Gypsum panels, methods, and systems

Patent metadata

Field	Value
Publication number	US-2019270675-A1
Application number	US-201816047108-A
Country	US
Kind code	A1
Filing date	Jul 27, 2018
Priority date	Mar 5, 2018
Publication date	Sep 5, 2019
Grant date	—

Abstract

Gypsum panels and methods of making gypsum panels are provided. A method of making a gypsum panel includes combining gypsum stucco and a halide salt sequestration agent with water to form a gypsum slurry and setting the gypsum slurry to form at least a portion of a gypsum core, wherein the halide salt sequestration agent is present in an amount effective to sequester at least a portion of halide salt present in the gypsum stucco. A gypsum panel includes a gypsum core that comprises set gypsum and a halide salt sequestration agent, wherein the halide sequestration agent sequesters at least a portion of halide salt present in the gypsum core.

First claim

1 . A method of making a gypsum panel, comprising:
combining gypsum stucco and a halide salt sequestration agent with water to form a gypsum slurry; and setting the gypsum slurry to form at least a portion of a gypsum core, wherein the halide salt sequestration agent is present in an amount effective to sequester at least 25 percent, by weight, of halide salt present in the gypsum stucco.

2 . The method of claim 1 , wherein the halide salt sequestration agent comprises alumina or perlite.

3 . The method of claim 1 , wherein the halide salt sequestration agent comprises activated alumina present in an amount of from about 0.01 to about 10 weight percent, by weight of the gypsum stucco.

4 . The method of claim 3 , wherein the activated alumina has an average particle size of less than 1 mm.

5 . The method of claim 1 , wherein the halide sequestration agent comprises perlite present in an amount in an amount of from about 0.01 to about 10 weight percent, by weight of the gypsum stucco.

6 . The method of claim 5 , wherein the perlite is perlite ore having an average particle size smaller than 30 mesh.

7 . The method of claim 5 , wherein the perlite is expanded perlite having an average particle size smaller than 16 mesh.

8 . The method of claim 1 , further comprising heating the halide sequestration agent prior to combining the halide sequestration agent with the gypsum stucco, wherein the heating is effective to expand or activate at least a portion of the halide sequestration agent.

9 . The method of claim 1 , further comprising associating a facer material with the gypsum slurry or the gypsum core.

10 . The method of claim 9 , wherein:
the facer material comprises a paper facer material, and the gypsum panel displays a paper facer to core humid bond strength of at least about 12 lbs/f.

11 . The method of claim 1 , wherein the gypsum stucco comprises gypsum obtained from a natural source or from a flue gas desulfurization process.

12 . A gypsum panel, comprising:
a gypsum core that comprises set gypsum and a halide salt sequestration agent; wherein the halide sequestration agent is present in an amount effective to sequester at least 25 percent, by weight, of halide salt present in the gypsum core.

13 . The gypsum panel of claim 12 , wherein the halide salt sequestration agent comprises alumina or perlite.

14 . The gypsum panel of claim 12 , wherein the halide salt sequestration agent comprises activated alumina present in an amount of from about 0.01 to about 10 weight percent, by weight of the set gypsum.

15 . The gypsum panel of claim 14 , wherein the activated alumina has an average particle size of less than 1 mm.

16 . The gypsum panel of claim 12 , wherein the halide sequestration agent comprises perlite present in an amount in an amount of from about 0.01 to about 10 weight percent, by weight of the gypsum stucco.

17 . The gypsum panel of claim 16 , wherein the perlite is perlite ore having an average particle size smaller than 30 mesh.

18 . The gypsum panel of claim 16 , wherein the perlite is expanded perlite having an average particle size smaller than 16 mesh.

19 . The gypsum panel of claim 12 , further comprising a facer material associated with the gypsum core.

20 . The gypsum panel of claim 19 , wherein:
the facer material comprises a paper facer material, and the gypsum panel displays a paper facer to core humid bond strength of at least about 12 lbs/f.

Assignees

• Georgia Pacific Gypsum Llc

Inventors

• Harrison Charles R
• Gilley Stuart Brandon

Classifications

• B32B13/08

  of paper or cardboard · CPC title

• B32B2607/00

  Walls, panels · CPC title

• C04B2103/0078

  Sorbent materials · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• C04B14/303

  Alumina · CPC title