High temperature sag resistant gypsum panel

Patent metadata

Field	Value
Publication number	US-12448334-B2
Application number	US-202217865747-A
Country	US
Kind code	B2
Filing date	Jul 15, 2022
Priority date	Jul 23, 2021
Publication date	Oct 21, 2025
Grant date	Oct 21, 2025

Abstract

A fire-resistant gypsum panel comprises: a gypsum core layer comprising set gypsum and a high temperature sag-resistant material including mineral wool in an amount between 0.2% and 3.0% by weight of gypsum.

First claim

What is claimed is:

1. A fire-resistant gypsum panel comprising:
a gypsum core layer comprising set gypsum and mineral wool in an amount of between greater than 0.9% and less than or equal to and 3.0% by weight of stucco, wherein the mineral wool includes spun or drawn mineral rock material, and wherein the gypsum panel at a temperature of 1600° F. has a sag reduction of at least 10% compared to a gypsum panel that includes glass fiber in place of the mineral wool but is otherwise likewise configured.

2. The gypsum panel of claim 1 , further comprising:
a facing material.

3. The gypsum panel of claim 1 , wherein the gypsum core further comprises a shrinkage-resistant material.

4. The gypsum panel of claim 1 , wherein the gypsum core further comprises one or more of a starch, a binder, a set accelerator, a dispersant, a set retarder, or a reinforcing fiber.

5. The gypsum panel of claim 1 , wherein the gypsum core has a chloride level of 300 ppm or greater.

6. The gypsum panel of claim 1 , wherein the gypsum core does not include glass fiber.

7. The gypsum panel of claim 1 , wherein the set gypsum core has a density between about 15 pcf and about 60 pcf.

8. The gypsum panel of claim 1 , wherein the gypsum panel comprises ceiling board, wallboard, or surface board.

9. A set gypsum core for a gypsum panel comprising:
a. set gypsum; and
b. a mineral wool in an amount greater than 0.9% and less than or equal to 3.0% by weight of the stucco, wherein the mineral wool includes spun or drawn mineral rock material,
wherein the gypsum panel at a temperature of 1600° F. has a sag reduction of at least 10% compared to a gypsum panel that includes glass fiber in place of the mineral wool but is otherwise likewise configured.

10. The set gypsum core of claim 9 , further comprising:
a shrinkage-resistant material.

11. The set gypsum core of claim 9 , wherein the gypsum core does not include glass fiber.

12. The set gypsum core of claim 9 , wherein the gypsum core has a chloride level of 300 ppm or greater.

13. A composition for forming a gypsum core for a gypsum panel comprising:
a. water;
b. stucco; and
c. mineral wool in an amount greater than 0.9% and less than or equal to and 3.0% by weight of the stucco, wherein the mineral wool includes spun or drawn mineral rock material;
wherein the gypsum panel at a temperature at 1600° F. has a sag reduction of at least 10% compared to a gypsum panel that includes glass fiber in place of the mineral wool but is otherwise likewise configured.

14. The composition of claim 13 , further comprising:
a shrinkage-resistant material.

15. The composition of claim 13 , further comprising:
a starch.

16. The composition of claim 13 , wherein the composition does not include glass fiber.

17. The set gypsum core of claim 16 , wherein the gypsum panel is a ceiling board.

18. The composition of claim 13 , wherein the gypsum panel is a ceiling board.

19. The composition of claim 13 , wherein the gypsum core has a chloride level of 300 ppm or greater.

20. A method for making a gypsum panel comprising:
a. preparing a slurry comprising water, stucco, and mineral wool in an amount greater than 0.9% and less than or equal to 3.0% by weight of the stucco, and wherein the mineral wool includes spun or drawn mineral rock material;
b. combining the prepared slurry with aqueous foam to provide an air-foamed slurry;
c. forming a gypsum core from the air-foamed slurry;
d. allowing the formed gypsum core to set; and
e. drying the gypsum core,
wherein the gypsum panel at a temperature at 1600° F. has a sag reduction of at least 10% compared to a gypsum panel that includes glass fiber in place of the mineral wool but is otherwise likewise configured.

21. The method of claim 20 , wherein the slurry further comprises a shrinkage-resistant material.

22. The method of claim 20 , wherein said forming a gypsum core comprises depositing the air-foamed slurry over a facing material.

23. The method of claim 20 , further comprising:
providing a facing material over the deposited air-foamed slurry.

24. The method of claim 20 , further comprising:
forming a densified layer on the gypsum core; and
providing the facing material over the densified layer.

25. The method of claim 20 , further comprising:
cutting the gypsum core into one or more panels.

26. The method of claim 25 , wherein the gypsum panels comprise ceiling boards, wallboards, or surface boards.

27. The method of claim 20 , further comprising:
applying the gypsum panel to a ceiling of a structure.

28. The method of claim 20 , wherein the gypsum core has a chloride level of 300 ppm or greater.

Assignees

• Knauf Gips Kg

Inventors

• Hemphill Mark K
• Li Qinghua
• Johnson Aaron D

Classifications

• C04B2201/20

  for the density · CPC title

• C04B2111/34

  Non-shrinking or non-cracking materials · CPC title

• C04B2111/28

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

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• C04B14/46

  Rock wool {; Ceramic or silicate fibres (C04B14/40, C04B14/42 take precedence)} · CPC title