Gypsum board and gypsum slurry formed using a phosphorus containing compound

Patent metadata

Field	Value
Publication number	US-11952315-B2
Application number	US-202217985202-A
Country	US
Kind code	B2
Filing date	Nov 11, 2022
Priority date	Nov 28, 2018
Publication date	Apr 9, 2024
Grant date	Apr 9, 2024

Abstract

In general, the present invention is directed to the use of particular phosphorus containing compounds for making a gypsum board. The phosphorus containing compound may be a phosphite or a phosphate having a certain formula. In this regard, the present invention is directed to a slurry for making a gypsum board wherein the slurry includes such phosphorus containing compound. The present invention is also directed to a method of making a gypsum board from the slurry as well as a resulting gypsum board.

First claim

The invention claimed is:

1. A gypsum board comprising
a gypsum core comprising
gypsum, and
a phosphorus containing compound comprising a phosphite, a phosphate having the formula P(O) n (X) m wherein n is from 0 to 4, m is from 1 to 6, the sum of n and m is from 3 to 6, and X is halogen, sulfur, or selenium, a salt thereof, or a mixture thereof.

2. The gypsum board of claim 1 , wherein the phosphorus containing compound comprises a salt.

3. The gypsum board of claim 2 , wherein the salt includes a monohalophosphate.

4. The gypsum board of claim 2 , wherein the salt includes an alkali metal, an alkaline earth metal, a transition metal, or a combination thereof.

5. The gypsum board of claim 1 , wherein the phosphorus containing compound comprises from 0.001 lbs/MSF to 150 lbs/MSF of the board weight.

6. The gypsum board of claim 1 , wherein the board exhibits a nail pull resistance of 70 lb f or more when measured according to ASTM C1396, a compressive strength of 300 psi or more when measured according to ASTM C1396, or both.

7. The gypsum board of claim 1 , wherein the phosphorus containing compound comprises a phosphite.

8. The gypsum board of claim 1 , wherein the phosphorus containing compound comprises a phosphate having the formula P(O) n (X) m wherein n is from 0 to 4, m is from 1 to 6, the sum of n and m is from 3 to 6, and X is halogen, sulfur, or selenium, a salt thereof.

9. The gypsum board of claim 8 , wherein X includes fluoro.

10. The gypsum board of claim 8 , wherein n is from 2 to 3.

11. The gypsum board of claim 8 , wherein m is from 1 to 2.

12. The gypsum board of claim 1 , wherein the phosphorus containing compound comprises a phosphate having the formula P(0) n (X) m wherein n is from 1 to 4, m is from 1 to 6, the sum of n and m is from 3 to 6, and X is halogen, sulfur, or selenium, a salt thereof.

13. The gypsum board of claim 1 , wherein the phosphorus containing compound comprises a halophosphate.

14. The gypsum board of claim 1 , wherein the phosphorus containing compound comprises sodium monofluorophosphate.

15. The gypsum board of claim 1 , wherein the phosphorus containing compound comprises from 0.001 lbs/MSF to 10 lbs/MSF of the board weight.

16. The gypsum board of claim 1 , wherein the gypsum core further comprises a dispersant.

17. The gypsum board of claim 16 , wherein the dispersant comprises a sulfonate, a polycarboxylate ether, a polycarboxylate ester, or a mixture thereof.

18. The gypsum board of claim 1 , wherein the board exhibits a nail pull resistance of 70 lb f or more when measured according to ASTM C1396.

19. The gypsum board of claim 1 , wherein the board exhibits a compressive strength of 300 psi or more when measured according to ASTM C1396.

20. A method for making the gypsum board of claim 1 , the method comprising
providing a first facing material,
depositing a gypsum slurry comprising stucco, water, and the phosphorus containing compound on the first facing material,
providing a second facing material on the gypsum slurry, and
allowing the stucco to convert to calcium sulfate dihydrate.

21. A gypsum board comprising
a gypsum core comprising
gypsum, and
a phosphorus containing compound comprising a sodium monofluorophosphate.

Assignees

• Gold Bond Building Products Llc

Inventors

• Iyer R G
• Stav Eli
• Miatudila Ma-Ikay
• Bailey Joseph J

Classifications

• C04B28/14 Primary

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

• C04B22/16

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

• C04B24/166

  obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• C04B2103/408

  Dispersants · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title