Gypsum plaster board with biochar

Patent metadata

Field	Value
Publication number	US-2024327288-A1
Application number	US-202418619598-A
Country	US
Kind code	A1
Filing date	Mar 28, 2024
Priority date	Mar 31, 2023
Publication date	Oct 3, 2024
Grant date	—

Abstract

According to one aspect, a plaster based construction material can include a gypsum based plaster, and at least 1 part by weight biochar per 100 parts by weight gypsum. The construction material can have a nail pull force according to ASTM C1396 of at least 51 lbf or a core hardness according to ASTM C473 Method B of at least 66 N.According to another aspect, a plaster based construction material can include a gypsum based plaster, at least 1 part by weight bichar per 100 parts by weight gypsum, and a stable or unstable surfactant. The plaster based construction material may have a relatively improved mechanical strength.

First claim

What is claimed is:

1 . A plaster based construction material comprising:
a gypsum plaster material; and at least 1 part by weight biochar per 100 parts by weight gypsum; wherein the construction material comprises at least one of the following: a nail pull force according to ASTM C473 Method B of at least 51 lbf; a core hardness according to ASTM C473 Method B of at least 66 N; a median pore size, D50 p of at least 200 microns; or a 90 th percentile pore size, D90 p of at least 750 microns.

2 . The construction material of claim 1 , wherein the construction material has an average nail pull force is at least 51 lbf or at least 52 lbf or at least 53 lbf or at least 54 lbf or at least 55 lbf.

3 . The construction material of claim 1 , wherein the construction material has an average nail pull force is less than 170 lbf or less than 160 lbf or less than 150 lbf or less than 140 lbf or less than 130 lbf or less than 120 lbf or less than 110 lbf or less than 100 lbf or less than 90 lbf or less than 80 lbf or less than 70 lbf or less than 60 lbf.

4 . The construction material of claim 1 , wherein the construction material has an average core hardness of at least 66 N or at least 67 N or at least 67.5 N or at least 68 N or at least 68.5 N or at least 69 N or at least 69.5 N or at least 70 N or at least 72 N or at least 74 N or at least 76 N or at least 78 N or at least 80 N or at least 82 N or at least 84 N or at least 85 N.

5 . The construction material of claim 1 , wherein the construction material has an average core hardness of less than 160 N or less than 150 N or less than 140 N or less than 130 N or less than 120 N or less than 110 N or less than 100 N or less than 90 N or less than 80 N.

6 . The construction material of claim 1 , wherein the construction material has a D50 p of at least 150 microns or at least 200 microns or at least 250 microns or at least 300 microns or at least 350 microns or at least 400 microns.

7 . The construction material of claim 1 , wherein the construction material has a D50 p of less than 1000 microns.

8 . The construction material of claim 1 , wherein the construction material has a D90 p of at least 750 microns or at least 800 microns or at least 850 microns or at least 900 microns or at least 950 microns or at least 1000 microns or at least 1050 microns or at least 1100 microns or at least 1150 microns or at least 1200 microns.

9 . The construction material of claim 1 , wherein the construction material has a D50 p of less than 10000 microns.

10 . The construction material of claim 1 , further comprising a foaming agent.

11 . The construction material of claim 10 , wherein the foaming agent comprises an alkyl ether sulfate blend or an ammonium salt of a sulfated linear alcohol ethoxylate.

12 . The construction material of claim 10 , wherein the foaming agent comprises sodium lauryl sulfate.

13 . The construction material of claim 10 , wherein the foaming agent comprises an ammonium salt of a sulfated linear alcohol ethoxylate.

14 . The construction material of claim 1 , wherein the construction material is 1-hour fire rated per ASTM E119.

15 . The construction material of claim 1 , wherein the construction material is rated for 2 hours total water absorption per ASTM C473 Method B.

16 . A method of forming construction materials comprising:
preparing a mixture comprising stucco, biochar and water; adding a foaming agent to the mixture; molding the mixture to form a construction material preform; and firing the construction material preform to form a construction material.

17 . The method of claim 16 , wherein the preform is fired until the preform is essentially free of water.

18 . The method of claim 16 , wherein the foaming agent comprises an alkyl ether sulfate blend or an ammonium salt of a sulfated linear alcohol ethoxylate.

19 . The method of claim 16 , wherein the foaming agent comprises sodium lauryl sulfate.

20 . The method of claim 16 , wherein the foaming agent comprises an ammonium salt of a sulfated linear alcohol ethoxylate.

Assignees

• Certainteed Gypsum Inc

Inventors

• Lespiat Remi
• Dujardin Agathe
• Kelleher Joseph

Classifications

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• C04B2103/42

  Pore formers · CPC title

• C04B2103/402

  anionic · CPC title

• C04B38/10

  by using foaming agents (C04B38/02 takes precedence){or by using mechanical means, e.g. adding preformed foam} · CPC title

• C04B24/16

  Sulfur-containing compounds · CPC title