Foaming Agent Composition for Lightweight Plasterboards
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Solution Overview
Problem
Current foaming agents for gypsum-based products, particularly those using unstable foam technology, fail to achieve optimal large-cell porous structures and high efficiency in reducing plasterboard weight, as they either form small pores or have unstable foam structures.
Innovation Solution
A foaming agent composition comprising a mixture of at least two different alkyl sulphates with a mean carbon atom number of 8.0 to 8.8 and an amino acid surfactant, such as sodium N-lauryl sarcosinate, which forms a unique large-cellular structure in plasterboards, enhancing foam stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If unstable foam technology products are used to form large pores and reduce board weight, then weight reduction is improved, but foam stability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the foaming agent by using a specific mixture of alkyl sulphates with controlled carbon atom numbers (mean from 8.0 to 8.8) and adding amino acid surfactants. This parameter optimization allows the foam to maintain stability while still forming large pores for weight reduction.
Solution Approach 2:
The patent creates a composite foaming agent system by combining multiple surfactant types (alkyl sulphates and amino acid surfactants) in specific proportions. This composite approach synergistically improves foam stability while maintaining the ability to form large pores, resolving the contradiction between stability and weight reduction.
2Stability of the object's composition
If classic resin soaps are used as foaming agents, then foam stability is improved, but manufacturing efficiency and weight reduction capability deteriorate
Solution Approach 1:
The patent transitions from classic resin soaps to a modern surfactant system with optimized carbon atom numbers (mean 8.0-8.8) and amino acid components. This parameter change improves manufacturing efficiency and weight reduction capability while maintaining adequate foam stability through the synergistic surfactant mixture.
3Stability of the object's composition
If alkyl sulphates with higher carbon atom numbers are used, then foam stability is improved, but pore size and weight reduction capability deteriorate
Solution Approach 1:
The patent optimizes the carbon atom number parameter to a specific range (mean from 8.0 to 8.8) that balances foam stability and pore formation capability. This precise parameter control allows the system to form large pores for weight reduction while maintaining sufficient foam stability during processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition achieves significant weight reduction in plasterboards by forming large pores with improved foam stability and efficiency, allowing for reduced dosages of foaming agents and gypsum, resulting in high-quality, lightweight boards with enhanced production efficiency.
Implementation Method 1
Foaming agents play an extremely important role in the process. These are mainly mixtures of surfactants the task of which is to reduce weight of a board by limiting gypsum dosage. This is achieved by the introduction of foam
Implementation Method 2
Due to the strong coalescence properties of the foam, the composition according to the invention is particularly useful for aerating gypsum-based products
Implementation Method 3
Due to the strong coalescence properties of the foam, the composition according to the invention is particularly useful for aerating gypsum-based products
Data Source
AI summary
The invention relates to a foaming agent composition containing water and anionic surfactants and the use of this composition as an aerating agent in the process of obtaining gypsum-based products, in particular plasterboards. The composition according to the invention contains a mixture of at least two different alkyl sulphates defined by the general formula (1): (ROSO3-)My+ (1) wherein: R denotes a linear and/or branched alkyl chain, wherein the number n of carbon atoms is an integer from 8 to 12, and the mean number of carbon atoms nm in the mixture of alkyl sulphates is from 8.0 to 8.8 and is equal to the weighted sum of the n values of individual alkyl sulphates contained in the mixture according to their weight share in this mixture, x denotes 1 or 2, My+ denotes an alkali metal cation or alkaline earth metal cation, whereby y = x, wherein said at least two alkyl sulphates differ in the number n of carbon atoms in the alkyl chain R, and the composition further comprises an amino acid surfactant.