Alkyl sulfate / alkyl ether sulfate gypsum foamer

Patent metadata

Field	Value
Publication number	US-12180116-B2
Application number	US-202318199529-A
Country	US
Kind code	B2
Filing date	May 19, 2023
Priority date	Apr 6, 2017
Publication date	Dec 31, 2024
Grant date	Dec 31, 2024

Abstract

A surfactant composition is disclosed comprising a first alkyl sulfate surfactant, optionally a second alkyl sulfate surfactant, and optionally an alkyl ether sulfate. The first and second alkyl sulfate surfactants have Formula (1):

R 1 —OSO 3 −+ M 1   (1)

and the alkyl ether sulfate has Formula (2):

R 2 —(OCH 2 CH 2 ) y OSO 3 −+ M 2   (2)

in which R 1 and R 2 are independently selected linear or branched alkyl or a combination thereof having from 6 to 14 carbon atoms, y has an average value from 0.1 to 5, and M 1 and M 2 are cations independently selected from sodium, calcium, ammonium, or a combination of two or all of these. Use of the composition as a foaming agent for gypsum slurries, and of the gypsum slurries for formation of gypsum boards, are disclosed.

First claim

The invention claimed is:

1. A gypsum slurry comprising gypsum, water, and a surfactant composition comprising
from 97.5 to 99.5 wt. % by total surfactant weight of a linear or branched alkyl sulfate having the structure of Formula (1):
R 1 —OSO 3 −+ M 1   (1)

in which R 1 is linear or branched alkyl having from 6 to 14 carbon atoms and M 1 is a cation selected from sodium, calcium, ammonium, or a combination of two or all of these,
an average number of carbon atoms, n m , in R 1 between 9 and 10, and
the following proportions by weight of species of Formula (1):
25% to 47% in which R 1 is straight or branched C 8 H 17 ;
38% to 55% in which R 1 is straight or branched C 10 H 21 ;
12% to 20% in which R 1 is straight or branched C 12 H 25 ;

and from 0.5 to 2.5 wt. % by total surfactant weight of a linear or branched alkyl ether sulfate having the structure of Formula (2):
R 2 —(OCH 2 CH 2 ) y OSO 3 −+ M 2   (2)

in which R 2 is branched alkyl or linear alkyl or a combination thereof having from 6 to 14 carbon atoms,
y has an average value from 0.1 to 5, and
M 2 is a cation selected from sodium, calcium, ammonium, or a combination of two or all of these,
an average number of carbon atoms, n m , in R 2 between 9 and 10, and
an average value of y from 0.5 to 2.5.

2. A gypsum board comprising a core having multiple foam voids and facing sheets, the core having been formed from a gypsum slurry according to claim 1 .

Assignees

• Stepan Co
• Saint Gobain Placo

Inventors

• Mirous Brian K
• Jaffel Hamouda

Classifications

• C08K5/41

  Compounds containing sulfur bound to oxygen · CPC title

• C08K5/36

  Sulfur-, selenium-, or tellurium-containing compounds {(C08K5/0091 takes precedence)} · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• C04B40/0039 Primary

  Premixtures of ingredients · CPC title

• C04B38/106

  by adding preformed foams · CPC title