Quick-drying building material composition based on a mineral hybrid binder

Patent metadata

Field	Value
Publication number	US-10167229-B2
Application number	US-201515300813-A
Country	US
Kind code	B2
Filing date	Mar 30, 2015
Priority date	Mar 31, 2014
Publication date	Jan 1, 2019
Grant date	Jan 1, 2019

Abstract

A quick-drying gypsum composition, in particular for use as gypsum filling compound and for the production of floor coverings, wherein the gypsum composition contains 20 to 70% of a mixture of calcium aluminate and calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate as hydraulic binders and 30 to 80% by weight of fillers, and wherein the weight ratio of calcium aluminate to calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate binders lies in the range from 1:1 to 1:5. Gypsum compositions of this type are characterized by a particularly beneficial shrinkage behavior, such that stresses and cracks in the dried composition can be avoided. At the same time, the gypsum compositions dry to readiness for covering in a time that is compatible with conventional cement filling compounds.

First claim

The invention claimed is:

1. A gypsum composition comprising
20 to 70 wt % of a mixture of calcium aluminate and calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate as hydraulic binders, where the weight ratio of calcium aluminate to calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate binder is in the range from 1:1 to 1:3.5, and
30 to 80 wt % of fillers,
the weight figures being based in each case on the dry weight of the gypsum composition, wherein
at least 80 wt % of the total amount of calcium sulfate hemihydrate, and anhydrite and dihydrate is accounted for by the calcium sulfate hemihydrate, and
the gypsum composition is composed of up to about 3 wt % cement binders.

2. The gypsum composition as claimed in claim 1 , wherein the weight ratio of calcium aluminate to calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate binder is in the range from 1:1.6 to 1:3.5.

3. The gypsum composition as claimed in claim 1 comprising 20 to 60 wt % of the mixture of calcium aluminate and calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate binder.

4. The gypsum composition as claimed in claim 1 wherein 35 to 75 wt % of the fillers are present in the gypsum composition.

5. The gypsum composition as claimed in claim 1 further comprising a lithium salt.

6. The gypsum composition as claimed in claim 1 further comprising lithium salts in an amount of 0.001 to 0.05 wt %.

7. The gypsum composition as claimed in claim 1 further comprising tartaric acid and/or a tartaric salt.

8. The gypsum composition as claimed in claim 7 , wherein the tartaric acid and/or the tartaric salt is present in the gypsum composition at an amount of 0.15 to 0.005 wt %.

9. The gypsum composition as claimed in claim 1 , wherein on account of its curing it exhibits after 28 days a shrinkage of not more than +/−0.5 mm/m when curing takes place at 25° C. and 50% relative humidity.

10. The gypsum composition as claimed in claim 1 , wherein on account of its curing it exhibits after 3 hours a shrinkage of not more than +/−0.5 mm/m when curing takes place at 25° C. and 50% relative humidity.

11. The gypsum composition as claimed in claim 1 , comprising fillers in the form of sand and one or both of calcium carbonate and finely ground limestone.

12. A method for applying a gypsum filling compound to a substrate, comprising:
mixing a gypsum composition as in claim 1 with water to form a fluid gypsum composition or a gypsum composition in paste form,
applying the fluid gypsum composition or the gypsum composition in paste form to a substrate, and
curing the fluid gypsum composition or the gypsum composition in paste form.

13. A gypsum filling compound or screed, comprising:
the gypsum composition of claim 1 .

14. A floor covering or a floor covering constituent, comprising:
the gypsum composition of claim 1 .

15. A gypsum composition comprising
20 to 70 wt % of a mixture of calcium aluminate and calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate as hydraulic binders, where the weight ratio of calcium aluminate to calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate binder is in the range from 1:1 to 1:3.5, and
30 to 80 wt % of fillers, the fillers comprising sand and one or both of calcium carbonate and finely ground limestone,
the weight figures being based in each case on the dry weight of the gypsum composition, wherein
at least 80 wt % of the total amount of calcium sulfate hemihydrate, and anhydrite and dihydrate is accounted for by the calcium sulfate hemihydrate, and
the gypsum composition is composed of up to about 5 wt % cement binders.

16. A gypsum composition comprising
20 to 70 wt % of a mixture of calcium aluminate and calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate as hydraulic binders, where the weight ratio of calcium aluminate to calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate binder is in the range from 1:1 to 1:3.5,
30 to 80 wt % of fillers, and
one or more additional additives selected from plasticizers, thickeners, dyes, color pigments, defoamers, stabilizers, curing retarders, and flexibilizing agents,
the weight figures being based in each case on the dry weight of the gypsum composition, wherein
at least 80 wt % of the total amount of calcium sulfate hemihydrate, and anhydrite and dihydrate is accounted for by the calcium sulfate hemihydrate, and
the gypsum composition is composed of up to about 5 wt % cement binders.

17. The gypsum composition as claimed in claim 16 , wherein the gypsum composition is composed of not more than about 3 wt % of the cement binders.

18. The gypsum composition as claimed in claim 16 , comprising fillers in the form of sand and one or both of calcium carbonate and finely ground limestone.

19. A gypsum composition comprising
20 to 70 wt % of a mixture of calcium aluminate and calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate as hydraulic binders, where the weight ratio of calcium aluminate to calcium sulfate hemihydrate and/or anhydrite and/or calcium sulfate dihydrate binder is in the range from 1:1 to 1:3.5, and
30 to 80 wt % of fillers,
the weight figures being based in each case on the dry weight of the gypsum composition, wherein
at least 80 wt % of the total amount of calcium sulfate hemihydrate, and anhydrite and dihydrate is accounted for by the calcium sulfate hemihydrate,
the gypsum composition is composed of up to about 5 wt % cement binders, and
the cement binders comprise at least one member selected from the group consisting of Portland cements, Portland composite cements, and blast-furnace cements.

20. The gypsum composition as claimed in claim 19 , comprising fillers in the form of sand and one or both of calcium carbonate and finely ground limestone.

Assignees

• Sika Tech Ag

Inventors

• Motzet Hubert
• Börsting Wolfgang
• Knoebel Markus
• Meinersmann Thomas

Classifications

• C04B28/141 Primary

  containing dihydrated gypsum before the final hardening step, e.g. forming a dihydrated gypsum product followed by a de- and rehydration step · CPC title

• C04B28/06

  Aluminous cements (monolithic refractories or refractory mortars C04B35/66) · CPC title

• C04B2103/32

  Superplasticisers · CPC title

• C04B28/145

  Calcium sulfate hemi-hydrate with a specific crystal form · CPC title

• C04B38/10

  by using foaming agents (C04B38/02 takes precedence){or by using mechanical means, e.g. adding preformed foam} · CPC title