Gypsum Board Containing a Polyol Compound

Patent metadata

Field	Value
Publication number	US-2022274879-A1
Application number	US-202217680467-A
Country	US
Kind code	A1
Filing date	Feb 25, 2022
Priority date	Feb 26, 2021
Publication date	Sep 1, 2022
Grant date	—

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

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 . (canceled)

13 . 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.

14 . (canceled)

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

16 . 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.

17 . 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.

18 . 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.

19 . 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.

20 . 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.

21 . (canceled)

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

23 . 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.

24 . 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.

25 . 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.

26 . (canceled)

27 . 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.

28 . 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.

29 . (canceled)

Assignees

• Gold Bond Building Products Llc

Inventors

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

Classifications

• C04B2111/00405

  Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another · CPC title

• C04B2111/00629

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

• C04B28/145

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

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• B32B5/02

  characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} · CPC title