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NZ738926B2 - Composite gypsum board and methods related thereto - Google Patents

Composite gypsum board and methods related thereto Download PDF

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Publication number
NZ738926B2
NZ738926B2 NZ738926A NZ73892616A NZ738926B2 NZ 738926 B2 NZ738926 B2 NZ 738926B2 NZ 738926 A NZ738926 A NZ 738926A NZ 73892616 A NZ73892616 A NZ 73892616A NZ 738926 B2 NZ738926 B2 NZ 738926B2
Authority
NZ
New Zealand
Prior art keywords
board
core
composite gypsum
concentrated layer
stucco
Prior art date
Application number
NZ738926A
Other versions
NZ738926A (en
Inventor
Brian J Christ
Gregg G Diefenbacher
Frederick T Jones
Alfred C Li
Yijun Sang
Weixin D Song
Bradley W Todd
Annamaria Vilinska
Original Assignee
United States Gypsum Company
Filing date
Publication date
Priority claimed from US15/186,232 external-priority patent/US10421251B2/en
Application filed by United States Gypsum Company filed Critical United States Gypsum Company
Priority claimed from PCT/US2016/038737 external-priority patent/WO2016209942A1/en
Publication of NZ738926A publication Critical patent/NZ738926A/en
Publication of NZ738926B2 publication Critical patent/NZ738926B2/en

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Classifications

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    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster

Abstract

Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

Claims (19)

1. (a) A composite gypsum board comprising: a board core comprising set gypsum formed from a first slurry comprising at least water, stucco, and optionally, strength-enhancing starch, the core having a dry density and dry thickness, the core defining first core and second core faces in opposing relation; and (b) a concentrated layer formed from a second slurry comprising at least water, stucco, and the strength-enhancing starch, the concentrated layer disposed in bonding relation to the first core face; wherein: (i) (ii) (iii) (iv) (v)
2. the amount of strength-enhancing starch is included in a higher amount by weight of the stucco in forming the concentrated layer than the amount of strength-enhancing starch by weight of the stucco in forming the board core, the board core has a thickness greater than the thickness of the concentrated layer, the latter thickness being from 0.05cm to 0.23cm, the concentrated layer has a dry density at least 1.1 times higher than the board core dry density, the second slurry having a water-stucco ratio that is at least 1.2 times higher than that of the first slurry; and the board has a nail pull resistance according to ASTM C473-10, Method B of at least 30.8 kg or 302.48 N. The composite gypsum board of claim 1, wherein: (i) (ii)
3. the concentrated layer is formed from at least about 1.2 times the strength-enhancing starch used in forming the board core, and the board core has a dry density of from about 380 kg/m3 (about 24 pcf) to about 640 kg/m3 (about 40 pcf). The composite gypsum board of claim 1, wherein the strength-enhancing starch is uncooked.
4. The composite gypsum board of any one of claims 1-3, wherein the strength enhancing starch is a non-migrating starch. 88
5. The composite gypsum board of any one of claims 1-4, wherein the concentrated layer is further formed from fiber in a greater concentration than in the board core.
6. The composite gypsum board of any one of claims 1, 4, or 5, wherein the strength-enhancing starch comprises a pregelatinized starch having a viscosity of from about 20 centipoise to about 700 centipoise when the viscosity is measured while the starch is subjected to conditions according to the VMA method.
7. The composite gypsum board of any one of claims 1 and 3-6, wherein the board core has a dry density of about 480 kg/m3 (30 pcf) or less.
8. The composite gypsum board of any one of claims 1-7, wherein the concentrated layer has a Young’s modulus that is at least about 1.5 times higher than a Young’s modulus of the board core.
9. The composite gypsum board of any one of claims 1-8, wherein the density differential between the concentrated layer and the board core is at least about 130 kg/m3 (8 pcf).
10. The composite gypsum board of any one of claims 1-9, wherein the thickness of the board core is from about 9 times to about 14 times thicker than the thickness of the concentrated layer.
11. The composite gypsum board of any one of claims 1-10, wherein the strength enhancing starch is included in forming the concentrated layer in an amount of from about 5% to about 40% by weight of the stucco and is included in forming the board core in an amount of from about 0% to about 4% by weight of the stucco.
12. The composite gypsum board of any one of claims 1-11, wherein the board core and/or the concentrated layer is further formed from a polyphosphate, wherein the polyphosphate is included in forming the concentrated layer in an amount of from about 0.2% to about 0.4% by weight of the stucco, and is included in forming the board core in an amount of from about 0% to about 0.2% by weight of the stucco, and wherein the polyphosphate is sodium trimetaphosphate, potassium trimetaphosphate, ammonium trimetaphosphate, lithium trimetaphosphate or any combination thereof. 89
13. The composite gypsum board of any one of claims 1-12, wherein the board core and/or the concentrated layer is further formed from a dispersant, wherein the dispersant is included in forming the concentrated layer in an amount from about 0.1% to about 0.2% by weight of the stucco, and is included in forming the board core in an amount of from about 0% to about 0.4% by weight of the stucco, and wherein the dispersant is a naphthalenesulfonate, polycarboxylate, lignosulfonate, sulfonated lignin, or any combination thereof.
14. The composite gypsum board of any one of claims 1-13, wherein the concentrated layer has an average core hardness that is at least about 4 times greater than the average core hardness of the board core, wherein the average core hardness is measured according to ASTM C10.
15. The composite gypsum board of any one of claims 1-14, wherein the water and stucco for forming the board core are in a water-stucco ratio of from about 0.3 to about 0.7, and wherein the water and stucco for forming the concentrated layer are in a water-stucco ratio of from about 0.7 to about 2.0.
16. The composite gypsum board of any one of claims 1-15, wherein the board further comprises a bonding layer disposed between a top cover sheet and the board core and/or between a bottom cover sheet and the board core, wherein the bonding layer has a thickness of from about 0.03 cm (about 0.01 inches) to about 0.04 cm (about 0.015 inches).
17. The composite gypsum board of any one of claims 1-16, wherein the strength enhancing starch is an uncooked acid modified corn starch having a molecular weight between 30,000 Daltons and 150,000,000 Daltons.
18. The composite gypsum board of any of claims 1-16, wherein the strength enhancing starch is one or more of Clinton 277 or Clineo 714.
19. The composite gypsum board of any of claims 1-16, wherein the strength enhancing starch is a waxy corn starch.
NZ738926A 2016-06-22 Composite gypsum board and methods related thereto NZ738926B2 (en)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
US201562184060P 2015-06-24 2015-06-24
US201662290361P 2016-02-02 2016-02-02
US15/186,232 US10421251B2 (en) 2015-06-24 2016-06-17 Composite gypsum board and methods related thereto
US15/186,212 US11040513B2 (en) 2015-06-24 2016-06-17 Composite gypsum board and methods related thereto
US15/186,257 US12090744B2 (en) 2015-06-24 2016-06-17 Composite gypsum board and methods related thereto
US15/186,176 US10421250B2 (en) 2015-06-24 2016-06-17 Composite gypsum board and methods related thereto
PCT/US2016/038737 WO2016209942A1 (en) 2015-06-24 2016-06-22 Composite gypsum board and methods related thereto

Publications (2)

Publication Number Publication Date
NZ738926A NZ738926A (en) 2024-10-25
NZ738926B2 true NZ738926B2 (en) 2025-01-28

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