WO2003043955A1 - Compositions and methods for treating set gypsum - Google Patents
Compositions and methods for treating set gypsum Download PDFInfo
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- WO2003043955A1 WO2003043955A1 PCT/US2002/037171 US0237171W WO03043955A1 WO 2003043955 A1 WO2003043955 A1 WO 2003043955A1 US 0237171 W US0237171 W US 0237171W WO 03043955 A1 WO03043955 A1 WO 03043955A1
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- set gypsum
- salt
- composition
- phosphate
- containing material
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Classifications
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- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5007—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with salts or salty compositions, e.g. for salt glazing
- C04B41/5015—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with salts or salty compositions, e.g. for salt glazing containing phosphorus in the anion, e.g. phosphates
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- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
- C04B41/61—Coating or impregnation
- C04B41/65—Coating or impregnation with inorganic materials
- C04B41/67—Phosphates
Definitions
- the present invention relates generally to compositions and methods for treating set gypsum products and to methods for making set gypsum-containing materials. More particularly, the invention relates to compositions and methods for treating and making set gypsum such that the set gypsum is imparted with enhanced characteristics, including surface hardness, strength, thermal stability, paintability, abrasion resistance, and/or water erosion resistance.
- gypsum (calcium sulfate dihydrate) is a well-known material that is used to make many types of products and that is included commonly in many types of products.
- gypsum-containing products are prepared by forming a mixture of calcined gypsum (calcium sulfate hemihydrate and/or calcium sulfate anhydrite) and water, and optionally other components, as desired.
- the mixture typically is cast into a pre-determined shape or onto the surface of a substrate.
- the calcined gypsum reacts with the water to form a matrix of crystalline hydrated gypsum (calcium sulfate dihydrate).
- set gypsum is a major component of molds made of plaster that are used in casting pottery figurines and the like using pressure casting or slip casting techniques known in the art.
- wet material for example, a mixture of water and clay is added to the mold.
- the plaster mold is designed to be porous so that it can absorb water that is drawn out from the clay being molded to form greenware.
- the mold becomes saturated with water and the water must be removed periodically from the mold, for example, via compressive air purging or other drying techniques, to form the desired molded product (greenware). Because the set gypsum of the plaster mold is somewhat soluble in water, the continual transfer of water into and out of the mold causes the set gypsum of the plaster mold to erode.
- plaster molds also are thermally and dimensionally unstable to some degree. Plaster molds often are subjected to sustained elevated temperatures, for example, to temperatures of 140° F or higher, for a time period of, for example, 30 minutes or longer.
- surface re-calcination of the set gypsum can also occur and has been observed. Surface re-calcination undesirably results in a loss of some strength because a portion of the set gypsum matrix is weakened. For example, surface re-calcination can cause the set gypsum component to contract and then cause cracks to form in the plaster molds.
- Paintability, or paint adhesion to the set gypsum surface of set gypsum-containing products such as statuary is also desirable, for example, in order to minimize the amount of paint needed to adequately cover the surface of the product, to minimize paint chipping, and the like.
- Conventional statuary, when made, must be dried at relatively low temperatures, inasmuch as elevated temperatures (e.g., 100 °C or higher) can lead to cracking and thermal contraction of the set gypsum.
- Statuary made of set-gypsum that is thermally and dimensionally stable could be dried at elevated temperatures, thereby enhancing the overall efficiency of the process.
- Veneer plasters are formulated to have a relatively soft surface so as to facilitate the application thereof to a substrate.
- the surface hardness and strength of the veneer plaster is compromised such that the plaster is more susceptible to scratching or abrasions.
- lime is added as an ingredient to the product, as is typical to enhance the workability of the veneer compound. Accordingly, the product's ability to resist abrasions is compromised.
- set gypsum with cellulosic fibers, for example, gypsum-wood fiber board such as FIBEROCK® brand composite panels, commercially available from United States Gypsum Company.
- calcined gypsum e.g., alpha calcium sulfate hemihydrate
- water penetrate the cellulosic fiber pores.
- the set gypsum forms in situ within and about the pores of the cellulosic fibers, thereby adding strength to the product.
- the set gypsum-fiber composite can suffer from water erosion, abrasions, and blisters.
- the water required to form the set gypsum causes blistering of the fibers.
- such products do not bind well with paint and, therefore, exhibit poor paintability such that relatively large quantities of paint are required.
- Set gypsum also is known to be used as a major component in floor underlayments.
- poured floor underlayments comprising set gypsum that include an embedded hot water heating system.
- the heat can cause some re-calcination of the set gypsum, thereby leading to thermal contraction and the formation of unsightly cracks in the floors.
- Set gypsum-containing floor underlayments also are vulnerable to water erosion and abrasion.
- the present invention provides a set gypsum-containing material, a composition for coating a set gypsum-containing material, a method for treating a set gypsum-containing material, and a method for making a set gypsum-containing material.
- Treating set gypsum can include post-set treatment of set gypsum. It also is possible to include trimetaphosphate salt during the formation of the set gypsum product followed by post-set treatment with one or both of the remaining types of salts, and still achieve the surprisingly enhanced surface strength, and stability characteristics of the set gypsum product. As will be appreciated, many different treatment combinations can be used while still achieving the benefits of the invention as described herein.
- the present invention provides an aqueous composition for coating a set gypsum-containing material, which is formed from at least one member from each of the classes of phosphate salts described above and which preferably imparts to the set gypsum-containing material an improvement in one or more of its strength, surface hardness, water erosion resistance, or abrasion resistance.
- the aqueous composition is formed from at least one monobasic phosphate salt; at least one trimetaphosphate salt; and at least one acyclic polyphosphate salt having at least three phosphate units.
- a water dispersible polymer or a water soluble polymer such as a polymer latex or the like, is also used to form the composition.
- the present invention also provides a method of treating a set gypsum-containing material.
- the method comprises applying to the set gypsum-containing material at least one member from each of at least two of the following types of inorganic phosphate salts: monobasic phosphate salts, trimetaphosphate salts, and acyclic polyphosphate salts having at least three phosphate units.
- the set gypsum-containing material is treated further with a water dispersible polymer or a water soluble polymer, such as a polymer latex or the like.
- the inorganic phosphate salts are applied in amounts sufficient to impart the set gypsum-containing material with an improvement, as compared with the untreated set gypsum-containing material, in one or more of the following characteristics: strength (e.g., flexural), surface hardness, abrasion resistance, water erosion resistance, or the like.
- the present invention provides a method of making a set gypsum-containing material. The method comprises forming a set gypsum matrix from water, calcined gypsum, and at least one trimetaphosphate salt.
- the set gypsum matrix is then treated with at least one of the following types of inorganic phosphate salts: monobasic phosphate salts and acyclic polyphosphate salts having at least three phosphate units.
- post-set treatment is used to treat the set gypsum with the salts described above.
- compositions and methods of the invention enhance set gypsum-containing products by improving one or more desirable characteristics of the products such as, for example, surface hardness, abrasion resistance, water erosion resistance, paintability, thermal stability, such as cracking resistance, dimensional stability such as shrinkage resistance, strength and the like.
- the compositions and methods of the invention can be used with any of a number of set gypsum-containing products, including, by way of example and not in limitation, plaster molds for pottery casting, interior/exterior statuary, veneer plasters, gypsum-cellulosic fiber products, floor underlayments, and the like.
- the present invention provides a composition and method for treating a set gypsum-containing material.
- the set gypsum- containing material can be any of a wide variety of products for which the beneficial effects of the invention are useful.
- the set gypsum-containing material can be in the form of plaster molds for pottery casting, interior/exterior statuary, gypsum-cellulosic fiber products, such as gypsum-wood fiber wallboard, veneer plasters, floor underlayments, and the like.
- composition and method of the invention desirably enhance one or more of the surface hardness, paintability, thermal stability, dimensional stability, water erosion resistance, abrasion resistance and the like as well as the strength (wet and/or dry) of the set gypsum-containing material.
- the set gypsum-containing material in accordance with the present invention comprises an interlocking set gypsum matrix prepared from a mixture comprising water and calcined gypsum, and which has been treated with a combination of two or more of the following three types of salts, monobasic phosphate salts, trimetaphosphate salts, and acyclic polyphosphate salts.
- the combination of salts for this treatment preferably is included in an aqueous solution.
- the calcined gypsum can be fibrous or non-fibrous. In some embodiments, a major portion (e.g., at least about 50 wt. %) of the calcined gypsum is non-fibrous, while in other embodiments, a major portion (e.g., at least about 50 wt. %) of the calcined gypsum is fibrous. In addition, the calcined gypsum can be in the form of alpha calcium sulfate hemihydrate, beta calcium sulfate hemihydrate, water- soluble calcium sulfate anhydrite or combinations thereof.
- the set gypsum-containing material comprises additional components, besides the set gypsum.
- the set gypsum-containing material can include one or more fillers, for example, inert fillers such as silica sand, hydrated lime, or the like, in amounts normally used in such set gypsum-containing materials, as will be appreciated readily by the ordinarily skilled artisan.
- the set gypsum- containing material is treated with at least two of the following inorganic phosphates: (a) at least one monobasic phosphate salt; (b) at least one trimetaphosphate salt; and/or (c) at least one acyclic polyphosphate salt having at least three phosphate units.
- the set gypsum-containing material is treated with at least one of each of the monobasic phosphate salt, trimetaphosphate salt, and acyclic polyphosphate salt having at least three phosphate units.
- the phosphate salt may be the salt itself or it may be a phosphate ion.
- a phosphate salt is added to water to form the composition, the formed aqueous composition, it is believed, includes phosphate ion, and the phosphate ion, it is believed, is used in the treatment of the set gypsum containing material.
- the treatment of a set gypsum material of a composition made using the salts described herein provide the benefits to the set gypsum product and applicants do not wish to be bound to any particular theory or mechanism by which the beneficial results may be achieved.
- the monobasic phosphate salt and the acyclic polyphosphate salt desirably are applied in a post-set treatment, that is, after a major portion and preferably after all of the set gypsum is formed.
- the monobasic phosphate salt and acyclic polyphosphate salt having at least three phosphate units can be added (e.g., via an aqueous solution) after the set gypsum is formed, and prior to or after drying off excess water.
- the post-set treatment can be used on wet (aqueous) set gypsum as well as on dry set gypsum.
- the trimetaphosphate salt is also provided in a post-set treatment, and preferably as a component of the post-set treatment composition along with the monobasic phosphate salt and acrylic polyphosphate salt to the extent such salts are included in the composition.
- trimetaphosphate salt in a pre-set treatment, for example, by including the trimetaphosphate salt in the mixture comprising water and calcined gypsum used to make the set gypsum, and then, in a post-set treatment to add the remaining phosphate salts to the set gypsum, for example, by spraying, soaking, or brushing with an aqueous phosphate solution.
- a pre-set treatment for example, by including the trimetaphosphate salt in the mixture comprising water and calcined gypsum used to make the set gypsum
- a post-set treatment to add the remaining phosphate salts to the set gypsum, for example, by spraying, soaking, or brushing with an aqueous phosphate solution.
- the monobasic phosphate salt and the acyclic polyphosphate salt having at least three phosphate units are not included in a pre-set treatment, because they are retarders of the rate of set gypsum formation and impair or even prevent the formation of the interlocking matrix of set gypsum, thereby leading to products with undesirable surface characteristics and strength.
- the monobasic phosphate salt, trimetaphosphate salt, and/or acyclic polyphosphate salt having at least three phosphate units can be applied in any suitable manner.
- the phosphates can be applied via spraying, dipping, spin-coating, brushing, rolling, or combinations thereof.
- Other suitable ways of applying the inorganic phosphates will be apparent to those of ordinary skill in the art.
- the phosphates can be applied during the process of purging water from the mold. In this respect, the phosphates can be included, if desired, in the air purge process.
- each phosphate can be applied individually, with or without a carrier such as water, or the phosphates can be applied by an aqueous composition comprising the desired phosphates.
- the phosphates are applied by an aqueous composition formed from at least two of the following inorganic phosphates: (a) at least one monobasic phosphate salt; (b) at least one trimetaphosphate salt; and (c) at least one acyclic polyphosphate salt having at least three phosphate units.
- the inorganic phosphate salts each contribute to various strength and surface characteristics of set gypsum in a way that, when combined, provides a superior set gypsum product.
- the monobasic phosphate salt enhances the dry compressive strength, wet or dry surface hardness, and abrasion resistance of set gypsum.
- the monobasic phosphate salt exhibits synergistic effects in combination with the trimetaphosphate salt and/or the acyclic polyphosphate salt having at least three phosphate units, with respect to other characteristics of the set gypsum-containing material.
- the anion is derived from an acid (e.g., phosphoric acid), in which one hydrogen atom is displaced per molecule.
- the displaced hydrogen is replaced with a cation.
- the monobasic phosphate salt can be selected from monoammonium phosphate, monosodium phosphate, monolithium phosphate, monopotassium phosphate, or combinations thereof.
- the monobasic phosphate salt is monoammonium phosphate.
- the monobasic phosphate salt is included in an amount sufficient to enhance desired characteristics of the set gypsum- containing material, such as, for example, the dry compressive strength, the wet or dry surface hardness and the like. It will be appreciated that the monobasic phosphate salt preferably is included in an aqueous composition which then is applied to the set gypsum product in a post-set treatment application. Preferably, the amount of monobasic salt used to treat the set gypsum is from about 0.05% to about 2% by weight of the set gypsum in the set gypsum-containing material.
- the composition when included in the aqueous composition, preferably includes a monobasic phosphate salt (or ion) in an amount of from about 0.1% to about 10% by weight, preferably of from about 1 % to about 4% by weight, and more preferably of from about 2% to about 3%.
- a monobasic phosphate salt (or ion) in an amount of from about 0.1% to about 10% by weight, preferably of from about 1 % to about 4% by weight, and more preferably of from about 2% to about 3%.
- the amounts can be varied depending on desired physical properties and cost effectiveness to be achieved.
- trimetaphosphate salt is believed to be beneficial for enhancing the strength, thermal stability and dimensional stability of the set gypsum-containing material.
- the trimetaphosphate salt acts synergistically with the monobasic phosphate salt and/or the acyclic polyphosphate salt having at least three phosphate units in order to enhance desired characteristics of the set gypsum-containing material.
- the trimetaphosphate salt has a cyclic structure that contains three phosphorous atoms in a six-membered ring. Any suitable trimetaphosphate salt (preferably water soluble) can be used in accordance with the present invention, including double salts, that is, trimetaphosphate salts having two different cations.
- trimetaphosphate salt can be selected, for example, from sodium trimetaphosphate, potassium trimetaphosphate, ammonium trimetaphosphate, lithium trimetaphosphate, or combinations thereof.
- Sodium trimetaphosphate is preferred.
- the trimetaphosphate salt can be provided in a pre-set or post- set treatment in an amount effective to enhance desired characteristics of the set gypsum-containing material, such as, for example, the strength, thermal stability and dimensional stability and the like. It will be appreciated that the trimetaphosphate salt can be included in an aqueous composition which then is applied to the set gypsum product in a post-set treatment application, or which is applied to the calcined gypsum in a pre-set treatment. The amount of trimetaphosphate salt that is added is sufficient to impart the desired characteristics to the set gypsum.
- the amount of trimetaphosphate salt used to treat the set gypsum, by either the post- set or pre-set techniques is from about 0.05% to about 2% by weight of the set gypsum in the set gypsum-containing material.
- the composition when included in an aqueous composition, the composition preferably includes a trimetaphosphate salt (or ion) in an amount of from about 0.5% to about 10% by weight, preferably of from about 1 % to about 4% by weight, and more preferably of from about 1 % to about 2%.
- the amounts can be varied depending on desired improvement of the set gypsum containing products and cost effectiveness.
- the acyclic polyphosphate salt having at least three phosphate units is believed to be beneficial for enhancing the wet or dry surface hardness and water erosion resistance of the set gypsum-containing material, and it acts synergistically with the monobasic phosphate salt and/or the trimetaphosphate salt to further enhance desired characteristics of the set gypsum-containing material.
- the acyclic polyphosphate salt can have various degrees of polymerization.
- the acyclic polyphosphate salt includes at least three phosphate units but the upper limit on the number of phosphate units can vary, so long as the acyclic polyphosphate salt remains water soluble.
- any suitable acyclic polyphosphate salt having at least three phosphate units can be utilized in accordance with the present invention.
- the acyclic polyphosphate salt has from about 6 to about 27 repeating phosphate units.
- suitable acyclic polyphosphate salts in accordance with the present invention include, but are not limited to, sodium hexametaphosphate having from about 6 to about 27 repeating phosphate units, potassium hexametaphosphate having from about 6 to about 27 repeating phosphate units, ammonium hexametaphosphate having from about 6 to about 27 repeating phosphate units, and combinations thereof.
- a preferred acyclic polyphosphate salt pursuant to the present invention is commercially available as CALGON® from Astaris, Inc., St. Louis, Missouri, which is a sodium hexametaphosphate having from about 6- 27 repeating phosphate units.
- the acyclic polyphosphate salt is included in an amount sufficient to enhance desired characteristics of the set gypsum- containing material, such as, for example, the wet or dry surface hardness and water erosion resistance, and the like. It will be appreciated that the acyclic polyphosphate salt preferably is included in an aqueous composition which then is applied to the set gypsum product in a post-set treatment application.
- the amount of acyclic polyphosphate salt that is added is sufficient to impart the desired characteristics to the set gypsum-containing material.
- the amount of acyclic polyphosphate salt used to treat the set gypsum is from about 0.05% to about 2% by weight of the set gypsum in the set gypsum-containing material.
- the composition when included in the aqueous composition, the composition preferably includes an acyclic polyphosphate salt (or ion) in an amount of from about 1% to about 10% by weight, preferably of from about 2% to about 8% by weight, and more preferably of from about 2% to about 4%.
- the amounts can be varied depending on desired improvement of the set gypsum products and cost effectiveness.
- inorganic phosphate salts namely the monobasic phosphate salt, the trimetaphosphate salt, and the acyclic polyphosphate salt
- various combinations of the inorganic phosphates produce unexpected benefits in terms of desired characteristics of the set gypsum-containing material.
- a combination of a monobasic phosphate salt and an acyclic polyphosphate salt having at least three repeating phosphate units, in combination exhibit unexpected benefits with respect to dry compressive strength, wet or dry surface hardness, and abrasion resistance.
- trimetaphosphate salt and the acyclic polyphosphate salt having at least three phosphate units synergistically enhance abrasion resistance.
- at least one of each of the monobasic phosphate salt, trimetaphosphate salt, and acyclic polyphosphate salt having at least three phosphate units are utilized together.
- the inorganic phosphates can be applied individually to the set gypsum-containing material, or, in some embodiments, a composition is provided that is formed from at least two of the following inorganic phosphates: (a) at least one monobasic phosphate salt, (b) at least one trimetaphosphate salt, and/or (c) at least one acyclic polyphosphate salt having at least three repeating phosphate units.
- the composition can include, for example, from about 2 wt.% to about 8 wt.% of the acyclic polyphosphate salt having three phosphate units, and from about 1 wt.% to about 4 wt.% of each of the trimetaphosphate salt and the monobasic phosphate salt.
- the set gypsum-containing material is post-set treated with a polymer solution comprising water dispersible or water soluble polymers, such as, for example, polymer latex.
- a polymer solution comprising water dispersible or water soluble polymers, such as, for example, polymer latex.
- the polymer solution acts synergistically with the inorganic phosphates of the present invention with respect to other desired characteristics of the set gypsum-containing material.
- use of the polymer solution requires less of the inorganic phosphates to be used. This is advantageous because polymer materials (e.g., polymer latex) are generally less expensive than the various inorganic phosphates which have been found to be useful in the practice of the present invention.
- the inorganic phosphates enhance the cross-linking of the water dispersible or water soluble polymers and the bonding of gypsum crystals on the surface of gypsum based products.
- the solubility of gypsum in an aqueous phosphate solution and the migration of phosphates and water dispersible or water soluble polymer to the surface of the gypsum- containing material during drying, catalyzes the formation of inorganic phosphate-organic polymer composites on the surface of the set gypsum-containing material.
- the water dispersible or water soluble polymer in combination with the inorganic phosphates of the present invention, the water erosion resistance, abrasion resistance, and flexural strength of the set gypsum-containing material is improved.
- any suitable water dispersible or water soluble polymer can be used in accordance with the present invention.
- the water dispersible or water soluble polymer can be selected from polyvinyl alcohol, polyvinyl acetate, guar gum, sulphonated polystyrene latex, acrylics, rubber latex, or the like, or blends or copolymers thereof.
- the polymer can be included, if desired, in the aqueous composition that includes the desired combination of inorganic phosphates, or, alternatively, the set gypsum-containing material can be treated with the polymer solution individually, separate from the inorganic phosphate treatment.
- the polymer can be present in any suitable amount in the aqueous composition.
- the polymer can be present in an amount of from about 0.1 % to about 2% by weight of the composition.
- the inorganic phosphates are applied to the set gypsum-containing material, or, in the case of the trimetaphosphate salt, applied to the set gypsum-containing material and/or added during preparation of the set gypsum-containing material, in amounts sufficient to improve one or more of the strength, surface hardness, abrasion resistance, or water erosion resistance of the set gypsum-containing material (e.g., the resultant product).
- some embodiments of the present invention exhibit a reduction in the water erosion of the set gypsum-containing material of at least about 25%.
- the water erosion is reduced by at least about 35%, or at least about 45% (e.g., at least about 55%, 65%, 75%, or more), as compared with the untreated set gypsum-containing material.
- two set gypsum-containing material cubes (2 in. X 2 in. X 2 in.) exhibiting the same type of treatment or no treatment (control) are submerged into a fresh water bath (24 in. X 48 in. X 4 in.) for one week.
- the water bath has a constant flow of 0.5 gallons per minute of fresh tap water flowing into it from one end with water flowing out of the other end.
- the water erosion is then measured after one week by comparing the weight of the two cubes before and after submersion in the water bath.
- the present invention provides a set gypsum-containing material that resists water erosion, as preferably characterized by exhibiting a weight loss of less than about 5%, more preferably, a weight loss of less than about 3%, after the one week submersion of the set gypsum-containing material in the fresh water bath.
- the abrasion resistance of the treated set-gypsum-containing material is improved by at least about 95%.
- the abrasion resistance is improved by at least about 96% or by at least about 97% (e.g., at least about 98%, at least about 99% or higher), as tested pursuant to ASTM D 4977-98b for a 30-cycle abrasion test at a 25 lb. load.
- the treated set gypsum-containing material exhibits no weight loss, indicating no surface damage and hence no abrasion.
- the present invention enhances the flexural strength of the treated set gypsum-containing material, as compared with the untreated set gypsum-containing material, by at least about 5%.
- the flexural strength is improved by at least about 10%, by at least about 12% (e.g., by at least about 14%) or more, as tested pursuant to ASTM C 473-95. It will be appreciated that some embodiments of the present invention exhibit an improvement in the surface hardness of the treated set gypsum-containing material, as compared with the untreated set gypsum-containing material, of at least about 15% (e.g., by at least about 25%).
- the surface hardness is improved by at least about 35% (e.g., at least about 45%), at least about 55% (e.g., at least about 65%), at least about 75% (e.g., at least about 85%), or even at least about 95% (e.g., at least about 105%, at least about 115%, or more), as tested on a Constant Diameter (C-D) Monotron device (manufactured by Shore Instrument and Manufacturing Company, New York, New York).
- C-D Constant Diameter
- the Monotron surface hardness test will be appreciated readily by the ordinarily skilled artisan (see, e.g., Davis et al., The Inspection of Engineering Materials, Third Edition, pp. 184-185, 200-203 (1964)).
- the surface hardness measurements represent the load required to force a 10 mm steel ball to penetrate 0.01 in. into the surface of a gypsum cast, but if the penetration requires a load in excess of 180 kg (the capacity of the instrument), a 0.005 in penetration is used.
- the test specimens used in the test are tensile strength briquettes or 2 in. compressive strength cubes.
- NaTMP sodium trimetaphosphate
- Two inch gypsum cubes were prepared at a 70 cc consistency (i.e., adding 100 gram plaster in 70 cc water) using No. 1 Molding Plaster (commercially available from United States Gypsum
- a 1 mm layer of DIAMOND® brand Interior Finish Plaster was trowel applied to a piece of 2.5" X 9" X ⁇ "IMPERIAL® brand gypsum board (commercially available from United States Gypsum Company). After the plaster was set and air dried, the desired post-treatment solution was brush applied to the plaster surface. Immediately after post treatment, the wet weight of the gypsum board was recorded. The difference between the wet weight and the dry weight was used to determine total chemical dosage of post treatment after the sample was re-dried in the air again. A standard 30-cycle abrasion test was conducted on the re-dried sample according to ASTM D4977 test apparatus (DUROWELD, Lake Bluff, IL).
- Table 2 lists the abrasion resistance and the surface hardness measurement of DIAMOND® Interior Finish Plaster, before and after application of post-treatment coatings.
- solution refers to aqueous solution containing various chemical compositions.
- Two inch gypsum cubes were prepared at a 70 cc consistency using No. 1 Molding plaster following the same sample preparation procedures as described in Example 1.
- four dried test cubes were soaked in a specified post-treatment solution for one hour. The treated cubes were taken out of the solutions and dried in a lab oven at 112 °F to reach a constant weight. The compressive strength of dried cubes was tested and averaged value was reported.
- the remaining test cube for each condition was then placed in a fresh water bath for one week of water erosion test. After the sample was taken out of the water bath, the cubes were re-dried and weighed. The weight loss before and after water erosion test was used to determine water erosion resistance. The results are shown in Table 3. TABLE 3
- the cube compressive strength was enhanced by post-treatment. Furthermore, as compared with the control sample (treated by tap water only), the water erosion resistance was also enhanced significantly by post-treatment, with the least amount of weight loss reflecting the least amount of water erosion. It is further evidenced from Example 16 that the combination of PVAC latex and inorganic phosphates provided the best water erosion resistance.
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- Aftertreatments Of Artificial And Natural Stones (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Paints Or Removers (AREA)
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2467543A CA2467543C (en) | 2001-11-19 | 2002-11-19 | Compositions and methods for treating set gypsum |
NZ532991A NZ532991A (en) | 2001-11-19 | 2002-11-19 | Compositions and methods for treating set gypsum |
DE60227095T DE60227095D1 (en) | 2001-11-19 | 2002-11-19 | COMPOSITIONS AND METHODS FOR TREATING SEPARATED GIPS |
MXPA04004778A MXPA04004778A (en) | 2001-11-19 | 2002-11-19 | Compositions and methods for treating set gypsum. |
EP02789761A EP1446369B1 (en) | 2001-11-19 | 2002-11-19 | Compositions and methods for treating set gypsum |
AU2002352807A AU2002352807B2 (en) | 2001-11-19 | 2002-11-19 | Compositions and methods for treating set gypsum |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US09/992,302 | 2001-11-19 | ||
US09/992,302 US6822033B2 (en) | 2001-11-19 | 2001-11-19 | Compositions and methods for treating set gypsum |
Publications (1)
Publication Number | Publication Date |
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WO2003043955A1 true WO2003043955A1 (en) | 2003-05-30 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2002/037171 WO2003043955A1 (en) | 2001-11-19 | 2002-11-19 | Compositions and methods for treating set gypsum |
Country Status (10)
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US (1) | US6822033B2 (en) |
EP (1) | EP1446369B1 (en) |
AU (1) | AU2002352807B2 (en) |
CA (1) | CA2467543C (en) |
DE (1) | DE60227095D1 (en) |
ES (1) | ES2306803T3 (en) |
MX (1) | MXPA04004778A (en) |
NZ (1) | NZ532991A (en) |
RU (1) | RU2294907C2 (en) |
WO (1) | WO2003043955A1 (en) |
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- 2002-11-19 NZ NZ532991A patent/NZ532991A/en not_active IP Right Cessation
- 2002-11-19 ES ES02789761T patent/ES2306803T3/en not_active Expired - Lifetime
- 2002-11-19 AU AU2002352807A patent/AU2002352807B2/en not_active Ceased
- 2002-11-19 MX MXPA04004778A patent/MXPA04004778A/en active IP Right Grant
- 2002-11-19 CA CA2467543A patent/CA2467543C/en not_active Expired - Fee Related
- 2002-11-19 DE DE60227095T patent/DE60227095D1/en not_active Expired - Lifetime
- 2002-11-19 RU RU2004118496/03A patent/RU2294907C2/en not_active IP Right Cessation
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US9382153B2 (en) | 2010-11-23 | 2016-07-05 | Saint Gobain Placo Sas | Calcium sulphate-based products and methods for the manufacture thereof |
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MXPA04004778A (en) | 2005-04-11 |
US20030100648A1 (en) | 2003-05-29 |
NZ532991A (en) | 2005-10-28 |
AU2002352807B2 (en) | 2008-02-21 |
ES2306803T3 (en) | 2008-11-16 |
EP1446369A1 (en) | 2004-08-18 |
EP1446369B1 (en) | 2008-06-11 |
RU2004118496A (en) | 2005-03-27 |
US6822033B2 (en) | 2004-11-23 |
DE60227095D1 (en) | 2008-07-24 |
CA2467543A1 (en) | 2003-05-30 |
RU2294907C2 (en) | 2007-03-10 |
CA2467543C (en) | 2011-01-18 |
AU2002352807A1 (en) | 2003-06-10 |
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