CA2478257A1 - Method and composition for polymer-reinforced composite cementitious construction material - Google Patents

Method and composition for polymer-reinforced composite cementitious construction material Download PDF

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Publication number
CA2478257A1
CA2478257A1 CA002478257A CA2478257A CA2478257A1 CA 2478257 A1 CA2478257 A1 CA 2478257A1 CA 002478257 A CA002478257 A CA 002478257A CA 2478257 A CA2478257 A CA 2478257A CA 2478257 A1 CA2478257 A1 CA 2478257A1
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CA
Canada
Prior art keywords
component
organic
wallboard
composition
matter
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002478257A
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French (fr)
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CA2478257C (en
Inventor
David S. Soane
Christopher D. Tagge
Jacob Freas Pollock
Ken Saito
Lennard F. Torres
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Saint Gobain Placo SAS
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Individual
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Priority claimed from US10/094,572 external-priority patent/US6743830B2/en
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Priority to CA2775717A priority Critical patent/CA2775717C/en
Publication of CA2478257A1 publication Critical patent/CA2478257A1/en
Application granted granted Critical
Publication of CA2478257C publication Critical patent/CA2478257C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/16—Sulfur-containing compounds
    • C04B24/161—Macromolecular compounds comprising sulfonate or sulfate groups
    • C04B24/163—Macromolecular compounds comprising sulfonate or sulfate groups obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/24—Macromolecular compounds
    • C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B24/2652—Nitrogen containing polymers, e.g. polyacrylamides, polyacrylonitriles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0066—Use of inorganic compounding ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
    • C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K9/00—Use of pretreated ingredients
    • C08K9/08—Ingredients agglomerated by treatment with a binding agent
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0045—Polymers chosen for their physico-chemical characteristics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0045—Polymers chosen for their physico-chemical characteristics
    • C04B2103/0046—Polymers chosen for their physico-chemical characteristics added as monomers or as oligomers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
    • C04B2111/00405—Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C04B2111/0062—Gypsum-paper board like materials

Abstract

A method and composition for organic-inorganic composite cementitious construction materials is described. The microstructure of the composite includes porosity. In one embodiment, a crosslinking component is mixed with a high molecular weight strengthening component and an inorganic cementitious material. The addition of the mixture to water causes a crosslinked molecular network to form within the hydrated, composite cementitious construction material. Porosity forms during drying and setting or as a result of the introduction of a stabilized foam or foaming agent. Both enhanced flexural strength and improved nail-pull resistance are shown, allowing a reduction in weight of the composite cementitious construction material compared to cementitious construction materials made according to other known methods.

Claims (58)

1. A wallboard for use in construction comprising:
porosity;
an organic strengthening component, having a high molecular weight;
a crosslinking component; and a hydrated, inorganic cementitious material, wherein the organic strengthening component is crosslinked by the crosslinking component forming a crosslinked molecular network with the hydrated, inorganic cementitious material.
2. The wallboard of Claim 1, wherein the strengthening component adheres to the hydrated, inorganic cementitious material.
3. The wallboard of Claim 1, wherein the organic strengthening component and the crosslinking component are portions of the same macromolecules.
4. The wallboard of Claim 3, wherein the macromolecules are selected from the group of macromolecules consisting of copolymers of vinyl pyrrolidone and styrene sulfonate, copolymers of vinyl caprolactam and vinyl sulfonate, copolymers of vinyl pyridine and acrylamido-2-methylpropane sulfonic acid, copolymers of acrylamide and an acrylic acid, and mixtures thereof.
5. The wallboard of Claim 1, wherein the organic strengthening component is selected from an organic strengthening component consisting of a polyacrylamide, poly(acrylamide-2-methyl-1-propane sulfonic acid), polyvinyl caprolactam), poly(2-ethyl-2-oxazoline), polyvinyl pyridine), polyvinyl imidazole), an acrylamide copolymer, a 2-ethyl-2-oxazoline copolymer, a vinyl caprolactam copolymer, a vinyl pyridine copolymer, a vinyl imidazole copolymer, and combinations thereof.
6. The wallboard of Claim 1, wherein the organic strengthening component is PVP
with a molecular weight of at least about 100,000.
7. The wallboard of Claim 6, wherein the organic crosslinking component is selected to crosslink the PVP.
8. The wallboard of Claim 7, wherein the organic crosslinking component has a molecular weight of at least about 100,000.
9. The wallboard of Claim 7, wherein the organic crosslinking component physically crosslinks the PVP by entanglement.
10. The wallboard of Claim 7, wherein the organic crosslinking component chemically crosslinks the PVP.
11. The wallboard of Claim 10, wherein the organic crosslinking component is PSS.
12. The wallboard of Claim 11, wherein the hydrated, inorganic cementitious material is one of a hydrated hemihydrate or a hydrated anhydrite.
13. The wallboard of Claim 5, wherein the organic crosslinking component is selected from the group of organic crosslinking components consisting of a poly(vinyl alcohol), a poly(acrylic acid), a copolymer of acrylic acid, a copolymer of methacrylic acid, a copolymer of styrene sulfonic acid, a copolymer containing salts of styrene sulfonic acid, a copolymer of acrylamido-2-methyl-1-propane-sulfonic acid, and mixtures thereof.
14. The wallboard of Claim 1, wherein the crosslinking component is a catalyst that initiates the formation of covalent bonds between polymer chains of the strengthening component.
15. The wallboard of Claim 7, wherein the organic crosslinking component is at least one of a polysulfonate, a polycarboxylate, or a polyphosphate.
16. The wallboard of Claim 1, wherein the hydrated inorganic cementitious material is a hydrated calcium sulfate anhydrite.
17. The wallboard of Claim 1, wherein the hydrated inorganic cementitious material is a hydrated calcium sulfate hemihydrate.
18. A composition of matter comprising porosity, a strengthening component selected from the group of strengthening components consisting of PVP, a vinyl pyrrolidone copolymer, a vinyl caprolactam copolymer, and mixtures thereof;
PSS; and a hydrated inorganic cementitious material, wherein the strengthening component is crosslinked by the PSS after mixing the strengthening component with the inorganic cementitious material, and wherein the strengthening component has a molecular weight of at least about 100,000 and PSS has a molecular weight of at least 70,000.
19. The composition of matter of Claim 18, wherein the molecular weight of strengthening component is no greater than 1.3 million.
20. A cementitious building material comprising:
porosity;
a water-dispersible organic strengthening component having a high molecular weight;
an organic crosslinking component having a molecular weight of at least 70,000, wherein the organic crosslinking component is selected to crosslink the organic strengthening component; and a hydrated, inorganic cementitious material, wherein the crosslinked organic strengthening component has an affinity for the inorganic cementitious material, wherein a crosslinked molecular network forms upon drying of the hydrated, inorganic cementitious material, wherein the crosslinked molecular network is co-continuous with the hydrated, inorganic cementitious material.
21. The cementitious building material of Claim 20, wherein the shape of the cementitious building material is in the form of a sheet.
22. The cementitious building material of Claim 21, wherein the cementitious building material is used as wallboard.
23. The cementitious building material of Claim 22, further comprising at least one layer of paper, wherein the at least one layer of paper is applied to at least one surface of the sheet.
24. The cementitious building material of Claim 22, wherein no paper is applied to the surface of the sheet.
25. The cementitious building material of Claim 24, further comprising a surface modifying additive that segregates to a stratified layer on at least one surface of the sheet.
26. The cementitious building material of Claim 25, wherein the surface modifying additive is not the same substance as either of the strengthening component or the crosslinking component.
27. The cementitious building material of Claim 26, wherein the surface modifying additive is a polyurethane dispersion.
28. A method of preparing a composite cementitious building material comprising mixing an organic strengthening component, an organic crosslinking component, and an inorganic cementitious material;
adding the mixture prepared by the step of mixing to water;
stirring the water and the mixture prepared by the step of mixing to form a slurry, wherein the organic strengthening component is crosslinked by the organic crosslinking component causing the organic strengthening component to form a gel within the slurry;
forming the slurry into a shape; and drying the slurry, whereby porosity is formed by the evaporation of water.
29. The method of Claim 28, wherein the step of forming creates a sheet having a length, a width and a thickness, wherein the thickness is much less than the length and the width of the sheet.
30. The method of Claim 29, further comprising:
applying at least one layer of paper on at least one surface of the flat sheet.
31. The method of Claim 29, further comprising:
adding at least one surface modifying addition that segregates to the surface of the flat sheet, wherein the at least one surface modifying addition forms at least one stratified layer on the surface of the flat sheet.
32. The method of Claim 31, wherein no paper is applied to the surface of the composite cementitious building material.
33. The method of Claim 31, wherein the surface modifying addition is not the same substance as either the strengthening component or the crosslinking component.
34. The method of Claim 33, wherein the surface modifying addition is a polyurethane dispersion.
35. A composition of matter comprising:
porosity;
a water-dispersible organic strengthening component with a high molecular weight, wherein the water-dispersible organic strengthening component is crosslinked by a catalytic crosslinking component; and a hydrated, inorganic cementitious material, wherein the catalytic crosslinking component crosslinked the water-dispersible organic strengthening component in situ such that the crosslinked organic strengthening component forms a network with the hydrated, inorganic cementitious material, whereby diffusion of the water-dispersible organic strengthening component to the surface of the composition of matter during drying is substantially reduced.
36. The composition of matter of Claim 35, wherein the water-dispersible organic strengthening component is poly(vinyl pyrrolidone).
37. The composition of matter of Claim 36, wherein the catalytic crosslinking component is an aqueous solution comprising hydrogen peroxide.
38. The composition of matter of Claim 37, wherein the aqueous solution further comprises copper (II) chloride.
39. A composition of matter comprising:
porosity;
poly(vinyl pyrrolidone) with a molecular weight at least about 100,000;
a crosslinking component; and an inorganic cementitious material, wherein the poly(vinyl pyrrolidone) is crosslinked by the crosslinking component in a molecularly crosslinked network with the inorganic cementitious material.
40. A molded article comprising;
porosity;
PVP having a molecular weight of at least 100,000;
PSS having a molecular weight of at least 70,000; and a hydrated inorganic cementitious material, wherein the PVP is crosslinked in situ by the PSS, and wherein the crosslinked PVP forms a crosslinked molecular network with the hydrated inorganic cementitious material.
41. A cement for use in construction, comprising:
PVP having a molecular weight of at least about 100,000;
A crosslinking component; and an inorganic cementitious material, wherein the crosslinking component is selected to crosslink the PVP when mixed with water and mixing water in excess of the amount required to hydrate the inorganic cementitious material produces porosity upon drying.
42. The cement of claim 41, wherein the crosslinking component is selected to be temperature sensitive, wherein the reaction leading to crosslinking of the PVP
occurs within a desired temperature range.
43. A concrete incorporating the cement of claim 41.
44. A joint compound incorporating the composition of matter of claim 18.
45. An adhesive incorporating the composition of matter of claim 18.
46. The wallboard of Claim 11, wherein the hydrated, inorganic cementitious material is hydrated calcium sulfate anhydrite.
47. The composition of matter of Claim 18, wherein the strengthening component is PVP.
48. The composition of matter of Claim 18, wherein the strengthening component is a vinyl pyrrolidone copolymer.
49. The composition of matter of Claim 18, wherein the strengthening component is a vinyl caprolactam copolymer.
50. The wallboard of Claim 1, wherein the core has a reduced density by addition of porosity.
51. A composition of matter for use in wallboard, comprising:
an organic binder that is polymerized in situ, wherein the polymerization reaction comprises at least one polymer forming material that is hydrophobic;
a foaming agent; and a plurality of inorganic particles coated by the organic binder, wherein the foaming agent forms porosity in the wallboard.
52. The composition of matter of claim 51, wherein the foaming agent comprises a surfactant stabilized aqueous solution.
53. The composition of matter of claim 51, wherein the foaming agent is a blowing agent.
54. A composition of matter for use in wallboard, comprising:
an organic binder that is polymerized in situ, wherein the polymerization reaction includes a plurality of polymer forming materials and at least one of the plurality of polymer forming materials is hydrophobic, and the polymerization reaction produces an expansion by decomposition of at least one of the plurality of polymer forming materials producing a gas phase; and a plurality of inorganic particles are coated by the organic binder and the gas phase forms porosity within the wallboard.
55. The composition of matter of claim 54, wherein one of the plurality of the organic binder comprises both hydrophobic and hydrophilic moieties.
56. The composition of matter of claim 54, wherein at least one of the plurality of polymer forming materials is a preexisting polymer.
57. The composition of matter of claim 54, wherein at least one of the plurality of polymer forming materials is a monomer.
58. The composition of matter of claim 54, wherein at least one of the plurality of polymer forming materials is selected from the group consisting of epoxies, polyurethanes, polyesters, polyketones/diamines and poly(maleic anhydride alt-octadecene)/diamenes.
CA2478257A 2002-03-07 2003-03-04 Method and composition for polymer-reinforced composite cementitious construction material Expired - Lifetime CA2478257C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2775717A CA2775717C (en) 2002-03-07 2003-03-04 Method and composition for polymer-reinforced composite cementitious construction material

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US10/094,572 2002-03-07
US10/094,572 US6743830B2 (en) 2001-03-07 2002-03-07 Construction board materials with engineered microstructures
US10/278,214 2002-10-21
US10/278,214 US7105587B2 (en) 2001-03-07 2002-10-21 Method and composition for polymer-reinforced composite cementitious construction material
PCT/US2003/006914 WO2003076502A1 (en) 2002-03-07 2003-03-04 Method and composition for polymer-reinforced composite cementitious construction material

Related Child Applications (1)

Application Number Title Priority Date Filing Date
CA2775717A Division CA2775717C (en) 2002-03-07 2003-03-04 Method and composition for polymer-reinforced composite cementitious construction material

Publications (2)

Publication Number Publication Date
CA2478257A1 true CA2478257A1 (en) 2003-09-18
CA2478257C CA2478257C (en) 2012-07-10

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US (1) US7105587B2 (en)
EP (1) EP1481022B1 (en)
CN (1) CN1305945C (en)
AT (1) ATE457964T1 (en)
AU (1) AU2003216545A1 (en)
CA (1) CA2478257C (en)
DE (1) DE60331293D1 (en)
HK (1) HK1071388A1 (en)
MX (1) MXPA04008632A (en)
WO (1) WO2003076502A1 (en)

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WO2003076502A1 (en) 2003-09-18
CN1305945C (en) 2007-03-21
CN1646612A (en) 2005-07-27
US20030092784A1 (en) 2003-05-15
ATE457964T1 (en) 2010-03-15
EP1481022A4 (en) 2006-09-06
EP1481022A1 (en) 2004-12-01
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AU2003216545A1 (en) 2003-09-22
HK1071388A1 (en) 2005-07-15

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