Classifications

• • 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
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B1/00—Producing shaped prefabricated articles from the material
  • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
  • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
• • 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
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
  • C04B41/5007—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with salts or salty compositions, e.g. for salt glazing
• • 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
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• • 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
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
  • C04B41/61—Coating or impregnation
  • C04B41/70—Coating or impregnation for obtaining at least two superposed coatings having different compositions
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • 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
  • E04C2/043—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 of plaster
• • 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
  • Y10T428/23—Sheet including cover or casing
  • Y10T428/232—Encased layer derived from inorganic settable ingredient
• • 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
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31844—Of natural gum, rosin, natural oil or lac
  • Y10T428/31848—Next to cellulosic

Definitions

• ABSTRACT OF THE DISCLOSURE A gypsum wallboard characterized by a set calcined gypsum core bonded to spaced paper surfaces; at least one surface rendered water repellent by a dispersed composition containing tall oil, an unsaturated aliphatic hydrocarbon and an aliphatic hydrocarbon. The water repellency is further improved by heating the paper surface containing the composition and by the presence of compounds of aluminum or ferric iron from water soluble salts in the paper surface.
• This invention relates to a water repellent gypsum board and more particularly to a method of rendering the paper of gypsum board water repellent without interfering with the normal production thereof as well as a product formed thereby.
• Gypsum boards are made by continuously forming a thick aqueous slurry, primarily of calcined gypsum and water, between enclosing paper surfaces. The resulting sheet, when set, is cut into lengths or boards and dried in a multiple deck dryer.
• the gypsum board paper is exceedingly water repellent such for example when the board is to be used in the bathroom particularly as a backup surface for ceramic, plastic, or metal tiles, also, when the boards are to be used as sheathing or soflits for exterior purposes.
• such treatment is desirable even if the board is subsequently painted which is an object of this invention.
• the treatment should also permit application of paint without bleedthrough which is a common failing of the prior art petrolatum and asphalt coatings.
• the ordinary integral sizing of gypsum board paper renders them somewhat water resistant, there is a limit to the amount of Waterproofness which can be obtained in this manner as a too highly sized paper will interfere with the proper formation of the board therefrom upon the machine. Also, such integral sizing does not materially increase the water repellency of the paper.
• a still further object is to provide a gypsum board sufficiently resistant to water that it may be used in the exterior construction of buildings, as well as interior areas exposed to water and water vapor, such, for example, as in bathrooms.
• An additional object is to improve the resistance of gypsum board paper to water at elevated temperatures.
• gypsum board is manufactured in a manner similar to that described in Patent No. 1,330,413.
• a thick aqueous slurry of calcined gypsum and water along with foam and a bond aiding material is placed between enclosing paper sheets.
• the bottom paper is continuously unwound from a roll and scored by grinding wheels to aid in folding.
• the aqueous slurry is deposited upon this paper and conveyed thereby to the forming means, usually spaced rolls called master rolls placed in a horizontal position. While the bottom paper is pulled through the space between these rolls it is folded over the edge and under the top paper which is in contact with and applied by the upper master roll. The slurry is thus completely enclosed thereby as it passes between the master rolls.
• the sheets are cut into lengths to form boards and subsequently dried in a multiple deck kiln, usually gas fired, so that the paper temperature is at least about 265 F. After drying the boards are bundled and are ready for shipment.
• a gypsum board of markedly high water repellency can be provided if a composition containing certain types of materials is added to the gypsum board paper surface prior to the passage of the board through the drying kiln. For some unexplainable reason such materials which render the paper water repellent after the board has been heated in the dryer are not effective before such treatment. Neither do these materials substantially improve the water resistance without heating.
• a particular material, which is suitable for this purpose, is that manufactured by the Protection Products Division of the United States Plywood Corporation and known as PPM 122.
• This material which is in emulsion form, is preferably applied to the paper surface as it passes through the calendar stacks. Care must be used to not permit the material to become too hot, i.e. not above F., and to assure that a uniform coat is applied so as to prevent streaking. When properly applied the material gives very little discoloration.
• the paper forming the outside face of the board is in the greatest need of a waterproofing treatment, though the back paper should also have some such treatment.
• the face paper usually has a colored surface liner applied over a chip base.
• the paper should also have an integrally applied size to augment the above treatment.
• the rosin size should be 2% or more of the bone dry weight of the paper and precipitated with alum or ferric sulfate.
• a wax emulsion containing 47% solids such as Parasol 404R, an aqueous emulsion of a fully refined paraffin Wax sold by the Hercules (10., can also be added integrally, if desired.
• This paper is then treated upon the surface by a wet calendar stack application of between about 3.8 and 4.6 lbs. of the PPM 122 emulsion, referred to above, per 1000 sq. ft.
• For surface sizing the back paper only between 2.8 and 3.6 lbs. need be used.
• the temperature should not be in excess of 120 F. when the emulsion is applied.
• the paper should be tested for water resistance following the Cobb sizing test procedure set forth in TAPPI No. T441-m60.
• the paper should show a weight increase of not over about 0.5 gram following this method.
• the product appears to be an aliphatic hydrocarbon, mostly straight chain, with some methyl and olefinic groups.
• Petroleum waxes such as crude scale wax, low molecular weight polypropylene, a low molecular weight copolymer of ethylene and propylene and pentadiene polymer and other polymerized dienes or reacted olefines as well as methacrylated paraftins. Visual observations indicates the polymers are of low molecular weight.
• Pentaerythritol 59 2 CTLA Heat reactive, olefinic hydrocarbon (probably mufbly dicyclopentadiene).
• Piceopale Composed of polymerized mixture of monomers (MW and essentially dienes and reactive olefins. It appears to be methy .ed parallin chains with limited amounts of unsaturation and also mi .rrcs of straight chain resins in which considerable cyclic but no arena-tic structures are present.
• the above were added to the surface of the paper as an emulsion containing about 25% solids.
• the emulsion was prepared by mixing, with agitation, 17 parts of 29% ammonium hydroxide and 295 parts of water heated to about F. with the formula indicated which was previously heated to at least 200 F. or to a fluid state.
• the emulsifying agent is obtained by forming ammonium soaps with the tall oil. Soaps from other alkaline material such as potassium hydroxide can also be formed.
• low molecular weight polypropylene In place of wax, low molecular weight polypropylene, a low molecular weight copolymer of polypropylene and polyethylene can be used.
• the paper be previously treated with an aluminum or ferric ion. This pretreatment of the paper is essential in order to obtain the best results. It is not essential that these ions be added integrally such as a size precipitant during the formation of the paper as they can be added as a solution to the finished paper surface. It is also not necessary that the paper he previously sized in order to obtain the benefits of this invention. It is important, however, that the paper be heated after the emulsion has been added to at least 265 F., preferably 300 F., in order to effectively bring out the water repellent and resistance properties. When this invention is properly carried out an integral size is not always necessary, except to obtain certain desirable paper characteristics needed for proper board formation.
• this invention comprises a gypsum board of improved water repellency and resistance obtained by the surface application, preferably at the calender stack, to the gypsum board paper which has been previously subjected to aluminum or ferric ions either by direct application or integrally such as a size precipitant, an emulsion composition, such as or similar to PPM 122 and heating the paper during the drying of the board to at least 265 F.
• a gypsum board paper is obtained in which the paper containing dried aluminum or ferric iron ions are treated with a heat activated water resistant composition.
• a water resistant gypsum board comprising a set calcined gypsum core and paper cover sheets encasing and secured to said core, the outer surface of at least one of said cover sheets containing a water resistant composition comprising (1) tall oil, (2) a fatty acid ester selected from the group consisting of glycerides and pentaerythritides and (3) an aliphatic hydrocarbon selected from the group consisting of petroleum wax, low molecular weight polypropylene, copolymers of ethylene and propylene, and pentadiene polymers.
• the gypsum board of claim 1 in which the aliphatic hydrocarbon is a mixture of petrolatum and a petroleum resin.
• a process of making water resistant gypsum board which comprises coating at least one cover sheet therefor with (1) a tall oil soap emulsion whose disperse phase contains (2) a fatty acid ester selected from the group consisting of glycerides and pentaerythritides and (3) an aliphatic hydrocarbon selected from the group consisting of petroleum wax, low molecular weight polypropylene, copolymers of ethylene and propylene, and pentadiene polymers; depositing an aqueous slurry of calcined gypsum bet-ween cover sheets, at least one of which has been so coated, permitting the calcined gypsum to set, cutting to desired lengths and drying in an elevated temperature atmosphere of at least about 265 F.
• a gypsum board formed from a set gypsum core surrounded by enclosing paper sheets, the improvement comprising increasing the water repellency of at least one of the paper surfaces by coating said surface with a composition containing a tall oil, a drying oil and an aliphatic hydrocarbon followed by heating in a gypsum board kiln, said surface containing a paper liner integrally sized with a size selected from the group consisting of rosin size, wax emulsion and mixture thereof precipitated by an acidic salt of a metal selected from the group of aluminum and ferric iron.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Structural Engineering (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Inorganic Chemistry (AREA)
• Architecture (AREA)
• Mechanical Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Manufacturing & Machinery (AREA)
• Civil Engineering (AREA)
• Paper (AREA)
• Cartons (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Laminated Bodies (AREA)
• Materials Applied To Surfaces To Minimize Adherence Of Mist Or Water (AREA)

Priority Applications (8)

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Citations (11)

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• 1964
  • 1964-01-20 US US338575A patent/US3383271A/en not_active Expired - Lifetime
• 1965
  • 1965-01-07 GB GB761/65A patent/GB1094139A/en not_active Expired
  • 1965-01-18 FR FR2329A patent/FR1421064A/fr not_active Expired
  • 1965-01-18 NO NO156402A patent/NO115524B/no unknown
  • 1965-01-19 LU LU47808A patent/LU47808A1/xx unknown
  • 1965-01-20 NL NL6500720A patent/NL6500720A/xx unknown
  • 1965-01-20 BE BE658549D patent/BE658549A/xx unknown
  • 1965-01-20 DE DEU11388A patent/DE1266200B/de active Pending

Patent Citations (11)

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