Reduced dusting gypsum composites and method of making them

Details Reduced dusting gypsum composites and method of making them Reduced dusting gypsum composites and method of making them

C - Chemistry, Metallurgy

04

B

C04B 28/14 (2006.01) C04B 18/24 (2006.01) C04B 18/26 (2006.01) C04B 40/00 (2006.01) C09K 3/22 (2006.01)

Patent

CA 2654721

A composite product is made from a slurry that includes host particles having alpha-calcined calcium sulfate hemihydrate crystals formed in the voids, cracks, fissures or other surface opening of the host particle, alpha-calcined calcium sulfate hemihydrate crystals and a dust reducing agent. The dust reducing agent is at least one of a synthetic wax and soy lecithin. As the slurry cools, the hemihydrate forms an interlocking matrix of calcium sulfate dihydrate crystals, some of which are attached to host particles. A process for making the slurry includes forming a slurry of host particles and calcium sulfate dihydrate, then heating the slurry to at least 140°C and autogenous pressure until substantially all of the calcium sulfate dihydrate has been converted to alpha-calcined calcium sulfate hemihydrate. The dust reducing agent is added to the slurry. A composite panel is made by further dewatering the slurry and forming a panel.

L'invention concerne un produit composite constitué d'une pâte renfermant des particules hôtes comprenant des cristaux d'hémihydrate de sulfate de calcium alpha-calciné formés dans les vides, les craquelures, les fissures ou d'autres ouvertures superficielles des particules hôtes, des cristaux d'hémihydrate de sulfate de calcium alpha-calciné et un agent anti-poussière. L'agent anti-poussière se présente sous la forme d'une cire synthétique et/ou de lécithine de soja. Lors du refroidissement de la pâte, l'hémihydrate forme une matrice entrecroisée de cristaux de dihydrate de sulfate de calcium dont certains sont fixés aux particules hôtes. Un procédé de préparation de cette pâte consiste à former une pâte de particules hôtes et de dihydrate de sulfate de calcium, puis à chauffer la pâte à une température d'au moins 140°C et à une pression autogène jusqu'à la conversion sensiblement complète du dihydrate de sulfate de calcium en hémihydrate de sulfate de calcium alpha-calciné. L'agent anti-poussière est alors additionné à la pâte. Un panneau composite est ensuite fabriqué par déshydratation de la pâte et par formage d'un panneau.

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