，且係由包括灰泥、預膠凝化澱粉及萘磺酸鹽分散劑之漿料製成。預膠凝化澱粉與萘磺酸鹽分散劑之組合亦可提供使定形石膏晶體黏結在一起的膠樣效果。在該等含石膏產品之切削、鋸割、銑槽、搭扣、釘釘或下擰或鑽鑿期間，該壁板調配物連同小氣泡空隙(及水分空隙)一起使得粉塵得以控制。本發明亦提供一種低粉塵、低密度石膏產品之製造方法，該方法包括將肥皂泡以足以形成較佳約80%至約92%之總空隙體積(包括空氣空隙)之量導入定形石膏芯內，此對應於約10pcf至約30pcf之定形石膏芯密度。藉由該方法製造之壁板在加工期間產生的粉塵顯著減少。

Description

輕重量石膏板
本發明係關於一種石膏壁板製造方法，其顯著減少壁板加工期間之粉塵產生。更特定言之，該方法包括將肥皂泡以足以形成約80%至約92%之總空隙體積之量導入定形石膏芯內，此對應於約10pcf至約30pcf之定形石膏芯密度，該方法提供在加工期間顯著減少之粉塵形成。本發明亦係關於一種利用該方法所製造之低起塵石膏壁板。
石膏(二水合硫酸鈣)之某些性質使其非常普遍地用於製造工業及建築產品，諸如石膏壁板。石膏為一種數量豐富且通常廉價之原材料，其經由脫水及復水方法可澆注、模製或成形為適用形狀。製造石膏壁板及其他石膏產品之基本材料為硫酸鈣之半水合物形式(CaSO4．1/2H2O)，通常稱之為"灰泥"，其藉由將硫酸鈣之二水合物形式(CaSO4．2H2O)熱轉化、自CaSO4．2H2O移除1-1/2個水分子而產生。
習知的含石膏產品(諸如石膏壁板)具有諸多優點，諸如低成本及易加工性，但在切削或鑽鑿該等產品時會產生大量石 膏粉塵。利用澱粉作為用於製造該等產品之漿料中之成分在含石膏產品之製造中已達成多種改良。預膠凝化澱粉可如同膠一般地增強含石膏產品(包括石膏壁板)之撓曲強度及壓縮強度。已知的石膏壁板含有小於約10lbs/MSF之量的澱粉。
含有預膠凝化澱粉之石膏漿料中亦有必要使用大量的水以確保漿料之適當流動性。然而，該水之大部分最後必須藉由乾燥驅除，此因乾燥過程中使用之燃料之高成本而代價昂貴。該乾燥步驟亦耗時。已發現，使用萘磺酸鹽分散劑可增強漿料之流體性，從而克服需水問題。此外，亦已發現，萘磺酸鹽分散劑使用量若足夠高，會與預膠凝化澱粉交聯而在乾燥之後使石膏晶體黏結在一起，從而增強石膏複合物之乾燥強度。因此，預膠凝化澱粉與萘磺酸鹽分散劑之組合可提供使定形石膏晶體黏結在一起的膠樣效果。過去一直未認識到三偏磷酸鹽可影響石膏漿料需水性。然而，發明人已發現，在特定分散劑存在下將三偏磷酸鹽之量增至迄今未知之量，可在出乎意料地減少之水量下達成適當的漿料流動性，即使在高澱粉量之存在下亦如此。當然，此舉由於又減少用於乾燥之燃料用量以及與隨後水移除方法步驟相關之處理時間而非常合乎需要。因此發明人亦發現，藉由在用於製造壁板之漿料中將萘磺酸鹽分散劑與預膠凝化澱粉組合使用可增強石膏板之乾燥強度。
本發明之石膏壁板應有別於不具有面板之隔音板或隔音瓦。此外，本發明之壁板應不同於包括聚苯乙烯作為輕質骨 材的隔音板或隔音瓦。重要的是，上述隔音板及隔音瓦不滿足適用於石膏壁板的多個ASTM標準。舉例而言，已知隔音板不具有石膏壁板(包括本發明之彼等石膏壁板)所需的撓曲強度。相反，欲使隔音板或隔音瓦滿足ASTM標準，則隔音板或隔音瓦之曝露表面需要具有凹形空隙或凹陷，此在石膏壁板中不需要且其對抗拔釘性質有不利影響。
粉塵產生為所有壁板安裝期間的潛在問題。在加工石膏壁板時，例如藉由切削、鋸割、銑槽、搭扣、釘釘或下擰或鑽鑿加工石膏壁板時，會產生大量的石膏粉塵。出於本揭示案之目的，"起塵"及"粉塵產生"意謂在含石膏產品加工(例如藉由壁板切削、割鋸、銑槽、刻劃/搭扣、釘釘或下擰或鑽鑿加工)期間粉塵釋入周圍工作空間內。加工通常亦可包括普通板處理，包括在輸送、搬運及安裝期間偶爾刮擦及對板圓鑿所產生之粉塵。若能發現顯著減少該粉塵產生的低密度壁板製造方法，則此方法將為此項技術提供特別有益之貢獻。
本發明大體上包含一種低起塵石膏壁板，其包括一形成於兩塊大體平行之覆蓋片之間的定形石膏芯，該定形石膏芯具有約75%至約95%之總空隙體積，該定形石膏芯係由包含水、灰泥、預膠凝化澱粉及萘磺酸鹽分散劑之含石膏漿料製成，其中以灰泥重量計，該預膠凝化澱粉以約0.5重量%至約10重量%之量存在。較佳地，以乾灰泥重量計，該萘磺酸鹽分散劑係以約0.1重量 %-3.0重量%之量存在。視情況，以灰泥重量計，三偏磷酸鈉係以至少約0.12重量%之量存在。在一較佳實施例中，以乾灰泥重量計，該三偏磷酸鹽係以約0.12-0.4重量%之量存在。
在一較佳實施例中，本發明包含低起塵石膏壁板，該石膏壁板包含一形成於兩塊大體平行之覆蓋片之間、包括預膠凝化澱粉及萘磺酸鹽分散劑的定形石膏芯，該定形石膏芯具有約80%至約92%之總空隙體積，其中至少60%之該總空隙體積包含平均直徑小於約100微米之空氣空隙，且該定形石膏芯具有約10pcf至約30pcf之密度。術語"pcf"定義為磅/立方呎(lb/ft3)。該定形石膏芯係由包含灰泥、預膠凝化澱粉及萘磺酸鹽分散劑之含石膏漿料製成，其中以灰泥重量計，該預膠凝化澱粉係以約0.5重量%至約10重量%之量存在。較佳地，以乾灰泥重量計，該萘磺酸鹽分散劑係以約0.1重量%-3.0重量%之量存在。
根據本發明所製造之石膏壁板具有高強度，而且重量遠較習知壁板輕。此外，已發現，藉由確保定形石膏芯之總芯部空隙體積為約75%至約95%，且較佳為約80%至約92%，則根據該實施例所製造之壁板在切削、鋸割、銑槽、搭扣、釘釘或下擰或鑽鑿時產生的粉塵大幅減少。
在又一實施例中，本發明包含一種如下製造高強度、低起塵之石膏壁板的方法：將包含水、灰泥、預膠凝化澱粉及萘磺酸鹽分散劑之含石膏漿料混合，其中以乾灰泥重量計，該萘磺酸鹽分散劑以約0.1重量%-3.0重量%之量存在，其中以灰泥重 量計，該預膠凝化澱粉以至少約0.5重量%之量直至約10重量%之量存在；以及將足量肥皂泡添加至該含石膏漿料中以在一完成壁板中形成約75%至約95%之包括空氣空隙在內之總空隙體積。將所得含石膏漿料沈積在第一紙片或其他適當覆蓋片上，且將第二紙片或其他適當覆蓋片置放在該沈積漿料上以形成一石膏壁板。在該含石膏漿料硬化至足以切削之後，切削該石膏壁板，且乾燥所得石膏壁板，以在該完成壁板中形成包括空氣空隙在內之總空隙體積為約75%至約95%的定形石膏芯。該含石膏漿料視情況可含有三偏磷酸鹽，例如三偏磷酸鈉。其他習知成分亦可用於該漿料中，視需要包括促進劑、黏合劑、防水劑、紙纖維、玻璃纖維、黏土、殺生物劑及其他已知成分。
在又一實施例中，本發明包含一種如下使用低起塵石膏壁板的方法：提供一具有一定形石膏芯的低起塵石膏壁板，該定形石膏芯具有約75%至約95%之總空隙體積，其中至少60%之該總空隙體積包含平均直徑小於約100微米之空氣空隙，且包括平均直徑小於約5微米之水分空隙；以產生石膏粉塵之方式(例如切削、鋸割、銑槽、刻劃/搭扣、釘釘或下擰或鑽鑿)加工該壁板；及捕集大部分石膏粉塵於該等空隙中。
圖1為說明本發明之一實施例之澆注石膏方塊樣本(11：08)的15倍放大率之掃描電子顯微照片。
圖2為說明本發明之一實施例之澆注石膏方塊樣本(11：30)的15倍 放大率之掃描電子顯微照片。
圖3為說明本發明之一實施例之澆注石膏方塊樣本(11：50)的15倍放大率之掃描電子顯微照片。
圖4為說明本發明之一實施例之澆注石膏方塊樣本(11：08)的50倍放大率之掃描電子顯微照片。
圖5為說明本發明之一實施例之澆注石膏方塊樣本(11：30)的50倍放大率之掃描電子顯微照片。
圖6為說明本發明之一實施例之澆注石膏方塊樣本(11：50)的50倍放大率之掃描電子顯微照片。
圖7為說明本發明之一實施例之澆注石膏方塊樣本(11：50)的500倍放大率之掃描電子顯微照片。
圖8為說明本發明之一實施例之澆注石膏方塊樣本(11：50)的2,500倍放大率之掃描電子顯微照片。
圖9至圖10為說明本發明之一實施例之澆注石膏方塊樣本(11：50)的10,000倍放大率之掃描電子顯微照片。
出乎意料地發現，使用包括灰泥、預膠凝化澱粉及萘磺酸鹽分散劑以及適量肥皂泡之含石膏漿料所製造之石膏壁板在定形石膏芯之總空隙體積為約80%至約92%時，不僅提供約10pcf至30pcf之極低板芯密度(及由此之低板重量)，而且在普通板處理及加工(諸如切削、鋸割、銑槽、刻劃/搭扣、釘釘或下擰或鑽鑿)中起塵較低。因此此壁板比其他已知產品更易切削。將肥皂泡導 入可產生小的氣(氣泡)空隙，其平均直徑可小於約100微米，但通常大於約10微米，且較佳大於約20微米。本發明需要該等小氣泡以及汽化水分空隙(直徑通常約5微米或更小，通常小於約2微米)大體上均勻地遍布於完成壁板產品之定形石膏芯中。舉例而言，定形石膏芯可具有約80%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微米之水分空隙。咸信在板切削、鋸割、銑槽、搭扣、釘釘或下擰或鑽鑿中，以此方式所製備之低密度板芯(該定形石膏芯總空隙體積為約80%至約92%，其為空氣空隙及水分空隙(總芯部空隙體積))可將大量小粉塵及其他碎屑捕集於所曝露之空隙中，以使得粉塵產生顯著減少且不會被空氣挾帶走。
硫酸鈣半水合物(灰泥)之復水及隨後硬化需要特定理論量之水(每莫耳灰泥需1-1/2莫耳水)以形成二水合硫酸鈣晶體。然而，商業過程通常需要過量水。此過量的商業過程用水在通常具有大體不規則形狀之石膏晶體基質中產生汽化水分空隙，且亦與其他水分空隙連通，在定形石膏晶體之間之大體上連續網路中形成不規則通道。相比之下，氣(氣泡)空隙係使用肥皂泡導入石膏漿料內。該等空氣空隙大體上為球形/圓形，且大體上亦與其他空氣空隙隔開，且因此通常為不連續的。水分空隙可分布於空氣空隙之壁內(參看(例如)圖8至圖10)。
粉塵捕集之有效性係視定形石膏芯之組成而定。已 發現，萘磺酸鹽分散劑在用量足夠高時可與預膠凝化澱粉交聯而在乾燥之後使石膏晶體黏結在一起，從而增強石膏複合物之乾燥強度。此外，現出乎意料地發現，預膠凝化澱粉與萘磺酸鹽分散劑(有機相)之組合可形成使定形石膏晶體黏結在一起的膠樣效果，且在將此調配物與特定空隙體積及空隙分布組合時，可在完成壁板刻劃/搭扣時產生較大尺寸的碎片。石膏碎片愈大，通常產生空氣可挾帶的粉塵愈少。相比之下，若使用習知壁板調配物，則因產生較小碎片而產生較多粉塵。舉例而言，習知壁板在鋸切時可產生平均直徑為約20-30微米且最小直徑為約1微米的粉塵碎片。相比之下，本發明之石膏壁板在鋸切時產生平均直徑為約30-50微米且最小直徑為約2微米的粉塵碎片；刻劃/搭扣可產生甚至更大的碎片。
在較軟壁板中，粉塵可被捕集於水分空隙與空氣空隙中(例如小石膏針晶作為單晶粉塵被捕集)。較硬壁板有利於粉塵捕集於空氣空隙中，因為在該等板加工時產生的定形石膏芯之碎塊或碎片較大。在此情況下，粉塵碎片對於水分空隙過大，但可截留於空氣空隙中。根據本發明之一實施例，可能藉由在定形石膏芯內導入較佳空隙/孔隙尺寸分布而達成粉塵捕集之增強。較佳為使小空隙尺寸與大空隙尺寸之分布與空氣空隙與水分空隙之分布相同。在一實施例中，較佳空氣空隙分布可使用肥皂泡製備。參看以下實例6及實例7。
在定形石膏芯內空氣空隙(大於約10微米)與水分空 隙(小於約5微米)之比率可在約1.8：1至約9：1之範圍內。定形石膏芯內空氣空隙(大於約10微米)與水分空隙(小於約5微米)之較佳比率可在約2：1至約3：1之範圍內。在一實施例中，定形石膏芯內之空隙/孔隙尺寸分布的範圍以所量測之總空隙之百分率計應為：約10-30%之空隙小於約5微米且約70-90%之空隙大於約10微米。換言之，定形石膏芯內空氣空隙(大於10微米)與水分空隙(小於5微米)之比率在約2.3：1至約9：1之範圍內。在一較佳實施例中，定形石膏芯內之空隙/孔隙尺寸分布的範圍以所量測之總空隙之百分率計應為：約30-35%之空隙小於約5微米且約65-70%之空隙大於約10微米。換言之，定形石膏芯內空氣空隙(大於10微米)與水分空隙(小於5微米)之比率在約1.8：1至約2.3：1之範圍內。
較佳地，平均氣(氣泡)空隙直徑尺寸小於約100微米。在一較佳實施例中，定形石膏芯內之空隙/孔隙尺寸分布為：大於約100微米(20%)、約50微米至約100微米(30%)及小於約50微米(50%)。亦即，較佳中值空隙/孔隙尺寸為約50微米。
較佳為將肥皂泡導入定形石膏芯中且控制定形石膏芯中氣(氣泡)空隙尺寸及分布以及控制定形石膏芯之密度。肥皂量之較佳範圍為約0.2lb/MSF至約0.6lb/MSF；更佳之肥皂量為約0.45lb/MSF。
肥皂泡必須以有效產生所要密度之量且以受控方式添加。為控制該過程，操作者必須監視石膏板成形線之高差且讓封套保持裝填狀態。若封套未保持裝填狀態，則壁板因漿料無法 裝填需要體積而產生中空邊緣。封套體積可藉由增加肥皂用量以防石膏板製造期間氣泡破裂(以便更好地維持氣泡)或藉由增加鼓風速率來保持裝填狀態。因此，通常封套體積可藉由增加或降低肥皂用量抑或藉由增加或降低鼓風速率來加以控制及調整。高差控制技術包括藉由添加肥皂泡以增加漿料體積或藉由降低肥皂泡用量以減少漿料體積來對工作台上之"動態漿料"加以調整。
根據本發明之一實施例，提供由含有灰泥、預膠凝化澱粉及萘磺酸鹽分散劑之含石膏漿料所製成之完成的含石膏產品。以乾灰泥重量計，萘磺酸鹽分散劑係以約0.1重量%-3.0重量%之量存在。以調配物中之乾灰泥重量計，預膠凝化澱粉係以至少約0.5重量%直至約10重量%之量存在。可用於漿料中之其他成分包括黏合劑、防水劑、紙纖維、玻璃纖維、黏土、殺生物劑及促進劑。本發明需要將肥皂泡添加至新調配之含石膏漿料中，以藉由將約75%至約95%之總空隙體積且較佳約80%至約92%之總空隙體積以小氣(氣泡)空隙及水分空隙之形式導入定形石膏芯內，從而來降低完成的含石膏產品(例如石膏壁板)之密度及控制起塵。較佳地，平均孔隙尺寸分布為約1微米(水分空隙)至約40-50微米(空氣空隙)。
視情況，約0.5重量%直至約10重量%之預膠凝化澱粉、約0.1重量%直至約3.0重量%之萘磺酸鹽分散劑與最低量至少約0.12重量%直至約0.4重量%之三偏磷酸鹽之組合(皆以石膏漿料中所使用之乾灰泥重量計)可出乎意料地顯著增加石膏漿料之流 體性。此顯著減少生產具有足夠流動性、用於製造含石膏產品(諸如石膏壁板)之石膏漿料所需水之量。咸信三偏磷酸鹽之量(至少約兩倍於標準調配物(如三偏磷酸鈉)之量)可激發萘磺酸鹽分散劑之分散活性。
萘磺酸鹽分散劑必須用於根據本發明所製備之含石膏漿料中。用於本發明之萘磺酸鹽分散劑包括聚萘磺酸及其鹽(聚萘磺酸鹽)及其衍生物(其為萘磺酸與甲醛之縮合產物)。特別適當之聚萘磺酸鹽包括萘磺酸鈉及萘磺酸鈣。萘磺酸鹽之平均分子量可在約3,000至27,000之範圍內，但較佳地，分子量為約8,000至22,000，且更佳地，分子量為約12,000至17,000。較之較低分子量分散劑，作為商業產品的較高分子量分散劑具有更高黏度及更低固體含量。適用的萘磺酸鹽包括可購自GEO Specialty Chemicals,Cleveland,Ohio的DILOFLO；可購自Hampshire Chemical Corp.,Lexington,Massachusetts的DAXAD；及可購自GEO Specialty Chemicals,Lafayette,Indiana的LOMAR D。萘磺酸鹽較佳例如以35-55重量%範圍之固體含量作為水溶液使用。萘磺酸鹽最佳例如以約40-45重量%範圍之固體含量以水溶液形式使用。或者，適當時，萘磺酸鹽可以例如乾固體或粉末形式(諸如LOMAR D)使用。
適用於本發明之聚萘磺酸鹽具有以下之通式結構(I)：
其中n>2，且其中M為鈉、鉀、鈣及其類似物。
以石膏複合調配物中所使用之乾灰泥重量計，萘磺酸鹽分散劑(較佳為約45重量%之水溶液)可以約0.5重量%至約3.0重量%之範圍使用。萘磺酸鹽分散劑之更佳範圍以乾灰泥重量計為約0.5重量%至約2.0重量%，且最佳範圍以乾灰泥重量計為約0.7重量%至約2.0重量%。相比之下，以乾灰泥重量計，已知石膏壁板含有此分散劑之量為約0.4重量%或更低。
換言之，以石膏複合調配物中所使用之乾灰泥重量計，磺酸鹽分散劑(以乾重計)可以約0.1重量%至約1.5重量%之範圍使用。萘磺酸鹽分散劑之更佳範圍(以乾固體計)為約0.25重量%至約0.7重量%(以乾灰泥重量計)，且最佳範圍(以乾固體計)為約0.3重量%至約0.7重量%(以乾灰泥重量計)。
含石膏漿料視情況可含有三偏磷酸鹽，例如三偏磷酸鈉。根據本發明可使用任何適當的水溶性偏磷酸鹽或聚磷酸鹽。較佳使用三偏磷酸鹽，包括複鹽，亦即具有兩種陽離子的三偏磷酸鹽。特別適用之三偏磷酸鹽包括三偏磷酸鈉、三偏磷酸鉀、三偏磷酸鈣、三偏磷酸鹽鈉鈣、三偏磷酸鋰、三偏磷酸銨及其類 似鹽，或其組合。較佳三偏磷酸鹽為三偏磷酸鈉。較佳地，三偏磷酸鹽例如以約10-15重量%範圍之固體含量作為水溶液使用。亦可使用其他環狀或非環狀聚磷酸鹽，如美國專利第6,409,825號(頒予Yu等人)中所述，該專利以引用之方式併入本文中。
三偏磷酸鈉為含石膏組合物中之已知添加劑，但以石膏漿料中所使用之乾灰泥重量計，其通常以約0.05重量%至約0.08重量%之範圍使用。在本發明之實施例中，以石膏複合調配物中所使用之乾灰泥重量計，三偏磷酸鈉(或其他水溶性偏磷酸鹽或聚磷酸鹽)可以約0.12重量%至約0.4重量%之範圍存在。以石膏複合調配物中所使用之乾灰泥重量計，三偏磷酸鈉(或其他水溶性偏磷酸鹽或聚磷酸鹽)之較佳範圍為約0.12重量%至約0.3重量%。
灰泥存在α及β兩種形式。該兩種類型之灰泥係藉由不同煅燒方式生產。在本發明中，灰泥之β形式抑或α形式皆可使用。
澱粉(尤其包括預膠凝化澱粉)必須用於根據本發明所製備之含石膏漿料中。較佳之預膠凝化澱粉為預膠凝化玉米澱粉(例如可購自Bunge Milling,St.Louis,Missouri之預膠凝化玉米粉)，其具有以下之典型分析結果：水分7.5%、蛋白質8.0%、油0.5%、粗纖維0.5%、灰分0.3%；具有0.48psi之生強度；且具有35.0lb/ft3之疏鬆容積密度。以含石膏漿料中所使用之乾灰泥重量計，預膠凝化玉米澱粉應以至少約0.5重量%直至約10重量%之量使用。
本發明人進一步發現，藉由在約0.1重量%至3.0重量%萘磺酸鹽分散劑存在下使用至少約0.5重量%直至約10重量%預膠凝化澱粉(較佳為預膠凝化玉米澱粉)(澱粉量及萘磺酸鹽量係以存在於調配物中之乾灰泥重量計)可獲得乾燥強度(尤其壁板之乾燥強度)之出乎意料之增強。無論水溶性三偏磷酸鹽或聚磷酸鹽存在與否，均可獲得此出乎意料之結果。
此外，已出乎意料地發現，預膠凝化澱粉可以至少約10lb/MSF或更高之量用於根據本發明所製造之乾燥石膏壁板中，仍可獲得高強度及低重量。業已證明，預膠凝化澱粉在石膏壁板中之量高達35-45lb/MSF亦有效。舉例而言，如以下表1及表2中所示，調配物B包括45lb/MSF，仍可產生具有優異強度之1042lb/MSF之板重量。在此實例(調配物B)中，萘磺酸鹽分散劑(作為45重量%之水溶液)係以1.28重量%之量使用。
當將萘磺酸鹽分散劑三偏磷酸鹽組合與預膠凝化玉米澱粉及視情況之紙纖維或玻璃纖維組合時，本發明可得到另一出乎意料之結果。由含有該三種成分之調配物所製成的石膏壁板具有增強之強度及減輕之重量，且因其製造中水需求減少而在經濟上更合乎需要。以乾灰泥重量計，紙纖維之適用量的範圍可高達約2重量%。以乾灰泥重量計，玻璃纖維之適用量的範圍可高達約2重量%。
本發明之含石膏組合物中可使用促進劑，如美國專利第6,409,825號(頒予Yu等人)中所述，該專利以引用之方式併入 本文中。一種適當之耐熱促進劑(HRA)可經由建築石膏粉(landplaster)(二水合硫酸鈣)之乾式研磨而製成。可使用少量添加劑(通常約5重量%)(諸如糖、右旋糖、硼酸及澱粉)製成此HRA。目前較佳為糖或右旋糖。另一適用促進劑為如美國專利第3,573,947號中所述之"氣候穩定化促進劑"或"氣候穩定促進劑"(CSA)，該專利以引用之方式併入本文中。
由於過量水最後必須藉由加熱驅除，因此水/灰泥(w/s)比率為重要參數。在本發明之實施例中，較佳w/s比率為約0.7至約1.3。
其他石膏漿料添加劑可包括促進劑、黏合劑、防水劑、紙纖維或玻璃纖維、黏土、殺生物劑及其他已知成分。
如同習知石膏壁板一般，覆蓋片可用紙製成，但可使用此項技術中已知之其他適用覆蓋片材料(例如纖維玻璃氈)。紙覆蓋片可在石膏壁板中提供強度特性。適用的覆蓋片紙包括Manila 7層及News-Line 5層(可購自United States Gypsum Corporation,Chicago,Illinois)；及Grey-Back 3層及Manila Ivory 3層(可購自Caraustar,Newport,Indiana)。紙覆蓋片包含頂覆蓋片或面紙，及底覆蓋片或背紙。較佳之背紙覆蓋片為5層News-Line。較佳之面紙覆蓋片為Manila 7層。
纖維氈亦可用作該等覆蓋片中之一或兩者。一種適用纖維氈為玻璃纖維之長絲係藉由黏結劑黏結在一起的玻璃纖維氈。較佳地，該等纖維氈為玻璃纖維之長絲係藉由黏結劑黏結在 一起的非編織玻璃纖維氈。最佳地，該等非編織玻璃纖維氈具有厚樹脂塗層。舉例而言，可使用購自Johns-Manville的Duraglass非編織玻璃纖維氈，其具有約1.2-2.0lb/100ft2之重量，其中氈重量之約40-50%來自樹脂塗層。其他適用的纖維氈包括但不限於編織玻璃氈及非纖維素織物。
以下實例進一步說明本發明。但不應將其視為以任何方式限制本發明之範疇。
實例1 樣本石膏漿料調配物
石膏漿料調配物展示於下表1中。表1中之所有數值係以重量百分率(以乾灰泥重量計)表示。括號中之數值為以磅計之乾重(lb/MSF)。
*用於預產生發泡體。 1 1.28重量%(作為45%之水溶液)。
實例2 壁板製備
根據美國專利第6,342,284號(頒予Yu等人)及第6,632,550號(頒予Yu等人)製備石膏壁板樣本，該等專利以引用之方式併入本文中。如該等專利之實例5中所述，此製備包括單獨形 成發泡體及將發泡體導入至其他所有成分之漿料中。
對使用實例1之調配物A及調配物B所製備之石膏壁板及普通對照板的測試結果展示於下表2中。如本實例及下文其他實例中所述，根據ASTM C-473進行抗拔釘性、芯部硬度及撓曲強度測試。此外，應注意，典型石膏壁板厚為約½吋厚度，且重量為約1600至1800磅/1,000平方呎材料或lb/MSF之間的重量。("MSF"為此項技術中千平方呎之標準縮寫；其為箱盒、波紋狀媒體及壁板之面積量測)。
MD：縱向XMD：橫向
如表2中所說明，較之對照板，使用調配物A及調配 物B漿料所製備之石膏壁板的重量顯著減輕。再次參考表1，調配物A板與調配物B板之對比最為驚人。在調配物A及調配物B中，水/灰泥(w/s)比率相似。亦用於調配物B中之萘磺酸鹽分散劑量顯著更高。此外，調配物B中使用約6重量%之顯著更多的預膠凝化澱粉，較調配物A增加100%以上，同時強度明顯增加。即便如此，在調配物B漿料中，產生所需流動性的需水量仍較低；較之調配物A，相差約10%。兩種調配物中之低需水性可歸因於石膏漿料中萘磺酸鹽分散劑與三偏磷酸鈉之組合之協同效應，此效應即使在顯著更多量之預膠凝化澱粉存在下仍可增強石膏漿料之流動性。
如表2中所說明，較之使用調配物A漿料所製備之壁板，使用調配物B漿料所製備之壁板具有顯著增加之強度。藉由合併增加量之預膠凝化澱粉及增加量之萘磺酸鹽分散劑與三偏磷酸鈉之組合，可使調配物B板之抗拔釘性較調配物A板提高45%。亦觀測到調配物B板之撓曲強度較調配物A板顯著增強。
實例3 1/2吋石膏壁板減重試驗
其他石膏壁板實例(板C、板D及板E)，包括漿料調配物及測試結果，皆展示於下表3中。表3之漿料調配物包括漿料之主要組分。括號中之數值係以重量百分率(以乾灰泥重量計)表示。
† ASTM標準：77lb 1 DILOFLO為45%萘磺酸鹽之水溶液。
如表3中所說明，較之對照板，板C、板D及板E由具有顯著增加量(以百分率計，澱粉及分散劑增加約兩倍，且三偏磷酸鹽增加兩倍至三倍)之澱粉、DILOFLO分散劑及三偏磷酸鈉的漿料製成，同時維持w/s比率恆定。然而，板重量顯著減輕且藉由抗拔釘性所量測之強度不受明顯影響。因此，在本發明之實施例之該實例中，新型調配物(諸如板D)可增加調配於適用之可流動漿料中的澱粉，同時維持相同w/s比率及足夠強度。
實例4 濕石膏方塊強度測試
藉由使用Southard CKS板灰泥(購自United States Gypsum Corp.,Chicago,Illinois)及實驗室中之自來水進行濕方塊強度測試以測定其濕壓縮強度。採用以下實驗室測試程序。
每一濕石膏方塊澆注件在約70℉下使用灰泥(1000g)、CSA(2g)及自來水(1200cc)。首先將預膠凝化玉米澱粉(20g，2.0%，以灰泥重量計)及CSA(2g，0.2%，以灰泥重量計)與灰泥於塑料袋中充分乾拌混合，之後再將其與含有萘磺酸鹽分散劑與三偏磷酸鈉的自來水溶液混合。所用分散劑為DILOFLO分散劑(1.0-2.0%，如表4中所示)。如表4中所示，亦可使用不同量之三偏磷酸鈉。
初始將乾成分與水溶液於實驗室Warning摻混機中合併，讓所產生之混合物浸泡10秒，接著將混合物慢速混合10秒以便製成漿料。將由此所形成之漿料澆注成三個2"X2"X2"之方塊模。接著將澆注方塊自模中移除，稱重，且將其密封於塑料袋內，以防止在進行壓縮強度測試之前損失水分。濕方塊之壓縮強度係使用ATS機量測且以磅/平方吋(psi)為單位記錄平均值。所得結果如下： 1 DILOFLO為45%萘磺酸鹽之水溶液。
如表4中所說明，具有本發明之約0.12-0.4%範圍內之三偏磷酸鈉量的樣本4-5、樣本10-11及樣本17較之三偏磷酸鈉超出此範圍之樣本通常提供更優的濕方塊壓縮強度。
實例5 1/2吋輕重量石膏壁板工廠生產試驗
進行進一步之試驗(試驗板1及試驗板2)，包括漿料調配物且測試結果，皆展示於下表5中。表5之漿料調配物包括漿料之主要組分。括號中之數值係以重量百分率(以乾灰泥重量計)表示。
† ASTM標準：77lb MD：縱向XMD：橫向1 DILOFLO為45%萘磺酸鹽之水溶液。2 90℉/90%相對濕度3顯然，在該等測試條件下，百分率失效率<50%可接受。
如表5中所說明，較之對照板，試驗板1及試驗板2係由具有顯著增加量之澱粉、DILOFLO分散劑及三偏磷酸鈉的漿料製成，同時w/s比率略低。然而，藉由抗拔釘性及撓曲測試所量測之強度得以維持或改良，且板重量顯著減輕。因此，在本發明之實施例之該實例中，新型調配物(諸如試驗板1及試驗板2)可增加調配於適用之可流動漿料中的三偏磷酸鹽及澱粉，同時大體上維持相同w/s比率及足夠強度。
實例6 1/2吋超輕重量石膏壁板工廠生產試驗
採用調配物B(實例1)，如實例2般進行進一步之試驗(試驗板3及試驗板4)，區別為將預膠凝化玉米澱粉用水製備為10%濃度(濕澱粉製備)且使用HYONIC 25 AS與PFM 33肥皂(購自GEO Specialty Chemicals,Lafayette,Indiana)之摻混物。舉例而言，用HYONIC 25 AS與PFM 33之摻混物(25AS在65-70重量%範圍內且其餘為PFM 33)製備試驗板3。舉例而言，用HYONIC 25AS/HYONIC PFM 33之70/30(重量/重量)摻混物製備試驗板4。試 驗結果展示於下表6中。
*除標記外。1 n=4 MD：縱向XMD：橫向a ASTM標準：77lb b ASTM標準：11lb c ASTM標準：36lb d ASTM標準：107lb
如表6中所說明，藉由抗拔釘性及芯部硬度所量測之強度特性高於ASTM標準。亦測得撓曲強度高於ASTM標準。同樣，在本發明實施例之該實例中，新型調配物(諸如試驗板3及試 驗板4)可增加調配於適用之可流動漿料中的三偏磷酸鹽及澱粉，同時維持足夠強度。
實例7 1/2吋厚度石膏壁板芯之空隙體積計算百分率與板重量及鋸切結果的關係
採用調配物B(實例1)，如實例2般進行進一步之試驗以便測定空隙體積及密度(試驗板第5號至第13號)，區別為將預膠凝化玉米澱粉用水製備為10%濃度(濕澱粉製備)、使用0.5%玻璃纖維且將萘磺酸鹽(DILOFLO)以1.2重量%之量作為45%之水溶液使用。肥皂泡係使用肥皂發泡器製備且以有效提供所要密度之量導入至石膏漿料中。在本實例中，肥皂係以0.25lb/MSF至0.45lb/MSF之量使用。亦即，肥皂泡用量視需要增加或減少。在各樣本中，壁板厚度為1/2吋，且芯部體積假設相同，為39.1ft3/MSF。橫跨4呎寬壁板樣本量測空隙體積，該等樣本之面紙及背紙已移除。面紙及背紙可具有11-18密耳圍內之厚度(每一側)。空隙體積/孔隙尺寸及孔隙尺寸分布係藉由掃描電子顯微術(參看下文實例8)及X射線CT掃描技術(XMT)測定。
1>10微米氣(氣泡)空隙2<5微米水分空隙3基於相同芯部體積=39.1ft3/MSF；亦即，總芯部空隙體積=發泡體空隙體積+汽化空隙體積/39.1×100 4基於相同芯部體積=39.1ft3/MSF；亦即，板芯密度(pcf)=板重量(lb/MSF)-紙覆蓋片之重量(lb/MSF)/39.1ft3/MSF=板重量(lb/MSF)-90lb/MSF/39.1ft3/MSF†所量測之總空隙百分率
如表7中所說明，製備總芯部空隙體積在79.0%至 92.1%範圍內之試驗板樣本，該等總芯部空隙體積分別對應於28pcf向下直至10pcf範圍內之板芯密度。舉例而言，鋸切試驗板10(具有81.8%之總芯部空隙體積及23pcf之板芯密度)產生較對照板少30%的粉塵。再舉例而言，若利用具有更少黏合劑(如具有或不具有分散劑之澱粉)的習知調配物製成顯著低於約75-80%總芯部空隙體積的壁板，則在切削、鋸割、銑槽、搭扣、釘釘或下擰或鑽鑿時預計會有顯著大量的粉塵產生。舉例而言，習知壁板在鋸切時會產生平均直徑約20-30微米且最小直徑約1微米的粉塵碎片。相比之下，本發明之石膏壁板在鋸切時產生平均直徑約30-50微米且最小直徑約2微米的粉塵碎片；刻劃/搭扣將產生甚至更大的碎片。
業已證明，將用於製成含石膏漿料之若干關鍵組分(亦即：灰泥、萘磺酸鹽分散劑、預膠凝化玉米澱粉、三偏磷酸鈉及玻璃纖維及/或紙纖維)之組合，與足夠且有效量的肥皂泡組合，可在適用之低密度石膏壁板製造中產生協同效應，此石膏壁板在刀切、鋸切、刻劃/搭扣、鑽鑿及普通板處理期間亦可顯著減少石膏粉塵之形成。
實例8 測定試驗板第10號之氣泡空隙尺寸及水分空隙尺寸，以及石膏晶體形態
藉由掃描電子顯微術(SEM)分析來自工廠試驗用以製備試驗板第10號的澆注石膏方塊(2吋×2吋×2吋)。觀測並量測氣 泡空隙及汽化水分空隙，以及石膏晶體尺寸及形狀。
製得三個樣本方塊且分別標記為11：08、11：30及11：50。圖1至圖3說明各樣本之15倍放大率之氣泡空隙尺寸及分布。圖4至圖6說明各樣本之50倍放大率之氣泡空隙尺寸及分布。
在更高倍放大率下，可觀測到水分空隙，例如在高達10,000倍放大率下，在樣本方塊11：50之大體上較大之氣泡空隙壁中，如圖7至圖10中所示。幾乎所有的石膏晶體均為針晶；幾乎觀測不到片晶。在氣泡空隙之表面上，該等針晶之密度及充填不同。在氣泡空隙壁中之水分空隙中亦觀測到石膏針晶。
SEM結果證明，在根據本發明所製備之含石膏產品中，空氣空隙及水分空隙大體上均勻地遍布於定形石膏芯中。所觀測之空隙尺寸及空隙分布亦證明，足夠的自由空間係作為空氣空隙及水分空隙(總芯部空隙體積)而形成，以使得在普通板處理中及在切削、鋸割、銑槽、搭扣、釘釘或下擰或鑽鑿期間，所產生之大量石膏粉塵被捕集於所曝露之周圍空隙中而不會被空氣挾帶走。
實例9 粉塵捕集於低粉塵石膏壁板中
若根據本發明之教示如實例7般製備壁板，則預計壁板加工時所產生之石膏粉塵會包含至少50重量%、直徑大於約10微米的石膏碎片。藉由切削、鋸割、銑槽、刻劃/搭扣、釘釘或下擰及鑽鑿加工壁板所產生之全部粉塵之至少約30%或更多將被捕 集。
在描述本發明之上下文(尤其在以下申請專利範圍之上下文)中使用術語"一"及"該"及類似指示物應理解為涵蓋單數與複數形式兩者，除非本文中另有說明或與上下文有明顯抵觸。本文中之數值範圍之敍述僅意欲作為個別指出屬於該範圍內之各獨立數值的簡述方法(除非本文中另有說明)，且各獨立數值併入本說明書中的程度如同其個別敍述於本文中一般。本文中所述所有方法可以任何適當順序進行，除非本文中另有說明或與上下文有明顯抵觸。本文中所提供之任何及所有實例或例示性措辭(例如"諸如")之使用僅意欲清楚地闡明本發明，而非限制本發明之範疇，除非申請專利範圍另有主張。本說明書中之措辭不應理解為指定任何未經主張之要素為實施本發明之必需。
本發明之較佳實施例，包括發明人已知之實施本發明之最佳方式，已描述於本文中。應瞭解，所說明之實施例僅具有例示性且不應視作限制本發明之範疇。

Claims (10)

  1. 一種石膏板，其包含：一置放於兩覆蓋片間之定形石膏芯；該包含一石膏晶體基質之定形石膏芯，其孔隙尺寸分佈包含(i)具有直徑小於約50微米之孔隙尺寸之空隙，(ii)具有直徑約50微米至約100微米之孔隙尺寸之空隙，(iii)具有直徑大於約100微米之孔隙尺寸之空隙，其中該等空隙係藉由掃描電子顯微照片計算；具有最大頻率之空氣空隙尺寸係約100微米或較小之直徑；該石膏晶體基質被形成為使該定形石膏芯具有至少約11磅(約5公斤)根據ASTM標準C-473所測定之平均芯部硬度；以及該板具有約35pcf(約560公斤/立方公尺(kg/m3))或以下之密度。
  2. 如請求項1之石膏板，其中具有直徑大於約100微米之孔隙尺寸之空隙係包含至少約20%該定形石膏芯之總空隙體積。
  3. 如請求項1之石膏板，其中該板之密度係約24pcf(約380kg/m3)至約31pcf(約500kg/m3)。
  4. 如請求項1之石膏板，其中平均空氣空隙尺寸之直徑係小於約100微米。
  5. 如請求項1之石膏板，該定形石膏芯係由漿料形成，該漿料包含水、肥皂泡、灰泥、及澱粉，相對於不含該澱粉之該石膏板，澱粉係有效增加該石膏板之芯部硬度。
  6. 如請求項1至5中任一項之石膏板，其中該澱粉為預膠凝化澱粉，其量為以乾灰泥重量計約0.5重量%至約10重量%。
  7. 如請求項6之石膏板，其中該漿料更包含以下之至少一者：(i)萘磺酸鹽分散劑，其量為以乾灰泥重量計約0.1重量%至約3.0重量%；以及(ii)水溶性多磷酸鹽，其量以乾灰泥重量計約0.12重量%至約0.4重量%。
  8. 一種石膏板，包含：一置放於兩覆蓋片間之定形石膏芯；該定形石膏芯係由漿料形成，該漿料以約0.7至約1.3之水/灰泥比例含有至少水與灰泥，該定形石膏芯包含一石膏晶體基質，其孔隙尺寸分佈包含(i)具有直徑小於約5微米之孔隙尺寸之水分空隙；(ii)具有直徑至少約5微米且小於約50微米之孔隙尺寸之空氣空隙；(iii)具有直徑約50微米至約100微米之孔隙尺寸之空氣空隙；以及(iv)具有直徑大於約100微米之孔隙尺寸之空氣空隙，使得具有直徑大於約100微米之孔隙尺寸之空氣空隙係包含至少約20%該定形石膏芯之總空隙體積，該等空隙係藉由掃描電子顯微照片計算； 平均空氣空隙尺寸之直徑係小於100微米；該石膏晶體基質被形成為使該定形石膏芯具有至少約11磅根據ASTM標準C-473所測定之平均芯部硬度；以及該板具有約35pcf(約560kg/m3)或以下之密度。
  9. 如請求項8之石膏板，其中該漿料更含有預膠凝化澱粉，其量為以乾灰泥重量計約0.5重量%至約10重量%。
  10. 如請求項8或9之石膏板，其中該板之密度係約24pcf(約380kg/m3)至約31pcf(約500kg/m3)。
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