Bubble-containing gypsum slurry

Patent metadata

Field	Value
Publication number	US-2024417323-A1
Application number	US-202318706174-A
Country	US
Kind code	A1
Filing date	Mar 13, 2023
Priority date	Mar 24, 2022
Publication date	Dec 19, 2024
Grant date	—

Abstract

Provided are a bubble-containing gypsum slurry and a method for producing the same, whereby, in bubble-containing gypsum slurries of the same specific gravity, a bubble size in the gypsum slurry can be increased with a small amount of a foaming component.
A bubble-containing gypsum slurry containing, a hydraulic powder containing gypsum, water, the following component (A1), optionally the following component (A2), and the following component (B),
component (A1): an alkyl or alkenyl sulfate or a salt thereof, component (A2): one or more selected from surfactants other than component (A1), and component (B): a nonionic compound with a Log P of 0 or more and 3.0 or less, wherein a mass ratio of a content of component (B) to a total content of components (A1) and (A2), (B)/[(A1)+(A2)], is 0.05 or more and 0.5 or less.

First claim

1 : A bubble-containing gypsum slurry, comprising:
a hydraulic powder comprising gypsum; water; a component (A1); optionally a component (A2); and a component (B); wherein: the component (A1) is an alkyl or alkenyl sulfate or a salt thereof; the component (A2) is a surfactant other than the component (A1); the component (B) is a nonionic compound with a Log P of 0 or more and 3.0 or less; and a mass ratio of the component (B) to a total of the components (A1) and (A2) in the slurry, (B)/[(A1)+(A2)], is 0.05.

2 : The bubble-containing gypsum slurry according to claim 1 , wherein a content of gypsum in the hydraulic powder is 80 mass % or more.

3 : The bubble-containing gypsum slurry according to claim 1 , wherein the component (A1) comprises an alkyl or alkenyl sulfate or a salt thereof having an alkyl group or an alkenyl group with 6 to 10 carbons, and an alkyl or alkenyl sulfate or a salt thereof having an alkyl group or an alkenyl group with 11 to 22 carbons.

4 : The bubble-containing gypsum slurry according to claim 1 , wherein a mass ratio of the component (A1) to the components (A1) and (A2) in the slurry, (A1)/[(A1)+(A2)], is 0.6 to 1.

5 : The bubble-containing gypsum slurry according to claim 1 , wherein a content of an alkyl or alkenyl sulfate or a salt thereof having an alkyl group or an alkenyl group with 10 carbons in the component (A1) is 60 mass % or more.

6 : The bubble-containing gypsum slurry according to claim 1 , wherein the nonionic compound of the component (B) is one or more selected from the group consisting of an alcohol, a glycol ether, and an aldehyde.

7 : The bubble-containing gypsum slurry according to claim 1 , wherein the hydraulic powder is free of a clinker ground product.

8 : The bubble-containing gypsum slurry according to claim 1 , wherein an average bubble size of a hardened product of the bubble-containing gypsum slurry is 300 to 800 μm.

9 : A method for producing a bubble-containing gypsum slurry, comprising:
foaming a liquid composition comprising a foaming agent composition for hydraulic compositions and water to obtain a foam; and mixing the obtained foam with a gypsum slurry to obtain the bubble-containing gypsum slurry; wherein: the liquid composition comprises:
a component (A1),
optionally a component (A2),
a component (B), and
water;
component (A1) is an alkyl or alkenyl sulfate or a salt thereof; component (A2) is a surfactant other than the component (A1); component (B) is a nonionic compound with a Log P of 0 or more and 3.0 or less; a mass ratio of the component (B) to the components (A1) and (A2) in the liquid composition, (B)/[(A1)+(A2)], is 0.05 to 0.5; and the gypsum slurry comprises a hydraulic powder comprising gypsum and water.

10 : The method for producing a bubble-containing gypsum slurry according to claim 9 , wherein a content of gypsum in the hydraulic powder is 80 mass % or more.

11 : The method for producing a bubble-containing gypsum slurry according to claim 9 , wherein the component (A1) comprises an alkyl or alkenyl sulfate or a salt thereof having an alkyl group or an alkenyl group with 6 to 10 carbons, and an alkyl or alkenyl sulfate or a salt thereof having an alkyl group or an alkenyl group with 11 to 22 carbons.

12 : A method for producing a gypsum board, comprising:
performing the method for producing a bubble-containing gypsum slurry according to claim 9 ; and molding and hardening the obtained bubble-containing gypsum slurry.

13 : A hardened product of a bubble-containing gypsum slurry formed by hardening the bubble-containing gypsum slurry according to claim 1 , wherein an average bubble size of the hardened product is 200 to 800 μm.

14 . (canceled)

15 : The bubble-containing gypsum slurry according to claim 1 , wherein the nonionic compound of the component (B) is one or more selected from the group consisting of a monohydric alcohol, a glycol ether having a hydrocarbon group with 7 or less carbons, and an aldehyde.

16 : The bubble-containing gypsum slurry according to claim 1 , wherein the nonionic compound of the component (B) is one or more selected from the group consisting of hexanol, octanol, 1-butanol, benzyl alcohol, benzaldehyde, diethylene glycol monobutyl ether, and cyclohexanol.

17 : The bubble-containing gypsum slurry according to claim 1 , wherein a water/hydraulic powder ratio in the slurry is 20 to 100 mass %.

18 : The bubble-containing gypsum slurry according to claim 1 , comprising the component (A1) in an amount of 0.001 to 0.1 parts by mass relative to 100 parts by mass of the hydraulic powder.

19 : The bubble-containing gypsum slurry according to claim 1 , comprising the component (B) in an amount of 0.00025 to 0.025 parts by mass relative to 100 parts by mass of the hydraulic powder.

20 : The bubble-containing gypsum slurry according to claim 1 , wherein a specific gravity of a hardened product of the bubble-containing gypsum slurry is 0.3 to 0.9.

21 : The hardened product of a bubble-containing gypsum slurry according to claim 13 , wherein a specific gravity of the hardened product is 0.3 to 0.9.

Assignees

• Kao Corp

Inventors

• TAMAGAWA Ojiro
• Nakano Tatsuya
• Tanimoto Ryu

Classifications

• C04B2103/304

  Air-entrainers · CPC title

• C04B2111/40

  Porous or lightweight materials · CPC title

• C04B2103/406

  non-ionic · CPC title

• C04B38/10 Primary

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

• C04B40/0032

  Controlling the process of mixing, e.g. adding ingredients in a quantity depending on a measured or desired value (B28C7/00 takes precedence) · CPC title