Struvite-K and Syngenite composition for use in building materials

Patent metadata

Field	Value
Publication number	US-10472284-B2
Application number	US-201615239145-A
Country	US
Kind code	B2
Filing date	Aug 17, 2016
Priority date	Aug 12, 2013
Publication date	Nov 12, 2019
Grant date	Nov 12, 2019

Abstract

A composition and process for the manufacture thereof for use in a hybrid building material comprising at least in part Syngenite (K 2 Ca(SO 4 ) 2 .H 2 O) and Struvite-K (KMgPO 4 ·6H 2 O). Specified constituents, including magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate) are mixed in predetermined ratios and the reaction proceeds through multiple phases reactions which at times are proceeding simultaneously and in parallel and reaction may even compete with each other for reagents if the Struvite-K reaction is not buffered to slow down the reaction rate). A number of variable factors, such as water temperature, pH mixing times and rates, have been found to affect resultant reaction products. Preferred ratios of chemical constituents and manufacturing parameters, including predetermined and specified ratios of Struvite-K and Syngenite may be provided for specified purposes, optimized in respect of stoichiometry to reduce the combined heat of formation to non-destructive levels.

First claim

What is claimed is:

1. A building composition for use in a building product comprising Struvite-K (KMgPO 4 ·6H 2 O), Syngenite (K 2 Ca(SO 4 ) 2 H 2 O), and one or more of stucco hemihydrate (CaSO 4 ·1/2H 2 O), gypsum (CaSO 4 ·2H 2 O), and Magnesium Oxide (MgO), wherein the one or more of stucco hemihydrate, gypsum, and Magnesium Oxide are randomly distributed in a matrix within the crystalline structures that are presented by Struvite-K and Syngenite.

2. The building composition for use in a building product according to claim 1 , wherein:
Struvite-K is present in an amount of from 0.1 to 67.0 weight percent;
Syngenite is present in an amount of from 2.5 to 60.0 weight percent; and
one or more of stucco hemihydrate, and Magnesium Oxide making up the remaining composition.

3. The building composition for use in a building product according to claim 2 , wherein:
Struvite-K is present in an amount of from 15.1 to 37.0 weight percent; and
Syngenite is present in an amount of from 12.5 to 46.0 weight percent; and
one or more of stucco hemihydrate, and Magnesium Oxide making up the remaining composition.

4. A fire-resistant hybrid wallboard comprising a composition according to claim 1 .

5. The fire-resistant hybrid wallboard according to claim 4 , further comprising a facing material including a randomly aligned inorganic fibrous mat with a coating comprising the composition.

6. The fire-resistant hybrid wallboard according to claim 4 , wherein the composition includes:
Struvite-K in an amount of from 0.1 to 67.0 weight percent;
Syngenite in an amount of from 2.5 to 60.0 weight percent; and
the one or more of stucco hemihydrate (CaSO 4 ·1/2H 2 O), gypsum (CaSO 4 ·2H 2 O), and Magnesium Oxide (MgO) making up the remaining composition.

7. The fire-resistant hybrid wallboard according to claim 6 , further comprising a facing material including a randomly aligned inorganic fibrous mat with a coating comprising the composition.

8. A fibrous mat comprising randomly aligned inorganic fiber strands and a coating comprising a composition according to claim 1 .

9. The fibrous mat according to claim 8 wherein the composition comprises stucco hemihydrate and Magnesium Oxide.

10. The fibrous mat according to claim 8 wherein the composition comprises:
Struvite-K in an amount of from 0.1 to 67.0 weight percent;
Syngenite in an amount of from 2.5 to 60.0 weight percent; and
the one or more of stucco hemihydrate, gypsum, and Magnesium Oxide making up the remaining composition.

11. The building composition of claim 1 , wherein the composition comprises stucco hemihydrate and magnesium oxide.

12. The building composition of claim 1 , wherein the one or more of stucco hemihydrate, gypsum, and magnesium oxide are amorphous.

13. The building composition of claim 1 , wherein:
Struvite-K is present in an amount of from 0.1 to 67.0 weight percent;
Syngenite is present in an amount of from 2.5 to 60.0 weight percent; and
one or more of stucco hemihydrate, gypsum, and magnesium oxide making up the remaining product.

14. The building composition of claim 1 , wherein:
Struvite-K is present in an amount of from 15.1 to 37.0 weight percent; and
Syngenite is present in an amount of from 12.5 to 46.0 weight percent; and
one or more of stucco hemihydrate, gypsum, and magnesium oxide making up the remaining product.

15. The building composition of claim 1 , further comprising a polysiloxane or a silicone.

16. The building composition of claim 1 , wherein the gypsum is present.

17. The building composition of claim 16 , further comprising a dispersant.

Assignees

• Certainteed Gypsum Inc

Inventors

• Hauber Robert J
• Boydston Gerald D
• Frailey Nathan
• Lamberet Severine
• Pattarkine Gaurav V
• Cherian Isaac K
• Centurione Sergio
• Ghosh Anirban

Classifications

• C04B12/027

  mixtures thereof with other inorganic cementitious materials · CPC title

• C04B11/28 Primary

  Mixtures thereof with other inorganic cementitious materials (C04B7/04, C04B7/153 take precedence) · CPC title

• C04B28/344 Primary

  the phosphate binder being present in the starting composition solely as one or more phosphates · CPC title

• C04B28/34

  containing cold phosphate binders · CPC title

• C04B2111/28

  Fire resistance, i.e. materials resistant to accidental fires or high temperatures · CPC title