Gypsum panels, methods, and systems
US-10427979-B2 · Oct 1, 2019 · US
Gypsum panels, systems, and methods
US11136757B2 · US · B2
| Field | Value |
|---|---|
| Publication number | US-11136757-B2 |
| Application number | US-201916557144-A |
| Country | US |
| Kind code | B2 |
| Filing date | Aug 30, 2019 |
| Priority date | Sep 28, 2018 |
| Publication date | Oct 5, 2021 |
| Grant date | Oct 5, 2021 |
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- Title
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- Abstract
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Abstract
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Gypsum panels and methods of making the same are provided. A gypsum panel includes a gypsum core containing set gypsum and unexpanded perlite ore, wherein the unexpanded perlite ore is present in the gypsum core in an amount greater than any other component, other than the gypsum.
First claim
Opening claim text (preview).
We claim: 1. A gypsum panel, comprising: a gypsum core comprising set gypsum and unexpanded perlite ore, wherein the unexpanded perlite ore is present in the gypsum core in an amount greater than any other component, other than the gypsum, wherein the gypsum core is free of vermiculite. 2. The gypsum panel of claim 1 , wherein the unexpanded perlite ore has an average particle size of about ASTM Sieve No. 400 (0.037 mm) to about ASTM Sieve No. 5 (4 mm). 3. The gypsum panel of claim 1 , wherein the gypsum core further comprises starch in an amount effective to bind the gypsum to the unexpanded perlite. 4. The gypsum panel of claim 3 , wherein the starch comprises pregelatinized starch or a combination of uncooked and pregelatinized starch. 5. The gypsum panel of claim 3 , wherein the starch is present in the gypsum core in an amount of about 1 lb/msf to about 70 lb/msf, for a gypsum panel having a thickness of about ¼ inch to about 1 inch. 6. The gypsum panel of claim 1 , wherein the gypsum core further comprises a polymer binder. 7. The gypsum panel of claim 1 , wherein the gypsum core further comprises a polyphosphate. 8. The gypsum panel of claim 1 , wherein the unexpanded perlite ore is present in the gypsum core in an amount of about 1 lb/msf to about 300 lb/msf, for a gypsum panel having a thickness of about ¼ inch to about 1 inch. 9. The gypsum panel of claim 8 , wherein the polyphosphate is sodium trimetaphosphate. 10. A method of making a gypsum panel, comprising: forming a first gypsum slurry by combining stucco, water, and unexpanded perlite ore; and setting the first gypsum slurry to form at least part of a core of the gypsum panel, wherein the unexpanded perlite ore is present in the gypsum core in an amount greater than any other component, other than the gypsum, and wherein the first gypsum slurry and the gypsum core are free of vermiculite. 11. The method of claim 10 , wherein the unexpanded perlite ore has an average particle size of about ASTM Sieve No. 400 (0.037 mm) to about ASTM Sieve No. 5 (4 mm). 12. The method of claim 10 , wherein the first gypsum slurry further comprises starch in an amount effective to bind the gypsum to the unexpanded perlite. 13. The method of claim 12 , wherein the starch comprises pregelatinized starch or a combination of uncooked and pregelatinized starch. 14. The method of claim 12 , wherein the starch is present in the gypsum core in an amount of about 1 lb/msf to about 70 lb/msf, for a gypsum panel having a thickness of about ¼ inch to about 1 inch. 15. The method of claim 10 , wherein the first gypsum slurry further comprises a polymer binder. 16. The method of claim 10 , wherein the first gypsum slurry further comprises a polyphosphate. 17. The method of claim 16 , wherein the polyphosphate is sodium trimetaphosphate. 18. The method of claim 10 , wherein the unexpanded perlite ore is present in the gypsum core in an amount of about 1 lb/msf to about 300 lb/msf, for a gypsum panel having a thickness of about ¼ inch to about 1 inch.
Assignees
Inventors
Classifications
- C04B28/145Primary
Calcium sulfate hemi-hydrate with a specific crystal form · CPC title
Fire resistance, i.e. materials resistant to accidental fires or high temperatures · CPC title
Gypsum-paper board like materials · CPC title
Intumescent materials · CPC title
- E04C2/043Primary
of plaster (E04C2/049 takes precedence) · CPC title
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Frequently asked questions
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- What does patent US11136757B2 cover?
- Gypsum panels and methods of making the same are provided. A gypsum panel includes a gypsum core containing set gypsum and unexpanded perlite ore, wherein the unexpanded perlite ore is present in the gypsum core in an amount greater than any other component, other than the gypsum.
- Who is the assignee on this patent?
- Georgia Pacific Gypsum Llc
- What technology area does this patent fall under?
- Primary CPC classification C04B28/145. Mapped technology areas include Chemistry & Metallurgy.
- When was this patent published?
- Publication date Tue Oct 05 2021 00:00:00 GMT+0000 (Coordinated Universal Time) (B2). Legal status and post-grant events are not shown on this page.
- What related patents are in patentsdb?
- We list 1 related publication on this page (citations in our corpus or others sharing the same primary CPC).