Methods for manufacturing building boards
The present disclosure relates generally to methods of manufacturing plasterboards, such as gypsum wallboards. One aspect of the disclosure is a method of manufacturing a building board that includes providing a wet building board by allowing a plaster slurry to set between opposing facings, the wet building board having a set plaster core disposed between the facings; and providing a surfactant (such as a quaternary ammonium salt surfactant) on at least one of the facings (e.g., by applying an aqueous surfactant-containing composition to the facing); then conducting the wet building board to a drying oven, for example, via one or more conveyers (e.g., rollers and/or belts and/or rails); and drying the wet building board in the drying oven to provide the building board.
1 . A method for manufacturing a building board comprising:
providing a wet building board by allowing a plaster slurry to set between opposing facings, the wet building board having a set plaster core disposed between the facings; and
applying a diesterquat surfactant on at least one of the facings of the wet building board, each of the at least one of the facings on which the diesterquat surfactant is provided being a paper facing; then
conducting the wet building board to a drying oven via one or more first conveyers in contact with the at least one facing on which the diesterquat surfactant is applied;
drying the wet building board in the drying oven to provide the building board; and
conducting the building board beyond the drying oven via one or more second conveyers in contact with the at least one facing on which the diesterquat surfactant is applied.
2 . The method of claim 1 , wherein the diesterquat esterquat has an ammonium cation having the structural formula (R 1 ) n N + ((CHR 2 ) x OC(O)R 3 ) (4-n) , in which n is 2; each R 1 is independently methyl, ethyl or benzyl; x is 2 or 3; each R 2 is independently hydrogen or methyl; and each R 3 is C 12 -C 22 alkyl.
3 . The method of claim 1 , wherein the diesterquat surfactant is provided on the facing by applying a diesterquat surfactant-containing aqueous composition to the facing, the diesterquat surfactant being present in the aqueous composition in an amount in the range of 0.005-2 wt %.
4 . The method of claim 1 , wherein the diesterquat surfactant is provided on the facing by applying a diesterquat surfactant-containing aqueous composition to the facing, the aqueous composition comprising a laundry fabric softener composition containing the diesterquat surfactant diluted with water.
5 . The method of claim 4 , wherein the aqueous composition comprises the laundry fabric softener in a ratio in the range of 0.1-10 parts of the laundry fabric softener composition per 100 parts of aqueous composition.
6 . The method of claim 1 , wherein the diesterquat surfactant is provided on the facing by applying a diesterquat surfactant-containing aqueous composition to the facing, the aqueous composition being applied to the facing at a treat rate in the range of 0.005-1 gal/MSF.
7 . The method of claim 1 , wherein the diesterquat surfactant is provided on the facing in an amount in the range of 0.01-10 g/MSF.
8 . The method of claim 1 , wherein the diesterquat surfactant is provided on the facing in an amount in the range of 0.2-5 g/MSF.
9 . The method of claim 1 , wherein the set plaster core comprises a silicone.
10 . The method of claim 9 , wherein the silicone is present in an amount in the range of 0.5-20 lbs/MSF/(⅝″).
11 . The method of claim 1 , wherein the plaster slurry is a stucco slurry, and wherein the set plaster core is a set gypsum core.
12 . The method of claim 1 , wherein the set plaster core has wherein the set plaster core has a thickness in the range of ¼″ to 1″.
13 . The method of claim 1 , wherein the one or more first conveyors comprise one or more rollers, belts and/or rails.
14 . The method of claim 2 , wherein each R 1 is methyl; x is 2; each R 2 is hydrogen; and each R 3 is C 14 -C 18 alkyl.
15 . The method of claim 1 , wherein the one or more second conveyors comprise one or more rollers, belts and/or rails.
16 . The method of claim 1 , wherein
the diesterquat has an ammonium cation having the structural formula (R 1 ) n N + ((CHR 2 ) x OC(O)R 3 ) (4-n) , in which n is 2; each R 1 is methyl; x is 2; each R 2 is independently hydrogen; and each R 3 is C 14-18 alkyl;
the set plaster core comprises a silicone present in an amount in the range of 0.5-20 lbs/MSF/(⅝″); and
the diesterquat surfactant is provided on the facing in an amount in the range of 0.2-5 g/MSF.
17 . The method of claim 1 , wherein
the set plaster core comprises a silicone present in an amount in the range of 0.5-20 lbs/MSF/(⅝″); and
the diesterquat surfactant is provided on the facing in an amount in the range of 0.2-5 g/MSF.
18 . The method of claim 1 , wherein
the diesterquat has an ammonium cation having the structural formula (R 1 ) n N + ((CHR 2 ) x OC(O)R 3 ) (4-n) , in which n is 2; each R 1 is independently methyl, ethyl or benzyl; x is 2 or 3; each R 2 is independently hydrogen or methyl; and each R 3 is C 12 -C 22 alkyl;
the set plaster core comprises a silicone present in an amount in the range of 0.5-20 lbs/MSF/(⅝″); and
the diesterquat surfactant is provided on the facing in an amount in the range of 0.2-5 g/MSF.
19 . The method of claim 1 , wherein the diesterquat surfactant is provided on the facing by spraying a diesterquat surfactant-containing aqueous composition on the facing.