Method and system for on-line blending of foaming agent with foam modifier for addition to cementitious slurries
AssigneeUnited States Gypsum Company
InventorsAnnamaria Vilinska, Alfred C. LI, Weixin D. SONG
Life of this patent
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Abstract
Disclosed is a method and system for blending a foam modifier with foaming agent online, e.g., as may be particularly useful for gypsum or cement slurries. The foam modifier comprises a fatty alcohol that is added to a gypsum or cement slurry that includes foaming agent, such as an alkyl sulfate surfactant. The fatty alcohol can be a C6-C16 fatty alcohol in some embodiments. The use of such a foam modifier can be used, for example, to stabilize the foam, reduce waste of foaming agent, improve void size control in the final product, and improve the gypsum board manufacturing process.
Claims20
A method of making a foamed cementitious board comprising:
- (a) blending a first amount of a first foaming agent, a second amount of a second foaming agent, and a third amount of a fatty alcohol to form an aqueous blended stream, wherein the first, second, and third amounts are in a first weight ratio;
- (b) controllably changing the first, second, and/or third amounts to form a second weight ratio, which is different than the first weight ratio;
- (c) inserting air into the blended stream to form foam;
- (d) mixing at least water, cementitious material, and the foam to form a slurry;
- (e) disposing the slurry between a first cover sheet and a second cover sheet to form a board precursor;
- (f) cutting the board precursor into a board;
- and
- (g) drying the board.
The method of claim wherein the first foaming agent is a stable soap and the second foaming agent is an unstable soap.
A system for forming a foam, the system comprising:
- (a) a foam generator;
- (b) an air supply conduit for introducing air into the foam generator;
- (c) a flow metering system configured to introduce a first amount of a foaming agent, a second amount of a second foaming agent, and a third amount of a fatty alcohol, irrespective of order, directly or indirectly into the foam generator;
- (d) a controller which communicates with the flow metering system to selectively change the relative amounts of first foaming agent, second foaming agent, and fatty alcohol that are introduced directly or indirectly into the foam generator.
A system for forming a foam, the system comprising:
- (a) a flow metering system comprising at least one pump operatively associated with one or more valve for controlling flow of a first foaming agent, a second foaming agent, and fatty alcohol into a blended stream conduit, irrespective of order;
- (b) a controller which communicates with the flow metering system to selectively change the relative amounts of first foaming agent, second foaming agent, and fatty alcohol that are introduced into the blended stream conduit;
- (c) a foam generator in fluid communication with the blended stream conduit;
- and
- (d) an air supply conduit for introducing air into the foam generator.
Dependencies are inferred from the claim text.