Colloidal vesicles for use as dedusting agents in construction panels

Patent metadata

Field	Value
Publication number	US-10988416-B2
Application number	US-201916366012-A
Country	US
Kind code	B2
Filing date	Mar 27, 2019
Priority date	Apr 23, 2018
Publication date	Apr 27, 2021
Grant date	Apr 27, 2021

Abstract

Ceiling tiles and wallboards can be produced with vesicle dedusting agent. For example, a ceiling tile can comprise: a dried base mat that includes: (a) mineral wool; (b) binder; (c) a vesicle dedusting agent at about 0.01 to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles; (d) optionally cellulosic fiber; (e) optionally perlite; (f) optionally glass fiber; and (g) optionally calcium sulfate dihydrate. For example, a wallboard produced from a slurry comprising: (a) calcium sulfate hemihydrate at 70 to 95 wt %; (b) a vesicle dedusting agent at about 0.01 to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles; (c) optionally cellulose fibers at about 0.5 to about 3 wt %; (d) optionally at least one dispersant at about 0.01 to about 2 wt %; and (e) water at a ratio of water to dry components of about 1:6 to about 20:1.

First claim

What is claimed is:

1. A wallboard having a layer produced from a slurry, the slurry comprising:
calcium sulfate hemihydrate at 70 wt % to 95 wt %;
a vesicle dedusting agent at about 0.01 wt % to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles;
optionally at least one dispersant at about 0.01 wt % to about 2 wt %; and
water at a ratio of water to dry components of about 1:6 to about 20:1.

2. The wallboard of claim 1 , wherein the slurry comprises:
the calcium sulfate hemihydrate at 70 wt % to 95 wt %;
the vesicle dedusting agent at about 0.01 wt % to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles;
cellulose fibers at about 0.5 wt % to about 3 wt %;
optionally the at least one dispersant at about 0.01 wt % to about 2 wt %; and
the water at a ratio of water to dry components of about 3:1 to about 20:1.

3. The wallboard of claim 1 , wherein the slurry further comprises: cellulose fibers at about 0.5 wt % to about 3 wt %.

4. The wallboard of claim 1 , wherein the vesicles comprise unilamellar vesicles.

5. The wallboard of claim 4 , wherein the unilamellar vesicles have an average diameter of about 50 nm up to 5000 nm and a polydispersity index of about 0.2 to about 0.5.

6. The wallboard of claim 1 , wherein the vesicles comprise multilamellar vesicles.

7. The wallboard of claim 6 , wherein the multilamellar vesicles have an average diameter of about 100 nm up to 5 microns and a polydispersity index of about 0.2 to about 0.5.

8. The wallboard of claim 1 , wherein the vesicles comprise lecithin.

9. The wallboard of claim 1 , wherein the vesicles comprise a polyethylene glycol phospholipid derivative and methoxypoly(ethylene glycol)-phosphatidylethanolamine (mPEG-PE).

10. The wallboard of claim 9 , wherein a weight percentage on a dry basis of the PEG in the polyethylene glycol phospholipid derivative and the mPEG-PE is cumulatively about 0.1 mol % to about 10 mol % based on a total vesicle composition.

11. The wallboard of claim 1 , wherein the vesicles comprise polyethylene oxide-block-poly(ε-caprolactone) and/or polyethylene oxide-block-polylactide.

12. A wallboard having a layer produced from a slurry, the slurry comprising:
calcium sulfate hemihydrate at 88 wt % to 99.6 wt %;
vesicle dedusting agent at about 0.01 wt % to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles;
at least one dispersant at about 0.01 wt % to about 2 wt %; and
water at a ratio of water to dry components of about 1:6 to about 1:1.

13. The wallboard of claim 12 , wherein the vesicles comprise lecithin.

14. The wallboard of claim 12 , wherein the vesicles comprise a polyethylene glycol phospholipid derivative and methoxypoly(ethylene glycol)-phosphatidylethanolamine (mPEG-PE).

Assignees

• United States Gypsum Co

Inventors

• Donovan Alexander J
• Immordino Salvatore C

Classifications

• C04B28/14

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

• C04B24/285 Primary

  Polylactides · CPC title

• C04B2103/0075

  Anti-dusting agents · CPC title

• C04B2111/00603

  Ceiling materials · CPC title

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title