Gypsum product composition, gypsum products, and a method for using a compound in gypsum board

Patent metadata

Field	Value
Publication number	US-10399904-B2
Application number	US-201516062532-A
Country	US
Kind code	B2
Filing date	Dec 18, 2015
Priority date	Dec 18, 2015
Publication date	Sep 3, 2019
Grant date	Sep 3, 2019

Abstract

A gypsum board composition was disclosed which comprises stucco, adhesive, water and additive for improving bonding, wherein the additive for improving bonding is shown in chemical formula as MIMII(OH)2(An−).mH2O, wherein MI is a divalent metal ion, MII is a trivalent metal ion, and An− is an interlayer anion, and wherein MI and MII are different metals. Also, a gypsum board made with the composition of the above and a method for using a compound shown in the aforesaid chemical formula were disclosed.

First claim

What is claimed is:

1. A gypsum board composition, comprising:
stucco, adhesive, water and additive for improving bonding,
wherein the additive for improving bonding is shown in chemical formula (1):
M I M II (OH) 2 (A n− ).mH 2 O  (1)

wherein M I is a divalent metal ion, M II is a trivalent metal ion, and A n− is an interlayer anion, and wherein M I and M II are different metals.

2. The composition according to claim 1 , wherein M I is selected from a group consisting of Mg 2+ , Ni 2+ , Fe 2+ , Ca 2+ , Zn 2+ , Cu 2+ , and Mn 2+ , wherein M II is selected from a group consisting of Fe 2+ , Al 2+ , Ni 2+ , and Co 2+ , and wherein A 2− is selected from a group consisting of CO 3 2+ , OH − , NO 3 − , PO 3 4− , and SO 4 2− .

3. The composition according to claim 1 , wherein M I is Mg 2+ , M II is Al 2+ , and A n− is CO 2 2− .

4. The composition according to claim 1 , wherein the content of the additive for improving bonding is less than or equal to 5 wt. % and greater than 0 wt. % of the stucco.

5. The composition according to claim 1 , wherein the adhesive is starch and/or Polyvinyl Alcohol, wherein the content of the adhesive is greater than 0.06 wt. % of the stucco.

6. The composition according to claim 1 , wherein the content of the additive for improving bonding is less than or equal to 5 wt. % and greater than 0 wt. % of the stucco, and the content of the adhesive is greater than 0.06 wt. % of the stucco.

7. A gypsum board, comprising:
a main gypsum plate comprising stucco, adhesive, and additive therein,
lining paper on both major surfaces of the main gypsum plate;
wherein the additive is shown in chemical formula (1):
M I M II (OH) 2 (A n− ).mH 2 O  (1)

wherein M I is a divalent metal ion, M II is a trivalent metal ion, and A n− is an interlayer anion comprising at least Cl − , and wherein M I and M II are different metals.

8. The gypsum board according to claim 7 , wherein M I is selected from a group consisting of Mg 2+ , Ni 2+ , Fe 2+ , Ca 2+ , Zn 2+ , Cu 2+ , and Mn 2+ , wherein M II is selected from a group consisting of Fe 2+ , Al 2+ , Ni 2+ , and Co 2+ , and wherein A n− additionally comprises an anion from a group consisting of CO 3 2− , OH − , NO 3 − , PO 3 4− , and SO 4 2− .

9. The gypsum board according to claim 7 , wherein M I is Mg 2+ , and M II is Al 2+ .

10. The gypsum board according to claim 7 , wherein the content of the additive is less than or equal to 5 wt. % and greater than 0 wt. % of the stucco.

11. The gypsum board according to claim 7 , wherein the content of the adhesive is greater than 0.06 wt. % of the stucco.

12. A method for using a compound shown in chemical formula (1):
M I M II (OH) 2 (A n− ).mH 2 O  (1)

wherein M I is a divalent metal ion, M II is a trivalent metal ion, and A n− is an interlayer anion, wherein M I and M II are different metals, and wherein the compound is used as additive for improving bonding in a gypsum board.

13. The method according to claim 12 , wherein M I is selected from a group consisting of Mg 2+ , Ni 2+ , Fe 2+ , Ca 2+ , Zn 2+ , Cu 2+ , and Mn 2+ , wherein M II is selected from a group consisting of Fe 2+ , Al 1+ , Cr 2+ , and Cu 2+ , wherein A n− is selected from a group consisting of CO 3 2− , OH − , NO 3 − , PO 3 2− , and SO 4 2− .

14. The method according to claim 12 , wherein M I is Mg 2+ , M II is Al 3+ , and A n− is CO 3 2− .

15. The method according to claim 12 , wherein the gypsum board comprises stucco and the content of the compound is less than or equal to 5 wt. % and greater than 0 wt. % of the stucco.

16. The method according to claim 12 , wherein the gypsum board comprises stucco and adhesive.

17. The method according to claim 16 , wherein the adhesive is starch and/or Polyvinyl Alcohol and the content of the adhesive is 0.3 wt. % of the stucco.

18. The method according to claim 16 , wherein the content of the compound is less than or equal to 5 wt. % and greater than 0 wt. % of the stucco, and the content of the adhesive is greater than 0.06 wt. % of the stucco.

19. A gypsum plaster composition, comprising stucco, water, and an additive of the following chemical formula,
M I M II (OH) 2 (A n− ).mH 2 O,  (1),

wherein M I is a divalent metal ion, M II is a trivalent metal ion, and A n− is an interlayer anion, and wherein M I and M II are different metals.

20. The gypsum plaster composition according to claim 19 , wherein, M I is selected from a group consisting of Mg 2+ , Ni 2+ , Fe 2+ , Ca 2+ , Zn 2+ , Cu 2+ , and Mn 2+ , wherein, M II is selected from a group consisting of Fe 2+ , Al 2+ , Ni 3+ , and Co 3+ , wherein A n− is selected from a group consisting of CO 3 2− , OH − , NO 3 − , PO 3 4− , and SO 4 2− .

21. The composition according to claim 19 , wherein M I is Mg 2+ , M II is Al 2+ , and A n− is CO 3 2− .

22. The composition of claim 19 , wherein the composition further comprises perlite, wherein the perlite is present in an amount of 1-10% relative to the weight of the gypsum particles.

23. The gypsum plaster composition of claim 19 , wherein the content of the additive is less than or equal to 5 wt. % and greater than 0 wt. % of the stucco.

24. A gypsum-based jointing compound composition, comprising:
stucco, water, polymer additives and an additive of the following chemical formula (1):
M I M II (OH) 2 (A n− ).mH 2 O  (1)

wherein M I is a divalent metal ion, M II is a trivalent metal ion, and A n− is an interlayer anion, and wherein M I and M II are different metals.

25. The gypsum-based jointing compound composition of claim 24 , wherein M I is selected from a group consisting of Mg 2+ , Ni 2+ , Fe 2+ , Ca 2+ , Zn 2+ , Cu 2+ , and Mn 2+ , wherein M II is selected from a group consisting of Fe 2+ , Al 2+ , Ni 2+ , and Co 2+ , and wherein A n− is selected from a group consisting of CO 3 2− , OH − , NO 3 − , PO 3 4− , and SO 4 1− .

26. The gypsum-based jointing compound composition of claim 24 , wherein M I is Mg 2+ , M II is Al 2+ , and A n− is CO 3 2− .

27. The gypsum-based jointing compound composition of claim 24 , wherein the content of the additive is less than or equal to 5 wt. % and greater than 0 wt. % of the stucco.

28. The composition according to claim 5 , wherein the content of the adhesive is from 0.3 wt. % to 1.0 wt. % of the stucco.

29. The composition according to claim 5 , wherein the content of the adhesive is from 0.3 wt. % to 0.5 wt. % of the stucco.

30. The composition according to claim 5 , wherein the content of the adhesive is 0.3 wt. % of the stucco.

31. The composition according to claim 6 , wherein the content of the adhesive is from 0.3 wt. % to 1.0 wt. % of the stucco.

32. The composition according to claim 6 , wherein the content of the adhesive is from 0.3 wt. % to 0.5 wt. % of the stucco.

33. The composition according to claim 6 , wherein the content of the adhesive is 0.3 wt. % of the stucco.

Assignees

• Ironside Kane
• Song Hao
• Saint Gobain Placo

Inventors

• Ironside Kane
• Song Hao

Classifications

• C04B22/16

  containing phosphorus in the anion, e.g. phosphates · CPC title

• C04B22/085

  containing nitrogen in the anion, e.g. nitrites · CPC title

• C04B22/06

  Oxides, Hydroxides (C04B22/0013 takes precedence) · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• C04B28/14 Primary

  containing calcium sulfate cements {(gypsum-paper plates E04C)} · CPC title