Geo Specialty Chemicals, Inc.

Henkel Corporation

Geo Speciality Chemicals, Inc.

Dawn P Elko

Arpad Savoly

Bennie Veal

James McCrary

David B Heller, Jr

Jiang Li

Lanny Clement

Timothy Hegge

Michelle L McMahon

James Mccrary

A dispersant composition for use in gypsum and/or cementitious compositions that includes, in combination, a polycarboxylate-based superplasticizer and a synergistically effective amount of an aluminum salt. The presence of the aluminum salt, such as aluminum chlorohydrate, improves the performance of the polycarboxylate-based superplasticizer.

Polycarboxylate-based superplasticizer compositions and methods of use

The present invention provides a plaster composition that includes calcined gypsum and a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight from about 17,000 to about 47,000. The present invention also provides a method of forming a plaster composition that includes belending calcined gypsum and a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight from about 17,000 to about 47,000 together to form a dry blend and contacting the dry blend with water to form a hardenable aqueous slurry.

Plaster composition and method of making same

The present invention provides a dispersant and foaming agent combination that is useful in the production of gypsum wallboard and other aqueous cementitious products, a method of forming a gypsum wallboard and a gypsum wallboard. The dispersant in the combination according to the invention is a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight of from about 17,000 to about 47,000. The alkali is preferably an alkali metal and/or an alkaline earth metal. The aldehyde is preferably formaldehyde. The foaming agent used in the combination according to the invention is a soap, preferably an alkali salt of an alkyl ether sulfate and/or an alkyl sulfate. The combination of a high molecular weight dispersant and a foaming agent produces a gypsum wallboard core effect that more efficiently entrains air (i.e., creates void space), thereby lowering overall board weight without detrimentally affecting strength. A gypsum wallboard formed using the dispersant and foaming agent combination according to the invention exhibits a higher nail pull value than gypsum wallboard formed using a conventional dispersant and a foaming agent at the same solids loading ratio.

Method of making wallboard

The present invention provides a sulfonated coal tar distillate salt polymer that is a condensation product of an aldehyde, preferably formaldehyde, and a sulfonated middle fraction obtained during coal tar distillation. The middle fraction includes from about 40% to about 95% by weight naphthalene and from about 5% to about 60% by weight of a plurality of compounds selected from the group consisting of quinoline, indene, biphenyl, indane, acenaphthene, anthracene, phenanthrene, methyl naphthalene, cresol, phenol, xylenol, and tetralin. The present invention also provides a method of forming a sulfonated coal tar distillate salt polymer. The method includes sulfonating the middle fraction to form a middle fraction sulfonic acid mass, optionally adding a first portion of water to the middle fraction sulfonic acid mass to form a mixture, reacting the mixture and an aldehyde to form a condensate, optionally adding a second portion of water to dilute the condensate, and adding a base to form a sulfonated middle fraction salt polymer. Sulfonated middle fraction salt polymers formed in accordance with the method of the invention are useful as dispersants and plasticizers in aqueous cementitious slurries.

Dispersant composition

The present invention provides a dispersant and foaming agent combination that is useful in the production of gypsum wallboard and other aqueous cementitious products. The dispersant in the combination according to the invention is a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight of from about to about The alkali is preferably an alkali metal and/or an alkaline earth metal. The aldehyde is preferably formaldehyde. The foaming agent used in the combination according to the invention is a soap, preferably an alkali salt of an alkyl ether sulfate and/or an alkyl sulfate. The combination of a high molecular weight dispersant and a foaming agent produces a gypsum wallboard core effect that more efficiently entrains air (i.e., creates void space), thereby lowering overall board weight without detrimentally affecting strength.

Dispersant and foaming agent combination

Surfactants containing a mixture of alkyl sulfate and alkyl ether sulfate in specific ratios are provided. Preferred compositions are blends of alkyl sulfate with narrow range alkoxylated alcohols are sulfonated. These compositions are used as improved foaming agent compositions and exhibit desirable foaming characteristics for use in the manufacture of gypsum board and concrete and in oil field applications.

Foaming agent composition and process

Narrow range alkoxylated alcohols are sulfonated and used as improved foaming agent compositions. These compositions exhibit desirable foaming characteristics for use in the manufacture of gypsum board and concrete and in oil field applications.

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Flemington, NJ, United States of America

Dawn P Elko