Gypsum Panel Containing a Polyoxazoline

Patent metadata

Field	Value
Publication number	US-2024254050-A1
Application number	US-202418411142-A
Country	US
Kind code	A1
Filing date	Jan 12, 2024
Priority date	Jan 19, 2023
Publication date	Aug 1, 2024
Grant date	—

Abstract

The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and a polyoxazoline. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and a polyoxazoline onto the first facing material, and providing a second facing material on the gypsum slurry.

First claim

1 - 30 . (canceled)

31 . A gypsum panel comprising a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core comprises gypsum and a polyoxazoline.

32 . The gypsum panel of claim 31 , wherein the gypsum is present in an amount of at least 60 wt. % based on the weight of the gypsum core.

33 . The gypsum panel of claim 31 , wherein the polyoxazoline has a repeating unit represented by the following formula:

wherein:
R 1 is R 3 —(C(H)(R 4 )) n —(C(O)N(H)) p —R 5 ;
R 2 is selected from H and optionally substituted C 1-5 alkyl;
R 3 is C(O), C(O)O, C(O)NH or C(S)NH;
R 4 is selected from H and optionally substituted C 1-5 alkyl;
R 5 is H; a C 1-5 alkyl; aryl; or a moiety comprising a functional group selected from an amine, an oxyamine, a thiol, a phosphine, an alkynyl, an alkenyl, an aryl, an aldehyde, a carbonyl, an acetal, an ester, a carboxyl, a carbonate, a chloroformate, a hydroxyl, an ether an azide, a vinyl sulfone, a maleimide, an isocyanate, isothiocyanate, an epoxide, orthopyridyl disulfide, sulfonate, halo acetamide, halo acetic acid, hydrazine, and anhydride;
m is 2 or 3;
n is 0-5; and
p is 0 or 1.

34 . The gypsum panel of claim 33 , wherein R 2 is H.

35 . The gypsum panel of claim 33 , wherein R 3 is C(O).

36 . The gypsum panel of claim 33 , wherein m is 2.

37 . The gypsum panel of claim 33 , wherein n is 0.

38 . The gypsum panel of claim 33 , wherein p is 0.

39 . The gypsum panel of claim 33 , wherein m is 2, n is 0, and p is 0.

40 . The gypsum panel of claim 33 , wherein R 5 is a C 1-5 alkyl.

41 . The gypsum panel of claim 33 , wherein R 5 is ethyl.

42 . The gypsum panel of claim 31 , wherein the polyoxazoline includes a poly(2-alkyl-2-oxazoline) and wherein the alkyl comprises a C 1 -C 10 alkyl group.

43 . The gypsum panel of claim 31 , wherein the polyoxazoline includes poly(2-ethyl-2-oxazoline).

44 . The gypsum panel of claim 31 , wherein the polyoxazoline is present in the gypsum panel in an amount from about 0.001 wt. % to about 5 wt. % based on the weight of the gypsum core.

45 . The gypsum panel of claim 31 , wherein the polyoxazoline is present in the gypsum panel in an amount from about 0.001 wt. % to about 2 wt. % based on the weight of the gypsum core.

46 . The gypsum panel of claim 31 , wherein the gypsum core further comprises a foaming agent including an alkyl sulfate foaming agent, an alkyl ether sulfate foaming agent, or a mixture thereof.

47 . The gypsum panel of claim 31 , wherein the gypsum core further comprises a pearl starch.

48 . The gypsum panel of claim 31 , wherein the gypsum core further comprises an acid-modified starch.

49 . The gypsum panel of claim 31 , wherein the gypsum core further comprises a pregelatinized starch.

50 . The gypsum panel of claim 31 , wherein the gypsum panel has an NRC value of 0.2 or more.

51 . The gypsum panel of claim 31 , wherein the gypsum panel has an interconnected core structure.

52 . The gypsum panel of claim 31 , wherein air voids have an average air void size of 200 microns or more.

53 . The gypsum panel of claim 31 , wherein air voids have an average air void size of 300 microns or more.

Assignees

• Gold Bond Building Products Llc

Inventors

• Busche Bradley J
• Iyer R G
• Bailey Joseph J

Classifications

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• C04B28/14 Primary

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

• C04B24/128

  Heterocyclic nitrogen compounds · CPC title