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Foamed slurry and building panel made therefrom

一种泡沫、石膏浆的技术，应用在泡沫浆料以及由其制得的建筑板材领域，能够解决改变表面化学、难获得孔结构等问题

Inactive Publication Date: 2010-08-04
USG CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The addition of conventional polycarboxylate dispersants significantly changes the surface chemistry of the cells, making it more difficult to achieve the desired pore structure

Method used

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  • Foamed slurry and building panel made therefrom
  • Foamed slurry and building panel made therefrom
  • Foamed slurry and building panel made therefrom

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0104] Trials under plant conditions were conducted to compare naphthalenesulfonate condensate dispersants ("NS") and polycarboxylate dispersants. During the trial period, gypsum building boards were produced at a constant line speed of 215 ft / min. Table 1 below shows the ingredients and process conditions used for each sample. Unless otherwise stated, the amount of each remaining ingredient is in pounds per 1000 square feet of building board product. "WSR" is the water to stucco ratio, which includes foam water, added water, and metered water. 0.32% by weight of the stucco of glass fiber was added to all samples. Glucose at 0.17% by weight of the stucco was added. These two components were added to each sample.

[0105] Two polycarboxylate dispersants were used. MELFLUX PCE 356L / 35% ND ("356") is a dispersion in water which is free of antifoams and optionally surfactants. MELFLUXPCE 410L / 35% FF is an aqueous mixture of polycarboxylate dispersants, defoamers, surfactants...

Embodiment 2

[0114] A slurry having a water stucco ratio (WSR) of 0.64 was produced using approximately 600 g of calcined gypsum from a Western gypsum source. The amount of Melflux PCE 410L / 35% FF added was sufficient to produce a constant block size, which was tested using the slump test.

[0115] Foam was generated by a separate foam generator and added to the mixer during the end of the mixing time. Foam was made using a foam generator from a soap and foam water mixture containing about 0.75% soap. The soap was a 90:10 mixture of HYONIC PFM-33 (GEO Specialty Chemicals, Ambler, PA.) and Steol CS-330 (Stepan Co., Northfield, It). The following steps further describe the remaining process conditions.

[0116] The mixing sequence and method are as follows:

[0117] 1. Place water, dispersant and additives into the barrel of a Hobart mixer and mix by hand.

[0118] 2. The stucco, pre-mixed with coagulant and specific additives, is added to the cylinder and soaked for a short period of ti...

Embodiment 3

[0130] A slurry having a water stucco ratio (WSR) of 0.730 was produced using approximately 600 g of calcined gypsum from a Western gypsum source. This WSR was chosen to achieve a slump patty size of 18 ± 0.5 cm without any dispersant or retarder.

[0131] Foam was generated by a separate foam generator and added to the mixer during the end of the mixing time. Foam was made using a foam generator from a soap and foam water mixture containing about 0.75% soap. The soap was added with various blends of HYONIC PFM-33 (GeoSpecialty Chemicals, Lafayette, IN) and Steol CS-330 (Stepan Co., Northfield, IL) to produce similar core void distributions in each case. The following steps describe the remaining process conditions.

[0132] The mixing sequence and method are as follows:

[0133] 1. Place water, any dispersants and additives into the barrel of a Hobart mixer and mix by hand.

[0134] 2. The stucco, pre-mixed with coagulant and specific additives, is added to the cylinder a...

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Abstract

A gypsum slurry is described that includes water, a hydraulic component comprising at least 50% calcined gypsum by weight based on the dry weight of the hydraulic component, foam, a defoamer and a polycarboxylate dispersant In some embodiments of the invention, the defoamer is combined with the dispersant prior to being added to the gypsum slurry The defoamer and dispersant can be added as a physical mixture, wherein the defoamer is attached onto the dispersant polymer, or a combination thereof. In some embodiments, a gypsum building panel is made from the gypsum slurry.

Description

[0001] Cross References to Related Applications [0002] This application is a continuation-in-part of co-pending U.S. Application Serial No. US 11 / 449,924, entitled "Gypsum Products Utilizing Two Repeating Unit Dispersants and Methods of Making the Same", Its filing date is June 9, 2006, and US11 / 449,924 is itself a continuation-in-part of US application serial number 11 / 152,418, entitled "Gypsum Products Utilizing Two Repeating Unit Dispersants and Their Manufacture" method", which was filed on 14 June 2005, has now been abandoned. The two aforementioned US applications are incorporated into this application by reference. [0003] This application is also related to U.S. Serial No. 11 / xxx,xxx (Attorney Docket No. PF [59988]), filed concurrently herewith, entitled "A Liquid Mixing Composition," which is incorporated by reference incorporated into this application. Background technique [0004] The present invention relates to foamed gypsum slurries. More specifically, it ...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C04B28/16
CPCC04B28/145C04B24/2647C04B2111/0062C04B28/14C04B24/165C04B2103/408C04B38/00C04B2103/0099C04B24/2658C04B7/02C04B14/04C04B22/064C04B22/10C04B24/10C04B24/38C04B24/42C04B2103/12C04B2103/22C04B2103/48C04B2103/65C04B2103/67C04B7/323C04B22/143C04B38/10
Inventor 大卫·R·布莱克本陆润海莎伦·L·特蕾西刘青霞詹姆士·R·维特博尔德布鲁斯·林恩·彼得森阿尔弗雷德·利约翰·L·福尔迈克尔·P·谢克克里斯·李
Owner USG CORP