Struvite-K and Syngenite Composition for Use in Building Materials

Patent metadata

Field	Value
Publication number	US-2016236979-A1
Application number	US-201415028372-A
Country	US
Kind code	A1
Filing date	Oct 14, 2014
Priority date	Aug 12, 2013
Publication date	Aug 18, 2016
Grant date	—

Abstract

A composition and process for manufacture thereof used in hybrid inventive building materials comprising Syngenite (K 2 Ca(SO 4 ) 2 .H 2 O) and Struvite-K (KMgPO 4 .6H 2 O). Starting constituents include magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate), mixed in predetermined ratios, cause reactions to proceed through multiple phases, which reactions variously are proceeding simultaneously and in parallel. Variables, e.g., water temperature, pH, mixing times and rates, have been found to affect resultant reaction products. Preferred ratios of chemical constituents and manufacturing parameters, including predetermined weight percent and specified ratios of Struvite-K and Syngenite are provided for building products used for specified purposes. Reactions are optimized in stoichiometry and additives to reduce the combined heat of formation to non-destructive levels. Various additives help control and guide reactions. Building products, such as board panels, include the resultant composition. A significant amount of the composition is disposed adjacent a building panel face.

First claim

1 . A process for the continuous manufacture of a building product composition for use in a building product comprising:
a) providing a mixer reaction chamber; b) continuously feeding predetermined constituent materials into the mixer reaction chamber; c) continuously mixing the predetermined constituent materials within said mixing reaction chamber for a length of time sufficient to produce a slurry; d) withdrawing the slurry from the mixer reaction chamber; and e) utilizing said slurry in the manufacture of a lightweight building product;
wherein said predetermined solid constituent materials comprise the following in specified ranges by weight percent:
MgO 3.33 to 70.00%
KH 2 PO 4 : 4.67 to 70.00%
stucco hemihydrate CaSO 4 .1/2H 2 O: 10.5 to 90.0%
and addition of water: 15 to 60% of the constituent solid materials.

2 . The process for the continuous manufacture of a composition according to claim 1 wherein the specified ranges of said predetermined solid constituent materials further comprise:
MgO: 10.0 to 40.0%
KH 2 PO 4 : 40.0 to 70.00%
stucco hemihydrate CaSO 4 .1/2H 2 O: 25.0 to 75.0% and including an amount of 15 to 60% by weight of liquid constituent products relative to the solid constituents.

3 . The process for the continuous manufacture of a composition according to claim 1 wherein the specified ranges of said predetermined solid constituent materials further comprise a ratio of the MgO to the KH 2 PO 4 between 1:1.0 and 1:3.37.

4 . The process for the continuous manufacture of a composition according to claim 3 wherein the specified ranges of said predetermined solid constituent materials further comprise a ratio of MgO to KH 2 PO 4 between 1:1.8 and 1:2.2.

5 . The process for the continuous manufacture of a composition according to claim 1 , wherein the predetermined constituent materials include a buffer, and the buffer further comprises a rate retarding compound, the rate retarding compound being selected from one or more of the group of compounds consisting of boric acid (H 3 BO 3 ) and sulfuric acid (H 2 SO 4 ).

6 . The process for the continuous manufacture of a composition according to claim 5 wherein the predetermined constituent materials further comprises a defoamer, a dispersant and a silicone oil selected from the group consisting of polysiloxane (C 2 H 6 OSi) n , polydimethylsiloxane (CH 3 [Si(CH 3 ) 2 O] n Si(CH 3 ) 3 ), polydimethylsiloxane and poly(methyl hydrogen) siloxane and
wherein the dispersant further comprises polynapthalene sulfonate.

7 . The process according to claim 1 wherein the constituent materials are reacted within the reaction mixer according to the following mechanism:
MgO+KH 2 PO 4 +CaSO 4 .1/2H 2 O to produce in varying predetermined amounts the reactant products: KMgPO 4 .6H 2 O and K 2 Ca(SO 4 ) 2 .H 2 O.

8 . The process according to claim 1 wherein the constituent materials are reacted within the reaction mixer according to the following equation:
3MgO+3KH 2 PO 4 +2CaSO 4 .1/2H 2 O+3H 2 O→KMgPO 4 .6H 2 O+K 2 Ca(SO 4 ) 2 .H 2 O+Ca +2 +2Mg +2 +2(PO 4 ) −3

wherein the reaction occurs in the presence of one or more of the compounds selected from a group consisting of sulfuric acid, boric acid, siloxanes and naphthalene sulfonate.

9 . A lightweight building board panel for use in constructing a building utilizing at least a building product composition produced from the process of one of claim 1 , and wherein said composition is disposed adjacent at least one of the faces of the board panel.

10 . A building composition for use in a building product comprising Struvite-K (KMgPO 4 .6H 2 O), Syngenite (K 2 Ca(SO 4 ) 2 .H 2 O) and one or more of anhydrite gypsum, stucco (CaSO 4 .1/2H 2 O) and hydrated gypsum (CaSO 4 .2H 2 O),wherein the composition is used for producing a building material having light weight, increased strength, fire resistance and integrity.

11 . The building composition for use in a building product according to claim 10 , wherein the resultant reaction products are in the following ranges:
KMgPO 4 .6H 2 O: of from 0.1 to 67.0 weight percent; K 2 Ca(SO 4 ) 2 .H 2 O: of from 2.5 to 60.0 weight percent; and amorphous phase products and unreacted raw materials making up the remaining product.

12 . The building composition for use in a building product according to claim 11 , wherein the resultant reaction products are in the following ranges:
KMgPO 4 .6H 2 O: of from 15.1 to 37.0 weight percent; and K 2 Ca(SO 4 ) 2 .H 2 O: of from 12.5 to 46.0 weight percent; and amorphous phase products and unreacted raw constituents making up the remaining product.

13 . A building board panel for use in constructing a wall in a building wherein at least one of the compositions recited in claim 10 is disposed adjacent at least one of the faces of the board panel.

14 . A building board panel for use in building construction in which at least one of the faces comprises a composition comprising Struvite-K (KMgPO 4 .6H 2 O), Syngenite (K 2 Ca(SO 4 ) 2 .H 2 O) and gypsum.

15 . The board panel for use in building construction according to claim 13 , wherein the amount of Struvite-K (KMgPO 4 .6H 2 O) and Syngenite (K 2 Ca(SO 4 ) 2 .H 2 O) comprising the face material exceeds 10 weight percent.

16 . The board panel for use in building construction according claim 14 , wherein the amount of Struvite-K (KMgPO 4 .6H 2 O) and Syngenite (K 2 Ca(SO 4 ) 2 .H 2 O) comprising the face material exceeds 10 weight percent.

17 . A building board panel for use in constructing a wall in a building wherein at least one of the compositions recited in claim 11 is disposed adjacent at least one of the faces of the board panel.

18 . A building board panel for use in constructing a wall in a building wherein at least one of the compositions recited in claim 12 is disposed adjacent at least one of the faces of the board panel.

Assignees

• Certain Teed Gypsum Inc
• Certainteed Gypsum Inc

Inventors

• Hauber Robert J
• Boydston Gerald D
• Frailey Nathan
• Lamberet Severine
• Pattarkine Gaurav V
• Cherian Isaac K
• Centurione Sergio
• Ghosh Anirban

Classifications

• C04B12/025

  Phosphates of ammonium or of the alkali or alkaline earth metals · CPC title

• C04B12/027

  mixtures thereof with other inorganic cementitious materials · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• C04B24/42

  Organo-silicon compounds · CPC title

• C04B22/141

  Acids · CPC title