Bubble-containing hydraulic composition

Abstract

Provided are: a bubble-containing hydraulic composition in which the specific gravity of a bubble-containing hydraulic composition hardened body is low, and the diameter of bubbles in the bubble-containing hydraulic composition hardened body is large; and a method for producing the bubble-containing hydraulic composition hardened body. Provided is a bubble-containing hydraulic composition containing a hydraulic powder, water, and (A) an alkyl or alkenyl sulfate ester or a salt thereof (hereinafter referred to as component (A)), the present invention is characterized by containing (A1) an alkyl or alkenyl sulfate having a C10 alkyl or alkenyl group or a salt thereof (hereinafter referred to as component (A1)) and (A2) an alkyl or alkenyl sulfate having a C12 alkyl or alkenyl group or a salt thereof (hereinafter referred to as component (A2)), the total content of component (A1) and component (A2) in component (A) being 99 mass% or more. The mass ratio (A1) / (A2) of the content of the component (A1) to the content of the component (A2) is 0.2-2.4 (inclusive).

Description

Technical Field

[0001] The present invention relates to a hydraulic composition containing bubbles, a method for producing the same, and a foaming agent for a hydraulic composition. Background Art

[0002] A method of making a hydraulic composition containing cement and gypsum as hardeners lighter by introducing bubbles has been practiced. Generally, a lightweight hydraulic composition containing bubbles is produced by mixing foam obtained by foaming a liquid composition containing a foaming agent and water with a hydraulic composition or fine aggregate and various admixtures.

[0003] In Japanese Patent Application Laid-Open No. 2018-527163, a surfactant composition for a gypsum board is disclosed for the purpose of reducing the weight of the gypsum board while still allowing the gypsum board to function as a building material. The surfactant composition contains a branched alkyl sulfate having 8 to 12 carbon atoms; an optional linear alkyl sulfate having 8 to 12 carbon atoms; and an optional alkyl ether sulfate having 8 to 13 carbon atoms. Moreover, in the examples, a surfactant composition containing 75% of an alkyl sulfate having 10 carbon atoms and 25% of an alkyl sulfate having 12 carbon atoms is disclosed.

[0004] In Japanese Patent Application Laid-Open No. 2004-529050, a composition is disclosed with the problem of providing a surfactant that can be easily manufactured from commercially available products and exhibits strong foaming power at low cost. The composition is a gypsum composition containing a surfactant composition containing an alkyl sulfate represented by the formula H(CH2) n OSO3 - M ＋ wherein n is 6 to 16, the average number of carbon atoms n in the alkyl sulfate composition m is 10 to 11, and M is a monovalent cation. Moreover, in the examples, a surfactant containing 84.2% by weight of C10 alkyl sulfate and 15.8% by weight of C12 alkyl sulfate is used, and as an evaluation of the surfactant composition, the amount of foam formed after mixing with water and stirring in a mixer is measured. Summary of the Invention

[0005] For a hardened body of a hydraulic composition containing bubbles with cement and gypsum as hardeners, further weight reduction is required from the viewpoints of environmental (CO2) reduction effects, cost, based on manufacturing, transportation, and raw material supply.

[0006] A hydraulic composition containing bubbles can reduce the specific gravity of the hardened body of the hydraulic composition and lighten its weight by containing bubbles. However, if the volume (proportion) of bubbles is increased to further lighten the hardened body of the hydraulic composition, the proportion of the hydraulic composition becomes smaller, and thus the strength of the hardened body tends to decrease. On the other hand, as described in paragraph 0004 of Japanese Patent Laid-Open No. 10-330174, in a hydraulic composition containing bubbles with the same specific gravity, by increasing the bubble diameter in the hydraulic composition containing bubbles, the strength of the hardened body of the hydraulic composition containing bubbles can be improved. In addition, when the bubble diameter in the hydraulic composition containing bubbles is increased, the drying during the production of the hardened body of the hydraulic composition containing bubbles becomes faster, and there are advantages such as reducing the fuel cost during drying and reducing the CO2 emission amount. In addition, when the bubble diameter in the hydraulic composition containing bubbles is increased, the distance between bubbles increases, and the connection of bubbles is less likely to occur, and the heat insulation and sound insulation can be improved.

[0007] Therefore, there is a need for a technology that can reduce the specific gravity of a hydraulic composition containing bubbles and increase the bubble diameter in the hydraulic composition containing bubbles.

[0008] The present invention provides a hydraulic composition containing bubbles, a method for producing the same, and a foaming agent for a hydraulic composition that can reduce the specific gravity of the hardened body of the hydraulic composition containing bubbles and increase the bubble diameter in the hardened body of the hydraulic composition containing bubbles, wherein the hardened body of the hydraulic composition containing bubbles has a low specific gravity and a large bubble diameter in the hardened body of the hydraulic composition containing bubbles.

[0009] The present invention relates to a hydraulic composition containing bubbles, which contains hydraulic powder, water, and (A) an alkyl or alkenyl sulfate or a salt thereof (hereinafter referred to as component (A)). As component (A), it contains (A1) an alkyl or alkenyl sulfate or a salt thereof having an alkyl or alkenyl group with 10 carbon atoms (hereinafter referred to as component (A1)) and (A2) an alkyl or alkenyl sulfate or a salt thereof having an alkyl or alkenyl group with 12 carbon atoms (hereinafter referred to as component (A2)). The total content of component (A1) and component (A2) in component (A) is 99% by mass or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more and 2.4 or less.

[0010] In addition, the present invention relates to a method for producing a hydraulic composition containing bubbles, which includes the following steps 1 and 2.

[0011] <Step 1>

[0012] A step of foaming a liquid composition containing the following foaming agent for a hydraulic composition and water to obtain foam.

[0013] Foaming agent for hydraulic composition: A foaming agent for a hydraulic composition as follows, which contains component (A). As component (A), it contains component (A1) and component (A2). The total content of component (A1) and component (A2) in component (A) is 99% by mass or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more and 2.4 or less.

[0014] <Process 2>

[0015] The process of mixing a hydraulic powder, water, and the foam obtained in Process 1.

[0016] Furthermore, the present invention relates to a foaming agent for a hydraulic composition, which contains component (A). As component (A), it contains component (A1) and component (A2). The total content of component (A1) and component (A2) in component (A) is 99% by mass or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more and 2.4 or less.

[0017] According to the present invention, it is possible to provide a foamed hydraulic composition and a method for producing the same, in which the specific gravity of the hardened body of the foamed hydraulic composition is low and the bubble diameter in the hardened body of the foamed hydraulic composition is large, and a foaming agent for a hydraulic composition that can reduce the specific gravity of the hardened body of the foamed hydraulic composition and increase the bubble diameter in the hardened body of the foamed hydraulic composition. Detailed Description

[0018] The foamed hydraulic composition and the method for producing the same according to the present invention can make the specific gravity of the hardened body of the foamed hydraulic composition low and increase the bubble diameter in the hardened body of the foamed hydraulic composition. In addition, the foaming agent for a hydraulic composition according to the present invention can reduce the specific gravity of the hardened body of the foamed hydraulic composition and increase the bubble diameter in the hardened body of the foamed hydraulic composition. The reason therefor is not certain, but it is presumed as follows. In the foaming agent for a hydraulic composition, a prescribed amount of component (A2) that forms a bubble film that is not easily broken and not easily merged is blended in component (A1) that has high fluidity and forms a bubble film in which bubbles are easily merged. Thereby, a bubble film that takes both softness and hardness into account can be formed, and while suppressing the disappearance of bubbles in the process of producing the foamed hydraulic composition, the weight reduction of the hardened body of the foamed hydraulic composition and the enlargement of the bubble diameter can be achieved simultaneously by the merging of bubbles. On the other hand, regarding the content ratio of component (A1) and component (A2), it is presumed that when the proportion of component (A1) is too large, the bubbles are easily broken, and although the enlargement of the bubble diameter in the hardened body of the foamed hydraulic composition can be achieved, the weight reduction of the hardened body becomes difficult.

[0019] [Foaming Agent for Hydraulic Composition]

[0020] <(A) Component>

[0021] The foaming agent for the hydraulic composition of the present invention contains an alkyl or alkenyl sulfate or a salt thereof as the (A) component.

[0022] In addition, the foaming agent for the hydraulic composition of the present invention contains, as the (A) component, (A1) an alkyl or alkenyl sulfate having an alkyl or alkenyl group with 10 carbon atoms or a salt thereof (hereinafter referred to as the (A1) component) and (A2) an alkyl or alkenyl sulfate having an alkyl or alkenyl group with 12 carbon atoms or a salt thereof (hereinafter referred to as the (A2) component).

[0023] The (A1) component is preferably an alkyl or alkenyl sulfate having a straight-chain alkyl or straight-chain alkenyl group with 10 carbon atoms or a salt thereof.

[0024] Specific examples of the (A1) component include one or more selected from decyl sulfate, 2-propylheptyl sulfate, and salts thereof, and preferably decyl sulfate or a salt thereof.

[0025] The (A2) component is preferably an alkyl or alkenyl sulfate having a straight-chain alkyl or straight-chain alkenyl group with 12 carbon atoms or a salt thereof.

[0026] Specifically, as the (A2) component, lauryl sulfate or a salt thereof is preferred.

[0027] Examples of the salts of the (A) component, (A1) component, and (A2) component include one or more selected from alkali metal salts such as sodium salts and potassium salts, ammonium salts, and organic ammonium salts.

[0028] <Composition, etc.>

[0029] In the foaming agent for the hydraulic composition of the present invention, from the viewpoints of increasing the large diameter of the bubbles in the hardened body of the hydraulic composition containing bubbles and reducing the specific gravity of the hardened body of the hydraulic composition containing bubbles, in the composition, it is preferably contained 2% by mass or more, more preferably 10% by mass or more, further preferably 15% by mass or more, still further preferably 20% by mass or more, still further preferably 25% by mass or more, and preferably 40% by mass or less, more preferably 35% by mass or less, further preferably 30% by mass or less of the (A) component.

[0030] In the present invention, the regulations on the mass of the (A) component and the (A1) component and (A2) component contained in the (A) component are made using the values converted to sodium salts.

[0031] In the foaming agent for hydraulic compositions of the present invention, from the viewpoints of increasing the bubble diameter in the hardened body of the hydraulic composition containing bubbles and reducing the specific gravity of the hardened body of the hydraulic composition containing bubbles, the total content of component (A1) and component (A2) in component (A) is 99% by mass or more, preferably 99.5% by mass or more, and 100% by mass or less, preferably 100% by mass.

[0032] In the foaming agent for hydraulic compositions of the present invention, from the viewpoints of increasing the bubble diameter in the hardened body of the hydraulic composition containing bubbles and reducing the specific gravity of the hardened body of the hydraulic composition containing bubbles, the content of component (A1) in component (A) is preferably 20% by mass or more, more preferably 30% by mass or more, further preferably 40% by mass or more, and preferably 75% by mass or less, more preferably 65% by mass or less, further preferably 53% by mass or less. From the viewpoints of increasing the bubble diameter in the hardened body of the hydraulic composition containing bubbles and reducing the specific gravity of the hardened body of the hydraulic composition containing bubbles, the content of component (A2) in component (A) is preferably 25% by mass or more, more preferably 35% by mass or more, further preferably 45% by mass or more, and preferably 80% by mass or less, more preferably 70% by mass or less, further preferably 65% by mass or less, further preferably 53% by mass or less.

[0033] In the foaming agent for hydraulic compositions of the present invention, from the viewpoints of increasing the bubble diameter in the hardened body of the hydraulic composition containing bubbles and reducing the specific gravity of the hardened body of the hydraulic composition containing bubbles, the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more, preferably 0.3 or more, more preferably 0.6 or more, further preferably 0.9 or more, and 2.4 or less, preferably 2.3 or less, more preferably 2.0 or less, further preferably 1.9 or less, further preferably 1.3 or less. In addition, in the foaming agent for hydraulic compositions of the present invention, from the viewpoint of reducing the concentration unevenness after freeze-thawing of the foaming agent for hydraulic compositions used in the production of the hydraulic composition containing bubbles of the present invention, the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is preferably 1.5 or less, more preferably 1.3 or less.

[0034] In the foaming agent for hydraulic compositions of the present invention, from the viewpoint of enjoying the effects of the present invention, as component (A), it is preferably free of alkyl or alkenyl sulfates or their salts having an alkyl or alkenyl group with 14 or more carbon atoms.

[0035] Examples of the alkyl or alkenyl sulfate or its salt having an alkyl or alkenyl group with 14 or more carbon atoms include one or more selected from myristyl sulfate, cetyl sulfate, stearyl sulfate, oleyl sulfate, and their salts.

[0036] The foaming agent for the hydraulic composition of the present invention may contain a polyoxyethylene alkyl or alkenyl ether sulfate or its salt. However, from the viewpoint of enjoying the effects of the present invention, its content is limited.

[0037] Examples of the polyoxyethylene alkyl or alkenyl ether sulfate or its salt include one or more selected from polyoxyethylene octyl ether sulfate, polyoxyethylene decyl ether sulfate, polyoxyethylene lauryl ether sulfate, polyoxyethylene tridecyl ether sulfate, polyoxyethylene myristyl ether sulfate, polyoxyethylene cetyl ether sulfate, polyoxyethylene stearyl ether sulfate, and their salts.

[0038] In the foaming agent for the hydraulic composition of the present invention, from the viewpoint of increasing the diameter of the bubbles in the hardened body of the hydraulic composition containing bubbles, the content of the polyoxyethylene alkyl or alkenyl ether sulfate or its salt is preferably 10% by mass or less, more preferably 5% by mass or less, further preferably 3% by mass or less, still further preferably 1% by mass or less, and even more preferably 0.5% by mass or less. In the present invention, the mass of the polyoxyethylene alkyl or alkenyl ether sulfate or its salt is used as the value converted to the sodium salt. In the foaming agent for the hydraulic composition of the present invention, from the viewpoint of increasing the diameter of the bubbles in the hardened body of the hydraulic composition containing bubbles, it is preferably free of the polyoxyethylene alkyl or alkenyl ether sulfate or its salt.

[0039] In the foaming agent for the hydraulic composition of the present invention, from the viewpoints of rapid foaming property and foam stability, as the component (B), a monohydric alcohol having 6 or more and 10 or less carbon atoms may be contained.

[0040] From the viewpoints of rapid foaming property and foam stability, the carbon number of the component (B) is 6 or more and 10 or less, preferably 8.

[0041] From the viewpoints of rapid foaming property and foam stability, the component (B) is a monohydric alcohol having a linear or branched hydrocarbon group, preferably a linear or branched alkyl group, and more preferably a linear alkyl group.

[0042] Specifically, examples of the component (B) include one or more selected from hexanol, octanol, decanol, 2-ethylhexanol, and 2-propylheptanol. From the viewpoint of foaming property, it is preferably to contain one or more selected from octanol and decanol, and more preferably to contain octanol.

[0043] In the foaming agent for hydraulic compositions of the present invention, from the viewpoints of increasing the diameter of the bubbles in the hardened body of the hydraulic composition containing bubbles and reducing the specific gravity of the hardened body of the hydraulic composition containing bubbles, as the component (C), a nonionic surfactant may be contained.

[0044] Examples of the nonionic surfactant include one or more selected from alkyl monoglycer ethers, polyoxyalkylene monoalkyl or alkenyl ethers, alkyl glycosides or alkyl polyglycosides (glycoside-type nonionic surfactants), sorbitan-based nonionic surfactants, aliphatic alkanolamides, fatty acid monoglycerides, and sucrose fatty acid esters. Among them, from the viewpoint of increasing the diameter of the bubbles in the hardened body of the hydraulic composition containing bubbles, a glycoside-type nonionic surfactant is preferably contained.

[0045] The foaming agent for hydraulic compositions of the present invention may contain water. The foaming agent for hydraulic compositions of the present invention preferably contains 10% by mass or more, more preferably 20% by mass or more, still more preferably 30% by mass or more, further preferably 40% by mass or more, and preferably 90% by mass or less, more preferably 80% by mass or less, still more preferably 70% by mass or less of water.

[0046] The foaming agent for hydraulic compositions of the present invention may optionally contain a thickener, a chelating agent, a heavy metal scavenger, a rust inhibitor, a preservative, a coloring agent, a fragrance, an antifoaming agent, a solvent, a dispersant, a flocculant, a water-soluble polymer, etc. However, substances other than the component (A), the component (A1), the component (A2), the component (B), and the component (C) are used.

[0047] The foaming agent for hydraulic compositions of the present invention can be obtained by mixing the component (A1), the component (A2), and optional components as the component (A). When mixing, it can be appropriately heated to reduce the solution viscosity.

[0048] Examples of the target uses of the foaming agent for hydraulic compositions of the present invention include hydraulic compositions containing bubbles such as gypsum slurries, lightweight emulsions (foamed emulsions, air-entrained emulsions), lightweight mortars (foamed mortars, air-entrained mortars), lightweight concretes (foamed concretes, air-entrained concretes), backfill grouting materials, injection grouting materials, building concrete blocks, ALC (lightweight foamed concrete), grouting materials, ceramic porous bodies, bricks, refractories, lightweight fills, and pumped mortar. In these hydraulic compositions containing bubbles, functions such as weight reduction, strength improvement, fluidity improvement, heat insulation, heat resistance, viscosity increase, and fluidity control brought about by the mixing of bubbles can be expected.

[0049] Among these hydraulic compositions containing bubbles, the foaming agent for hydraulic compositions of the present invention is suitably used for gypsum slurries.

[0050] [Hydraulic Composition Containing Bubbles and Method for Producing the Same]

[0051] Regarding the method for producing a hydraulic composition containing bubbles, from the aspect of continuously generating uniform bubbles, a method is preferably adopted in which the hydraulic composition of the present invention is foamed with a foaming agent, incorporated into a hydraulic substance in the form of foam, and then incorporated and lightened. The hydraulic composition of the present invention can also be directly mixed into a paste, slurry, mortar, or concrete using cement or gypsum as the hydraulic substance in the form of a foaming agent or a mixed solution obtained by diluting it with water. There is no limitation on the method of adding the hydraulic composition of the present invention to the hydraulic composition using a foaming agent, and there is also no limitation on the method of foaming the hydraulic composition of the present invention with a foaming agent or a mixed solution obtained by diluting it with water.

[0052] The present invention provides a hydraulic composition containing bubbles, which contains a hydraulic powder, water, and component (A). As component (A), it contains component (A1) and component (A2). The total content of component (A1) and component (A2) in component (A) is 99% by mass or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more and 2.4 or less.

[0053] The hydraulic composition containing bubbles of the present invention may further contain component (B).

[0054] The hydraulic composition containing bubbles of the present invention may further contain component (C).

[0055] The hydraulic composition containing bubbles of the present invention can appropriately apply the matters described in the foaming agent for the hydraulic composition of the present invention.

[0056] Component (A), component (A1), component (A2), component (B), and component (C) are the same as those described in the foaming agent for the hydraulic composition of the present invention.

[0057] The so-called hydraulic powder is a powder having the physical property of hardening due to a hydration reaction, and examples thereof include cement and gypsum, and gypsum is preferred.

[0058] Examples of the cement include ordinary Portland cement, belite cement, medium heat cement, quick-drying cement, ultra-quick-drying cement, sulfuric acid-resistant cement, etc., and blast furnace slag cement, fly ash cement, silica fume cement, etc. obtained by adding blast furnace slag, fly ash, silica fume, stone powder (calcium carbonate powder), etc. thereto may also be used.

[0059] One or more of them can be used.

[0060] In the hydraulic composition containing bubbles according to the present invention, from the viewpoint of the fluidity of the hydraulic composition slurry, the water / hydraulic powder ratio is preferably 20% by mass or more, more preferably 30% by mass or more, further preferably 40% by mass or more, still more preferably 50% by mass or more, still more preferably 60% by mass or more, and from the viewpoint of the strength of the hardened body of the hydraulic composition, it is preferably 100% by mass or less, more preferably 90% by mass or less, further preferably 80% by mass or less.

[0061] Here, the water / hydraulic powder ratio is the mass percentage (% by mass) of water and hydraulic powder in the hydraulic composition, and is calculated by water / hydraulic powder × 100. The water / hydraulic powder ratio is calculated based on the amount of powder having the property of hardening due to the hydration reaction. When the powder having the property of hardening due to the hydration reaction contains a high-strength admixture, the amount of the high-strength admixture is also included in the amount of the hydraulic powder. The same applies to the relationship of other amounts of the hydraulic composition related to the hydraulic powder.

[0062] In the hydraulic composition containing bubbles according to the present invention, from the viewpoints of reducing the specific gravity of the hardened body of the hydraulic composition and increasing the large diameter of the bubbles, it is preferably contains 0.0005 parts by mass or more, more preferably contains 0.002 parts by mass or more, further preferably contains 0.004 parts by mass or more, still more preferably contains 0.008 parts by mass or more, and preferably contains 0.1 parts by mass or less, more preferably contains 0.05 parts by mass or less, further preferably contains 0.03 parts by mass or less, still more preferably contains 0.01 parts by mass or less of component (A).

[0063] In the hydraulic composition containing bubbles according to the present invention, from the viewpoints of reducing the specific gravity of the hardened body of the hydraulic composition and increasing the large diameter of the bubbles, the total content of component (A1) and component (A2) in component (A) is 99% by mass or more, preferably 99.5% by mass or more, and 100% by mass or less, preferably 100%.

[0064] In the air-entrained hydraulic composition of the present invention, from the viewpoints of increasing the bubble diameter in the hardened body of the hydraulic composition and reducing the specific gravity of the hardened body of the hydraulic composition, the content of component (A1) in component (A) is preferably 20% by mass or more, more preferably 30% by mass or more, further preferably 40% by mass or more, still further preferably 45% by mass or more, and preferably 75% by mass or less, more preferably 65% by mass or less, further preferably 53% by mass or less. From the viewpoints of increasing the bubble diameter in the hardened body of the hydraulic composition and reducing the specific gravity of the hardened body of the hydraulic composition, the content of component (A2) in component (A) is preferably 25% by mass or more, more preferably 35% by mass or more, further preferably 45% by mass or more, and preferably 80% by mass or less, more preferably 70% by mass or less, further preferably 65% by mass or less, still further preferably 53% by mass or less.

[0065] In the air-entrained hydraulic composition of the present invention, from the viewpoints of reducing the specific gravity of the hardened body of the hydraulic composition and increasing the bubble diameter, the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more, preferably 0.3 or more, more preferably 0.6 or more, further preferably 0.9 or more, and 2.4 or less, preferably 2.3 or less, more preferably 2.0 or less, further preferably 1.9 or less, still further preferably 1.3 or less. In addition, in the air-entrained hydraulic composition of the present invention, from the viewpoint of reducing the concentration unevenness after freeze-thawing of the air-entraining agent for hydraulic composition used in the production of the air-entrained hydraulic composition of the present invention, the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is preferably 1.5 or less, more preferably 1.3 or less.

[0066] In the air-entrained hydraulic composition of the present invention, from the viewpoint of enjoying the effects of the present invention, as component (A), it is preferably free of alkyl or alkenyl sulfates having an alkyl or alkenyl group with 14 or more carbon atoms or salts thereof.

[0067] The air-entrained hydraulic composition of the present invention may contain polyoxyethylene alkyl or alkenyl ether sulfates or salts thereof, but from the viewpoint of enjoying the effects of the present invention, its content is limited.

[0068] In the air-entrained hydraulic composition of the present invention, based on 100 parts by mass of the hydraulic powder, from the viewpoint of increasing the bubble diameter in the hardened body of the hydraulic composition, the content of polyoxyethylene alkyl or alkenyl ether sulfates or salts thereof is preferably 0.001 part by mass or less, more preferably 0.0008 part by mass or less, further preferably 0.0006 part by mass or less, still further preferably 0.0001 part by mass or less.

[0069] In the hydraulic composition containing bubbles of the present invention, from the viewpoint of increasing the bubble diameter in the hardened body of the hydraulic composition, it is preferably free of polyoxyethylene alkyl or alkenyl ether sulfate or its salt.

[0070] The hydraulic composition containing bubbles of the present invention may contain fine aggregate and / or coarse aggregate. In addition, the hydraulic composition containing bubbles of the present invention may contain admixtures and supplementary cementitious materials known in the art.

[0071] The hardened body of the hydraulic composition containing bubbles of the present invention can be obtained by drying and curing.

[0072] From the viewpoint of strength, the specific gravity of the hardened body of the hydraulic composition containing bubbles of the present invention is preferably 0.3 or more, more preferably 0.4 or more, still more preferably 0.5 or more, and from the viewpoint of workability, it is preferably 0.9 or less, more preferably 0.8 or less, still more preferably 0.7 or less.

[0073] The hydraulic composition containing bubbles of the present invention contains bubbles. From the viewpoint of improving the strength of the hardened body, the average bubble diameter of the hardened body of the hydraulic composition containing bubbles of the present invention is preferably 230 μm or more, more preferably 250 μm or more, still more preferably 300 μm or more, and from the viewpoint of the aesthetics of the cross-section, it is preferably 800 μm or less, more preferably 700 μm or less, still more preferably 600 μm or less, even more preferably 500 μm or less, and even more preferably 400 μm or less.

[0074] The average bubble diameter is calculated as follows: a hardened body of the hydraulic composition containing bubbles is prepared, the hardened body is arbitrarily cut to form a cross-section, the cross-section is observed with a digital microscope, the diameters of 100 bubble cross-sections are arbitrarily measured, and the average value (arithmetic mean) of these values is calculated. It should be noted that for the measurement of the diameter of the bubble cross-section, the diameter is measured when the bubble cross-section is circular, the major axis is measured when the bubble cross-section is elliptical, and the longest part is taken as the diameter when the bubble cross-section is irregular.

[0075] The present invention provides a method for manufacturing a hydraulic composition containing bubbles, which method includes the following steps 1 and 2.

[0076] The foaming agent for the following hydraulic composition is the same as the foaming agent for the hydraulic composition of the present invention, and the methods described in the foaming agent for the hydraulic composition of the present invention can be appropriately applied.

[0077] <Step 1>

[0078] A step of foaming a liquid composition containing a foaming agent for a hydraulic composition and water to obtain foam.

[0079] Foaming agent for hydraulic composition: A foaming agent for a hydraulic composition as follows, which contains component (A), and as component (A), it contains component (A1) and component (A2). The total content of component (A1) and component (A2) in component (A) is 99% by mass or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more and 2.4 or less.

[0080] <Process 2>

[0081] A step of mixing a hydraulic powder, water, and the foam obtained in Process 1.

[0082] It should be noted that in Process 2, a hydraulic composition containing a hydraulic powder and water can be prepared, and the hydraulic composition can be mixed with the foam obtained in Process 1.

[0083] The hydraulic composition containing bubbles of the present invention can be prepared by using this manufacturing method.

[0084] The manufacturing method of the hydraulic composition containing bubbles of the present invention can be appropriately applied to the foaming agent for a hydraulic composition of the present invention and the methods described in the hydraulic composition containing bubbles of the present invention.

[0085] In the manufacturing method of the hydraulic composition containing bubbles of the present invention, the content of each component described in the hydraulic composition containing bubbles of the present invention and their mass ratios can be appropriately applied by replacing the content of each component with the mixing amount.

[0086] In Process 1, although the foaming ratio of the above liquid composition also depends on the use of the hydraulic composition, etc., from the economic point of view, it is preferably 5 times or more, more preferably 7 times or more, further preferably 10 times or more, and from the viewpoint of kneadability, it is preferably 30 times or less, more preferably 25 times or less, further preferably 20 times or less.

[0087] In Process 2, although it also depends on the use of the hydraulic composition, etc., from the viewpoint of lightening the weight of the hardened body of the hydraulic composition containing bubbles, it is preferably mixed with 50% by volume or more, more preferably 100% by volume or more, further preferably 150% by volume or more of foam, and from the viewpoint of the strength of the hardened body of the hydraulic composition containing bubbles, it is preferably mixed with 400% by volume or less, more preferably 300% by volume or less, further preferably 200% by volume or less of foam. In this manufacturing method, in Process 1 and / or Process 2, a mixing agent and a mixing material well known in the art can be mixed.

[0088] [Hydraulic composition containing air bubbles and method for producing the same]

[0089] In the hydraulic composition containing air bubbles of the present invention, the hydraulic powder is preferably gypsum. In the present invention, the hydraulic composition containing air bubbles in which the hydraulic powder is gypsum is also referred to as a gypsum slurry containing air bubbles.

[0090] That is, the present invention provides a gypsum slurry containing air bubbles, which contains gypsum, water, and component (A). As component (A), it contains component (A1) and component (A2). The total content of component (A1) and component (A2) in component (A) is 99% by mass or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more and 2.4 or less. The gypsum slurry containing air bubbles of the present invention is suitable for use as a gypsum board.

[0091] The gypsum slurry containing air bubbles of the present invention can appropriately apply the matters described in the foaming agent for hydraulic compositions of the present invention, the hydraulic composition containing air bubbles of the present invention, and the method for producing the hydraulic composition containing air bubbles of the present invention.

[0092] The gypsum slurry containing air bubbles of the present invention may further contain component (B).

[0093] The gypsum slurry containing air bubbles of the present invention may further contain component (C).

[0094] Component (A), component (A1), component (A2), component (B), and component (C) are the same as described in the foaming agent for hydraulic compositions of the present invention.

[0095] In the gypsum slurry containing air bubbles of the present invention, the content of each component and their mass ratio described in the hydraulic composition containing air bubbles of the present invention can be appropriately applied by replacing the hydraulic powder with gypsum.

[0096] In the hardened body of the gypsum slurry containing air bubbles of the present invention, the range of specific gravity and average bubble diameter is the same as that described in the hydraulic composition containing air bubbles of the present invention.

[0097] As the gypsum, any gypsum such as high-quality neutralized gypsum, phosphogypsum as a by-product of phosphoric acid, flue gas desulfurization gypsum generated in thermal power generation, natural gypsum containing various impurities and clay, and their mixtures can also be used.

[0098] The clay contained in gypsum is mainly composed of hydrous silicate minerals with a layered structure (hereinafter referred to as clay minerals). As the clay minerals contained in the clay in the form of fine-grained minerals, kaolin minerals (kaolinite, dickite, and nacrite), serpentine (lizardite, antigorite, chrysotile), mica clay minerals (illite, sericite, glauconite, apatite), chlorite, vermiculite, green clay (montmorillonite, beidellite, nontronite, talc, hectorite) can be cited.

[0099] Gypsum includes anhydrite, hemihydrate gypsum, dihydrate gypsum, etc. As raw material gypsum, natural gypsum or chemical gypsum such as neutralized gypsum or by-product gypsum can be used alone or two or more of them can be used in combination. As the main chemical gypsum, phosphogypsum, fluoro gypsum, titanium gypsum, flue gas desulfurization gypsum, etc. can be exemplified. In addition, recycled gypsum can be contained in the raw material gypsum. Any recycled gypsum can be used as long as it is recycled from waste gypsum boards generated by gypsum board manufacturers themselves, waste gypsum boards generated during new construction and demolition, etc. The present invention can be suitably used for one or more of these arbitrary raw material gypsums, and excellent effects can also be obtained for gypsums mixed in various proportions.

[0100] The foamed gypsum slurry of the present invention may contain additives used in applications such as gypsum board. Such additives include general water reducers, defoamers, foam stabilizers, hardening regulators, water repellents, adhesives, retarders, etc. In addition, glass fibers, carbon fibers, waste paper, pulp, etc. can be added as reinforcing fibers, or gypsum boards can be made together with perlite, foamed steel, etc. as lightweight aggregates.

[0101] The present invention provides a method for manufacturing a foamed gypsum slurry, which includes the following steps 1 and 2.

[0102] The foaming agent for hydraulic composition described below is the same as the foaming agent for hydraulic composition of the present invention, and the methods described in the foaming agent for hydraulic composition of the present invention can be appropriately applied.

[0103] <Step 1>

[0104] A step of foaming a liquid composition containing the foaming agent for hydraulic composition described below and water to obtain foam.

[0105] Foaming agent for hydraulic composition: The following foaming agent for hydraulic composition contains component (A). As component (A), it contains component (A1) and component (A2). The total content of component (A1) and component (A2) in component (A) is 99% by mass or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) is 0.2 or more and 2.4 or less.

[0106] <Process 2>

[0107] A process of mixing gypsum, water, and the foam obtained in Process 1.

[0108] It should be noted that in Process 2, a gypsum slurry containing gypsum and water can also be prepared, and the gypsum slurry is mixed with the foam obtained in Process 1.

[0109] The present invention's manufacturing method can be used to prepare the gypsum slurry containing air bubbles of the present invention.

[0110] The manufacturing method of the gypsum slurry containing air bubbles of the present invention can be appropriately applied in the manner described in the foaming agent for hydraulic composition, the hydraulic composition containing air bubbles and its manufacturing method, and the gypsum slurry containing air bubbles of the present invention.

[0111] In the manufacturing method of the hydraulic composition containing air bubbles of the present invention, the content of each component and their mass ratio described in the hydraulic composition containing air bubbles of the present invention can be appropriately applied by replacing the hydraulic powder with gypsum and further replacing the content of each component with the mixing amount. The temperature of the foam and the gypsum slurry used in the mixing is preferably 15°C or higher and 40°C or lower.

[0112] Process 1 and Process 2 can be carried out in accordance with the manufacturing method of the hydraulic composition containing air bubbles of the present invention.

[0113] Examples

[0114] The following shows the components used in the examples and comparative examples.

[0115] Component (A)

[0116] · C10AS: Sodium decyl sulfate, Component (A1)

[0117] · C12AS: Sodium lauryl sulfate, Component (A2)

[0118] · C14AS: Sodium myristyl sulfate

[0119] (1) Preparation of the foaming agent for hydraulic composition

[0120] The foaming agents for hydraulic composition shown in Tables 1 and 2 were prepared using the following method.

[0121] The respective raw materials were added to a 50 mL screw tube in a specified ratio so that the total was 30 g, and stirred with a magnetic stirrer at 1000 rpm for 3 hours. When the solution viscosity was high and the stirring efficiency was poor, heating at 40°C was appropriately carried out.

[0122] (2) Preparation of the gypsum slurry

[0123] The prepared hydraulic compositions in Tables 1 and 2 were mixed with a foaming agent and water at a mass ratio of 0.3:99.7 to prepare an aqueous solution with a concentration (w / v) of 0.3% by mass of the foaming agent for the hydraulic composition. 19 g of the prepared aqueous solution was placed in a 1-L disposable cup, and using a flat six-blade paddle (FP-50, manufactured by ASONE Co., Ltd.), it was stirred at 2000 rpm (EUROSTAR 200 control, manufactured by IKA Japan Co., Ltd.) for 15 seconds while manually rotating the container, and after allowing the container to stand, it was further stirred for 45 seconds to obtain foam.

[0124] 200 g of hemihydrate gypsum, 4 g of dihydrate gypsum, 127 g of tap water in which 1.5 g of potassium sulfate was dissolved, and 0.36 g of a water reducing agent (MIGHTY 150, manufactured by Kao Corporation) were added to a 500-mL disposable cup, and using a whisk (MK-H4, manufactured by Panasonic Corporation), it was stirred at speed 3 for 5 seconds to prepare a gypsum slurry before foam addition. The entire amount of the prepared gypsum slurry was poured into 19 g of the foam prepared in a 1-L disposable cup, and using the above-mentioned flat six-blade paddle in the 1-L disposable cup, it was kneaded at 1500 rpm for 10 seconds to obtain a gypsum slurry containing bubbles. Regarding the temperatures of the foam and the gypsum slurry used during kneading, both were at 20 °C.

[0125] (3)Measurement of the specific gravity of the gypsum specimen

[0126] The obtained gypsum slurry containing bubbles was poured into a mold box for cylindrical specimens (Plamold, manufactured by Nifco Inc.) with a diameter of 5 cm and a height of 10 cm, and allowed to stand at room temperature for 1 hour or more. The hardened gypsum slurry was removed from the mold box for cylindrical specimens, and after drying by standing in a constant temperature bath at 80 °C for 17 hours, the weight of the obtained specimen was measured. The specific gravity of the gypsum specimen was calculated by dividing the weight of the obtained specimen by the volume of the mold box. The results are shown in Tables 1 and 2.

[0127] (4)Measurement of the average bubble diameter in the gypsum specimen

[0128] An incision was made in a 5-cm height portion of the gypsum specimen obtained in (3) to prepare a cross-section of the gypsum specimen. This cross-section was observed using a digital microscope (42 times magnification), and starting from the smallest recognizable bubbles, the diameters of 100 bubble cross-sections were measured in sequence, and the average bubble diameter was calculated based on the arithmetic mean of these values. It should be noted that regarding the measurement of the diameter of the bubble cross-section, the diameter was measured when the bubble cross-section was circular, the major axis was measured when the bubble cross-section was elliptical, and the longest part was taken as the diameter when the bubble cross-section was irregular. The results are shown in Tables 1 and 2.

[0129] (5)Penetration resistance test

[0130] Measure the penetration resistance value when a needle with a diameter of 12.5 mm penetrates 6 cm into the side surface of the gypsum sample obtained in (3). Regarding the measurement, on the side surface of the gypsum sample, measure 3 times at positions 2.5 cm, 5 cm, and 7.5 cm relative to the bottom surface, and set the average value thereof as the penetration resistance value of the gypsum sample. Evaluate Examples 1-1, Comparative Examples 1-2, and 1-3. The results are shown in Table 2. The higher the penetration resistance value, the higher the strength of the gypsum sample.

[0131] [Table 1]

[0132]

[0133] [Table 2]

[0134]

[0135] In Table 1, the foaming agents for hydraulic compositions of Examples 1-1 to 1-6 can reduce the specific gravity while setting the average bubble diameter of the gypsum sample to 250 μm or more, compared with the foaming agents for hydraulic compositions of Comparative Examples 1-1, 1-4, and 1-5. It should be noted that Comparative Examples 1-4 and 1-5 have a higher specific gravity than Examples 1-1 to 1-6, and there are no bubbles in the gypsum sample in an amount that can be accurately measured, so the average bubble diameter was not measured.

[0136] In addition, in Table 2, the foaming agent for the hydraulic composition of Example 1-1 has the same specific gravity as the foaming agents for the hydraulic compositions of Comparative Examples 1-2 and 1-3, but can increase the average bubble diameter in the gypsum. As shown in the results of Table 2, it can improve the strength of the gypsum sample.

[0137] (6) Performance evaluation after freeze-thaw

[0138] Add 85 mL of the foaming agent for the hydraulic composition of Example 1-3 to a MARUEMU screw cap bottle No. 8 (height 12 cm, capacity 110 mL), store it at 0 °C for 3 days to freeze it. Let the solidified or precipitated sample stand at 20 °C for 2 hours to melt it, recover 2 mL of the foaming agent for the hydraulic composition from a liquid level height of 1 cm, and set it as the upper layer. On the other hand, recover 2 mL of the foaming agent for the hydraulic composition from a height of 0.5 cm relative to the bottom surface of the MARUEMU screw cap bottle, and set it as the lower layer. Using these recovered foaming agents for the hydraulic composition, prepare a gypsum slurry in the same manner as in (2) above, and find the average bubble diameter in the gypsum sample in the same manner as in (4) above. The results are shown in Table 3.

[0139] [Table 3]

[0140]

[0141] In Table 3, regarding the foaming agents for hydraulic compositions of Examples 1-3, the difference in the average bubble diameter in the gypsum specimens prepared using the foaming agents in the upper layer and the lower layer after freeze-thawing was small, indicating that the concentration unevenness after solidifying and redissolving the foaming agents for hydraulic compositions was small.

Claims

1. A hydraulic composition containing bubbles, which contains hydraulic powder, water, and Component A, and Component A is an alkyl or alkenyl sulfate or a salt thereof. As Component A, it contains Component A1 and Component A2. Component A1 is an alkyl or alkenyl sulfate or a salt thereof having an alkyl or alkenyl group with 10 carbon atoms, and Component A2 is an alkyl or alkenyl sulfate or a salt thereof having an alkyl or alkenyl group with 12 carbon atoms. The total content of Component A1 and Component A2 in Component A is 99% by mass or more, and the mass ratio A1 / A2 of the content of Component A1 to the content of Component A2 is 0.2 or more and 2.4 or less.

2. The hydraulic composition containing bubbles according to claim 1, wherein the average bubble diameter of the hardened body of the hydraulic composition containing bubbles is 220 μm or more and 800 μm or less.

3. The hydraulic composition containing bubbles according to claim 1 or 2, which does not contain an alkyl or alkenyl sulfate or a salt thereof having an alkyl or alkenyl group with 14 or more carbon atoms.

4. The hydraulic composition containing bubbles according to any one of claims 1 to 3, wherein 0.0005 part by mass or more and 0.01 part by mass or less of Component A is contained relative to 100 parts by mass of the hydraulic powder.

5. The hydraulic composition containing bubbles according to any one of claims 1 to 4, wherein the content of polyoxyethylene alkyl or alkenyl ether sulfate or a salt thereof is 0.001 part by mass or less relative to 100 parts by mass of the hydraulic powder.

6. The hydraulic composition containing bubbles according to any one of claims 1 to 5, wherein the hydraulic powder is gypsum.

7. The hydraulic composition containing bubbles according to any one of claims 1 to 6, wherein Component A1 is an alkyl or alkenyl sulfate or a salt thereof having a straight-chain alkyl or straight-chain alkenyl group with 10 carbon atoms, and Component A2 is an alkyl or alkenyl sulfate or a salt thereof having a straight-chain alkyl or straight-chain alkenyl group with 12 carbon atoms.

8. The hydraulic composition containing bubbles according to any one of claims 1 to 7, wherein the content of Component A1 in Component A is 20% by mass or more and 75% by mass or less, and the content of Component A2 in Component A is 25% by mass or more and 80% by mass or less.

9. A method for manufacturing a hydraulic composition containing bubbles, which includes the following Step 1 and Step 2: <Step 1> A step of foaming a liquid composition containing the following hydraulic composition, a foaming agent, and water to obtain foam; The foaming agent for the hydraulic composition contains Component A, and Component A is an alkyl or alkenyl sulfate or a salt thereof. As Component A, it contains Component A1 and Component A2. Component A1 is an alkyl or alkenyl sulfate or a salt thereof having an alkyl or alkenyl group with 10 carbon atoms, and Component A2 is an alkyl or alkenyl sulfate or a salt thereof having an alkyl or alkenyl group with 12 carbon atoms. The total content of Component A1 and Component A2 in Component A is 99% by mass or more, and the mass ratio A1 / A2 of the content of Component A1 to the content of Component A2 is 0.2 or more and 2.4 or less; <Step 2> A step of mixing the hydraulic powder, water, and the foam obtained in Step 1.

10. The manufacturing method of the hydraulic composition containing bubbles according to claim 9, wherein, The average bubble diameter of the hardened body of the hydraulic composition containing bubbles is 220 μm or more and 800 μm or less.

11. The manufacturing method of the hydraulic composition containing bubbles according to claim 9 or 10, wherein, The hydraulic powder is gypsum.

12. A foaming agent for a hydraulic composition, which contains component A. Component A is an alkyl or alkenyl sulfate or its salt. As component A, it contains component A1 and component A2. Component A1 is an alkyl or alkenyl sulfate or its salt having an alkyl or alkenyl group with 10 carbon atoms. Component A2 is an alkyl or alkenyl sulfate or its salt having an alkyl or alkenyl group with 12 carbon atoms. The total content of component A1 and component A2 in component A is 99% by mass or more, and the mass ratio A1 / A2 of the content of component A1 to the content of component A2 is 0.2 or more and 2.4 or less.

13. The foaming agent for a hydraulic composition according to claim 12, wherein the foaming agent does not contain an alkyl or alkenyl sulfate or its salt having an alkyl or alkenyl group with 14 or more carbon atoms.

14. The foaming agent for a hydraulic composition according to claim 12 or 13, wherein the foaming agent contains 2% by mass or more and 40% by mass or less of component A.

15. The foaming agent for a hydraulic composition according to any one of claims 12 to 14, wherein, The content of polyoxyethylene alkyl or alkenyl ether sulfate or its salt is 10% by mass or less.

16. The foaming agent for a hydraulic composition according to any one of claims 12 to 15, which is used for gypsum slurry.

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