Lightweight, reduced density fire rated gypsum panels

Patent metadata

Field	Value
Publication number	US-2017183868-A1
Application number	US-201715457466-A
Country	US
Kind code	A1
Filing date	Mar 13, 2017
Priority date	Feb 25, 2011
Publication date	Jun 29, 2017
Grant date	—

Abstract

A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.

First claim

1 . A fire resistant gypsum panel comprising a gypsum core disposed between two cover sheets, the gypsum core comprising a crystalline matrix of set gypsum and high expansion particles expandable to about 300% or more of their original volume after being heated for about one hour at about 1560° F. (about 850° C.), the gypsum core having a density (D) of about 40 pounds per cubic foot (about 640 kg/m3) or less and a core hardness of at least about 11 pounds (about 5 kg), and the gypsum core effective to provide a Thermal Insulation Index (TI) of about 20 minutes or greater.

2 .- 30 . (canceled)

31 . A method for making a fire resistant gypsum panel, the method comprising:
(A) preparing a gypsum slurry having high expansion particles dispersed therein; (B) disposing the gypsum slurry between a first cover sheet and a second cover sheet to form an assembly comprising a set gypsum core; (C) cutting the assembly into a panel of predetermined dimensions; and (D) drying the panel; such that the set gypsum core has a density (D) of about 40 pounds per cubic foot or less and a core hardness of at least about 11 pounds, and the gypsum core is effective to provide a Thermal Insulation Index (TI) of about 20 minutes or greater.

Assignees

• United States Gypsum Co

Inventors

• Yu Qiang
• Veeramasuneni Srinivas
• Song Weixin D
• Luan Wenqi

Classifications

• C04B38/08

  by adding porous substances · CPC title

• E04C2/00

  Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels (materials or manufacture, see the relevant subclasses, e.g. B27N, D21J; made in situ E04B; specially designed for insulation or other protection E04B1/62; load-carrying floor structures E04B5/02, E04B5/16; roofs consisting of self-supporting slabs E04B7/20; roof or like covering elements E04D3/00; for lining or finishing E04F13/00) · CPC title

• E04B1/88

  Insulating elements for both heat and sound · CPC title

• C04B20/06 Primary

  Expanding clay, perlite, vermiculite or like granular materials · CPC title

• C04B28/145 Primary

  Calcium sulfate hemi-hydrate with a specific crystal form · CPC title