Gypsum panels, systems, and methods

Patent metadata

Field	Value
Publication number	US-2022212996-A1
Application number	US-202017608492-A
Country	US
Kind code	A1
Filing date	May 6, 2020
Priority date	May 6, 2019
Publication date	Jul 7, 2022
Grant date	—

Abstract

Disclosed is a gypsum panel comprising a gypsum core comprising set gypsum and a colloidal material comprising colloidal silica, colloidal alumina, or both.

First claim

1 . A gypsum panel, comprising:
a gypsum core comprising set gypsum and a colloidal material comprising colloidal silica, colloidal alumina, or both.

2 . The gypsum panel of claim 1 , wherein the colloidal material is present in the gypsum core in an amount, by weight, greater than any other component, other than the gypsum

3 . The gypsum panel of claim 1 , wherein the colloidal material is present in the gypsum core in an amount of about 1 lb/msf to about 300 lb/msf, for a gypsum panel having a thickness of about ¼ inch to about 1 inch.

4 . The gypsum panel of claim 1 , wherein the colloidal material is present in the gypsum core in an amount of about 1 lb/msf to about 200 lb/msf, for a gypsum panel having a thickness of about ¼ inch to about 1 inch.

5 . The gypsum panel of claim 1 , wherein the gypsum core is free of vermiculite.

6 . The gypsum panel of claim 1 , wherein the gypsum core further comprises vermiculite, perlite, clay, wollastonite, and/or diatomaceous earth.

7 . The gypsum panel of claim 1 , wherein the colloidal material is colloidal silica.

8 . The gypsum panel of claim 7 , wherein the colloidal silica comprises from about 7 to about 50 percent silicon dioxide.

9 . The gypsum panel of claim 7 , wherein the colloidal silica has an average particle surface area of from about 30 to about 1,100 m 2 /g.

10 . The gypsum panel of claim 7 , wherein the colloidal silica has a pH of from about 2 to about 12.

11 . The gypsum panel of claim 7 , wherein the colloidal silica comprises amorphous silicon dioxide.

12 . The gypsum panel of claim 1 , wherein the colloidal material is colloidal alumina.

13 . The gypsum panel of claim 12 , wherein the colloidal alumina comprises from about 7 to about 50 percent aluminum oxide.

14 . The gypsum panel of claim 12 , wherein the colloidal alumina comprises amorphous aluminum oxide.

15 . The gypsum panel of claim 1 , wherein the gypsum core further comprises starch in an amount effective to bind the gypsum to the colloidal material.

16 . The gypsum panel of claim 15 , wherein the starch comprises pregelatinized starch or a combination of uncooked and pregelatinized starch.

17 . The gypsum panel of claim 15 , wherein the starch is present in the gypsum core in an amount of about 1 lb/msf to about 70 lb/msf, for a gypsum panel having a thickness of about ¼ inch to about 1 inch.

18 . The gypsum panel of claim 1 , wherein the gypsum core further comprises a polyphosphate.

19 . The gypsum panel of claim 18 , wherein the polyphosphate is sodium trimetaphosphate.

20 - 27 . (canceled)

28 . A method of making a gypsum panel, comprising:
forming a first gypsum slurry by combining stucco, water, and a colloidal material comprising colloidal silica, colloidal alumina, or both; and setting the first gypsum slurry to form at least part of a core of the gypsum panel.

29 - 67 . (canceled)

Assignees

• Georgia Pacific Gypsum Llc

Inventors

• Yuan yongan
• Gilley Stuart Brandon

Classifications

• C04B28/14 Primary

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

• C04B14/062

  Microsilica, e.g. colloïdal silica (preparing microsilica slurries or suspensions C04B18/148) · CPC title

• C04B2111/28

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

• C04B22/16

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

• C04B2111/00629

  the covering sheets being made of material other than paper · CPC title