TWI623419B - 輕重量石膏板 - Google Patents
輕重量石膏板 Download PDFInfo
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- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
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- 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
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B29/00—Layered products comprising a layer of paper or cardboard
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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 form; Layered products 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 form; Layered products 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
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- 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
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- C—CHEMISTRY; METALLURGY
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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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- C—CHEMISTRY; METALLURGY
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- 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
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
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- 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
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- 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
Abstract
本發明提供具有一獨特微結構之石膏牆板,於該微結構中,強化空隙間之壁(walls)的厚度及強度以實質上改善牆板之強度及加工特性。本發明亦提供一種製造輕重量石膏牆板之方法。
Description
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。
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(CaSO4.1/2H2O),通常稱為「灰泥」,其係藉由二水合物形式的硫酸鈣(CaSO4.2H2O)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,亦已發現若萘磺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,增加三偏磷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內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、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。
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0.5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0.1重量%至約0.4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0.2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27pcf至約30pcf之凝固石膏芯密度之有效量存在。「pcf」係定義為多少磅/立方英呎(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。
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;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;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內之空氣空隙分佈、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
石膏芯內之空氣空隙分佈、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內之空氣空隙分佈、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內之空氣空隙分佈、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內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內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內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內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內之空隙間的壁之平均厚度以及微結構特徵。
出乎意料地,已發現使用含石膏漿料(含有灰泥、預膠化澱粉、萘磺酸鹽分散劑、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,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磅/MSF至約1260磅/MSF,並具有約27pcf至約30pcf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20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、釘釘子或鎖螺絲、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50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30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120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程度可賦予較厚的空氣空隙壁。
咸信該等壁表面的強化係由於在板的初始乾燥期間,預膠化澱粉/分散劑/三偏磷酸鈉移至空氣空隙表面,填補壁表面的針狀空隙並因此緻密化該表面。此強化了凝固石膏芯之微結構,製造具有增加的強度及提高的加工特質之牆板。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著壁表面延伸。儘管咸信此強化的表面包含經移動之預膠化澱粉、分散劑、以及三偏磷酸鈉,本案發明人並非意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,該等空隙係由具有強化的緻密表面之增厚的壁所界定。一較佳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0.5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0.1重量%至約0.4重量%(以灰泥之重量計)之量存在之三偏磷酸鈉、以及以最高為約0.2重量%(以灰泥之重量計)之量存在之視需要的玻璃纖維。
硫酸鈣半水合物(灰泥)之再水合及隨後的硬化需要一特定理論的水量(莫耳水/莫耳灰泥),以形成硫酸鈣二水合物晶體。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體基質內產生蒸發水的空隙,其形狀實質上常為不規則的且與其他水空隙互相連接,形成凝固石膏晶體間之廣泛連續網絡中之不規則的通道。與此相反,使用肥皂泡沫將空氣(泡泡)空隙引入至石膏漿料中。空氣空隙通常為球狀/圓球狀,且一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內部(請參照例如第8圖至第10圖)。
塵埃抓取的效果係取決於凝固石膏芯之組成而定。已發現若萘磺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,因而可增加石膏複合體
的乾強度。此外,出乎意料地,目前已發現預膠化澱粉與萘磺酸鹽分散劑之組合(有機相)可提供一類膠效果而將凝固石膏晶體結合在一起,且當此調配物結合一特殊的空隙體積及空隙分佈時,對最終牆板刻痕/刨痕時會產生較大尺寸的碎片。本發明之增加的壁厚度及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。舉例言之,傳統牆板因鋸切所產生的塵埃碎片具有約20至30微米之平均直徑,且最小的直徑約為1微米。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(例如抓取如單一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膏芯之碎塊或碎片。在此情況下,塵埃碎片對於水空隙而言是過大的,但可困於空氣空隙中。根據本發明之一實施態樣,可藉由在凝固石膏芯內引入一較佳空隙/孔洞尺寸分佈而實現增加的塵埃抓取。空氣及水空隙之分佈較佳係具有小空隙及大空隙尺寸之分佈。於一實施態樣中,可使用肥皂泡沫來製備一較佳空氣空隙分佈。請參照後述之實施例6及實施例7。
凝固石膏芯內之空氣空隙(大於約10微米)對水空隙(小於約5微米)之比例為約1.8:1至約9:1。凝固石膏芯內之
空氣空隙(大於約10微米)對水空隙(小於約5微米)之較佳比例為約2:1至約3:1。於一實施態樣中,凝固石膏芯內之空隙/孔洞尺寸分佈應為約10至30%之空隙係小於約5微米,且約70至90%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,凝固石膏芯內之空氣空隙(大於10微米)對水空隙(小於5微米)之比例為約2.3:1至約9:1。於一較佳實施態樣中,凝固石膏芯內之空隙/孔洞尺寸分佈應為約30至35%之空隙係小於約5微米,且約65至70%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,凝固石膏芯內之空氣空隙(大於10微米)對水空隙(小於5微米)之比例為約1.8:1至約2.3:1。
空氣(泡泡)空隙尺寸之平均直徑較佳係低於約100微米。於一較佳實施態樣中,凝固石膏芯內之空隙/孔洞尺寸分佈為:大於約100微米(20%)、約50微米至約100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50微米。
空氣空隙會減弱經起泡之低密度凝固石膏芯與覆蓋薄片之間的接合強度。因為泡沫的關係,複合體石膏板超過一半的體積係由空氣空隙所構成,因此泡沫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,視需要提供一未經起泡(或經降低起泡)之接合高密度層於頂部覆蓋薄片、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皂(泡沫)之外。視需要,為了形成此接合層,可以機械方式將泡沫從芯調配物中移除,或可於經起泡之低密度凝固石膏芯/覆蓋薄片介面塗敷一不同的無泡沫調配物。
較佳係引入肥皂泡沫以控制凝固石膏芯內之空氣(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0.2磅/MSF至約0.7磅/MSF;更佳肥皂含量為約0.45磅/MSF至約0.5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(board forming line)的前端,並使殼模保持填滿。若殼模未保持填滿,由於漿料無法填滿必需的體積而會得到帶有空洞邊緣之牆板。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)、或藉由增加空氣泡沫率而使殼模體積保持填滿的。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沫率來控制及調整的。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0.1重量%至約3.0重量%(以灰泥之乾重計)之量存在。該預膠化澱粉係以至少約0.5重量%至最高約10重量%(以調配物內之灰泥之乾重計)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內,引入約75%至約95%,較佳為約80%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1微米(水空隙)至約40至50微米(空氣空隙)。
視需要,皆以石膏漿料內所用之灰泥之乾重計,約0.5重量%至最高約10重量%之預膠化澱粉、約0.1重量%至最高約3.0重量%之萘磺酸鹽分散劑、以及至少約0.12重量%至最高約0.4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流動性。此實質上減少製造具足夠流動性之石膏漿料所需之水量,該石膏漿料係用以製造含石膏產品,例如石膏牆板。咸信標準調配物(如三偏磷酸鈉)含量之至少約兩倍之三偏磷酸鹽的含量,可促進萘磺酸鹽分散劑之分散劑活性。
於根據本發明所製備之含石膏漿料中,必須使用萘磺酸鹽分散劑。本發明所使用之萘磺酸鹽分散劑包含聚萘磺酸及其鹽類(聚萘磺酸鹽)及其衍生物,該些化合物為萘磺酸與甲醛的縮合產物(condensation products)。特別所欲之聚萘磺酸鹽包含
萘磺酸鈉及萘磺酸鈣。萘磺酸鹽之平均分子量為約3,000至約27,000,儘管其較佳分子量為約8,000至約22,000,且更佳分子量為約12,000至約17,000。作為一商業產品,與較低分子量之分散劑相比,較高分子量之分散劑具有較高的黏性及較低的固體含量。可用的萘磺酸鹽包含可得自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35至55重量%固體含量之水溶液形式的萘磺酸鹽。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LOMAR D。
可用於本發明之聚萘磺酸鹽具有結構(I):
其中n>2,且其中M為鈉、鉀、鈣等。
萘磺酸鹽分散劑(較佳係呈約45重量%水溶液形式)之使用範圍係約0.5重量%至約3.0重量%(以用於石膏複合體調配物內之灰泥之乾重計)。更佳的萘磺酸鹽分散劑範圍係約0.5重量%
至約2.0重量%(以灰泥之乾重計);且最佳的萘磺酸鹽分散劑範圍係約0.7重量%至約2.0重量%(以灰泥之乾重計)。與此相反,已知的石膏牆板含有此分散劑的含量係約0.4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重量%至約1.5重量%(以用於石膏複合體調配物內之灰泥之乾重計)。較佳的萘磺酸鹽分散劑(以乾固體計)範圍係約0.25重量%至約0.7重量%(以灰泥之乾重計);且最佳的萘磺酸鹽分散劑(以乾固體計)範圍係約0.3重量%至約0.7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。較佳的三偏磷酸鹽為三偏磷酸鈉。較佳係使用呈水溶液形式之三偏磷酸鹽,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6,409,825號中所述,該篇專利內容併於本文以供參考。
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重量%至約0.08重量%(以用於石膏漿料內之灰泥之乾重計)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0.10重量%至約0.4重量%(以用於石膏複合體調配物內之灰泥之乾重計)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內之灰泥之乾重計)。
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,例如可得自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8.0%,油為0.5%,天然纖維為0.5%,粉塵(ash)為0.3%;具有0.48psi之生坯強度(green 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0.5重量%至最高約10重量%(以用於含石膏漿料中之灰泥之乾重計)之量使用。於一更佳實施態樣中,預膠化澱粉係以約0.5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。
本案發明人更進一步發現藉由於約0.1重量%至約3.0重量%之萘磺酸鹽分散劑的存在下,使用至少約0.5重量%至最高約10重量%之預膠化澱粉(較佳係預膠化玉米澱粉),(尤其是於牆板中)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,該篇專利內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號中所述,該篇專利內容併於本文以供參考。
水/灰泥(w/s)比率係一重要的參數,因為過量水最終必須藉由加熱而除去。於本發明之實施態樣中,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,如同傳統石膏牆板中所用一般。紙覆蓋薄片可提供石膏牆板內之強度特質。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;可得自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,高張力)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-ply。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,
該非織造玻璃纖維墊片具有一厚重的樹脂塗層。例如可使用可得自Johns-Manville之Duraglass非織造玻璃纖維墊片,其具有約1.2至2.0磅/100平方英呎之重量且約40至50%的墊片重量係來自於樹脂塗層。其他可用之纖維墊片包含,但不限於,織造玻璃墊片及非纖維素織物。
以下實施例將進一步闡述本發明,但無論如何不應將其視為限制本發明之範圍。
石膏漿料調配物試樣
石膏漿料調配物係如以下表1所示。表1中的所有數值皆係以灰泥之乾重計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)。
製備牆板
石膏牆板試樣係根據由Yu等人所著之美國專利第6,342,284號及Yu等人所著之美國專利第6,632,550號所製得,該二專利內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及調配物B所製得之石膏牆板、以及常規的控制組板之測試結果。在此實施例及後述實施例中,抗拔釘力、芯硬度、以及撓曲強度測試係根據ASTM C-473來進行。此外,需注意典型的石膏牆板係大約1/2英吋厚且具有約1600至1800磅/千平方英呎材料(或磅/MSF)的重量。(在本領域中,「MSF」係千平方英呎之標準縮寫;其係用於箱子、瓦楞芯紙(corrugated media)、以及牆板的面積測量。)
如表2所示,與控制組板相比,使用調配物A及調配物B之漿料所製得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。
1/2英吋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。
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、DILOFLO分散劑、以及三偏磷酸鈉(澱粉與分散劑,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)的漿料而製得,且同時仍維持w/s比率不
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。
濕石膏立方體強度測試
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℉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(20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DILOFLO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攪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,以製造漿料。將如此所形成之漿料澆鑄至三個2吋×2吋×2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機器來測量,並以平均每平方英呎多少磅(psi)的單位來記錄。所獲得之結果如下:
1 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。
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。
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。
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)摻混物外,如同實施例2一般使用調配物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。
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日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。
於1/2英吋厚之石膏牆板芯內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
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%含量之萘磺酸鹽(DILOFLO)(呈45%水溶液形式)外,如同實施例2一般使用調配物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磅/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11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。
如表7所示,所製得之試驗板試樣具有79.0%至92.1%之總芯空隙體積,其係個別符合28pcf降至10pcf之板芯密度。舉例言之,總芯空隙體積為81.8%及板芯密度為23pcf之試驗板10的鋸切,會產生比控制組板少30%的塵埃。以另一例子為例,若牆板係以具有較少黏合劑(例如澱粉,具有或不具有分散劑)之傳統調配物所製得,該等牆板具有明顯少之約75至80%之總芯空隙體積,當對該些牆板進行裁切、鋸開、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,傳統牆板因鋸切所產生的塵埃碎片具有約20至30微米之平均直徑,且最小的直徑約為1微米。與此相反,本發明之石膏牆板因鋸切所產生的塵埃碎片具有約30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。
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、萘磺酸鹽分散劑、預膠化玉米澱粉、三偏磷酸鈉、以及玻璃和/或紙纖維的組合,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/刨痕、鑽孔、以及常規板處理過程中所形成的石膏塵埃。
試驗板10內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之澆鑄石膏立方體(2吋×2吋×2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。
製得三個試樣立方體,並分別標記為11:08、11:30、以及11:50。第1圖至第3圖所示為在15倍放大倍率下,各該試樣中之空氣泡泡空隙尺寸及分佈。第4圖至第6圖所示為在50倍放大倍率下,各該試樣中之空氣泡泡空隙尺寸及分佈。
在更高的放大倍率下,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10圖所示,最高為10,000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內觀測到石膏針狀物。
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),可將於一般之板加工時及對板進
行裁切、鋸開、挖槽、刨痕、釘釘子或鎖螺絲、或鑽孔等工作期間中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。
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50重量%直徑大於約10微米之石膏碎片。可抓取至少約30%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。
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
1 DILOFLO係一45%萘磺酸鹽水溶液2 95重量/5重量之HYONIC 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。
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℉/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(請參照後述實施例12)及能量分散光譜(EDS)來分析板試樣。亦可以X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50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1吋長的最終牆板部分,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。
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14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ASTM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、銼磨(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。
試驗板14內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×2吋×2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。
第11圖至第19圖之SEM結果說明,在類似於上述實施例8之SEM顯微照片的增加的放大倍率下之壁厚度。這些SEM結果,如第13圖及第14圖所示,分別比較試驗板14及控制組板A,顯示出以下兩個改良:1)試驗板中之空氣泡泡空隙實質上係大於控制組板中之空氣泡泡空隙,以及2)試驗板中之空隙間的平均壁厚度係遠大於控制組板中之空隙間的平均壁厚度。一般而言,試驗板14中之空隙間的平均壁厚度係至少約50微米至最高約200微米。與此相反,控制組板A中之空隙間的平均壁厚度通常為約20至30微米。此外,第15圖之500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。
如前所述,空氣空隙間之平均壁厚度較大,可對最終牆板提供較高的強度,即較佳的抗拔釘力、較佳的芯/邊緣硬度、
以及較佳的加工特質,例如鑽孔、裁切、以及鋸開時的塵埃減量。
測定平均空隙尺寸、壁厚度、以及緻密強化的壁表面之存在
藉由對所測試之牆板試樣刻痕並刨削穿過芯,以分成適當尺寸的試樣來製備芯試樣。隨後藉由例如直接以強力的氣流橫越該經刻痕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
在芯試樣內隨機取樣的10個位置處拍攝50倍放大倍率的10張顯微照片。測量橫越該10張顯微照片內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
在芯試樣內隨機取樣的10個位置處拍攝50倍放大倍率的10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之各空隙間的距離。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
在芯試樣內隨機取樣的10個位置處拍攝50倍放大倍率的10張顯微照片。檢測這些顯微照片中所呈現之經放大的空隙是否有沿著空隙邊緣分佈之厚白線,如同那些在第15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。
除非在此或上述文中有另外說明,於本發明之說明書中(尤其是在後述專利申請範圍中)所使用之「一」、「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,於此文中所列舉之數值範圍僅作為個別提及落在該範圍內之各個單獨數值的簡記法,且各個單獨數值係併入說明書中,如同其在本文中所個別列舉。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。
Claims (53)
- 一種輕重量石膏板,包含一凝固石膏芯,係置於二紙覆蓋薄片之間;該凝固石膏芯係由一包含水、灰泥、澱粉、萘磺酸鹽分散劑及泡沫的漿料所形成;該凝固石膏芯包含一石膏晶體基質,該石膏晶體基質係具有壁以界定並分開該石膏晶體基質內之空氣空隙,於該空氣空隙間之該壁的平均厚度為30微米至200微米,平均的空氣空隙孔洞尺寸為直徑低於100微米,該平均壁厚度及平均空氣空隙孔洞尺寸係使用掃描電子顯微成像測得;該石膏晶體基質係經形成使該凝固石膏芯具有如根據ASTM C-473測定之至少11磅,即約5公斤,之平均芯硬度;及該板具有35磅/立方英呎(pounds per cubic foot,pcf),即約560公斤/立方公尺,或更低之密度。
- 如請求項1所述之輕重量石膏板,其中該平均的空氣空隙孔洞尺寸為直徑50微米至直徑100微米。
- 如請求項1所述之輕重量石膏板,其中該壁係具有70微米至120微米之平均厚度。
- 如請求項1所述之輕重量石膏板,其中該壁係界定:(i)具有直徑大於100微米之孔洞尺寸的空氣空隙,(ii)具有直徑50微米至100微米之孔洞尺寸的空氣空隙,以及(iii)具有直徑小於50微米之孔洞尺寸的空氣空隙,該孔洞尺寸係使用掃描電子顯微成像測得。
- 如請求項4所述之輕重量石膏板,其中該具有直徑大於100毫米之孔洞尺寸的空氣空隙係佔該凝固石膏芯之總空隙體積的至少20%。
- 如請求項1所述之輕重量石膏板,其中該平均的空氣空隙孔洞尺寸為直徑10微米至直徑100微米。
- 如請求項6所述之輕重量石膏板,其中該平均的空氣空隙孔洞尺寸為直徑20微米至直徑100微米。
- 如請求項1所述之輕重量石膏板,其中該板具有24磅/立方英呎至31磅/立方英呎,即約380公斤/立方公尺至約500公斤/立方公尺,之密度。
- 如請求項1所述之輕重量石膏板,其中該板具有24磅/立方英呎至35磅/立方英呎,即約380公斤/立方公尺至約560公斤/立方公尺,之密度。
- 如請求項1至9中任一項所述之輕重量石膏板,其中該漿料包含可有效增加該凝固石膏芯之芯硬度之量的澱粉,相對於一由不含澱粉之漿料所形成的凝固石膏芯。
- 如請求項1所述之輕重量石膏板,其中該萘磺酸鹽分散劑之量為0.1重量%至3重量%,以灰泥之重量計。
- 如請求項1所述之輕重量石膏板,其中該萘磺酸鹽分散劑之量為0.2重量%至2重量%,以灰泥之重量計。
- 如請求項1所述之輕重量石膏板,其中該澱粉之量為0.5重量%至10重量%,以灰泥之重量計。
- 如請求項1所述之輕重量石膏板,其中該漿料更包含三偏磷酸鈉。
- 如請求項14所述之輕重量石膏板,其中該三偏磷酸鈉之量為0.1重量%至0.4重量%,以灰泥之重量計。
- 一種輕重量石膏板,包含一凝固石膏芯,係置於二紙覆蓋薄片之間;該凝固石膏芯係由一包含水、灰泥、澱粉、萘磺酸鹽分散劑及泡沫的漿料所形成;該凝固石膏芯包含一石膏晶體基質,該石膏晶體基質係具有壁以界定並分開於該石膏晶體基質內之空氣空隙,於該空氣空隙間之該壁的平均厚度為30微米至200微米,平均的空氣空隙孔洞尺寸為直徑低於100微米,該平均壁厚度與平均空氣孔隙孔洞尺寸係使用X射線CT掃描技術(XMT)所獲得之三維成像測得;該石膏晶體基質係經形成使該凝固石膏芯具有如根據ASTM C-473測定之至少11磅,即至少約5公斤,之平均芯硬度;及該板具有35磅/立方英呎,即560公斤/立方公尺,或更低之密度。
- 如請求項16所述之輕重量石膏板,其中該板具有24磅/立方英呎至31磅/立方英呎,即約380公斤/立方公尺至約500公斤/立方公尺,之密度。
- 如請求項16所述之輕重量石膏板,其中該平均的空氣空隙孔洞尺寸為直徑10微米至直徑100微米。
- 如請求項16所述之輕重量石膏板,其中該壁的平均厚度為70微米至120微米。
- 如請求項16所述之輕重量石膏板,其中該萘磺酸鹽分散劑之量為0.1重量%至3重量%,以灰泥之重量計。
- 如請求項16所述之輕重量石膏板,其中該澱粉之量為0.5重量%至10重量%,以灰泥之重量計。
- 如請求項16所述之輕重量石膏板,其中該漿料更包含三偏磷酸鈉。
- 如請求項22所述之輕重量石膏板,其中該三偏磷酸鈉之量為0.1重量%至0.4重量%,以灰泥之重量計。
- 一種輕重量石膏板,包含一凝固石膏芯,係置於二紙覆蓋薄片之間;該凝固石膏芯係由一包含水、灰泥、澱粉、萘磺酸鹽分散劑及泡沫的漿料所形成;該凝固石膏芯係包含一石膏晶體基質,該石膏晶體基質係具有壁以界定並分開於該石膏晶體基質內之空氣空隙,於該空氣空隙間之該壁的平均厚度係30微米至200微米,平均的空氣空隙孔洞尺寸為直徑低於100微米,該平均壁厚度與平均空氣空隙孔洞尺寸係使用掃描式電子顯影成像所測得;該石膏晶體基質係經形成使該壁展現4至8之抗拔釘力對芯硬度之比,各值係如根據ASTM C-473測定,當該板為1/2英吋,即約1.3公分,厚時;及該板具有約35磅/立方英吋,即約560公斤/立方公尺,或更低之密度。
- 如請求項24所述之輕重量石膏板,其中該板具有24磅/立方英呎至31磅/立方英呎,即約380公斤/立方公尺至約500公斤/立方公尺,之密度。
- 如請求項24所述之輕重量石膏板,其中該壁與該空氣空隙係安排於凝固石膏芯中使得根據ASTM C-473測定之芯硬度為至少11磅,即至少約5公斤。
- 如請求項24所述之輕重量石膏板,其中該壁具有70微米至120微米之平均厚度。
- 如請求項24所述之輕重量石膏板,其中部分之該空氣空隙係具有直徑50微米至100微米之孔洞尺寸,部分之該空氣空隙係具有直徑大於100微米之孔洞尺寸,其中該具有直徑大於100微米之孔洞尺寸的空氣空隙係佔該凝固石膏芯之總空隙體積的至少20%,該孔洞尺寸係使用掃描式電子顯微成像測得。
- 如請求項24所述之輕重量石膏板,其中該平均空氣空隙孔洞尺寸為直徑50微米至直徑100微米。
- 如請求項24所述之輕重量石膏板,其中該澱粉之量為0.5重量%至10重量%,以灰泥之重量計。
- 如請求項24所述之輕重量石膏板,其中該萘磺酸鹽分散劑之量為0.1重量%至3重量%,以灰泥之重量計。
- 如請求項24所述之輕重量石膏板,其中該漿料更包含三偏磷酸鈉。
- 如請求項32所述之輕重量石膏板,其中該三偏磷酸鈉之量為0.1重量%至0.4重量%,以灰泥之重量計。
- 一種輕重量石膏板,包含一凝固石膏芯,係置於二紙覆蓋薄片之間;該凝固石膏芯係由一包含水、灰泥、澱粉、萘磺酸鹽分散劑及泡沫的漿料所形成;該凝固石膏芯係包含一石膏晶體基質,該石膏晶體基質係具有提供一總空隙體積及孔洞尺寸分布的多個空隙,包含(i)具有直徑小於5微米之孔洞尺寸的空隙、(ii)具有直徑10微米至100微米之孔洞尺寸的空氣空隙、以及(iii)具有直徑大於100微米之孔洞尺寸的空氣空隙,該空隙係使用掃描電子顯微成像量測;10至35%之空隙係直徑小於5微米,且孔洞尺寸大於10微米之空隙與孔洞尺寸小於5微米之空隙之比例為2.3:1至約9:1;以及晶體基質具有壁,以界定並分開石膏基質內之空氣空隙,於該空氣空隙間之該壁的平均厚度為30微米至200微米,該平均壁厚度係使用掃描電子顯微成像測得;且該石膏晶體基質係經形成使該凝固石膏芯具有如根據ASTM C-473測定之至少11磅,即約5公斤,之芯硬度,且小於5微米之空隙、10微米至100微米之空隙及大於100微米之空隙的量係使得該板具有35磅/立方英呎(pounds per cubic foot,pcf),即約560公斤/立方公尺,或更低之密度。
- 如請求項34所述之輕重量石膏板,其中至少一部分之該壁係包含強化的緻密牆表面。
- 如請求項34所述之輕重量石膏板,其中該凝固石膏芯係由一包含水、灰泥及澱粉的漿料所形成,該澱粉之用量係足以使得該凝固石膏芯具有較使用不含澱粉之漿料形成之凝固石膏芯增加的芯硬度。
- 如請求項34所述之輕重量石膏板,其中該澱粉包含以灰泥之重量計為0.5重量%至10重量%之預膠化澱粉。
- 如請求項34所述之輕重量石膏板,其中該萘磺酸鹽分散劑之量為0.1重量%至3重量%,以灰泥之重量計。
- 如請求項34所述之輕重量石膏板,其中該漿料更包含三偏磷酸鈉。
- 如請求項34所述之輕重量石膏板,其中該壁具有70微米至120微米之平均厚度。
- 一種輕重量石膏板,包含一凝固石膏芯,係置於二紙覆蓋薄片之間;該凝固石膏芯係由一包含水、灰泥、澱粉、萘磺酸鹽分散劑及泡沫的漿料所形成;該凝固石膏芯包含一石膏晶體基質,該石膏晶體基質係具有壁以界定並分開於該石膏晶體基質內之空氣空隙,於空氣空隙間之該壁具有30微米至200微米之平均厚度,出現頻率最高之空氣空隙尺寸為100微米或更低的直徑,平均壁厚度係使用掃描式電子顯微成像測得;該石膏晶體基質係經形成使該凝固石膏芯具有如根據ASTM C-473測定之至少11磅,即至少約5公斤,之平均芯硬度,及該板具有35磅/立方英呎,即約560公斤/立方公尺,或更低之密度。
- 如請求項41所述之輕重量石膏板,其中該壁係界定:(i)具有直徑大於100微米之孔洞尺寸的空氣空隙,(ii)具有直徑50微米至100微米之孔洞尺寸的空氣空隙,以及(iii)具有直徑小於50微米之孔洞尺寸的空氣空隙,該孔洞尺寸係使用掃描式電子顯微成像測得。
- 如請求項41所述之輕重量石膏板,其中該萘磺酸鹽分散劑之量為0.1重量%至3重量%,以灰泥之重量計。
- 如請求項41所述之輕重量石膏板,其中該澱粉之量為0.5重量%至10重量%,以灰泥之重量計。
- 如請求項41所述之輕重量石膏板,其中該漿料更包含三偏磷酸鈉。
- 如請求項45所述之輕重量石膏板,其中該三偏磷酸鈉之量為0.1重量%至0.4重量%,以灰泥之重量計。
- 一種輕重量石膏板,包含一凝固石膏芯,係置於二紙覆蓋薄片之間;該凝固石膏芯係由一包含水、灰泥、澱粉、萘磺酸鹽分散劑及泡沫的漿料所形成;該凝固石膏芯包含一石膏晶體基質,該石膏晶體基質係具有壁以界定並分開於該石膏晶體基質內之空氣空隙,於該空氣空隙間之該壁的平均厚度為30微米至200微米,多數空氣空隙具有100微米或更低的直徑,該平均壁厚度係使用掃描電子顯微成像測得;該石膏晶體基質係經形成使該凝固石膏芯具有如根據ASTM C-473測定之至少11磅,即至少約5公斤,之芯硬度;及該板具有35磅/立方英吋,即約560公斤/立方公尺,或更低之密度。
- 如請求項47所述之輕重量石膏板,其中部分之該空氣空隙係具有直徑為50微米至100微米之孔洞尺寸,部分之該空氣空隙係具有直徑大於100微米之孔洞尺寸,且具有直徑大於100微米之孔洞尺寸的空氣空隙係佔該凝固石膏芯之總空隙體積的至少20%,其中該空隙係使用掃描式電子顯微成像測得。
- 如請求項48所述之輕重量石膏板,其中具有直徑為大於50微米之孔洞尺寸的空氣空隙係佔該凝固石膏芯之總空隙體積的至少50%。
- 如請求項47所述之輕重量石膏板,其中該萘磺酸鹽分散劑之量為0.1重量%至3重量%,以灰泥之重量計。
- 如請求項47所述之輕重量石膏板,其中該澱粉之量為0.5重量%至10重量%,以灰泥之重量計。
- 如請求項47所述之輕重量石膏板,其中該漿料更包含三偏磷酸鈉。
- 如請求項52所述之輕重量石膏板,其中該三偏磷酸鈉之量為0.1重量%至0.4重量%,以灰泥之重量計。
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US11/906,479 US9840066B2 (en) | 2005-06-09 | 2007-10-02 | Light weight gypsum board |
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TW103206899U TWM495365U (zh) | 2007-10-02 | 2008-10-01 | 以高含量之澱粉及高含量之分散劑所製造之微結構特徵的石膏牆板 |
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