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Composite light weight gypsum wallboard

Active Publication Date: 2013-03-12
UNITED STATES GYPSUM CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention is a light weight gypsum composite board made using a foamed low density set gypsum core and a specific mixture of ingredients. The top and bottom surfaces of the foamed low density set gypsum core are covered with non-foamed (or reduced-foamed) bonding high density layers. The light weight gypsum composite board has a reduced weight and is easy to handle. The technical effect of the invention is to provide a light weight gypsum composite board with improved strength and durability.

Problems solved by technology

Unfortunately, most of this water must eventually be driven off by drying, which is expensive due to the high cost of the fuels used in the drying process.
The drying step is also time-consuming.
However, conventional wallboards are heavy, typically weighing up to 1600-1700 lb / MSF.
Thinner bonding layers would be expected to be more difficult to apply and to present other drawbacks.
Unfortunately, the use of these thick bonding layers can decrease the core hardness in the finished wallboard.

Method used

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  • Composite light weight gypsum wallboard

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0036]Sample Gypsum Slurry Formulations

[0037]Gypsum slurry formulations are shown in Table 1 below. All values in Table 1 are expressed as weight percent based on the weight of dry stucco. Values in parentheses are dry weight in pounds (lb / MSF).

[0038]

TABLE 1ComponentFormulation AFormulation BStucco (lb / MSF)(732) (704)sodium trimetaphosphate0.20(1.50)0.30(2.14)Dispersant (naphthalenesulfonate)0.18(1.35)0.581(4.05)Pregelatinized starch (dry powder)2.7(20)6.4(45)Board starch0.41(3.0)0Heat resistant accelerator (HRA)(15)(15)Glass fiber0.27 (2.0)0.28(2.0)Paper fiber00.99(7.0)Soap*0.03(0.192)0.03(0.192)Total Water (lb.)805852Water / Stucco ratio1.101.21*Used to pregenerate foam11.28% by weight as a 45% aqueous solution.

example 2

[0039]Preparation of Wallboards

[0040]Sample gypsum wallboards wee prepared in accordance with U.S. Pat. No. 6,342,284, to Yu et al. and U.S. Pat. No. 6,632,550 to Yu et al., herein incorporated by reference. This includes the separate generation of foam and introduction of the foam into the slurry of all of the other ingredients as described in Example 5 of these patents.

[0041]Test results for gypsum wallboards made using the Formulation A and B of Example 1, and a normal control board are shown in Table 2 below. As in this example and other examples below, nail pull resistance, core hardness, and flexural strength tests were performed according to ASTM C-473. Additionally, it is noted that typical gypsum wallboard is approximately ½ inch thick and has a weight of between about 1600 to 1800 pounds per 1,000 square feet of material, or lb / MSF. (“MSF” is a standard abbreviation in the art for a thousand square feet; it is an area measurement for boxes, corrugated media and wallboard.)...

example 3

[0045]½ Inch Gypsum Wallboard Weight Reduction Trials

[0046]Further gypsum wallboard examples (Boards C, D and E), including slurry formulations and test results are shown in Table 3 below. The slurry formulations of Table 3 include the major components of the slurries. Values in parentheses are expressed as weight percent based on the weight of dry stucco.

[0047]

TABLE 3Control FormulationFormulationFormulationBoardC BoardD BoardE BoardTrial formulationcomponent / parameterDry stucco (lb / MSF)1300128111961070Accelerator (lb / MSF)9.29.29.29.2DILOFLO1 (lb / MSF)4.1(0.32%)8.1(0.63%)8.1(0.68%) 8.1(0.76%)Regular starch (lb / MSF)5.6(0.43%)000Pregelatinized corn starch010(0.78%)10(0.84%)10(0.93%)(lb / MSF)Sodium trimetaphosphate0.7 (0.05%)1.6 (0.12%)1.6 (0.13%)1.6(0.15%)(lb / MSF)Total water / stucco ratio0.820.820.820.84(w / s)Trial formulationtest resultsDry board weight1611157014511320(lb / MSF)Nail pull resistance (lb)77.3†85.577.265.2†ASTM standard: 77 lb1DILOFLO is a 45% Naphthalensulfonate solution in...

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Abstract

The invention provides a light weight composite gypsum board including a foamed low density set gypsum core, a top non-foamed (or reduced-foamed) bonding high density layer and a bottom non-foamed (or reduced-foamed) bonding high density layer, a top cover sheet bonded to the foamed low density set gypsum core by the top non-foamed (or reduced-foamed) bonding high density layer, and a bottom cover sheet bonded to the foamed low density set gypsum core by the bottom non-foamed (or reduced-foamed) bonding high density layer. The foamed low density set gypsum core is prepared having a density of less than about 30 pcf using soap foam in the gypsum-containing slurry. The combination of components provide a composite gypsum board having light weight and high strength.

Description

[0001]This application is a continuation-in-part of U.S. patent application Ser. No. 11 / 449,177, filed Jun. 7, 2006 now U.S. Pat. No. 7,731,794, and is a continuation-in-part of U.S. patent application Ser. No. 11 / 445,906, filed Jun. 2, 2006 now abandoned, each one of which claims the benefit of U.S. Provisional Application No. 60 / 688,839, filed Jun. 9, 2005. The entire disclosures of each of the foregoing patent applications are hereby incorporated by reference.FIELD OF THE INVENTION[0002]This invention pertains to unique light weight composite gypsum boards having high strength. It also pertains to a method of making such light weight composite gypsum boards using a unique gypsum-containing slurry to form a foamed low density set gypsum core and non-foamed (or reduced-foamed) bonding high density layers that bond the top and bottom cover sheets to the core.BACKGROUND OF THE INVENTION[0003]Certain properties of gypsum (calcium sulfate dihydrate) make it very popular for use in maki...

Claims

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Application Information

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IPC IPC(8): B32B3/26B32B13/00C04B28/14
CPCC04B28/14C04B14/42C04B18/24C04B22/16C04B24/226C04B24/383C04B2111/0062Y10T428/24479C04B2103/408Y02W30/91C04B24/38
Inventor YU, QIANGSONG, WEIXIN D.
Owner UNITED STATES GYPSUM CO
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