Fire Resistant Gypsum Panel

Patent metadata

Field	Value
Publication number	US-2025091321-A1
Application number	US-202418889477-A
Country	US
Kind code	A1
Filing date	Sep 19, 2024
Priority date	Sep 20, 2023
Publication date	Mar 20, 2025
Grant date	—

Abstract

The present disclosure is directed to a gypsum panel and a method of making a gypsum panel. For instance, the gypsum panel comprises: a first facing material having an outer surface and an inner surface opposing the outer surface; a thermal barrier layer adjacent the inner surface of the first paper material, the thermal barrier layer comprising a thermal additive; a gypsum core having an outer surface facing the thermal barrier layer and an inner surface opposing the outer surface, the gypsum core comprising a first filler comprising silica, alumina, or a mixture thereof; and a second facing material adjacent the inner surface of the gypsum core.

First claim

1 . A gypsum panel comprising:
a first facing material having an outer surface and an inner surface opposing the outer surface; a thermal barrier layer adjacent the inner surface of the first facing material, the thermal barrier layer comprising a thermal additive; a gypsum core having an outer surface facing the thermal barrier layer and an inner surface opposing the outer surface, the gypsum core comprising a first filler comprising silica, alumina, or a mixture thereof; and a second facing material adjacent the inner surface of the gypsum core.

2 . The gypsum panel of claim 1 , wherein the thermal additive comprises an inorganic fiber.

3 . The gypsum panel of claim 2 , wherein the inorganic fiber comprises glass fibers, mineral fibers, ceramic fibers, or a mixture thereof.

4 . The gypsum panel of claim 2 , wherein the inorganic fiber has a nominal diameter of from 5 μm or more to 30 μm or less.

5 . The gypsum panel of claim 2 , wherein the inorganic fiber has an average length of from 0.3 cm or more to 4 cm or less.

6 . The gypsum panel of claim 1 , wherein the thermal additive is unbound.

7 . The gypsum panel of claim 1 , wherein the thermal additive is bound by a binder.

8 . The gypsum panel of claim 1 , wherein the thermal barrier layer comprises a non-woven sheet.

9 . The gypsum panel of claim 1 , wherein the thermal barrier layer is present in an amount of 10 lbs/MSF or more to 50 lbs/MSF or less.

10 . The gypsum panel of claim 1 , wherein the thermal additive comprises glass fibers.

11 . The gypsum panel of claim 1 , wherein the thermal additive comprises mineral fibers.

12 . The gypsum panel of claim 1 , wherein the thermal additive comprises ceramic fibers.

13 . The gypsum panel of claim 1 , wherein the first filler comprises silica.

14 . The gypsum panel of claim 13 , wherein the silica has an average particle size of from 3 nm or more to 100 nm or less.

15 . The gypsum panel of claim 13 , wherein the silica has an average particle size of from 5 nm or more to 20 nm or less.

16 . The gypsum board of claim 13 , wherein the silica is a colloidal silica, a precipitated silica, or a mixture thereof.

17 . The gypsum panel of claim 1 , wherein the first filler comprises alumina.

18 . The gypsum panel of claim 1 , wherein the first filler comprises a mixture of silica and alumina.

19 . The gypsum panel of claim 1 , wherein the first filler is present in the gypsum core in an amount of from 0.001 wt. % or more to 15 wt. % or less based on the weight of the gypsum core.

20 . The gypsum panel of claim 1 , wherein the first facing material comprises a paper facing material.

21 . The gypsum panel of claim 1 , wherein the second facing material comprises a paper facing material.

22 . The gypsum panel of claim 1 , wherein the gypsum core further comprises vermiculite.

23 . A method of making the gypsum panel of claim 1 , the method comprising:
providing the first facing material; depositing the thermal additive adjacent the inner surface of the first facing material to form the thermal barrier layer; depositing a gypsum slurry comprising stucco, water, and the first filler comprising silica, alumina, or a mixture thereof adjacent the thermal barrier layer; providing the second facing material adjacent the gypsum slurry; and allowing the stucco to convert to calcium sulfate dihydrate to form the gypsum core.

Assignees

• Gold Bond Building Products Llc

Inventors

• Evans Veda
• Iyer Ratnasabapathy Gurunathan
• Bailey Joseph J

Classifications

• B32B29/002

  as the main or only constituent of a layer, which is next to another layer of the same or of a different material (next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10) · CPC title

• E04C2/043

  of plaster (E04C2/049 takes precedence) · CPC title

• C04B30/02

  containing fibrous materials · CPC title

• C04B26/06

  Acrylates · CPC title

• C04B28/14

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