Gypsum board containing a polyol compound

Patent metadata

Field	Value
Publication number	US-12098103-B2
Application number	US-202217680467-A
Country	US
Kind code	B2
Filing date	Feb 25, 2022
Priority date	Feb 26, 2021
Publication date	Sep 24, 2024
Grant date	Sep 24, 2024

Abstract

The present invention is directed to a gypsum board and a method of making such gypsum board. For instance, the gypsum board comprises a gypsum core, a first facing material, and a second facing material wherein the first facing material and the second facing material sandwich the gypsum core. The gypsum core comprises a first gypsum core section and a second gypsum core section each comprising gypsum, wherein the first gypsum core section comprises a polyol compound and has a density higher than a density of the second gypsum core section.

First claim

The invention claimed is:

1. A gypsum board comprising:
a gypsum core comprising a first gypsum core section and a second gypsum core section each comprising gypsum, wherein the first gypsum core section comprises a polyol compound and has a density higher than a density of the second gypsum core section; and
a first facing material and a second facing material, wherein the first facing material and the second facing material sandwich the gypsum core.

2. The gypsum board of claim 1 , wherein the polyol compound comprises a sugar, a sugar alcohol, a polyether, a polysaccharide, or a mixture thereof.

3. The gypsum board of claim 1 , wherein the polyol compound comprises a sugar alcohol.

4. The gypsum board of claim 3 , wherein the sugar alcohol comprises maltitol, sorbitol, mannitol, xylitol, erythritol, isomalt, threitol, arabitol, galactitol, fucitol, iditol, inositol, volemitol, lactitol, or a mixture thereof.

5. The gypsum board of claim 3 , wherein the sugar alcohol comprises glycerol.

6. The gypsum board of claim 1 , wherein the polyol compound comprises a sugar.

7. The gypsum board of claim 6 , wherein the sugar comprises glucose, sucrose, fructose, lactose, or a mixture thereof.

8. The gypsum board of claim 1 , wherein the polyol compound comprises a polyether.

9. The gypsum board of claim 8 , wherein the polyether comprises polyethylene glycol, polypropylene glycol, or a mixture thereof.

10. The gypsum board of claim 1 , wherein the polyol compound comprises a polysaccharide.

11. The gypsum board of claim 1 , wherein the polyol compound has a molecular weight of from 25 g/mol to 5,000 g/mol.

12. The gypsum board of claim 1 , wherein the polyol compound is present in an amount of from 0.001 lbs/MSF to 10 lbs/MSF based on the weight of the gypsum board.

13. The gypsum board of claim 1 , wherein the second gypsum core section does not include a polyol compound.

14. The gypsum board of claim 1 , wherein the gypsum board exhibits a gypsum content of 75% or more when determined based on the front of the gypsum board.

15. The gypsum board of claim 1 , wherein the gypsum board exhibits a gypsum content of 65% or more when determined based on the back of the gypsum board.

16. The gypsum board of claim 1 , wherein the gypsum board exhibits an edge hardness of 15 lb f to 50 lb f when measured according to ASTM C1396 and ASTM C473.

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

18. The gypsum board of claim 1 , wherein the second gypsum core section has a density that is 0.1% or more to 80% or less the density of the first gypsum core section.

19. The gypsum board of claim 1 , wherein the gypsum core comprises a third gypsum core section comprising gypsum and the polyol compound.

20. The gypsum board of claim 1 , wherein the gypsum core comprises a third gypsum core section and a fourth gypsum core section comprising gypsum and the polyol compound.

21. The gypsum board of claim 1 , wherein the gypsum core comprises a third gypsum core section, a fourth gypsum core section, and a fifth gypsum ore section comprising gypsum and the polyol compound.

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

23. A method for making the gypsum board of claim 1 , the method comprising
providing a first facing material;
depositing onto a first facing material
a first gypsum slurry comprising stucco, a polyol compound, and water,
a second gypsum slurry comprising stucco and water, and
a third gypsum slurry comprising stucco, a polyol compound, and water,
wherein the second gypsum slurry is deposited between the first gypsum slurry and the second gypsum slurry;

providing a second facing material on the first, second, and third gypsum slurries; and
allowing the stucco to convert to calcium sulfate dihydrate.

24. A method for making the gypsum board of claim 1 , the method comprising:
providing a first facing material;
depositing a first gypsum slurry comprising stucco, a polyol compound, and water onto the first facing material;
depositing onto the first gypsum slurry
a second gypsum slurry comprising stucco, a polyol compound, and water,
a third gypsum slurry comprising stucco and water, and
a fourth gypsum slurry comprising stucco, a polyol compound, and water,
wherein the third gypsum slurry is deposited between the second gypsum slurry and the third gypsum slurry;

providing a second facing material on the second, third, and fourth gypsum slurries; and
allowing the stucco to convert to calcium sulfate dihydrate.

Assignees

• Gold Bond Building Products Llc

Inventors

• Stav Eli
• Whittington Gene
• Busche Bradley J
• Iyer R G
• Burgess Elizabeth
• Bailey Joseph J

Classifications

• C04B24/38

  Polysaccharides or derivatives thereof {(C04B24/243 takes precedence)} · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• B28B19/0092 Primary

  to webs, sheets or the like, e.g. of paper, cardboard · CPC title

• B32B13/08

  of paper or cardboard · CPC title

• C04B2201/20

  for the density · CPC title