องค์ประกอบไฮดรอลิกที่มีฟองอากาศ

Abstract

DEPCT68 การประดิษฐ์ปัจจุบันจัดให้มีองค์ประกอบไฮดรอลิกที่มีฟองอากาศและวิธีการสำหรับการผลิตสิ่ง เดียวกันที่ได้มาซึ่งความถ่วงจำเพาะต่ำของผลิตภัณฑ์ที่ถูกทำให้แข็งขององค์ประกอบไฮดรอลิกที่มี ฟองอากาศและฟองอากาศขนาดใหญ่ในผลิตภัณฑ์ที่ถูกทำให้แข็งขององค์ประกอบไฮดรอลิกที่มีฟองอากาศ องค์ประกอบไฮดรอลิกที่มีฟองอากาศที่มีผงไฮดรอลิก,น้ำ,และ(A)อัลคิลหรืออัลคีนิลซัลเฟตหรือ เกลือของสิ่งนั้น(นับแต่นี้ไปถูกอ้างถึงดังส่วนประกอบ(A))ที่ซึ่งองค์ประกอบมี,ดังส่วนประกอบ(A),(A1) อัลคิลหรืออัลคีนิลซัลเฟตที่มีหมู่อัลคิลหรืออัลคีนิลที่มี10คาร์บอน,หรือเกลือของสิ่งนั้น(นับแต่นี้ไปถูก อ้างถึงดังส่วนประกอบ(A1)),และ(A2)อัลคิลหรืออัลคีนิลซัลเฟตที่มีหมู่อัลคิลหรืออัลคีนิลที่มี12คาร์บอน, หรือเกลือของสิ่งนั้น(นับแต่นี้ไปถูกอ้างถึงดังส่วนประกอบ(A2)),ปริมาณรวมของส่วนประกอบ(A1) และ(A2)ในส่วนประกอบ(A)คือ99%โดยมวลหรือมากกว่า,และอัตราส่วนมวลของปริมาณของ ส่วนประกอบ(A1)ต่อปริมาณของส่วนประกอบ(A2),(A1) / (A2),คือ0.2หรือมากกว่าและ2.4หรือน้อย กว่า;

Description

Cell-containing hydraulic composition

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

[0002] BACKGROUND ART Air bubbles are introduced into hydraulic compositions using cement or gypsum as a hardening agent to reduce their weight. Typically, lightweight air-bubble hydraulic compositions are produced by foaming a liquid composition containing a foaming agent and water, and mixing the foam with the hydraulic composition, or with fine aggregate or various admixtures.

[0003] JP 2018-527163 A discloses a surfactant composition for gypsum board, which contains a branched alkyl sulfate having 8 to 12 carbon atoms; optionally a linear alkyl sulfate having 8 to 12 carbon atoms; and optionally an alkyl ether sulfate having 8 to 13 carbon atoms, for the purpose of reducing the weight of gypsum wallboard while still allowing the gypsum wallboard to function as a building material. In the examples, a surfactant composition comprising 75% alkyl sulfate having 10 carbon atoms and 25% alkyl sulfate having 12 carbon atoms is disclosed.

[0004] JP-A No. 2004-529050 describes a surfactant that can be easily produced from a commercially available product and that has a strong foaming power and is inexpensive, and that can be produced by combining gypsum with water and reacting with a compound of the formula H(CH ２ ) ｎ OSO ３ － M ＋ wherein n is 6 to 16, and the average number of carbon atoms in the alkyl sulfate composition, n ｍ is 10 to 11, and M is a monovalent cation. In the examples, a surfactant containing 84.2% by weight of C10 alkyl sulfate and 15.8% by weight of C12 alkyl sulfate was used, and the surfactant composition was evaluated by measuring the amount of foam formed after mixing with water and stirring in a mixer.

[0005] Summary of the Invention The hardened product of the air-bubble hydraulic composition using cement or gypsum as a hardening agent has environmental (CO ) impacts caused by its production, transportation, and raw material procurement. ２ From the viewpoint of the effect of reducing the amount of carbon dioxide and the cost, further weight reduction is required. By including air bubbles in a bubble-containing hydraulic composition, the specific gravity of the set body of the hydraulic composition can be reduced, thereby reducing the weight. However, if the volume (proportion) of air bubbles is increased to further reduce the weight of the set body of the hydraulic composition, the proportion of hydraulic composition decreases, and the strength of the set body tends to decrease. On the other hand, as described in paragraph 0004 of JP-A-10-330174, the strength of the set body of the bubble-containing hydraulic composition can be increased by increasing the diameter of the air bubbles in the bubble-containing hydraulic composition for a bubble-containing hydraulic composition of the same specific gravity. Furthermore, when the diameter of the air bubbles in the bubble-containing hydraulic composition is increased, the drying time when obtaining the set body of the bubble-containing hydraulic composition is accelerated, which reduces the fuel cost required for drying and CO2 emissions. ２ This has the advantage of reducing emissions. Furthermore, when the bubble diameter in a bubble-containing hydraulic composition is increased, the distance between the bubbles increases, making it difficult for the bubbles to communicate with each other, thereby improving heat insulation and sound insulation. Therefore, there is a need for a technology that can reduce the specific gravity of a bubble-containing hydraulic composition and increase the bubble diameter in the bubble-containing hydraulic composition.

[0006] The present invention provides a bubble-containing hydraulic composition that has a low specific gravity and a large bubble diameter in the cured product of the bubble-containing hydraulic composition, a method for producing the same, and a foaming agent for hydraulic compositions that can reduce the specific gravity of the cured product of the bubble-containing hydraulic composition and increase the bubble diameter in the cured product of the bubble-containing hydraulic composition.

[0007] The present invention relates to a bubble-containing hydraulic composition containing hydraulic powder, water, and (A) an alkyl or alkenyl sulfate ester or a salt thereof (hereinafter referred to as component (A)), wherein component (A) contains (A1) an alkyl or alkenyl sulfate ester having an alkyl or alkenyl group with 10 carbon atoms, or a salt thereof (hereinafter referred to as component (A1)), and (A2) an alkyl or alkenyl sulfate ester having an alkyl or alkenyl group with 12 carbon atoms, or a salt thereof (hereinafter referred to as component (A2)), wherein the total content of components (A1) and (A2) in component (A) is 99 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.

[0008] The present invention also relates to a method for producing a bubble-containing hydraulic composition, comprising the following steps 1 and 2. <Step 1> A step of foaming a liquid composition containing the following foaming agent for hydraulic compositions and water to obtain a foam. Foaming agent for hydraulic compositions: A foaming agent for hydraulic compositions containing component (A), which contains components (A1) and (A2) as component (A), the total content of components (A1) and (A2) in component (A) being 99 mass% or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) being 0.2 or more and 2.4 or less. <Step 2> A step of mixing hydraulic powder, water, and the foam obtained in step 1.

[0009] The present invention also relates to a foaming agent for hydraulic compositions containing component (A), which contains component (A1) and component (A2) as component (A), the total content of component (A1) and component (A2) in component (A) being 99 mass% or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) being 0.2 or more and 2.4 or less.

[0010] According to the present invention, there are provided a bubble-containing hydraulic composition and a method for producing the same, which produce a bubble-containing hydraulic composition cured body having a low specific gravity and a large bubble diameter, as well as a foaming agent for hydraulic compositions, which can reduce the specific gravity of the bubble-containing hydraulic composition cured body and increase the bubble diameter in the bubble-containing hydraulic composition cured body.

[0011] Modes for Carrying Out the Invention The reasons why the bubble-containing hydraulic composition and its manufacturing method of the present invention can reduce the specific gravity of the bubble-containing hydraulic composition cured body and increase the bubble diameter in the bubble-containing hydraulic composition cured body, and why the foaming agent for hydraulic compositions of the present invention can reduce the specific gravity of the bubble-containing hydraulic composition cured body and increase the bubble diameter in the bubble-containing hydraulic composition cured body, are not entirely clear, but are presumed to be as follows: In the foaming agent for hydraulic compositions, by blending a predetermined amount of component (A1), which forms a bubble film with high fluidity and in which bubbles easily coalesce, with a predetermined amount of component (A2), which forms a bubble film in which bubbles are less likely to break and coalesce, it is presumed that a bubble film that is both flexible and hard can be formed, and that this suppresses the loss of bubbles during the process of manufacturing the bubble-containing hydraulic composition, while at the same time achieving both a lighter weight and larger bubble diameter in the bubble-containing hydraulic composition cured body due to the coalescence of the bubbles. On the other hand, with regard to the content ratio of the components (A1) and (A2), if the proportion of the component (A1) is too high, the bubbles will be more likely to break, and although it is possible to increase the diameter of the bubbles in the bubble-containing hydraulic composition hardened body, it is presumed that it will be difficult to reduce the weight of the hardened body.

[0012] [Foaming Agent for Hydraulic Compositions] <Component (A)> The foaming agent for hydraulic compositions of the present invention contains, as component (A), an alkyl or alkenyl sulfate ester or a salt thereof. The foaming agent for hydraulic compositions of the present invention also contains, as component (A), (A1) an alkyl or alkenyl sulfate ester having an alkyl or alkenyl group with 10 carbon atoms, or a salt thereof (hereinafter referred to as component (A1)), and (A2) an alkyl or alkenyl sulfate ester having an alkyl or alkenyl group with 12 carbon atoms, or a salt thereof (hereinafter referred to as component (A2)). Component (A1) is preferably an alkyl or alkenyl sulfate ester having a linear alkyl or alkenyl group with 10 carbon atoms, or a salt thereof. Specific examples of component (A1) include one or more selected from decyl sulfate, 2-propylheptyl sulfate, and salts thereof, with decyl sulfate or a salt thereof being preferred. Component (A2) is preferably an alkyl or alkenyl sulfate ester having a linear alkyl group or linear alkenyl group having 12 carbon atoms, or a salt thereof. Specifically, component (A2) is preferably lauryl sulfate ester or a salt thereof. Examples of salts of components (A), (A1), and (A2) include one or more salts selected from alkali metal salts such as sodium salts and potassium salts, ammonium salts, and organic ammonium salts.

[0013] <Composition, etc.> From the viewpoint of increasing the bubble diameter in the bubble-containing hardened hydraulic composition and decreasing the specific gravity of the bubble-containing hardened hydraulic composition, the foaming agent for hydraulic compositions of the present invention contains component (A) in an amount of preferably 2% by mass or more, more preferably 10% by mass or more, even more preferably 15% by mass or more, still more preferably 20% by mass or more, still more preferably 25% by mass or more, and preferably 40% by mass or less, more preferably 35% by mass or less, and even more preferably 30% by mass or less. In the present invention, the masses of component (A) and components (A1) and (A2) contained in component (A) are specified using values ​​converted to sodium salts.

[0014] In the foaming agent for hydraulic compositions of the present invention, the total content of the components (A1) and (A2) in the 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, from the viewpoint of increasing the bubble diameter in the bubble-containing hardened hydraulic composition and decreasing the specific gravity of the bubble-containing hardened hydraulic composition.

[0015] In the foaming agent for hydraulic compositions of the present invention, the content of component (A1) in component (A) is preferably 20% by mass or more, more preferably 30% by mass or more, even more preferably 40% by mass or more, and preferably 75% by mass or less, more preferably 65% ​​by mass or less, and even more preferably 53% by mass or less, from the viewpoints of increasing the bubble diameter in the cured product of the bubble-containing hydraulic composition and decreasing the specific gravity of the cured product of the bubble-containing hydraulic composition. The content of component (A2) in component (A) is preferably 25% by mass or more, more preferably 35% by mass or more, even more preferably 45% by mass or more, and preferably 80% by mass or less, more preferably 70% by mass or less, even more preferably 65% ​​by mass or less, and even more preferably 53% by mass or less, from the viewpoints of increasing the bubble diameter in the cured product of the bubble-containing hydraulic composition and decreasing the specific gravity of the cured product of the bubble-containing hydraulic composition.

[0016] In the foaming agent for hydraulic compositions of the present invention, the mass ratio (A1) / (A2) of the content of the component (A1) to the content of the component (A2) is 0.2 or more, preferably 0.3 or more, more preferably 0.6 or more, even more preferably 0.9 or more, and 2.4 or less, preferably 2.3 or less, more preferably 2.0 or less, even more preferably 1.9 or less, even more preferably 1.3 or less, from the viewpoint of increasing the bubble diameter in the foaming agent for hydraulic compositions of the present invention and decreasing the specific gravity of the foaming agent for hydraulic compositions of the present invention. Furthermore, in the foaming agent for hydraulic compositions of the present invention, the mass ratio (A1) / (A2) of the content of the component (A1) to the content of the component (A2) is preferably 1.5 or less, more preferably 1.3 or less, from the viewpoint of reducing concentration unevenness after freezing and thawing of the foaming agent for hydraulic compositions of the present invention used in producing the foaming composition of the present invention.

[0017] From the viewpoint of enjoying the effects of the present invention, the foaming agent for hydraulic compositions of the present invention preferably does not contain, as component (A), an alkyl or alkenyl sulfate ester having an alkyl or alkenyl group having 14 or more carbon atoms, or a salt thereof. Examples of the alkyl or alkenyl sulfate ester having an alkyl or alkenyl group having 14 or more carbon atoms, or a salt thereof, include one or more selected from myristyl sulfate ester, cetyl sulfate ester, stearyl sulfate ester, oleyl sulfate ester, and salts thereof.

[0018] The foaming agent for hydraulic compositions of the present invention may contain polyoxyethylene alkyl or alkenyl ether sulfate or a salt thereof, but the content thereof is limited from the viewpoint of enjoying the effects of the present invention. Examples of the polyoxyethylene alkyl or alkenyl ether sulfate or a salt thereof 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 salts thereof.

[0019]

[0033] From the viewpoint of increasing the bubble diameter in the bubble-containing hardened hydraulic composition, the content of polyoxyethylene alkyl or alkenyl ether sulfate or its salt in the foaming agent for hydraulic compositions of the present invention is preferably 10% by mass or less, more preferably 5% by mass or less, even more preferably 3% by mass or less, still more preferably 1% by mass or less, and even more preferably 0.5% by mass or less. In the present invention, the mass of polyoxyethylene alkyl or alkenyl ether sulfate or its salt is used as the value converted to the sodium salt. From the viewpoint of increasing the bubble diameter in the bubble-containing hardened hydraulic composition, it is preferable that the foaming agent for hydraulic compositions of the present invention does not contain polyoxyethylene alkyl or alkenyl ether sulfate or its salt.

[0020] The foaming agent for hydraulic compositions of the present invention may contain, as component (B), a monohydric alcohol having 6 to 10 carbon atoms, from the viewpoint of rapid foaming and foam stability. The number of carbon atoms in component (B) is 6 or more and 10 or less, preferably 8, from the viewpoint of rapid foaming and foam stability. Component (B) is a monohydric alcohol having a linear or branched hydrocarbon group, preferably a linear or branched alkyl group, more preferably a linear alkyl group, from the viewpoint of rapid foaming and foam stability.

[0021] Specific examples of the component (B) include one or more selected from hexanol, octanol, decanol, 2-ethylhexanol, and 2-propylheptanol. From the viewpoint of foaming properties, it is preferable that the component (B) contains preferably one or more selected from octanol and decanol, and more preferably octanol.

[0022] The foaming agent for hydraulic compositions of the present invention can contain a nonionic surfactant as component (C) from the viewpoint of increasing the bubble size in the bubble-containing hardened hydraulic composition and decreasing the specific gravity of the bubble-containing hardened hydraulic composition. Examples of nonionic surfactants include one or more selected from alkyl monoglyceryl 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 these, a glycoside-type nonionic surfactant is preferred from the viewpoint of increasing the bubble size in the bubble-containing hardened hydraulic composition.

[0023] The foaming agent for hydraulic compositions of the present invention may contain water, and preferably contains water in an amount of 10% by mass or more, preferably 20% by mass or more, more preferably 30% by mass or more, even more preferably 40% by mass or more, and preferably 90% by mass or less, more preferably 80% by mass or less, even more preferably 70% by mass or less.

[0024] The foaming agent for hydraulic compositions of the present invention may optionally contain thickeners, chelating agents, heavy metal scavengers, rust inhibitors, preservatives, colorants, fragrances, defoamers, solvents, dispersants, flocculants, water-soluble polymers, etc. However, these do not fall under the category of component (A), component (A1), component (A2), component (B), and component (C).

[0025] The foaming agent for hydraulic compositions of the present invention can be obtained by mixing the components (A1), (A2), and optional components as the component (A). During mixing, heating may be performed as appropriate to reduce the solution viscosity.

[0026] Target applications of the foaming agent for hydraulic compositions of the present invention include gypsum slurries, lightweight foams (aerated foams, aerated foams), lightweight mortars (aerated mortar, aerated mortar), lightweight concrete (aerated concrete, aerated concrete), backfill fillers, core fillers, architectural concrete blocks, ALC (lightweight aerated concrete), grout materials, porous ceramics, bricks, refractories, lightweight embankments, and mortars for pumping. In these hydraulic compositions containing air bubbles, the incorporation of air bubbles is expected to impart functions such as weight reduction, improved strength, improved fluidity, thermal insulation, heat resistance, viscosity, and fluidity control. Among these hydraulic compositions containing air bubbles, the foaming agent for hydraulic compositions of the present invention is suitable for use in gypsum slurries.

[0027] [Air-Bubble-Containing Hydraulic Composition and Its Manufacturing Method] A preferred method for manufacturing a air-bubble-containing hydraulic composition is to foam the foaming agent for hydraulic compositions of the present invention and incorporate the foam into a hydraulic substance to achieve blending and weight reduction, since this method entrains uniform air bubbles. The foaming agent for hydraulic compositions of the present invention or a mixed solution obtained by diluting it with water may be directly kneaded into paste, slurry, mortar, or concrete containing cement or gypsum as the hydraulic substance. There are no limitations on the method for adding the foaming agent for hydraulic compositions of the present invention to a hydraulic composition, nor on the method for foaming the foaming agent for hydraulic compositions of the present invention or a mixed solution obtained by diluting it with water.

[0028] The present invention provides a bubble-containing hydraulic composition containing hydraulic powder, water, and component (A), wherein component (A) contains components (A1) and (A2), the total content of components (A1) and (A2) in component (A) being 99 mass% or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) being 0.2 to 2.4. The bubble-containing hydraulic composition of the present invention can further contain component (B). The bubble-containing hydraulic composition of the present invention can further contain component (C). The features described for the foaming agent for hydraulic compositions of the present invention can be applied to the bubble-containing hydraulic composition of the present invention as appropriate. The components (A), (A1), (A2), (B), and (C) are the same as those described for the foaming agent for hydraulic compositions of the present invention.

[0029] The hydraulic powder is a powder that has the physical property of hardening through a hydration reaction, and examples thereof include cement, gypsum, etc., with gypsum being preferred. Examples of cement include ordinary Portland cement, belite cement, moderate-heat cement, early-strength cement, ultra-early-strength cement, and sulfate-resistant cement. These may also be used to form blast furnace slag cement, fly ash cement, silica fume cement, or silica fume cement, which may be obtained by adding blast furnace slag, fly ash, silica fume, stone powder (calcium carbonate powder), or the like. One or more of these may be used.

[0030] The bubble-containing hydraulic composition of the present invention has a water / hydraulic powder ratio of preferably 20% by mass or more, more preferably 30% by mass or more, even more preferably 40% by mass or more, even more preferably 50% by mass or more, and even more preferably 60% by mass or more, from the viewpoint of the fluidity of the hydraulic composition slurry, and preferably 100% by mass or less, more preferably 90% by mass or less, and even more preferably 80% by mass or less, from the viewpoint of the strength of the set body of the hydraulic composition. Here, the water / hydraulic powder ratio is the mass percentage (mass %) of water and hydraulic powder in the hydraulic composition, and is calculated as water / hydraulic powder x 100. The water / hydraulic powder ratio is calculated based on the amount of powder having physical properties that harden upon hydration reaction. If the powder having physical properties that harden upon hydration reaction contains a high-strength admixture, the amount of the high-strength admixture is also included in the amount of hydraulic powder. The same applies to other quantitative relationships of the hydraulic composition regarding the hydraulic powder.

[0031] The bubble-containing hydraulic composition of the present invention contains component (A) in an amount of preferably 0.0005 part by mass or more, more preferably 0.002 part by mass or more, even more preferably 0.004 part by mass or more, still more preferably 0.008 part by mass or more, and preferably 0.1 part by mass or less, more preferably 0.05 part by mass or less, even more preferably 0.03 part by mass or less, and still more preferably 0.01 part by mass or less, per 100 parts by mass of hydraulic powder, from the viewpoint of reducing the specific gravity of the hardened body of the hydraulic composition and increasing the bubble diameter.

[0032] In the bubble-containing hydraulic composition of the present invention, the total content of the components (A1) and (A2) in the 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, from the viewpoint of reducing the specific gravity of the cured product of the hydraulic composition and increasing the bubble diameter.

[0033] In the bubble-containing hydraulic composition of the present invention, the content of component (A1) in component (A) is preferably 20% by mass or more, more preferably 30% by mass or more, even more preferably 40% by mass or more, even more preferably 45% by mass or more, and preferably 75% by mass or less, more preferably 65% ​​by mass or less, and even more preferably 53% by mass or less, from the viewpoints of increasing the bubble diameter in the cured product of the hydraulic composition and decreasing the specific gravity of the cured product 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, even more preferably 45% by mass or more, and preferably 80% by mass or less, more preferably 70% by mass or less, even more preferably 65% ​​by mass or less, and even more preferably 53% by mass or less, from the viewpoints of increasing the bubble diameter in the cured product of the hydraulic composition and decreasing the specific gravity of the cured product of the hydraulic composition.

[0034] In the bubble-containing hydraulic composition of the present invention, the mass ratio (A1) / (A2) of the content of the component (A1) to the content of the component (A2) is 0.2 or more, preferably 0.3 or more, more preferably 0.6 or more, even more preferably 0.9 or more, and 2.4 or less, preferably 2.3 or less, more preferably 2.0 or less, even more preferably 1.9 or less, even more preferably 1.3 or less, from the viewpoint of reducing the specific gravity of the cured product of the hydraulic composition and increasing the bubble diameter. Furthermore, in the bubble-containing hydraulic composition of the present invention, the mass ratio (A1) / (A2) of the content of the component (A1) to the content of the component (A2) is preferably 1.5 or less, more preferably 1.3 or less, from the viewpoint of reducing concentration unevenness after freezing and thawing of the foaming agent for hydraulic compositions used in producing the bubble-containing hydraulic composition of the present invention.

[0035] From the viewpoint of enjoying the effects of the present invention, the bubble-containing hydraulic composition of the present invention preferably does not contain, as component (A), an alkyl or alkenyl sulfate ester having an alkyl or alkenyl group having 14 or more carbon atoms, or a salt thereof.

[0036] The bubble-containing hydraulic composition of the present invention may contain a polyoxyethylene alkyl or alkenyl ether sulfate or a salt thereof, but the content is limited from the viewpoint of enjoying the effects of the present invention. In the bubble-containing hydraulic composition of the present invention, the content of the polyoxyethylene alkyl or alkenyl ether sulfate or a salt thereof is preferably 0.001 part by mass or less, more preferably 0.0008 part by mass or less, even more preferably 0.0006 part by mass or less, and even more preferably 0.0001 part by mass or less, per 100 parts by mass of hydraulic powder, from the viewpoint of increasing the bubble size of the cured product of the hydraulic composition. Preferably, the bubble-containing hydraulic composition of the present invention does not contain a polyoxyethylene alkyl or alkenyl ether sulfate or a salt thereof, from the viewpoint of increasing the bubble size of the cured product of the hydraulic composition.

[0037] The bubble-containing hydraulic composition of the present invention may contain fine aggregate and / or coarse aggregate, and may also contain admixtures or additives known in the art.

[0038] The bubble-containing hydraulic composition of the present invention can be dried and cured to obtain a hardened product. The specific gravity of the hardened product of the bubble-containing hydraulic composition of the present invention is preferably 0.3 or more, more preferably 0.4 or more, and even more preferably 0.5 or more from the viewpoint of strength, and is preferably 0.9 or less, more preferably 0.8 or less, and even more preferably 0.7 or less from the viewpoint of handleability.

[0039] The bubble-containing hydraulic composition of the present invention contains bubbles. From the viewpoint of improving the strength of the cured product, the average bubble diameter of the cured product of the bubble-containing hydraulic composition of the present invention is preferably 230 μm or more, more preferably 250 μm or more, and even more preferably 300 μm or more. From the viewpoint of cross-sectional aesthetics, it is preferably 800 μm or less, more preferably 700 μm or less, even more preferably 600 μm or less, even more preferably 500 μm or less, and even more preferably 400 μm or less. The average bubble diameter is calculated by preparing a cured product of the bubble-containing hydraulic composition, cutting the cured product at random to prepare a cross-section, observing the cross-section with a digital microscope, measuring the diameters of 100 randomly selected bubble cross-sections, and averaging (arithmetic mean) these values. The diameter of the bubble cross-section is measured when the bubble cross-section is circular; when the bubble cross-section is elliptical, the diameter is the major axis; and when the bubble cross-section is irregular, the diameter is the longest part.

[0040] The present invention provides a method for producing a foam-containing hydraulic composition, comprising the following steps 1 and 2. The foaming agent for hydraulic compositions described below is the same as the foaming agent for hydraulic compositions of the present invention, and the embodiments described for the foaming agent for hydraulic compositions of the present invention can be applied as appropriate. <Step 1> A step of foaming a liquid composition containing the foaming agent for hydraulic compositions described below and water to obtain a foam. Foaming agent for hydraulic compositions: A foaming agent for hydraulic compositions containing component (A), which contains components (A1) and (A2) as component (A), the total content of components (A1) and (A2) in component (A) being 99 mass% or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) being 0.2 or more and 2.4 or less. <Step 2> A step of mixing hydraulic powder, water, and the foam obtained in step 1. In step 2, a hydraulic composition containing hydraulic powder and water may be prepared, and the hydraulic composition may be mixed with the foam obtained in step 1.

[0041] The bubble-containing hydraulic composition of the present invention can be prepared by this manufacturing method. The foaming agent for hydraulic compositions of the present invention and the aspects described for the bubble-containing hydraulic composition of the present invention can be applied as appropriate to the manufacturing method for the bubble-containing hydraulic composition of the present invention. In the manufacturing method for the bubble-containing hydraulic composition of the present invention, the contents and mass ratios of each component described for the bubble-containing hydraulic composition of the present invention can be applied as appropriate by replacing the contents of each component with the mixing amounts.

[0042] In step 1, the expansion ratio of the liquid composition varies depending on the application of the hydraulic composition, etc., but from the viewpoint of economy, it is preferably 5 times or more, more preferably 7 times or more, and even more preferably 10 times or more, and from the viewpoint of kneadability, it is preferably 30 times or less, more preferably 25 times or less, and even more preferably 20 times or less.

[0043] In step 2, depending on the application of the hydraulic composition, foam is mixed with the hydraulic composition in an amount of preferably 50% by volume or more, more preferably 100% by volume or more, and even more preferably 150% by volume or more from the viewpoint of reducing the weight of the cured product of the bubble-containing hydraulic composition, and preferably 400% by volume or less, more preferably 300% by volume or less, and even more preferably 200% by volume or less from the viewpoint of the strength of the cured product of the bubble-containing hydraulic composition. In this production method, admixtures and additives known in the art can be mixed in step 1 and / or step 2.

[0044] [Gas-Containing Gypsum Slurry and Its Manufacturing Method] In the gas-bubble hydraulic composition of the present invention, the hydraulic powder is preferably gypsum. In the present invention, a gas-bubble hydraulic composition in which the hydraulic powder is gypsum is also referred to as a gas-bubble gypsum slurry. That is, the present invention provides a gas-bubble gypsum slurry containing gypsum, water, and component (A), wherein component (A) contains components (A1) and (A2), the total content of components (A1) and (A2) in component (A) is 99 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 gas-bubble gypsum slurry of the present invention is suitable for use in gypsum boards.

[0045] The foaming agent for hydraulic compositions of the present invention, the foaming composition for hydraulic compositions of the present invention, and the manufacturing method for the foaming composition for gas-bubble-containing hydraulic compositions of the present invention can be appropriately applied to the gas-bubble-containing gypsum slurry of the present invention. The gas-bubble-containing gypsum slurry of the present invention can further contain component (B). The gas-bubble-containing gypsum slurry of the present invention can further contain component (C). The components (A), (A1), (A2), (B), and (C) are the same as those described for the foaming agent for hydraulic compositions of the present invention. In the gas-bubble-containing gypsum slurry of the present invention, the contents and mass ratios of each component described for the gas-bubble-containing hydraulic composition of the present invention can be appropriately applied by replacing the hydraulic powder with gypsum. In the hardened product of the gas-bubble-containing gypsum slurry of the present invention, the ranges of specific gravity and average gas bubble diameter are the same as those described for the gas-bubble-containing hydraulic composition of the present invention.

[0046] Any type of gypsum can be used, including high-quality neutralized gypsum, phosphogypsum, a by-product of phosphoric acid, flue gas desulfurization gypsum produced in thermal power plants, natural gypsum containing various impurities and clay, and mixtures thereof. The clay contained in gypsum is primarily composed of hydrous silicate minerals (hereinafter referred to as clay minerals) with a layered structure. Clay minerals contained as fine particles in this clay include kaolin minerals (kaolinite, dickite, and nacrite), serpentine (lizardite, antigorite, and chrysotile), mica clay minerals (illite, sericite, glauconite, and celadonite), chlorite, vermiculite, and smectite (montmorillonite, beidellite, nontronite, saponite, and hectorite).

[0047] Examples of gypsum include anhydrous gypsum, hemihydrate gypsum, and dihydrate gypsum. As the raw gypsum, natural gypsum, neutralized gypsum, by-product gypsum, or other chemical gypsum can be used alone, or a mixture of two or more of these can be used. Examples of major chemical gypsum include phosphate gypsum, hydrofluoric gypsum, titanic gypsum, and flue gas desulfurization gypsum. The raw gypsum may also include recycled gypsum. The recycled gypsum may be any recycled gypsum recovered from waste gypsum board generated in-house by gypsum board manufacturers, waste gypsum board generated during new construction and demolition, and the like. The present invention can be suitably used with one or more of these raw gypsums, and excellent effects can be obtained with blends of these raw gypsums in various ratios.

[0048] The bubble-containing gypsum slurry of the present invention can contain additives used for gypsum boards, etc. Such additives include general-purpose water-reducing agents, antifoaming agents, foam stabilizers, hardening regulators, water repellents, adhesives, retarders, etc. Furthermore, gypsum boards can be produced by adding reinforcing fibers such as glass fiber, carbon fiber, waste paper, virgin pulp, etc., or by adding lightweight aggregates such as perlite or foamed steel.

[0049] The present invention provides a method for producing a foam-containing gypsum slurry, including the following steps 1 and 2. The foaming agent for hydraulic compositions described below is the same as the foaming agent for hydraulic compositions of the present invention, and the embodiments described for the foaming agent for hydraulic compositions of the present invention can be applied as appropriate. <Step 1> A step of foaming a liquid composition containing the foaming agent for hydraulic compositions described below and water to obtain a foam. Foaming agent for hydraulic compositions: A foaming agent for hydraulic compositions containing component (A), which contains components (A1) and (A2) as component (A), the total content of components (A1) and (A2) in component (A) being 99 mass% or more, and the mass ratio (A1) / (A2) of the content of component (A1) to the content of component (A2) being 0.2 or more and 2.4 or less. <Step 2> A step of mixing gypsum, water, and the foam obtained in step 1. In step 2, a gypsum slurry containing gypsum and water may be prepared, and the gypsum slurry may be mixed with the foam obtained in step 1.

[0050] The gas bubble-containing gypsum slurry of the present invention can be prepared by this manufacturing method. The manufacturing method of the gas bubble-containing gypsum slurry of the present invention can appropriately apply the embodiments described for the foaming agent for hydraulic compositions of the present invention, the gas bubble-containing hydraulic composition and its manufacturing method of the present invention, and the gas bubble-containing gypsum slurry of the present invention. In the manufacturing method of the gas bubble-containing hydraulic composition of the present invention, the contents and mass ratios of each component described for the gas bubble-containing hydraulic composition of the present invention can be appropriately applied by replacing the hydraulic powder with gypsum and further replacing the contents of each component with the mixing amounts. The temperatures of the foam and gypsum slurry used for mixing are preferably 15°C or higher and 40°C or lower, respectively. Steps 1 and 2 can be performed in accordance with the manufacturing method of the gas bubble-containing hydraulic composition of the present invention.

[0051] Examples The components used in the examples and comparative examples are as follows: Component (A) C10AS: sodium decyl sulfate, Component (A1) C12AS: sodium lauryl sulfate, Component (A2) C14AS: sodium myristyl sulfate

[0052] (1) Preparation of foaming agent for hydraulic composition The foaming agents for hydraulic compositions shown in Tables 1 and 2 were prepared by the following method. Each raw material was added to a 50 mL screw tube in the specified ratio so that the total amount was 30 g, and the mixture was stirred at 1000 rpm for 3 hours using a stirrer. When the solution viscosity was high and stirring efficiency was poor, the mixture was heated to 40°C as needed.

[0053] (2) Preparation of Gypsum Slurry The foaming agents for hydraulic compositions prepared in Tables 1 and 2 and water were mixed in a mass ratio of 0.3 to 99.7 to prepare an aqueous solution with a foaming agent for hydraulic compositions concentration (as is) of 0.3 mass%. 19 g of the prepared aqueous solution was added to a 1 L disposable cup, and the mixture was stirred by hand using a flat six-blade paddle blade (FP-50, manufactured by AS ONE Corporation) at 2000 rpm (EUROSTAR 200 control, manufactured by IKA Japan Co., Ltd.) for 15 seconds while rotating the container, and then the container was placed and stirred for another 45 seconds to obtain a foam. 200 g of calcined gypsum, 4 g of dihydrate gypsum, 127 g of tap water in which 1.5 g of potassium sulfate had been 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 the mixture was stirred for 5 seconds at a setting of 3 using a hand mixer (MK-H4, manufactured by Panasonic Corporation) to prepare a gypsum slurry before adding foam. The entire amount of the prepared gypsum slurry was added to 19 g of foam prepared in a 1 L disposable cup, and the mixture was kneaded for 10 seconds at 1,150 rpm using the flat six-blade paddle in the 1 L disposable cup to obtain a gypsum slurry containing bubbles. The temperatures of the foam and gypsum slurry used for kneading were both 20°C.

[0054] (3) Measurement of specific gravity of gypsum specimen The obtained gypsum slurry containing bubbles was poured into a cylindrical specimen mold (Plamold, manufactured by Nifco Co., Ltd.) having a diameter of 5 cm and a height of 10 cm and left to stand at room temperature for 1 hour or more. The hardened gypsum slurry was demolded from the cylindrical specimen mold and left to dry in a thermostatic chamber at 80 ° C. for 17 hours, and 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. The results are shown in Tables 1 and 2.

[0055] (4) Measurement of the average bubble diameter in the gypsum specimen (3) A slit was made in a 5 cm high section of the gypsum specimen to create a cross section of the gypsum specimen. The cross section was observed with a digital microscope (42x magnification), and the diameters of 100 bubble cross sections were measured in order from the smallest visible bubbles, and the average bubble diameter was calculated from the arithmetic mean of these values. The diameter of the bubble cross section was measured as the diameter if the bubble cross section was circular, the major axis if the bubble cross section was elliptical, and the longest part if the bubble cross section was irregular. The results are shown in Tables 1 and 2.

[0056] (5) Penetration Resistance Test The penetration resistance value was measured when a needle with a diameter of 12.5 mm was pushed 6 cm into the side of the gypsum specimen obtained in (3). The measurement was performed three times on the side of the gypsum specimen at points 2.5 cm, 5 cm, and 7.5 cm from the bottom, and the average value was taken as the penetration resistance value of the gypsum specimen. Example 1-1 and Comparative Examples 1-2 and 1-3 were evaluated. The results are shown in Table 2. The higher the penetration resistance value, the higher the strength of the gypsum specimen.

[0057]

[0058]

[0059] In Table 1, the foaming agents for hydraulic compositions of Examples 1-1 to 1-6 can reduce the specific gravity while maintaining an average bubble diameter of 250 μm or more in the gypsum specimens, compared to the foaming agents for hydraulic compositions of Comparative Examples 1-1, 1-4, and 1-5. Note that the specific gravity of Comparative Examples 1-4 and 1-5 was higher than that of Examples 1-1 to 1-6, and the average bubble diameter was not measured because the gypsum specimens did not contain an accurately measurable amount of bubbles. Also, in Table 2, the foaming agent for hydraulic compositions of Example 1-1 can increase the average bubble diameter in the gypsum compared to the foaming agents for hydraulic compositions of Comparative Examples 1-2 and 1-3, although the specific gravity of the gypsum specimens is the same. As a result, as shown in Table 2, the foaming agent for hydraulic compositions of Example 1-1 can increase the average bubble diameter in the gypsum, thereby increasing the strength of the gypsum specimens.

[0060] (6) Performance Evaluation After Freezing and Thawing 85 mL of the foaming agent for hydraulic compositions from Examples 1-3 was placed in a Maruemu screw cap No. 8 (height 12 cm, capacity 110 mL) and stored at 0°C for 3 days before freezing. The solidified or precipitated sample was allowed to stand at 20°C for 2 hours and thawed. 2 mL of foaming agent for hydraulic compositions was recovered from a liquid surface height of 1 cm, which was designated the upper layer. Meanwhile, 2 mL of foaming agent for hydraulic compositions was recovered from a liquid surface height of 0.5 cm from the bottom of the Maruemu screw cap, which was designated the lower layer. Using the recovered foaming agent for hydraulic compositions, a gypsum slurry was prepared in the same manner as in (2) above, and the average bubble diameter in the gypsum specimen was determined in the same manner as in (4) above. The results are shown in Table 3.

[0061]

[0062] In Table 3, it can be seen that the foaming agent for hydraulic compositions in Examples 1-3 has a small difference in average bubble diameter in the gypsum specimens prepared using the foaming agent for hydraulic compositions in the upper and lower layers after freezing and thawing, and the concentration unevenness after solidifying and redissolving is small.

Claims

DEPCT681. A hydraulic composition containing air bubbles which is composed of hydraulic powder, water, and (A) an alkyl or alkenyl sulfate or a salt of such (hereinafter referred to as Component (A)) in which the composition is, as in Component (A), (A1) an alkyl or alkenyl sulfate containing a 10-carbon alkyl or alkenyl group, or a salt of such (hereinafter referred to as Component (A1)), and (A2) an alkyl or alkenyl sulfate containing a 12-carbon alkyl or alkenyl group, or a salt of such. (hereinafter referred to as component(A2)), the total volume of components(A1) and(A2) in component(A) is 99% by mass or greater, and the mass ratio of the volume of component(A1) to the volume of component(A2),(A1) / (A2), is 0.2 or greater and 2.4 or less.

2. Hydraulic components with air bubbles according to claim 1 where the average air bubble size of the solidified product of the hydraulic components with air bubbles is 220 µm or greater and 800 µm or less. 3.

4. Any hydraulic composition under Relief 1 to 3 where the composition contains component (A) in an amount of 0.0005 parts by mass or more and 0.01 parts by mass or less relative to 100 parts by mass of the hydraulic powder.

5. Any hydraulic composition under Relief 1 to 4 where the amount of polyoxyethylene alkyl or alkenyl ether sulfate or salt of such is 0.001 parts by mass or less relative to 100 parts by mass of the hydraulic powder.

6. Any hydraulic composition under Relief 1 to 5 where the hydraulic powder is gypsum. 7.

8. Hydraulic components containing air bubbles under any of the claims 1 through 6, where component (A1) is an alkyl or alkenyl sulfate containing a linear alkyl or alkenyl group of 10 carbons, or a salt of such, and component (A2) is an alkyl or alkenyl sulfate containing a linear alkyl or alkenyl group of 12 carbons, or a salt of such.

9. Hydraulic components containing air bubbles under any of the claims 1 through 7, where the amount of component (A1) in component (A) is 20% by mass or more and 75% by mass or less, and the amount of component (A2) in component (A) is 25% by mass or more and 80% by mass or less.The method for producing air-bubbled hydraulic components consists of the following steps 1 and 2: <Step 1> The process of foaming the liquid component with a foaming agent for hydraulic components and water to obtain foam. The foaming agent for hydraulic components contains (A) an alkyl or alkenyl sulfate or a salt of that (hereinafter referred to as component (A)), in which the substance contains, as component (A), (A1) an alkyl or alkenyl sulfate containing an alkyl or alkenyl group containing 10 carbons, or a salt of that. That (hereinafter referred to as component (A1)), and (A2) alkyl or alkenyl sulfate containing 12-carbon alkyl or alkenyl groups, or salts of that (hereinafter referred to as component (A2)), the total amount of components (A1) and (A2) in component (A) is 99% by mass or more, and the mass ratio of the amount of component (A1) to the amount of component (A2), (A1) / (A2), is 0.2 or more and 2.4 or less and <Step 2> the step of mixing the hydraulic powder, water, and foam obtained in step 110.Methods for the production of air-bubbled hydraulic components under claim 9 where the average air bubble size of the hardened product of the air-bubbled hydraulic component is 220 µm or more and 800 µm or less; 11. Methods for the production of air-bubbled hydraulic components under claim 9 or 10 where the hydraulic powder is gypsum; 12. Foaming agent for hydraulic components which contains (A) an alkyl or alkenyl sulfate or salt of that (hereinafter referred to as component (A)) where the substance contains, Component (A), (A1) an alkyl or alkenyl sulfate containing a 10-carbon alkyl or alkenyl group, or a salt of such (hereinafter referred to as Component (A1)), and (A2) an alkyl or alkenyl sulfate containing a 12-carbon alkyl or alkenyl group, or a salt of such (hereinafter referred to as Component (A2)), the total amount of components (A1) and (A2) in component (A) is 99% by mass or greater, and the mass ratio of the amount of component (A1) to the amount of component (A2), (A1) / (A2), is 0.2 or greater and 2.4 or less.Foaming agent for hydraulic components under claim 12 where the substance does not contain an alkyl or alkenyl sulfate containing an alkyl or alkenyl group of 14 or more carbons, or a salt of such; 14. Foaming agent for hydraulic components under claim 12 or 13 where the substance contains component (A) in an amount of 2% by mass or more and 40% by mass or less; 15. Foaming agent for hydraulic components under any of claims 12 to 14 where the amount of polyoxyethylene alkyl or alkenyl ether sulfate or a salt of such is 10% by mass or less; 16. Foaming agent for hydraulic components under any of claims 12 to 15 where the substance is used for gypsum slurry.