Glass mat faced gypsum board and gypsum slurry formed using a phosphorus containing compound

Patent metadata

Field	Value
Publication number	US-2022402240-A1
Application number	US-202217896232-A
Country	US
Kind code	A1
Filing date	Aug 26, 2022
Priority date	Nov 28, 2018
Publication date	Dec 22, 2022
Grant date	—

Abstract

In general, the present invention is directed to the use of particular phosphorus containing compounds for making a glass mat faced gypsum board. The phosphorus containing compound may be a phosphite or a phosphate having a certain formula. In this regard, the present invention is directed to a glass mat faced gypsum board including a gypsum core that is formed from a gypsum slurry comprising such phosphorus containing compound. The present invention is also directed to a method of making a glass mat faced gypsum board.

First claim

1 . A glass mat faced gypsum board comprising
a gypsum core sandwiched between a first glass mat facing material and a second glass mat facing material; wherein the gypsum core is formed from a gypsum slurry comprising
stucco,
water, and
a phosphorus containing compound comprising a phosphite, a phosphate having the formula P(O) n (X) m wherein n is from 0 to 4, m is from 0 to 6, the sum of n and m is from 3 to 6, and X is hydrogen, halogen, sulfur, or selenium, a salt thereof, or a mixture thereof; and
wherein the gypsum core penetrates at least one of the glass mat facing materials from 10% or more to less than 100% of the thickness of the at least one of the glass mat facing materials for 70% or more of the length of the gypsum board.

2 . The glass mat faced gypsum board of claim 1 , wherein the phosphorus containing compound comprises a phosphite.

3 . The glass mat faced gypsum board of claim 1 , wherein the phosphorus containing compound comprises a phosphate having the formula P(O) n (X) m wherein n is from 0 to 4, m is from 0 to 6, the sum of n and m is from 3 to 6, and X is hydrogen, halogen, sulfur, or selenium, a salt thereof.

4 . The glass mat faced gypsum board of claim 3 , wherein X includes fluoro.

5 . The glass mat faced gypsum board of claim 3 , wherein n is from 2 to 3.

6 . The glass mat faced gypsum board of claim 3 , wherein m is from 1 to 2.

7 . The glass mat faced gypsum board of claim 1 , wherein the phosphorus containing compound comprises a halophosphate.

8 . The glass mat faced gypsum board of claim 1 , wherein the phosphorus containing compound comprises a monohalophosphate.

9 . The glass mat faced gypsum board of claim 1 , wherein the phosphorus containing compound comprises a salt including an alkali metal, an alkaline earth metal, a transition metal, or a combination thereof.

10 . The glass mat faced gypsum board of claim 1 , wherein the phosphorus containing compound comprises sodium monofluorophosphate.

11 . The glass mat faced gypsum board of claim 1 , wherein the phosphorus containing compound is present in the slurry in an amount of from 0.01 wt. % to 5 wt. % based on the weight of the stucco.

12 . The glass mat faced gypsum board of claim 1 , wherein the weight ratio of the water to the stucco is from 0.1 to 3.

13 . The glass mat faced gypsum board of claim 1 , wherein the slurry further comprises a dispersant.

14 . The glass mat faced gypsum board of claim 13 , wherein the dispersant comprises a sulfonate, a polycarboxylate ether, a polycarboxylate ester, or a mixture thereof.

15 . The glass mat faced gypsum board of claim 1 , wherein the gypsum slurry is characterized by having a set time of 3.5 minutes or less using a ¼ pound Gillmore needle according to ASTM C266.

16 . The glass mat faced gypsum board of claim 1 , wherein the gypsum board exhibits an absorption of from 0% to 40%.

17 . The glass mat faced gypsum board of claim 1 , wherein the gypsum board exhibits a Z-direction tensile strength of from 30 lbf to 100 lbf.

18 . A method for making the glass mat faced gypsum board of claim 1 , the method comprising
depositing the gypsum slurry on the first glass mat facing material, providing the second glass mat facing material on the gypsum slurry, and allowing the stucco to convert to calcium sulfate dihydrate.

19 . A glass mat faced gypsum board comprising
a gypsum core sandwiched between a first glass mat facing material and a second glass mat facing material; wherein the gypsum core comprises
gypsum, and
a phosphorus containing compound comprising a phosphite, a phosphate having the formula P(O) n (X) m wherein n is from 0 to 4, m is from 0 to 6, the sum of n and m is from 3 to 6, and X is hydrogen, halogen, sulfur, or selenium, a salt thereof, or a mixture thereof;
wherein the gypsum penetrates at least one of the glass mat facing materials from 10% or more to less than 100% of the thickness of the at least one of the glass mat facing materials for 70% or more of the length of the gypsum board.

20 . The glass mat faced gypsum board of claim 19 , wherein the phosphorus containing compound comprises a salt.

21 . The glass mat faced gypsum board of claim 20 , wherein the salt includes a monohalophosphate.

22 . The glass mat faced gypsum board of claim 20 , wherein the salt includes an alkali metal, an alkaline earth metal, a transition metal, or a combination thereof.

23 . The glass mat faced gypsum board of claim 19 , wherein the phosphorus containing compound comprises from 0.001 lbs/MSF to 150 lbs/MSF of the board weight.

24 . The glass mat faced gypsum board of claim 19 , wherein the board exhibits a nail pull resistance of 70 lb f or more when measured according to ASTM C1396, a compressive strength of 300 psi or more when measured according to ASTM C1396, or both.

Assignees

• Gold Bond Building Products Llc

Inventors

• Randall Brian G
• Stav Eli
• Iyer R G
• Bland Brian

Classifications

• B32B2262/101

  Glass fibres · CPC title

• B32B2250/40

  Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA · 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

• C04B22/16

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

• B32B2260/021

  Fibrous or filamentary layer · CPC title