CN102991013A - 耐水性水泥制品及其制造方法 - Google Patents

耐水性水泥制品及其制造方法 Download PDF

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CN102991013A
CN102991013A CN2012103555046A CN201210355504A CN102991013A CN 102991013 A CN102991013 A CN 102991013A CN 2012103555046 A CN2012103555046 A CN 2012103555046A CN 201210355504 A CN201210355504 A CN 201210355504A CN 102991013 A CN102991013 A CN 102991013A
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fibrofelt
cement
slurry
cement slurry
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CN102991013B (zh
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迪克·C·恩布雷希特
刘清侠
迈克尔·P·沙克
王旭明
大卫·保罗·米勒
迈克尔·L·博林德
保罗·里德
唐纳德·L·罗埃夫斯
拉斐尔·布里
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United States Gypsum Co
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    • 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
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    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • 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
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    • 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
    • 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
    • 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
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/27—Water resistance, i.e. waterproof or water-repellent 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
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    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2164—Coating or impregnation specified as water repellent

Abstract

本发明涉及耐水性水泥制品及其制造方法。具体地，本发明涉及一种纤维毡面水泥制品，包括：(a)水泥芯；和(b)包括聚合物或矿物纤维以及在其至少一个表面上的疏水性涂层的第一纤维毡，其中疏水性涂层与水泥芯接触。本发明还具体涉及一种制造纤维毡面水泥制品的方法，以及一种制造耐水性水泥制品的方法，包括：(a)制备硅氧烷水分散液，其中该分散液包括约4wt％～约8wt％的硅氧烷；(b)将硅氧烷分散液与水泥混合物混合以提供水泥浆料；(c)将水泥浆料沉积在基材上；和(d)使水泥浆料固化，由此提供水泥制品。

Description

耐水性水泥制品及其制造方法
本申请是申请日为2008年2月7日、申请号为200880004796.0、发明名称为
“耐水性水泥制品及其制造方法”的发明专利申请的分案申请。
对相关申请的交叉引用
本申请要求2007年4月20日提交的美国专利申请11/738316和20075年2月12日提交的美国临时专利申请60/889487的权益，其全部公开内容通过引用合并于此。
背景技术
诸如石膏板和水泥板等水泥制品用于各种应用中，其中一些要求一定程度的耐水性。传统的纸面水泥制品在高湿条件下或暴露在室外时，性能并不是一直很好。由此，对于这种应用，通常理想的是使用玻璃或聚合物类纤维毡代替纸来覆面的水泥制品。在水泥芯中使用改善芯材料自身耐水性的添加剂也是有利的。
诸如石膏板和水泥板等水泥制品的制造工艺通常包括将水泥浆料沉积在第一覆面材料上，并用相同类型的第二覆面材料覆盖湿浆料，使得水泥浆料夹在两层覆面材料之间。之后，干燥除去浆料中多余的水。在最终干燥之前，使水泥浆料固化以制造固体制品。
因此，水泥制品的制造工艺通常要求覆面材料具有充分的渗透性，以便在干燥工艺中能够从水泥浆料中除去多余的水。例如，无纺纤维玻璃毡经常用作覆面材料，其中纤维之间的空间提供渗透性。然而，纤维覆面材料的渗透性使制造工艺更难，这是因为沉积在纤维毡覆面材料上的水泥浆料易于渗透毡而在网架和装配线上产生浆料堆积。浆料堆积必须定期处理。增加浆料的粘度可减少渗透过纤维毡覆面材料的浆料量，但由于例如在混合、沉淀、干燥或固化特性上的变化，所需的高粘度并不总是最适于现有工厂生产工艺。
此外，纤维毡覆面材料的渗透性也降低水泥制品的耐水性，因为在使用期间，水可渗入毡并与水泥芯接触。为了缓减此问题，有时涂布疏水性树脂外部涂层。但是，这通常需要实施额外的后加工步骤，增加成本且不方便。
另一种方法是通过在水泥浆料中包含疏水性添加剂以进一步提高水泥芯材料的耐水性。用于此目的的优选添加剂为硅氧烷油。然而，使用这种添加剂的方法需要在其实施和效率上进一步改善。
由此，仍需要一种新的耐水性水泥制品，以及制备这种制品的方法。
发明内容
在一个方面，本发明提供一种纤维毡面水泥制品，包括：(a)水泥芯；和(b)包括聚合物或矿物纤维以及在其至少一个表面上的疏水性涂层的第一纤维毡，其中疏水性涂层与水泥芯接触。
在另一个方面，本发明提供一种制造纤维毡面水泥制品的方法，包括：(a)将水泥浆料沉积在包括聚合物或矿物纤维及其至少一个表面上的疏水性涂层的第一纤维毡上，其中水泥浆料沉积在疏水性涂层上；和(b)使水泥浆料固化，由此提供纤维毡面水泥制品。
在又一个方面，本发明提供一种制造耐水性水泥制品的方法，包括：(a)制备在水中包括约4wt％～约8wt％硅氧烷的硅氧烷水分散液；(b)将硅氧烷分散液与水泥混合物混合以提供水泥浆料；(c)将水泥浆料沉积在基材上；和(d)使水泥浆料固化，由此提供水泥制品。
由此处提供的本发明的说明书，本发明的这些和其它优点以及其它发明性特征将是显而易见的。
具体实施方式
根据本发明，纤维毡面水泥制品的实施方式包括(a)水泥芯和(b)包括聚合物或矿物纤维以及在其至少一个表面上的疏水性涂层的第一纤维毡，其中疏水性涂层与水泥芯接触。理想地，疏水性涂层在加工过程中防止制品的水泥芯以任何实际程度渗入第一纤维毡。
第一纤维毡包括任何适宜类型的聚合物或矿物纤维或者它们的组合。适宜纤维的非限制性实例包括玻璃纤维、聚酰胺纤维、芳族聚酰胺纤维、聚丙烯纤维、聚酯纤维(例如聚对苯二甲酸乙二醇酯(PET)、聚乙烯醇(PVOH)、聚乙酸乙烯酯(PVAc)、纤维素纤维(例如棉花、人造纤维等)等)以及它们的组合。此外，毡的纤维可为疏水或亲水的、涂敷或未涂敷的。当然，纤维的选择部分取决于将使用水泥制品的应用类型。例如，当水泥制品用于需要耐热或耐火的应用时，在纤维毡内应使用适当的耐热或耐火纤维。
第一纤维毡可为纺织的或无纺的，但优选无纺毡。无纺毡包括用粘结剂粘结在一起的纤维。粘结剂可为通常用于毡工业中的任何粘结剂。适宜的粘结剂包括但不限于，脲甲醛、三聚氰胺甲醛、硬脂酸化三聚氰胺甲醛、聚酯、丙烯酸树脂、聚乙酸乙烯酯、用聚乙酸乙烯酯或丙烯酸、苯乙烯丙烯酸聚合物改性或共混的脲甲醛或三聚氰胺甲醛以及它们的组合。适宜的纤维毡包括可购得的用作水泥制品覆面材料的毡。
水泥制品的第一纤维毡包括在其至少一个表面上的疏水性涂层，该疏水性涂层与水泥芯接触。可使用任何疏水性涂层材料。优选地，疏水性涂层提供具有疏水度的表面，使得涂到该表面上的水呈现约70°或更大的接触角，例如约70°～约130°，或者呈现约90°或更大的接触角，例如约90°～约120°。接触角可用任何适当技术测定。
适宜的疏水性涂层材料的实例包括但不限于以下组合物，其包括，或其必要组成为，或其组成为滑石、蜡、硅类化合物(例如硅烷或硅氧烷)、疏水性树脂、脂肪酸(例如油酸)及其盐(例如多价盐)、聚乙二醇(PEG)以及长链烃和氟碳表面活性剂(例如具有12个或更多个碳原子)以及它们的组合。
涂层材料可用本领域已知的任何方法以液体或固体材料(例如树脂、湿分散粉末、干粉末或膜)涂到第一纤维毡上。例如，疏水性涂层材料可通过刷涂、喷涂、辊涂、浇注、浸渍、筛撒或覆涂疏水性涂层材料进行涂布。诸如粉末等固体材料在涂布之前可用任何常用溶剂(例如水、醇等)或分散剂分散，只要溶剂或分散剂与纤维毡材料不发生反作用。还可使用腐蚀纤维毡的表面纤维并由此增强涂层材料粘附到毡的能力的溶剂。优选地，所用任何溶剂或分散剂都易干且不会留下阻碍涂层粘附到纤维毡上的残留物。液体或分散的涂层材料可具有适合涂布到纤维毡的任何粘度。通常，液体或分散的涂层材料的粘度可为约50～200克雷布斯单位(KU)(约300～20000cP)，例如约80～150克雷布斯单位(KU)(约800～8000cP)。
考虑到，纤维毡的表面为不规则表面，涂层材料不需要提供完全连续的涂层。例如，当使用液体或粉末涂层组合物时，涂层材料会落入毡的纤维之间的空隙中，在涂层中留下间隙或孔隙。然而，优选以足够量涂布涂层材料以提供连续且理想地与第一纤维毡的尺寸共同扩张的涂层。
涂布第一纤维毡的疏水性涂层优选为层的形式。该层理想地足够厚，以使得在生产过程能减缓或防止水泥浆料渗透过第一纤维毡。不希望受任何具体理论的限制，确信与不含疏水层和/或物理阻塞纤维毡孔隙的纤维毡相比，由于疏水层上水泥浆料的表面张力减小，疏水层能够减缓或阻止浆料渗透。通常，涂层将在毡(和任何用于粘结毡纤维的树脂粘结剂)上提供层，该层的平均厚度为至少约25微米(例如至少约25～约500微米)、至少约100微米(例如至少约100～约500微米或约200～约400微米)，或至少约200微米(例如约200～约500微米或约200～约400微米)，或者甚至至少约300微米(例如约300～约500微米或约300～约400微米)。
根据本发明的优选方面，第一纤维毡并非充分嵌入水泥芯内。优选地，将小于约50％的毡厚嵌入水泥芯内，更优选将小于约30％、小于约15％、小于约10％，或者甚至是小于约2％(例如小于约1％)的毡厚嵌入水泥芯内。不希望受任何具体理论的限制，确信第一纤维毡的疏水性涂层在生产过程中至少在某种程度上防止第一纤维毡嵌入到水泥芯中。在本发明相关且优选的方面，至少一部分水泥芯粘附到疏水性涂层上。
应理解的是，第一纤维毡具有两个覆面表面：面向外的表面和面向水泥芯的表面。根据本发明，面向水泥芯的第一纤维毡的表面包括疏水性涂层。面向外的表面不需要包括疏水性涂层。然而，根据本发明的一个实施方式，纤维毡面向外的表面也可包括在此说明的疏水性涂层。或者，面向外的表面可用本领域公知的任何方法进行其它处理，或者可保持未处理。
水泥制品可选择地包括含有聚合物或矿物纤维的第二纤维毡，其中水泥芯放置在第一纤维毡和第二纤维毡之间。第二纤维毡可与第一纤维毡相同或不同。此外，第二纤维毡可包括在此说明的疏水性涂层，或者可不含这种涂层。当水泥制品为板或盘(例如石膏板、水泥板等)的形式时，第二纤维毡优选在材料和相对于水泥芯的取向上都与第一纤维毡相同，或者具有与第一纤维毡十分相似的膨胀和收缩性能，由此减少或消除水泥制品的翘曲。当第二纤维毡与第一纤维毡相同时，应理解的是，第一和第二纤维毡可通过连续的单片材料来提供，例如通过折叠单片纤维毡以使其包裹在水泥芯的周围。
水泥芯可包括任何材料、物质、或者包含或来自水凝水泥的组合物以及任何适宜的添加剂。可用于水泥芯的材料的非限制性实例包括波特兰水泥、栗色水泥(sorrel cement)、矿渣水泥、粉煤灰水泥、铝酸钙水泥、水溶性硫酸钙无水石膏、α-半水硫酸钙、β-半水硫酸钙、天然、合成或化学改性的半水硫酸钙、二水硫酸钙(“石膏”、“硬石膏”或“水石膏”)以及它们的混合物。在此使用的术语“硫酸钙材料”是指以上提及的任何形式的硫酸钙。
添加剂可为通常用于制造诸如石膏板或水泥板等水泥制品的任何添加剂。这些添加剂包括但不限于，诸如矿棉、连续或切断的玻璃纤维(也称作玻璃丝)、珍珠岩、粘土、蛭石、碳酸钙、聚酯和纸纤维等结构添加剂；以及诸如发泡剂、填充剂、促进剂、糖等化学添加剂；诸如磷酸盐、膦酸盐、硼酸盐等增强剂；缓凝剂；粘结剂(例如淀粉和胶乳)；着色剂；杀真菌剂；抗微生物剂等。这些或其它添加剂的一些使用实例例如在美国专利6,342,284、6,632,550、6,800,131、5,643,510、5,714,001和6,774,146以及美国专利公布2004/0231916A1、2002/0045074A1和2005/0019618A1中进行了说明。
优选地，水泥芯包括硫酸钙材料、波特兰水泥或者它们的混合物。有利地，水泥芯还包括适量的诸如硅类材料(例如硅烷、硅氧烷或硅树脂基体)等疏水剂以改善芯材料的耐水性。还优选水泥芯包括硅氧烷催化剂，例如氧化镁(例如重烧氧化镁)、粉煤灰(例如C级粉煤灰)或者它们的混合物。硅氧烷和硅氧烷催化剂可用任何适宜的方法以任何适宜量加入，该方法为在此说明的有关制备本发明的耐水性水泥制品的方法，或者例如在美国专利公布2006/0035112A1或2007/0022913A1中说明的方法。理想地，水泥芯还包括诸如磷酸盐(例如在美国专利6,342,284、6,632,550和6,800,131以及美国专利公布2002/0045074A1、2005/0019618A1和2007/0022913A1中说明的多磷酸盐)等强度改善剂和/或预共混的不稳定和稳定的脂肪酸盐(例如在美国专利5,683,635和5,643,510中说明)。水泥芯可包括纸或玻璃纤维，但优选基本不含纸和/或玻璃纤维(例如包括低于约1wt％、低于约0.5wt％、低于约0.1wt％，或者甚至低于约0.05wt％的纸和/或玻璃纤维，或者不含这种纤维)。
水泥制品可为适于所需应用的任何类型或形状。水泥制品的非限制性实例包括任何尺寸或形状的石膏板材和水泥板材。
水泥制品可用任何适宜方法制备，包括但不限于在此说明的创造性方法。根据本发明，制备纤维毡面水泥制品的方法的实施方式包括：(a)将水泥浆料沉积在包括聚合物或矿物纤维的第一纤维毡上，其中第一纤维毡在其至少一个表面上包括疏水性涂层，且水泥浆料沉积在疏水性涂层上；和(b)使水泥浆料固化，由此提供纤维毡面水泥制品。
根据本发明，制备水泥制品的方法可通过在本领域已知的用于制造纤维毡面水泥制品的现有石膏板生产线上实施。简单地说，该工艺通常包括将纤维毡材料放到传送带或靠着传送带的网架上，然后放置在混合机的排出管下(例如本领域已知的出口-罐-进料口装置或者在美国专利6,494,609和6,874,930中说明的装置)。将水泥浆料的各组分进料给包括排出管的混合机，它们在混合机内经搅拌形成水泥浆料。可将泡沫加入到排出管内(例如在美国专利5,683,635和6,494,609中说明的出口中)。将水泥浆料排放到纤维毡覆面材料上。需要时，将浆料在纤维毡覆面材料上展开，且可选择地用第二覆面材料覆盖，第二面材料可为纤维毡或其它类型的覆面材料(例如纸、箔、塑料等)。将由此提供的湿水泥部件传送到将制品尺寸制成所需厚度的成形处和将制品切成所需长度的一个或多个刀片区域以提供水泥制品。使水泥制品固化，且可选择地用干燥工艺(例如风干或将水泥制品通过干燥炉)除去多余的水。用于执行此类步骤的上述各步骤以及工艺和设备是本领域已知的。在诸如石膏和水泥板等水泥制品的制造中也经常在沉积初始浆料之前将较厚层的浆料沉积在覆面材料上，并利用振动以消除沉积浆料中的大孔隙或气囊。而且，有时也使用本领域已知的硬边。这些步骤或组成部分(厚浆料层、振动和/或硬边)能够可选择地与本发明结合使用。
根据制备水泥制品的方法，所用第一纤维毡的所有方面如关于本发明的水泥制品所作说明。
尽管水泥浆料与第一纤维毡的疏水性涂层接触，但水泥浆料优选基本不渗入第一纤维毡，由此防止第一纤维毡以任何实际程度嵌入水泥浆料。优选地，水泥浆料渗入低于约50％的毡厚度，更优选低于约30％、低于约15％、低于约10％，或者甚至低于约2％(例如低于约1％)的毡厚度。最优选地，水泥浆料一点也不渗透过毡上的疏水性涂层。根据本发明相关且优选的方面，至少一部分水泥浆料优选粘附在疏水性涂层上。
在第一纤维毡传送到生产线上之前，可将疏水性涂层涂布到第一纤维毡上。或者，可在生产线上将疏水性涂层涂布到第一纤维毡上。在这点上，本发明的方法可进一步包括在第一纤维毡上沉积水泥浆料之前将疏水性涂层沉积到第一纤维毡上。正如在此之前所述，可使用任何适宜的疏水性涂层材料。疏水性涂层可通过本领域任何一种技术沉积在第一纤维毡上，例如刷涂、喷涂、辊涂、浇注、浸涂、筛撒或覆涂疏水性涂层材料。
当以液体涂布时，疏水性涂层优选在将水泥浆料沉积到第一纤维毡上之前干燥。疏水性涂层可用任何适宜方法干燥，例如对涂层或包含涂层的毡供热。
可选择地，制备纤维毡面水泥制品的方法可进一步包括在使水泥浆料固化之前，将水泥浆料与第二纤维毡接触，其中水泥浆料布置在第一纤维毡和第二纤维毡之间。第一和第二纤维毡的所有其它方面如关于本发明的水泥制品所作说明。
水泥浆料包括前文关于水泥制品的水泥芯所述适宜的或优选的任何水泥材料和添加剂以及用于提供适宜粘度的足量的水。当用坍塌试验测定时，水泥浆料通常产生一个直径为约5″～约8″(或者约10cm～约20cm)的饼形，例如约6″～约7″(或者约15cm～约18cm)。用坍塌试验测定浆料粘度的程序是本领域已知的。简单地说，2″(或者5cm)直径的管内装有4″(10cm)高的浆料。在5秒钟内从生产线上对浆料取样，将浆料从管内释放到平坦的水平面上并展开成饼形。当浆料停止展开时，测定浆料饼的最宽直径(在浆料饼为非圆形(例如椭圆形)时，将浆料饼的最宽直径与最宽直径垂直方向上的浆料饼直径平均)。
制备纤维毡面水泥制品的方法的其它方面如关于本发明的水泥制品所作说明。在此并未具体说明的制备纤维毡面水泥制品的方法的那些方面可通过常规水泥制品、特别是纤维毡面水泥制品的制造中已知并使用的技术来提供。
在一个相关方面，本发明提供一种制备耐水性水泥制品的方法，包括：(a)制备在水中包括约4wt％～约8wt％硅氧烷的硅氧烷水分散液；(b)将硅氧烷分散液与水泥混合物混合以提供水泥浆料；(c)将水泥浆料沉积在覆面或其它类型的基材上；和(d)使水泥浆料固化，由此提供水泥制品。
可使用任何适于对水泥混合物提供耐水性的硅氧烷。硅氧烷可为环状氢改性硅氧烷，或者优选线型氢改性硅氧烷。硅氧烷理想为液体(例如硅氧烷油)。通常，在本发明的实践中适用的线型氢改性硅氧烷包括具有通式-Si(H)(R)-O-的重复单元的硅氧烷，其中R表示饱和或不饱和一价烃基。在优选的实施方式中，R表示烷基，且最优选R为甲基。优选的硅氧烷能够形成高度交联的硅树脂。在聚合过程中，端基通过缩聚除去并硅氧烷基连接在一起以形成硅树脂。也发生链的交联。所得硅树脂在石膏基体形成时对其提供耐水性。适宜的此类硅氧烷可购得，并在专利文献中进行了说明(例如瓦克化学有限责任公司(德国，慕尼黑)销售的商品名为SILRES BS 94的低溶剂或无溶剂甲基氢硅氧烷液体)。
硅氧烷分散液优选通过将硅氧烷和水以足量加入到混合机中以提供在水中包括约4wt％～约8wt％硅氧烷、优选约4wt％～约5wt％硅氧烷的分散液，并加工该混合物以制成分散液来制备。更优选地，分散液包括在水中高于4wt％和/或低于8wt％的硅氧烷。作为示例，分散液可包括在水中从约4.1wt％、4.2wt％、4.3wt％、4.4wt％、4.5wt％到约5wt％、6wt％或7wt％的硅氧烷。优选地，分散液包括在水中的硅氧烷液滴，其中液滴具有约50微米或更小的平均粒径，优选约30微米或更小，或者甚至是约20微米或更小(例如约10微米或更小)。更优选地，液滴具有粒径分布，使得约75％或更多、80％或更多、85％或更多、甚至90％或更多或者甚至95％或更多的液滴具有约50微米或更小的平均粒径，优选约30微米或更小，或者甚至是约20微米或更小(例如约10微米或更小)。分散液中硅氧烷液滴的粒径和粒径分布可用常规技术测定，例如通过动态光散射分析测定。
根据本发明的优选方面，将分散液稳定，使得硅氧烷液滴在足以使分散液与水泥芯的其它组分混合期间内在水中仍保持分散(即，硅氧烷相与水相没有实际分离)。例如，根据本发明的优选方面，分散液将具有稳定性，使得混合后立即取出并使其静止的分散液样品在1分钟内(例如2分钟内)在样品表面上不呈现出可视液滴聚结。
理想地，使用高剪切或超高剪切混合机在水中分散硅氧烷。高剪切或超高剪切混合机可为能够制造硅氧烷在水中的分散液的任何混合机，在分散液中硅氧烷液滴具有上述粒径或粒径分布特性。合适类型的高剪切混合机包括机械剪切混合机，例如销型、叶片型、转子-定子型和圆盘型混合机以及液压剪切混合机。优选的混合机为那些能够产生约9000～约15000英尺/分钟(FPM)(或者约40～约80米/秒(mps))的叶片端速，例如为约10000～约12000FPM(或者约50～约60mps)。可使用的高剪切混合机的非限制性实例包括Silverson Machines公司(East Longmeadow，MA)制造的312/45MS高剪切混合机(20hp，3600RPM)和Charles Ross & Son公司(Hauppauge，NY)制造的X-系列乳化混合机(30～75HP)，例如ME-430XS-6、ME-440XS-9、ME-475XS-12、HSM709X-40、HMS712X-75。
硅氧烷和水可单独或一起、同时或以任何次序先后引入分散混合机中，优选高剪切混合机。当分散液通过间歇混合制备时，水优选在硅氧烷之前加入。但对于连续生产法间歇混合通常是不方便或不经济的。由此，优选使用串联分散混合机，以便以连续方式生产分散液，其中硅氧烷和水以适当比例连续且同时供应给串联分散混合机。硅氧烷水分散液优选不包括乳化剂或分散剂。
硅氧烷水分散液与水泥混含物混含以提供水泥浆料。本领域技术人员应理解，水泥混合物包括固体组分和液体组分。作为示例，在水中包括上述量的硅氧烷的硅氧烷分散液可直接引入包含水泥混合物的固体组分和/或液体组分的混合机(例如板式混合机)中。但优选硅氧烷分散液首先与水泥混合物的液体组分(例如水)混合，然后与水泥混合物的固体组分混合(例如将硅氧烷分散液加入到定量水或其它水中，随后送到板式混合机中)。基于最终水泥产品(例如固化、干燥的水泥产品)的重量，硅氧烷分散液优选以足以在最终水泥产品中提供约0.3wt％～约2wt％、例如约0.5wt％～约1.5wt％或约0.6wt％～约1wt％的硅氧烷含量的量加入到水泥混合物中。例如，假定为1500Ibs/msf的水泥板材(例如标准1/2″的石膏板材)，硅氧烷分散液能够以足以在最终的水泥产品(例如固化、干燥的水泥产品)中提供约5Ibs硅氧烷/1000sq.ft～约30Ibs硅氧烷/1000sq.ft(或者约20克硅氧烷/平方米～约150克硅氧烷/平方米)、例如约7Ibs硅氧烷/1000sq.ft～约20Ibs硅氧烷/1000sq.ft(或者约30克硅氧烷/平方米～约100克硅氧烷/平方米)或者甚至约10Ibs硅氧烷/1000sq.ft～约14Ibs硅氧烷/1000sq.ft(或者约50克硅氧烷/平方米～约70克硅氧烷/平方米)的量加入到水泥混合物中。
水泥浆料可选择地包括硅氧烷催化剂，例如粉煤灰、特别是C级粉煤灰、氧化镁、特别是重烧氧化镁或者最优选它们的组合。基于干的水泥组分重量(例如灰泥的干重)，粉煤灰优选以约0.1％～约5％的量使用。基于干水泥组分重量(例如灰泥的干重)，氧化镁优选以约0.1％～约0.5％的量使用。粉煤灰与氧化镁的比例理想地为约2∶1～约3∶1。
水泥浆料的其它方面如前文关于根据本发明制备毡面水泥制品的方法所作说明。制备硅氧烷水乳液并使水乳液与水泥浆料混合的其它方面如美国专利公布2007/0022913A1中所作说明。
如本文关于制备纤维毡面水泥制品的方法所作说明，水泥浆料可根据已知方法沉积在基材上并在现有生产线上进行，只要纤维毡面材料无需用作基材。相反地，基材可为任何合适的基材，例如通常用于覆面水泥制品的任何覆面材料(例如纸覆面材料)。但优选基材为包括聚合物或矿物纤维的纤维毡覆面材料。
将包括聚合物或矿物纤维的第一纤维毡用作基材特别有利，其中第一纤维毡在其至少一个表面上具有疏水性涂层。当使用这种基材时，进一步优选在纤维毡的疏水性涂层上沉积浆料。此外，可有利地使用第一和第二纤维毡，其中水泥浆料布置在纤维毡之间。适宜的此类纤维毡、疏水性涂层以及使用它们以提供水泥制品的方法如关于本发明的纤维毡面水泥制品和用于制备纤维毡面水泥制品的方法所作说明。
制备耐水性水泥制品的方法的所有其它方面如关于纤维毡面水泥制品或制造毡面水泥制品的方法所作说明。在此未具体描述的制备耐水性水泥制品的方法的各方面可通过常规水泥制品、特别是纤维毡面水泥制品制造中已知并使用的技术来提供。
实施例1
以下实施例说明根据本发明的纤维毡面水泥制品的制备。
制备两种类型的纤维毡：包括全部是玻璃纤维的第一毡和包括85wt％玻璃纤维和15wt％聚酯纤维共混物的第二毡。两种毡均是无纺的，且包括19wt％的三聚氰胺甲醛/丙烯酸粘结剂。
水泥浆料通过表1中提供的配方在板式混合机内制备。用SilversonMachines公司(East Longmeadow，MA)制造的高剪切混合机(例如312/45MS高剪切混合机(20hp，3600rpm))和Charles Ross & Son公司(Hauppauge，NY)制造的X-系列乳化混合机(60Hz，3,600rpm)将浆料的硅氧烷组分分散在水中(例如4.1～4.4wt％的硅氧烷水分散液)，并引入用于制备浆料的定量水中。
将纤维毡固定以用作水泥板材的正面(向下形成)和背面(向上形成)。使毡通过拉紧和取向系统，并使正面毡折叠以在所需板宽度(例如48″)上形成所需厚度(例如5/8″)和所需侧边(例如正方形)。优选地，将疏水性涂层涂布到正面毡上。使正面毡从板式混合机下方通过，并将水泥浆料沉积在正面毡上。在沉积水泥浆料之前并不沉积稠厚层，并关闭任何浆料振动装置以有助于减少浆料渗透过毡。
表1
将在适当位置具有浆料的折叠正面毡形成外壳，并在成型板的下面通过。在形成的正面毡进入成型板的地方，布置背面毡与正面毡的各侧边接触。使用合成胶颗粒在两个毡交叠的地方将正面玻璃毡与背面玻璃毡粘合。在此交叠处，浆料不与正面和背面玻璃毡接触。
将充满浆料、已完成的玻璃毡外壳从成型板中引出并传送给板传送带。导向装置将各侧边保持在合适的位置上，直至浆料在约30秒时沿着板传送带与水化合，此时侧边自承重。板进一步沿着线移动直至其开始自承重。之后，用板刀将板切成略长于其所需最终长度的长度。倒置板并移入干燥炉内以除去多余的水。
制得的产品为耐水性改善的纤维毡面水泥产品。
实施例2
以下实施例说明将疏水性涂层涂布到纤维毡覆面材料上用于防止水泥浆料渗透过纤维毡的效率。
在不同的固体含量和粘度下，将分散在包含0.05wt％多磷酸三钾(分散剂)的水中的滑石粉(Talcron 40～26，5微米粒径)涂布到无纺玻璃纤维毡上以5密耳或15密耳(基于湿膜厚度)的厚度涂布毡。表2中提供了涂层的固体含量、粘度和厚度。涂层5～7还包含羟乙基纤维素粘度增强剂(0.05wt％)。涂层7进一步包括1wt％的白蜡。之后，将水泥浆料沉积在涂层材料上。
表2
  涂层   厚度(密耳)   固体(％)   粘度(KU)   结果
  1   5   50   70   浆料渗透减少
  2   15   50   70   无浆料渗透
  3   5   60   119   无浆料渗透
  4   15   60   119   无浆料渗透
  5   5   20   83   浆料渗透减少
  6   15   20   83   浆料渗透减少
  7   5   20   83   浆料渗透减少
8(对照标准) (n/a) (n/a) (n/a) 浆料渗透程度高
目测浆料渗透量并与通过将相同的浆料涂布到玻璃纤维毡上提供的对照标准进行比较，该玻璃纤维毡与用于测试涂层1～7的毡相同，但不包括涂层材料。
与对照标准毡相比，更少量的浆料将渗透包括涂层材料的毡，表明对纤维毡覆面材料使用疏水性涂层可减少或消除浆料渗透过纤维毡。
实施例3
以下实施例说明根据本发明的耐水性水泥制品的制备。
水泥浆料用表1中提供的配方在板式混合机内制备。用SilversonMachines公司(East Longmeadow，MA)制造的312/45MS高剪切混合机(20hp，3600RPM)将浆料的硅氧烷组分分散在水中(例如4.1～4.4wt％的硅氧烷水分散液)，并引入用于制备浆料的定量水中。将硅氧烷分散液以足以提供包括11Ib硅氧烷/msf板(约0.43％wt/wt)的最终水泥产品的量引入到板式混合机内。将浆料与标准制造工艺结合使用以制造符合ASTM C1396/C1396M-06标准的纸面板材产品，该产品利用ASTM标准测试法C 473进行2个小时浸没的目标是形成不含10％板缺陷的覆面和5％的耐水性石膏背衬板。
第二水泥浆料以相同方式制备，区别在于使用Charles Ross & Son公司(Hauppauge，NY)制造的X-系列乳化混合机ME-430XS-6代替Silverson混合机，并将硅氧烷分散液以足以提供包括10Ib硅氧烷/msf板(约0.39％wt/wt)的最终水泥产品的量加入到板式混合机内。将浆料与标准制造工艺结合使用以制造符合A STM C1396/C 1396M-06标准的纸面板材产品，该产品利用ASTM标准测试法C 473进行2个小时浸没的目标是形成不含10％板缺陷的覆面和5％的耐水性石膏背衬板。
为了用常规工艺生产出符合ASTM C1396标准的产品，通常需要更高含量的硅氧烷(例如相当于12.5Ibs硅氧烷/msf或约0.5％wt/wt)。上述实施例说明了根据本发明制备耐水性水泥制品可有利地与较低的硅氧烷含量一起使用。
由此，在此引用的包括公布、专利申请和专利的所有参考文献通过引用以相同程度合并，就如将各个参考文献单独而具体地说明以通过引用而合并，且在此以其整体进行陈述。
在此说明了本发明的优选实施方式。对本领域技术人员来说，在阅读上述说明的基础上，对优选的实施方式进行变更而不背离本发明的精神和范围是显而易见的。因此，本发明包括所有修改和适用法律许可的此处所附权利要求书中陈述的主题等效物。此外，在其所有可能变更中，上述要素的任何组合也包含在本发明中，除非在此另外说明或者在上下文中明显矛盾。

Claims (25)

1.一种纤维毡面水泥制品，包括：
(a)水泥芯；和
(b)包括聚合物或矿物纤维以及在其至少一个表面上的疏水性涂层的第一纤维毡，其中所述疏水性涂层与所述水泥芯接触。
2.根据权利要求1所述的水泥制品，其中所述疏水性涂层包括滑石、蜡、疏水性树脂、硅类化合物、脂肪酸或其盐、聚乙二醇、具有12个或更多个碳原子的烃或氟碳表面活性剂或它们的组合。
3.根据权利要求1所述的水泥制品，其中所述疏水性涂层提供厚度至少为约25微米的层。
4.根据权利要求1所述的水泥制品，其中聚合物或矿物纤维为玻璃纤维、聚酯纤维或它们的组合。
5.根据权利要求1所述的水泥制品，进一步包括含有聚合物或矿物纤维的第二纤维毡，其中所述水泥芯放置在所述第一纤维毡和所述第二纤维毡之间。
6.根据权利要求1所述的水泥制品，其中所述水泥芯基本不含矿物纤维或纸纤维。
7.根据权利要求1所述的水泥制品，其中所述水泥芯包括疏水性添加剂。
8.根据权利要求7所述的水泥制品，其中所述疏水性添加剂为硅类材料。
9.根据权利要求1所述的水泥制品，其中所述水泥芯包括不稳定的脂肪酸盐和稳定的脂肪酸盐。
10.根据权利要求1所述的水泥制品，其中所述水泥芯包括多磷酸盐。
11.根据权利要求10所述的水泥制品，其中所述多磷酸盐为三偏磷酸钠。
12.一种制造纤维毡面水泥制品的方法，包括：
(a)将水泥浆料沉积在第一纤维毡上，所述第一纤维毡包括聚合物或矿物纤维以及在其至少一个表面上的疏水性涂层，其中所述水泥浆料沉积在所述疏水性涂层上；和
(b)使所述水泥浆料固化，由此提供纤维毡面水泥制品。
13.根据权利要求12所述的方法，其中所述疏水性涂层包括滑石、蜡、疏水性树脂、硅类化合物、脂肪酸或其盐、聚乙二醇、具有12个或更多个碳原子的烃或氟碳表面活性剂或它们的组合。
14.根据权利要求12所述的方法，其中所述方法进一步包括在将所述水泥浆料沉积在所述第一纤维毡上之前，将疏水性涂层沉积在所述纤维毡上。
15.根据权利要求14所述的方法，其中所述方法进一步包括在将所述水泥浆料沉积在所述第一纤维毡上之前，干燥所述疏水性涂层。
16.根据权利要求14所述的方法，其中所述疏水性涂层提供厚度至少为约25微米的层。
17.根据权利要求12所述的方法，其中所述聚合物或矿物纤维为玻璃纤维、聚酯纤维或它们的组合。
18.根据权利要求12所述的方法，进一步包括在使所述水泥浆料固化之前，将所述水泥浆料与第二纤维毡接触，其中所述水泥浆料放置在所述第一纤维毡和所述第二纤维毡之间。
19.根据权利要求12所述的方法，其中所述水泥浆料基本不含纸纤维或矿物纤维。
20.根据权利要求12所述的方法，其中所述水泥浆料包括疏水性添加剂。
21.根据权利要求20所述的方法，其中所述疏水性添加剂为硅氧烷。
22.根据权利要求12所述的方法，其中将所述水泥浆料在包括排出管的混合机内混合，并且在将所述浆料沉积在所述第一纤维毡之前，将泡沫加入到所述排出管内的水泥浆料中。
23.根据权利要求12所述的方法，其中所述水泥浆料包括预共混的不稳定脂肪酸盐和稳定的脂肪酸盐。
24.根据权利要求12所述的方法，其中所述水泥浆料包括多磷酸盐。
25.根据权利要求24所述的方法，其中所述多磷酸盐为三偏磷酸钠。
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