WO2017179844A1 - Gypsum board composition, method for manufacturing gypsum board, and gypsum board manufactured therefrom - Google Patents

Abstract

The present invention relates to a gypsum board composition, a method for manufacturing a gypsum board, and a gypsum board manufactured therefrom, and the purpose of the present invention is to use a fly ash as a filler for a common gypsum board. To this end, the present invention provides a composition of a gypsum board produced from a mixture of calcined gypsum and a filler, wherein the mixture comprises: 90 to 99% by weight of calcined gypsum as a main material and 1 to 10% by weight of fly ash as a filler; a method for manufacturing a gypsum board using the composition; and a gypsum board manufactured therefrom. As such, it is possible to enhance the compressive strength of the gypsum board and improve the sagging property thereof, but also to reduce the cost of raw materials by an amount of calcine gypsum which is replaced by fly ash.

Description

Gypsum board composition, gypsum board manufacturing method, and gypsum board manufactured therefrom

The present invention relates to a gypsum board composition, a gypsum board manufacturing method, and a gypsum board manufactured therefrom, and more specifically, using a fly ash (fill ash) as a filler in a general gypsum board, the compressive strength of the gypsum board The present invention relates to a gypsum board composition, a gypsum board manufacturing method, and a gypsum board manufactured therefrom, which can reduce raw material cost by the difference of reinforcing, improving sag and replacing existing gypsum usage with fly ash.

In general, gypsum board is mixed with fiber, vermiculite, etc. in plaster, and if necessary, foaming agent, hardening agent, etc. is added to it and then poured into empty sheet between two sheets. It is used to prevent the flames from propagating to the main structure inside the adjacent compartment or gypsum board.

In recent years, the weight of gypsum board has been reduced due to the continuous increase in the price of main materials or subsidiary materials, the increase in energy costs, and the restriction of carbon emission.

In this regard, the Republic of Korea Patent Publication No. 10-2005-0041090 (2005.05.04 publication) discloses a technique for manufacturing a lightweight gypsum board and sandwich panel.

According to this, by manufacturing a gypsum board using a material such as pulp, porous minerals, inorganic fibers, inorganic binders, it is possible to manufacture a sandwich panel of environmentally friendly and excellent performance in heat insulation and fire resistance.

However, this focuses on the insulation and fire resistance performance, and customer complaints such as core strength and deflection, which are the core quality of gypsum board, have been raised, requiring efforts to improve them.

On the other hand, fly ash is a particulate matter collected by a dust collector of a pulverized coal combustion boiler among coal ashes generated from a coal-fired power plant and the like, and is close to a spherical shape, and its main component is composed of SiO ₂ , Al ₂ O ₃ , glass, and the like.

Such fly ash is used commercially, especially in the cement field, but is used in some specialty boards in gypsum board manufacturing, but not in general gypsum board.

Therefore, the present invention has been made to meet the above requirements, the technical problem to be solved by the present invention, while using a fly ash as a filler on a general gypsum board, while improving the compressive strength of the gypsum board and improve the deflection It is to provide a gypsum board composition, a gypsum board manufacturing method, and a gypsum board manufactured therefrom which can reduce raw material cost for the use of calcined gypsum as much as fly ash.

One embodiment of the present invention for achieving the above object is a composition of gypsum board produced from a mixture of plaster and filler, wherein the mixture is 90 to 99 weight of plaster as a main material with respect to 100% by weight of the mixture as a whole %, And 1 to 10% by weight of fly ash as a filler.

Another embodiment of the present invention for achieving the above object is a method for producing a gypsum board by adding a hardening agent, water, foaming agent and subsidiary materials to the gypsum mixture mixed with the gypsum and filler to form a gypsum slurry and to mold and harden the gypsum slurry A raw material mixing step of mixing 100 to 100% by weight of the calcined gypsum mixture as a main material, 90 to 99% by weight of calcined gypsum and 1 to 10% by weight of fly ash as a filler; A slurry blending step of blending a slurry by adding a curing agent, water, a blowing agent, and at least one component selected from clay and starch to the mixture obtained in the raw material mixing step; Continuously spread the lower frame made of gypsum board paper and continuously fill the slurry with the slurry obtained in the slurry mixing process (b) to cover the top with another gypsum board paper to produce a gypsum board molding with a long overall length. Molding and curing step of curing while running on the molding belt; A primary cutting process of primaryly cutting the plasterboard molding cured in the molding and curing process into a length that can be accommodated in the dryer at the end of the molding belt; It is a gypsum board manufacturing method comprising a; drying step of drying the first cut cut in the first cutting process through a dryer.

The gypsum board manufacturing method of the present invention may be implemented in another embodiment, further comprising; a secondary cutting and stacking step of cutting the first cut dried in the drying step to the product length and accumulates to a specified number of sheets.

Another embodiment of the present invention for achieving the above object is a gypsum board made of the gypsum board composition, and a gypsum board manufactured by the gypsum board manufacturing method.

According to the present invention, since the fly ash obtained from the raw gypsum obtained through the calcination process is mixed with a fly ash as a filler, it is possible to enhance the compressive strength of the gypsum board and improve the sag property while manufacturing the gypsum board. There is an advantage that can reduce the raw material cost for the amount of calcined gypsum replaced.

1 is a cross-sectional view of a gypsum board specimen prepared from a gypsum board composition according to an embodiment of the present invention.

Figure 2 is a flow chart schematically illustrating a gypsum board manufacturing process using a gypsum board composition according to the present invention.

3 is a schematic configuration diagram of a gypsum board manufacturing apparatus applied to the gypsum board manufacturing process according to the present invention.

4A and 4B are compressive strength graphs and deflection graphs illustrating measured values of the specimens of Examples 1 and 2 and Comparative Examples 1 and 2, respectively.

Hereinafter, the structure and operation of gypsum board composition, gypsum board manufacturing method, and gypsum board manufactured therefrom according to a preferred embodiment of the present invention and the effect thereof will be described in detail with reference to the accompanying drawings.

The terms or words used in this specification and claims are not to be construed as limiting in their usual or dictionary meanings, and the inventors may properly define the concept of terms in order to best explain their invention in the best way possible. It should be interpreted as meaning and concept corresponding to the technical idea of the present invention. Therefore, since the embodiments described in the specification and the configuration shown in the drawings are only one of the most preferred embodiments of the present invention, it is understood that there may be various equivalents and modifications that can replace them at the time of the present application. shall.

The gypsum board composition of the present invention is 90 to 99% by weight of gypsum hemihydrate as a main material and 1 to 10% by weight of fly ash as a filler, based on 100% by weight of the mixture of calcined gypsum and filler. It is comprised by%, and may contain a hardening | curing agent further. In this case, the fly ash is not significantly improved in the compressive strength or deflection when the content is less than 1% by weight compared to the gypsum weight percent contained in 100% by weight of the mixture. The strength of the gypsum board may not be adhered to, and the amount of the plasterboard may not be adhered. Preferably, when the content is 5 to 8% by weight, it may be a desirable quantity that can have a great effect on quality improvement and cost reduction. . When the fly ash is contained in the gypsum board composition, there is no significant change in the overall gypsum board manufacturing process, and only the input equipment that can be added according to the content is required. In addition, manufacturing cost can be reduced due to the difference between the production cost of plaster and the purchase price of fly ash, and the production cost reduction increases proportionally according to the production volume.

Plastered gypsum (or hemihydrate gypsum) is obtained from a raw gypsum obtained through a calcination process.

Fly ash is melted when the coal is burned to a high temperature of about 1,400 ~ 1,500 ℃ in coal-fired power plant, and the ash is melted rapidly along with the combustion gas of high temperature to form a spherical shape by the surface tension As the powder, those collected using an electric or mechanical dust collector are used.

The main component of fly ash is composed of silica (SiO ₂ ), alumina (Al ₂ O ₃ ), iron dioxide (Fe ₂ 0 ₃ ), magnesium oxide (MgO), etc. Components such as phosphorus (P), cobalt (Co), molybdenum (Mo), boron (B), and magnesium (Mg) may be included.

The fly ash contained in the gypsum board composition of the present invention is used in the following compartment as shown in Table 1, and as can be seen in the table, based on 100% by weight of the fly ash, 30 to 60% by weight of silica; 10 to 30 weight percent of alumina; 5 to 15 weight percent of iron dioxide; Calcium oxide 1-10 wt%; And 1 to 10% by weight of magnesium oxide; as a constituent, one having a powder degree (cm 2 / g) of 3000 or more, a density (g / cm 3) of 1.95 or more, and a loss of ignition (%) of less than 5.0.

Fly ash	SiO 2 (%)	Al 2 O 3 (%)	Fe 2 O 3 (%)	CaO (%)	MgO (%)	Powder level (cm 2 / g)	Ignition loss (%)	Density (g / cm 3 )
standard	30-60	10-30	5-15	1-10	1-10	More than 3000	Less than 5.0	1.95 or more

Granularity

Fly ash is a glass sphere containing some carbon with some crystalline materials, and is divided into solid particles containing several layers of spherical particles and hollow porous particles filled with carbon dioxide and nitrogen gas inside. Therefore, such a fly ash increases the fluidity of the slurry by the ball bearing action when mixed in the gypsum slurry, and can act as a factor having a good effect on the gypsum material properties by filling the gypsum slurry pores.

density

The higher the density, the better the fly ash's engineering properties, such as increased water tightness.

Ignition loss

The amount of unburned carbon present in the fly ash depends on the quality of the fly ash and the combustion conditions.However, the amount of unburned carbon is generally 2-10% and is often around 5%. The fly ash becomes gray from cement color. The amount of unburned carbon in the fly ash is a problem, especially in the cement or concrete admixture portion. In general, unburned carbon adsorbs AE agent in concrete, so when using fly ash having a large amount of unburned carbon, more AE agent is required to secure the required air volume, and when the fly ash mixing rate is the same, The large loss of ash results in a decrease in strength, so the KS standard (KS L 5405) specifies a limit of 5% of fly ash loss. Therefore, fly ash containing a lot of unburned carbon has the drawback of blackening the appearance of concrete and reducing the effect of admixture, and therefore, low ash loss value for cement or concrete admixture is required.

Powder

Powder level is a very important property that affects workability. In general, when the powder is high, the particles are fine, and thus the watertightness can be improved by filling the voids between the aggregates. There are two methods for measuring the powder level, the sieve method and the specific surface area measurement method by the Blaine permeation method. In the case of the sieve, it is generally measured by a 45 µm (NO325) sieve. In KS L 5405, the degree of powder is regulated to 3,000 cm2 / g or more, and ASTM C618 regulates the residual amount of 45 µm sieve (less than 34%). In JIS A 6201, the 45 µm sieve residual (less than 25%) and specific surface area 2,400 It regulates simultaneously in cm <2> / g or more. The powder density of the fly ash obtained in the electrostatic precipitator is generally in the range of 3,000-4,500 cm 2 / g. The degree of powderiness increases as the value of the specific surface area is large or the amount of 45 µm remaining body is small, and the workability is improved as the powderiness is higher.

As a result, the gypsum board composition of the present invention can stably maintain the product core strength at a level of 3.0 Mpa or more, and improve the sag by using fly ash as a filler mixed with the calcined gypsum mixture.

1 is a cross-sectional view of a gypsum board specimen prepared from a gypsum board composition according to an embodiment of the present invention, Figure 2 is a flow chart schematically illustrating a gypsum board manufacturing process using a gypsum board composition according to the present invention, Figure 3 Is a schematic configuration diagram of a gypsum board manufacturing apparatus applied to the gypsum board manufacturing process according to the present invention, the gypsum board manufacturing method of the present invention is a raw material mixing step (a), slurry mixing step (b) ), Forming and curing process (c), the first cutting step (d), it may be configured to include a drying step (e), the gypsum board manufacturing method of the present invention is a secondary cutting and loading step (f) It may be configured to include more. The gypsum board manufacturing method of the present invention can be applied at the time of manufacturing gypsum board used in building materials.

The raw material mixing step (a) is 90 to 99% by weight of the calcined gypsum obtained through the firing process from the raw material gypsum as the main material and 1 to 10 weight of the fly ash as the filler, based on 100% by weight of the mixture of the calcined gypsum 12a and the filler. It is a process of mixing%. The fly ash 12b used as a filler in this raw material mixing process (a) is 30 to 60 weight% of silica with respect to 100 weight% of fly ash; 10 to 30% by weight of alumina; 5 to 15 weight percent of iron dioxide; Calcium oxide 1 to 10% by weight; And 1 to 10% by weight of magnesium oxide. In addition, the fly ash used as a filler in such a raw material mixing process (a) uses the thing of the powder degree (cm2 / g) 3000 or more, the loss on ignition loss (%) 5.0, and the density (g / cm3) 1.95 or more.

The slurry blending step (b) is a step of mixing the slurry 12 by adding a curing agent to the mixture obtained in the raw material mixing step (a) and adding at least one member selected from water, a blowing agent, clay and starch. .

Forming and curing step (c), as illustrated in Figure 3, continuously spread the lower frame 11 made of gypsum board paper and continuously filling the lower frame with the slurry 12 obtained in the slurry blending step (b) Through the process of continuously covering the top with a cover paper 13 made of another gypsum board base paper to produce a gypsum board molding of long overall length, and thus produced gypsum board molding of long and continuous gasket Is a step of curing while running on the forming belt (14).

The primary cutting step (d) is a step of primary cutting the gypsum board molding 15 cured in the molding and curing step (c) into a length that can be accommodated in the dryer 16 at the end of the molding belt.

The drying step (e) is a step of putting the first cut 15a cut in the first cutting step into a drier and drying it.

The secondary cutting and dropping step (f) is a step of secondary cutting the first cut dried in the drying step into a product length for carrying out and packing, and dropping the second cut 15b to a specified number of sheets.

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. However, these examples are only for the understanding of the present invention, and the scope of the present invention in any sense is not limited to these examples.

Examples 1 and 2 and Comparative Examples 1 and 2

As shown in Table 2 below, the mixture is mixed with the contents of calcined gypsum and fly ash, and after mixing the conventional amount of the curing agent in each mixture, and then adding the usual amount of water, foaming agent and other materials to each gypsum slurry After spreading the lower frame made of gypsum board base material continuously, fill each gypsum slurry, cover the upper part with other gypsum board base continuously, shape the gypsum board, cut it and put it in the dryer at the same temperature. The plasterboard specimens of Examples 1 and 2 and Comparative Examples 1 and 2 were prepared by drying for the same time, and the core compressive strength (mm) and deflection (mm) of the specimens were measured. The numerical values of the measured values of the specimens of Examples 1 and 2 and Comparative Examples 1 and 2 thus measured are shown in Table 2 below, and also for better understanding of these numerical values, FIGS. 4A and 4B. The compressive strength and deflection graphs are respectively shown in FIG.

division		Example 1	Example 2	Comparative Example 1	Comparative Example 2
Plaster		95	92.2	99.9	89.4
Fly ash		5	7.8	0.1	10.6
Compressive strength (mm)		3.56	3.51	3.38	3.39
Deflection (mm)	Longitudinal direction	3.52	3.51	4.38	3
	Width direction	4.32	4.52	6.22	4.5

As can be seen from the numerical value of Table 2 and the bar graphs of FIGS. 4A and 4B, when the filler is replaced with 1 to 10% by weight of fly ash, which is a main raw material of general gypsum board, as a filler, When the weight ratio of ash is about 95: 5, 92.2: 7.8, it can be seen that the compressive strength is improved compared to the existing products, and the deflection in the longitudinal direction and the width direction is also improved. As a result of the difference in the purchase price of ash, it can be seen that the cost savings for the use of calcined gypsum can be obtained.

As described above, the present invention has been described by way of limited embodiments and drawings, but the present invention is not limited to the above-described embodiments, which can be variously modified and modified by those skilled in the art to which the present invention pertains. Modifications are possible. Therefore, the spirit of the present invention should be grasped only by the claims described below, and all equivalent or equivalent modifications thereof will belong to the scope of the present invention.

Claims (11)

1. In the gypsum board composition prepared from a mixture of plaster and filler,

   The mixture, gypsum board composition containing 90 to 99% by weight of plaster as a main material and 1 to 10% by weight of fly ash as a filler, based on 100% by weight of the mixture.
2. The method of claim 1, wherein the mixture,

   A gypsum board composition comprising 92 to 95% by weight of calcined gypsum and 5 to 8% by weight of fly ash as a filler, based on 100% by weight of the mixture.
3. The method of claim 1, wherein the fly ash,

   30 to 60 weight percent silica; 10 to 30 weight percent of alumina; 5 to 15 weight percent of iron dioxide; Calcium oxide 1-10 wt%; And 1 to 10% by weight of magnesium oxide; gypsum board composition characterized in that it comprises a.
4. The method of claim 3, wherein the fly ash,

   Gypsum board composition, characterized in that the powder degree (cm2 / g) 3000 or more, loss of ignition (%) less than 5.0, density (g / cm3) 1.95 or more.
5. Gypsum board made of a composition according to any one of claims 1 to 4.
6. In the method of manufacturing a gypsum board by adding a hardening agent, water, foaming agent and subsidiary materials to the gypsum mixture mixed with the gypsum and the filler to mix the gypsum slurry, and molding and curing the gypsum slurry,

   (a) a raw material mixing step of mixing 90 to 99% by weight of calcined gypsum as a main material and 1 to 10% by weight of fly ash as a filler, based on 100% by weight of the total calcined gypsum mixture;

   (b) a slurry blending step of blending a slurry by adding a curing agent, water, a blowing agent, and at least one component selected from clay and starch to the mixture obtained in the raw material mixing step (a); And

   (c) Continuously spread the lower frame made of gypsum board paper and continuously cover the upper part with other gypsum board paper while continuously filling the lower frame with the slurry obtained in the slurry mixing step (b). A molding and curing step of preparing a board molding and curing the running belt on a molding belt;

   (d) a primary cutting process of primaryly cutting the plasterboard molding cured in the forming and curing process (c) to a length that can be accommodated inside the dryer at the end of the molding belt;

   (e) a drying step of drying the first cut cut in the first cutting process through a dryer; gypsum board manufacturing method comprising a.
7. The method of claim 6,

   (f) a secondary cutting and dropping step of cutting the first cut dried in the drying step to a product length and dropping to a specified number of sheets; gypsum board manufacturing method characterized in that it further comprises.
8. According to claim 6, wherein the raw material mixing step (a),

   Gypsum board manufacturing method characterized by mixing; 92 to 95% by weight of calcined gypsum as a main material, and 5 to 8% by weight of fly ash as a filler, based on 100% by weight of the mixture.
9. The fly ash used as the filler in the raw material mixing step (a),

   30 to 60 weight percent silica; 10 to 30% by weight of alumina; 5 to 15 weight percent of iron dioxide; Calcium oxide 1 to 10% by weight; And magnesium oxide 1 to 10% by weight; gypsum board manufacturing method characterized in that the component containing.
10. 10. The fly ash according to claim 9, wherein the fly ash used as the filler in the raw material mixing step (a),

    Gypsum board manufacturing method characterized in that the powder degree (cm2 / g) 3000 or more, loss on ignition (%) less than 5.0, density (g / cm3) 1.95 or more.
11. Gypsum board manufactured by the manufacturing method according to any one of claims 6 to 10.

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