CA2494935A1 - Dispersant and foaming agent comprising naphthalene sulfonate and aldehyde condensate - Google Patents

Dispersant and foaming agent comprising naphthalene sulfonate and aldehyde condensate Download PDF

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Publication number
CA2494935A1
CA2494935A1 CA002494935A CA2494935A CA2494935A1 CA 2494935 A1 CA2494935 A1 CA 2494935A1 CA 002494935 A CA002494935 A CA 002494935A CA 2494935 A CA2494935 A CA 2494935A CA 2494935 A1 CA2494935 A1 CA 2494935A1
Authority
CA
Canada
Prior art keywords
dispersant
foaming agent
naphthalene sulfonate
gypsum wallboard
alkali salt
Prior art date
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
CA002494935A
Other languages
French (fr)
Other versions
CA2494935C (en
Inventor
Arpad Savoly
Dawn P. Elko
Bennie Veal
James Mccrary
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Geo Specialty Chemicals Inc
Original Assignee
Individual
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to CA2676721A priority Critical patent/CA2676721C/en
Publication of CA2494935A1 publication Critical patent/CA2494935A1/en
Application granted granted Critical
Publication of CA2494935C publication Critical patent/CA2494935C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • 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
    • C04B24/20—Sulfonated aromatic compounds
    • C04B24/22—Condensation or polymerisation products thereof
    • C04B24/226—Sulfonated naphtalene-formaldehyde condensation products
    • 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
    • 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
    • C04B2103/40—Surface-active agents, dispersants
    • C04B2103/408—Dispersants
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S516/00—Colloid systems and wetting agents; subcombinations thereof; processes of
    • Y10S516/905—Agent composition per se for colloid system making or stabilizing, e.g. foaming, emulsifying, dispersing, or gelling
    • Y10S516/909—The agent contains organic compound containing sulfoxy*

Abstract

The present invention provides a dispersant and foaming agent combination that is useful in the production of gypsum wallboard and other aqueous cementitious products, a method of forming a gypsum wallboard and a gypsum wallboard. The dispersant in the combination according to the invention is a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight of from about 17,000 to about 47,000. The alkali is preferably an alkali metal and/or an alkaline earth metal. The aldehyde is preferably formaldehyde. The foaming agent used in the combination according to the invention is a soap, preferably an alkali salt of an alkyl ether sulfate and/or an alkyl sulfate. The combination of a high molecular weight dispersant and a foaming agent produces a gypsum wallboard core effect that more efficiently entrains air (i.e., creates void space), thereby lowering overall board weight without detrimentally affecting strength. A gypsum wallboard formed using the dispersant and foaming agent combination according to the invention exhibits a higher nail pull value than gypsum wallboard formed using a conventional dispersant and a foaming agent at the same solids loading ratio.

Claims (14)

1. A dispersant and foaming agent combination for use in the production of gypsum wallboard comprising:
a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight from about 17,000 to about 47,000; and a soap.
2. The dispersant and foaming agent combination according to claim 1 wherein the aldehyde in the naphthalene sulfonate-aldehyde condensate alkali salt polymer is selected from the group consisting of formaldehyde, paraformaldehyde, and gluteraldehyde.
3. The dispersant and foaming agent combination according to claim 1 wherein the soap comprises an alkyl sulfate and/or an alkyl ether sulfate.
4. The dispersant and foaming agent combination according to claim 1 wherein the aldehyde in the naphthalene sulfonate-aldehyde condensate alkali salt polymer is formaldehyde and the soap comprises a mixture of an alkyl sulfate and an alkyl ether sulfate.
5. The dispersant and foaming agent combination according to claim 4 wherein the naphthalene sulfonate-aldehyde condensate alkali salt polymer is a sodium salt.
6. The dispersant and foaming agent combination according to claim 4 wherein the naphthalene sulfonate-aldehyde condensate alkali salt polymer is a calcium salt.
7. A method of fabricating a gypsum wallboard comprising:
forming an aqueous slurry comprising:
calcined gypsum;
a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight from about 17,000 to about 47,000; and a soap;
molding the aqueous slurry into a sheet;
allowing calcined gypsum to rehydrate; and removing excess water from the sheet to form a hardened wallboard.
8. The method of fabricating a gypsum wallboard according to claim 7 wherein the aldehyde in the naphthalene sulfonate-aldehyde condensate alkali salt polymer is selected from the group consisting of formaldehyde, paraformaldehyde, and gluteraldehyde.
9. The method of fabricating a gypsum wallboard according to claim 7 wherein the soap comprises an alkyl sulfate and/or an alkyl ether sulfate.
10. The method of fabricating a gypsum wallboard according to claim 7 wherein the aldehyde in the naphthalene sulfonate-aldehyde condensate alkali salt polymer is formaldehyde and the soap comprises a mixture of an alkyl sulfate and an alkyl ether sulfate.
11. The method of fabricating a gypsum wallboard according to claim 10 wherein the naphthalene sulfonate-aldehyde condensate alkali salt polymer is a sodium salt.
12. The method of fabricating a gypsum wallboard according to claim 10 wherein the naphthalene sulfonate-aldehyde condensate alkali salt polymer is a calcium salt.
13. A wallboard comprising a hardened gypsum-containing core having a layer of paper disposed thereon, wherein the paper has a maximum weight about 35 pounds per thousand square feet and the wallboard has an overall weight rating of less than about 1,500 pounds per thousand square feet based upon a one-half inch board thickness and a nail pull resistance of at least about 77 pounds based upon a one-half inch board thickness as measured in accordance with the ASTM C473-00.
14. A dispersant for use in the production of gypsum wallboard comprising a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight from about 17,000 to about 47,000.
CA002494935A 2002-08-07 2003-07-18 Dispersant and foaming agent comprising naphthalene sulfonate and aldehyde condensate Expired - Lifetime CA2494935C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2676721A CA2676721C (en) 2002-08-07 2003-07-18 Dispersant and foaming agent comprising naphthalene sulfonate and aldehyde condensate

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/214,467 2002-08-07
US10/214,467 US6774146B2 (en) 2002-08-07 2002-08-07 Dispersant and foaming agent combination
PCT/US2003/022391 WO2004014531A1 (en) 2002-08-07 2003-07-18 Dispersant and foaming agent combination

Related Child Applications (1)

Application Number Title Priority Date Filing Date
CA2676721A Division CA2676721C (en) 2002-08-07 2003-07-18 Dispersant and foaming agent comprising naphthalene sulfonate and aldehyde condensate

Publications (2)

Publication Number Publication Date
CA2494935A1 true CA2494935A1 (en) 2004-02-19
CA2494935C CA2494935C (en) 2009-11-24

Family

ID=31494656

Family Applications (2)

Application Number Title Priority Date Filing Date
CA002494935A Expired - Lifetime CA2494935C (en) 2002-08-07 2003-07-18 Dispersant and foaming agent comprising naphthalene sulfonate and aldehyde condensate
CA2676721A Expired - Lifetime CA2676721C (en) 2002-08-07 2003-07-18 Dispersant and foaming agent comprising naphthalene sulfonate and aldehyde condensate

Family Applications After (1)

Application Number Title Priority Date Filing Date
CA2676721A Expired - Lifetime CA2676721C (en) 2002-08-07 2003-07-18 Dispersant and foaming agent comprising naphthalene sulfonate and aldehyde condensate

Country Status (5)

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US (3) US6774146B2 (en)
EP (1) EP1534413B1 (en)
AU (1) AU2003261182A1 (en)
CA (2) CA2494935C (en)
WO (1) WO2004014531A1 (en)

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CA2494935C (en) 2009-11-24
CA2676721C (en) 2010-05-04
EP1534413A1 (en) 2005-06-01
CA2676721A1 (en) 2004-02-19
US20040091751A1 (en) 2004-05-13
US6929875B2 (en) 2005-08-16
EP1534413A4 (en) 2010-07-21
WO2004014531A1 (en) 2004-02-19
US20040092676A1 (en) 2004-05-13
US20040028956A1 (en) 2004-02-12
AU2003261182A1 (en) 2004-02-25
EP1534413B1 (en) 2014-12-03
US6774146B2 (en) 2004-08-10

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