Gypsum-based mortars using water retention agents prepared from raw cotton linters

• US 20050241541A1
• Filed: 04/25/2005
• Published: 11/03/2005
• Est. Priority Date: 04/27/2004
• Status: Abandoned Application

• Current Assignee: Christian Morgenroth, Dieter Schweizer, Wilfried Hohn
• Original Assignee: Christian Morgenroth, Dieter Schweizer, Wilfried Hohn
• Inventors: Hohn, Wilfried, Morgenroth, Christian, Schweizer, Dieter
• Application Number:
  US11/113,685
• Publication Number:
  US 20050241541A1
• Time in Patent Office: Days
• US Class Current: 106/805
• CPC Class Codes: B63H 3/008 characterised by self-adjusting pitch, e.g. by means of springs, centrifugal forces, hydrodynamic forces
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/365 Gypsum synthetic gypsum C04B18/0445, C04B18/064
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/00 Function or property of ingredients for mortars, concrete or artificial stone
• CPC Class Codes: C04B 2103/0057 added as redispersable powders
• CPC Class Codes: C04B 2103/0086 Chelating or complexing agents
• CPC Class Codes: C04B 2103/0099 Aspecific ingredients, i.e. high number of alternative specific compounds mentioned for the same function or property
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/20 Retarders
• CPC Class Codes: C04B 2103/30 Water reducers, plasticisers, air-entrainers, flow improvers
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2103/46 Water-loss or fluid-loss reducers, hygroscopic or hydrophilic agents, water retention agents
• CPC Class Codes: C04B 2103/50 : Defoamers, air detrainers
• CPC Class Codes: C04B 2111/00094 : Sag-resistant materials
• CPC Class Codes: C04B 2111/00129 : Extrudable mixtures
• CPC Class Codes: C04B 2111/00482 : Coating or impregnation materials
• CPC Class Codes: C04B 2111/00637 : as glue or binder for uniting building or structural materials
• CPC Class Codes: C04B 2111/00646 : Masonry mortars
• CPC Class Codes: C04B 2111/00672 : Pointing or jointing materials
• CPC Class Codes: C04B 2111/34 : Non-shrinking or non-cracking materials
• CPC Class Codes: C04B 2111/56 : Compositions suited for fabrication of pipes, e.g. by centrifugal casting, or for coating concrete pipes
• CPC Class Codes: C04B 2201/10 : for the viscosity
• CPC Class Codes: C04B 24/04 : Carboxylic acids; Salts, anhydrides or esters thereof
• CPC Class Codes: C04B 24/10 : Carbohydrates or derivatives thereof
• CPC Class Codes: C04B 24/168 : Polysaccharide derivatives, e.g. starch sulfate
• CPC Class Codes: C04B 24/22 : Condensation or polymerisation products thereof
• CPC Class Codes: C04B 24/223 : Sulfonated melamine-formaldehyde condensation products
• CPC Class Codes: C04B 24/226 : Sulfonated naphtalene-formaldehyde condensation products
• CPC Class Codes: C04B 24/2623 : Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2647 : containing polyether side chains
• CPC Class Codes: C04B 24/2652 : Nitrogen containing polymers, e.g. polyacrylamides, polyacrylonitriles
• CPC Class Codes: C04B 24/32 : Polyethers, e.g. alkylphenol polyglycolether
• CPC Class Codes: C04B 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 26/02 : Macromolecular compounds
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 40/0039 : Premixtures of ingredients
• CPC Class Codes: C04B 40/0608 : Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A mixture composition of a cellulose ether made from raw cotton linters and at least one additive is used in a gypsum based dry mortar composition wherein the amount of the cellulose ether in the gypsum based dry mortar composition is significantly reduced. When this gypsum based dry mortar composition is mixed with water and applied to a substrate, the water retention, sag resistance, and workability of the wet plaster mortar are comparable or improved as compared to when using conventional similar cellulose ethers.

Claims

1. A mixture composition for use in gypsum-based dry mortars comprising

a) a cellulose ether in an amount of 20 to 99.9 wt % selected from the group consisting of alkylhydroxyalkyl celluloses, hydroxyalkyl celluloses, and mixtures thereof, prepared from raw cotton linters, and

b) at least one additive in an amount of 0.1 to 80 wt % selected from the group consisting of organic or inorganic thickening agents, anti-sag agents, air entraining agents, wetting agents, defoamers, superplasticizers, dispersants, calcium-complexing agents, retarders, accelerators, water repellants, redispersible powders, biopolymers, and fibres,

wherein when the mixture is used in a gypsum-based dry mortars formulation and mixed with a sufficient amount of water, the formulation will produce a plasters mortar that can be applied to substrates, wherein the amount of the mixture in the plaster mortar is significantly reduced while water retention, sag-resistance, and workability of the plaster mortar are comparable or improved as compared to when using conventional similar cellulose ethers.

2. The mixture composition of claim 1 wherein the alkyl group of the alkylhydroxyalkyl cellulose has 1 to 24 carbon atoms, and the hydroxyalkyl group has 2 to 4 carbon atoms.

3. The mixture composition of claim 1 wherein the cellulose ether is selected from the group consisting of methylhydroxyethylcelluloses (MHEC), methylhydroxypropylcelluloses (MHPC), hydroxyethylcellulose (HEC), ethylhydroxyethylcelluloses (EHEC), methylethylhydroxyethylcelluloses (MEHEC), hydrophobically modified ethylhydroxyethylcelluloses (HMEHEC), hydrophobically modified hydroxyethylcelluloses (HMHEC) and mixtures thereof.

4. The mixture composition of claim 1, wherein the mixture also comprises one or more conventional cellulose ethers selected from the group consisting of methylcellulose (MC), methylhydroxyethylcellulose (MHEC), methylhydroxypropylcellulose (MHPC), hydroxyethylcellulose (HEC), ethylhydroxyethylcellulose (EHEC), hydrophobically modified hydroxyethylcellulose (HMHEC), hydrophobically modified ethylhydroxyethylcellulose (HMEHEC), methylethylhydroxyethylcellulose (MEHEC), sulfoethyl methylhydroxyethylcelluloses (SEMHEC), sulfoethyl methylhydroxypropylcelluloses (SEMHPC), and sulfoethyl hydroxyethylcelluloses (SEHEC).

5. The mixture composition of claim 1, wherein the amount of the cellulose ether is 70 to 99 wt %.

6. The mixture composition of claim 1, wherein the amount of the additive is 0.5 to 30 wt %.

7. The mixture composition of claim 1, wherein the at least one additive is selected from the group consisting of polysaccharides.

8. The mixture composition of claim 7, wherein the polysaccharides are selected from the group consisting of starch ether, starch, guar/guar derivatives, dextran, chitin, chitosan, xylan, xanthan gum, welan gum, gellan gum, mannan, galactan, glucan, arabinoxylan, alginate, and cellulose fibres.

9. The mixture composition of claim 1, wherein the at least one additive is selected from the group consisting of homo- or co-polymers of acrylamide, gelatine, polyethylenegylcol, casein, lignin sulfonates, naphthalene-sulfonate, sulfonated melamine-formaldehyde condensate, sulfonated naphthalene-formaldehyde condensate, polyacrylates, polycarboxylate ether, polystyrene sulphonates, phosphates, phosphonates, calcium-salts of organic acids having 1 to 4 carbon atoms, salts of alkanoates, aluminum sulfate, metallic aluminum, bentonite, montmorillonite, sepiolite, polyamide fibres, polypropylene fibres, polyvinyl alcohol, and homo-, co-, or terpolymers based on vinyl acetate, maleic ester, ethylene, styrene, butadiene, vinyl versatate, and acrylic monomers.

10. The mixture composition of claim 1, wherein the at least one additive is selected from the group consisting of calcium chelating agents, fruit acids, and surface active agents.

11. The mixture composition of claim 1, wherein the significantly reduced amount of the mixture used in the gypsum based system is at least 5% reduction.

12. The mixture composition of claim 1, wherein the significantly reduced amount of the mixture used in the gypsum based system is at least 10% reduction.

13. The mixture composition of claim 4, wherein the mixture is MHEC and an additive selected from the group consisting of homo- or co-polymer of acrylamide, starch ether, and mixtures thereof.

14. The mixture composition of claim 13, wherein the polyacrylamide is a homo-/co-polymers of acrylamide selected from the group consisting of polyacrylamide, poly(acrylamide-co-sodium-acrylate), poly(acrylamide-co-acrylic acid), poly(acrylamide-co-sodium-acrylamido methylpropanesulfonate), poly(acrylamide-co-acrylamido methylpropanesulfonic acid), poly(acrylamide-co-diallyldimethylammonium chloride), poly(acrylamide-co-(acryloylamino)propyltrimethylammoniumchloride), poly(acrylamide-co-(acryloyl)ethyltrimethylammoniumchloride), and mixtures thereof.

15. The mixture composition of claim 13, wherein the starch ether is selected from the group consisting of hydroxyalkylstarches where the alkyl has 1 to 4 carbon atoms, carboxymethylated starch ethers, and mixtures thereof.

16. The mixture composition of claim 4, wherein the mixture is MHPC and an additive selected from the group consisting of homo- or co-polymers of acrylamide, starch ether, and mixtures thereof.

17. The mixture composition of claim 4, wherein the mixture is HEC and an additive selected from the group consisting of homo- or co-polymers of acrylamide, starch ether, and mixtures thereof.

18. The mixture composition of claim 4, wherein the mixture is HMHEC and an additive selected from the group consisting of homo- or co-polymers of acrylamide, starch ether, and mixtures thereof.

19. A gypsum-based dry mortar composition comprising at least gypsum and a water-retaining agent of at least one cellulose ether prepared from raw cotton linters,

wherein the gypsum-based dry mortar, when mixed with a sufficient amount of water, produces a plaster that can be applied to substrates, wherein the amount of water-retaining agent in the plaster is significantly reduced while the water retention, sag-resistance, and workability are comparable or improved as compared to when using conventional similar cellulose ethers.

20. The gypsum based dry mortar composition of claim 19, wherein the at least one cellulose ether is selected from the group consisting of alkylhydroxyalkyl celluloses and hydroxyalkyl celluloses and mixtures thereof, prepared from raw cotton linters.

21. The gypsum based dry mortar composition of claim 20, wherein the alkyl group of the alkylhydroxyalkyl celluloses has 1 to 24 carbon atoms and the hydroxyalkyl group has 2 to 4 carbon atoms.

22. The gypsum based dry mortar composition of claim 19, wherein the at least one cellulose ether is selected from the group consisting of methylhydroxyethylcelluloses (MHEC), methylhydroxypropylcelluloses (MHPC), hydroxyethylcelluloses (HEC), methylethylhydroxyethylcelluloses (MEHEC), ethylhydroxyethylcelluloses (EHEC), hydrophobically modified ethylhydroxyethylcelluloses (HMEHEC), hydrophobically modified hydroxyethylcelluloses (HMHEC) and mixtures thereof.

23. The gypsum-based dry mortar composition of claim 22, wherein the cellulose ether, where applicable, has a methyl or ethyl degree of substitution of 0.5 to 2.5, hydroxyethyl or hydroxypropyl molar substitution (MS) of 0.01 to 6, and molar substitution (MS) of the hydrophobic substituents of 0.01-0.5 per anhydroglucose unit.

24. The gypsum based dry mortar composition of claim 19, wherein the gypsum based dry mortar composition also comprises one or more conventional cellulose ethers selected from the group consisting of methylcellulose (MC), methylhydroxyethylcellulose (MHEC), methylhydroxypropylcellulose (MHPC), hydroxyethylcellulose (HEC), ethylhydroxyethylcellulose (EHEC), hydrophobically modified hydroxyethylcellulose (HMHEC), hydrophobically modified ethylhydroxyethylcellulose (HMEHEC), methylethylhydroxyethylcellulose (MEHEC), sulfoethyl methylhydroxyethylcelluloses (SEMHEC), sulfoethyl methylhydroxypropylcelluloses (SEMHPC), and sulfoethyl hydroxyethylcelluloses (SEHEC).

25. The gypsum-based dry mortar composition of claim 19, wherein the amount of cellulose ether is 0.05 to 2.0 wt %.

26. The gypsum-based dry mortar composition of claim 19 in combination with one or more additives selected from the group consisting of organic or inorganic thickening agents, anti-sag agents, air entraining agents, wefting agents, defoamers, superplasticizers, dispersants, calcium-complexing agents, retarders, accelerators, water repellants, redispersible powders, biopolymers, and fibres.

27. The gypsum-based dry mortar composition of claim 26, wherein the one or more additives are organic thickening agents selected from the group consisting of polysaccharides.

28. The gypsum-based dry mortar composition of claim 27, wherein the polysaccharides are selected from the group consisting of starch ether, starch, guar, guar derivatives, dextran, chitin, chitosan, xylan, xanthan gum, welan gum, gellan gum, mannan, galactan, glucan, arabinoxylan, alginate, and cellulose fibres.

29. The gypsum-based dry mortar composition of claim 26, wherein the one or more additives are selected from the group consisting of homo- and co-polymers of acrylamide, gelatin, polyethylenegylcol, casein, lignin sulfonates, naphthalene-sulfonate, sulfonated melamine-formaldehyde condensate, sulfonated naphthalene-formaldehyde condensate, polyacrylates, polycarboxylate ether, polystyrene sulphonates, fruit acids, phosphates, phosphonates, calcium-salts of organic acids having 1 to 4 carbon atoms, salts of alkanoates, aluminum sulfate, metallic aluminum, bentonite, montmorillonite, sepiolite, polyamide fibres, polypropylene fibres, poly vinyl alcohol, and homo-, co-, or terpolymers based on vinyl acetate, maleic ester, ethylene, styrene, butadiene, vinyl versatate, and acrylic monomers.

30. The gypsum-based dry mortar composition of claim 26, wherein the amount of additives is between 0.0001 and 25 wt %.

31. The gypsum-based dry mortar composition of claim 19, wherein a fine aggregate material is present.

32. The gypsum-based dry mortar composition of claim 31, wherein the fine aggregate material is selected from the group consisting of silica sand, dolomite, limestone, light weight aggregates, rubber crumbs, and fly ash.

33. The gypsum-based dry mortar composition of claim 32, wherein lightweight aggregates are selected from the group consisting of perlite, expanded polystyrene, hollow glass spheres, expanded vermiculite, and cork.

34. The gypsum-based dry mortar composition of claim 31, wherein the fine aggregate material is present in the amount of 0.001 to 80 wt %.

35. The gypsum-based dry mortar composition of claim 31, wherein the fine aggregate material is present in the amount of 10 to 50 wt %.

36. The gypsum-based dry mortar composition of claim 19, wherein the gypsum is present in the amount of 20 to 99.95 wt %.

37. The gypsum-based dry mortar composition of claim 19, wherein the gypsum is present in the amount of 30 to 80 wt %.

38. The gypsum-based dry mortar composition of claim 19 in combination with hydrated lime.

39. The gypsum-based dry mortar composition of claim 38, wherein the hydrated lime is present in the amount of 0.001 and 20 wt %.

40. The gypsum based dry mortar composition of claim 19, wherein the MHEC or MHPC has an aqueous solution Brookfield viscosity of greater than 80,000 mPas as measured on a Brookfield RVT viscometer at 2 wt %, 20°

C., and 20 rpm, using a spindle no. 7.

41. The gypsum based dry mortar composition of claim 19, wherein the MHEC or MHPC has an aqueous Brookfield solution viscosity of greater than 90,000 mPas as measured on a Brookfield RVT viscometer at 2 wt %, 20°

C. and 20 rpm, using a spindle no. 7.

42. The gypsum based dry mortar composition of claim 19, wherein the significantly reduced amount of the cellulose ether used in the gypsum based composition is at least 5% reduction.

43. The gypsum based dry mortar composition of claim 19, wherein the significantly reduced amount of the mixture used in the gypsum based composition is at least 10% reduction.