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Moisture-resistant gypsum boards and methods of making them
US2025171361A1 · US · A1
| Field | Value |
|---|---|
| Publication number | US-2025171361-A1 |
| Application number | US-202418955351-A |
| Country | US |
| Kind code | A1 |
| Filing date | Nov 21, 2024 |
| Priority date | Nov 29, 2023 |
| Publication date | May 29, 2025 |
| Grant date | — |
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- Title
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- Abstract
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Abstract
Official abstract text for this publication.
A gypsum-based construction material can include gypsum core including a stucco component, a siloxane component at a content of not greater than about 2.0 wt. % relative to a content of the stucco component, and a calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the stucco component. The gypsum-based construction material can have a pH of at least about 7.5 and not greater than about 10.
First claim
Opening claim text (preview).
What is claimed is: 1 . A gypsum-based slurry composition comprising: a precursor stucco component, a precursor siloxane component at a content of not greater than about 2.0 wt. % relative to a content of the precursor stucco component, and a precursor calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the precursor stucco component, wherein the gypsum-based slurry composition has a pH of at least about 7.5 and not greater than about 10. 2 . The gypsum-based slurry composition of claim 1 , wherein the precursor siloxane component comprises polymethylhydrosiloxane (PMHS). 3 . The gypsum-based slurry composition of claim 1 , wherein the gypsum-based slurry composition comprises the precursor siloxane component at a content of at least about 0.2 wt. % and not greater than about 2.0 wt. % relative to the content of the precursor stucco component. 4 . The gypsum-based slurry composition of claim 1 , wherein the precursor calcium hydroxide catalyst comprises calcium hydroxide. 5 . The gypsum-based slurry composition of claim 1 , wherein the gypsum-based slurry composition comprises the precursor calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the precursor stucco component. 6 . The gypsum-based slurry composition of claim 1 , wherein the gypsum-based slurry composition comprises an ASTM C473 water absorption improvement percentage of at least about 5% relative to the ASTM C473 standard material. 7 . The gypsum-based slurry composition of claim 1 , wherein the gypsum-based slurry composition comprises a pH of at least about 7.6 and not greater than about 9.9. 8 . A gypsum-based construction material comprising a gypsum core, wherein the gypsum core comprises: a stucco component, a siloxane component at a content of not greater than about 2.0 wt. % relative to a content of the stucco component, and a calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the stucco component, wherein the gypsum-based construction material has a pH of at least about 7.5 and not greater than about 10. 9 . The gypsum-based construction material of claim 8 , wherein the siloxane component comprises polymethylhydrosiloxane (PMHS). 10 . The gypsum-based construction material of claim 8 , wherein the gypsum-based construction material composition comprises the siloxane component at a content of at least about 0.2 wt. % and not greater than about 2.0 wt. % relative to the content of the stucco component. 11 . The gypsum-based construction material of claim 8 , wherein the calcium hydroxide catalyst comprises calcium hydroxide. 12 . The gypsum-based construction material of claim 8 , wherein the gypsum-based construction material composition comprises the calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the stucco component. 13 . The gypsum-based construction material of claim 8 , wherein the gypsum-based slurry composition comprises an ASTM C473 water absorption improvement percentage of at least about 5% relative to the ASTM C473 standard material. 14 . The gypsum-based construction material of claim 8 , wherein the gypsum-based slurry composition comprises a pH of at least about 7.6 and not greater than about 9.9. 15 . The gypsum-based construction material of claim 8 , wherein the construction material is rated for 2 hours total water absorption per ASTM C473 Method B. 16 . A method of forming a gypsum-based construction material, wherein the method comprises providing a gypsum-based slurry composition comprising: a precursor stucco component, a precursor siloxane component at a content of not greater than about 2.0 wt. % relative to a content of the precursor stucco component, and a precursor calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the precursor stucco component, wherein the gypsum-based slurry composition has a pH of at least about 7.5 and not greater than about 10, depositing the slurry composition to form a gypsum preform of the gypsum-based construction material preform, and firing the gypsum preform of the gypsum-based construction material to form a gypsum core. 17 . The method of claim 16 , wherein the precursor siloxane component comprises polymethylhydrosiloxane (PMHS). 18 . The method of claim 16 , wherein the gypsum-based slurry composition comprises the precursor siloxane component at a content of at least about 0.2 wt. % and not greater than about 2.0 wt. % relative to the content of the precursor stucco component. 19 . The method of claim 16 , wherein the precursor calcium hydroxide catalyst comprises calcium hydroxide. 20 . The method of claim 16 , wherein the gypsum-based slurry composition comprises the precursor calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the precursor stucco component.
Assignees
Inventors
Classifications
Flow improvers · CPC title
Gypsum-paper board like materials · CPC title
Calcium sulfate hemi-hydrate with a specific crystal form · CPC title
containing dihydrated gypsum before the final hardening step, e.g. forming a dihydrated gypsum product followed by a de- and rehydration step · CPC title
Cellulose or derivatives thereof · CPC title
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- What does patent US2025171361A1 cover?
- A gypsum-based construction material can include gypsum core including a stucco component, a siloxane component at a content of not greater than about 2.0 wt. % relative to a content of the stucco component, and a calcium hydroxide catalyst at a content of at least about 0.01 wt. % and not greater than about 0.1 wt. % relative to the content of the stucco component. The gypsum-based constructio…
- Who is the assignee on this patent?
- Certainteed Gypsum Inc
- What technology area does this patent fall under?
- Primary CPC classification C04B28/144. Mapped technology areas include Chemistry & Metallurgy.
- When was this patent published?
- Publication date Thu May 29 2025 00:00:00 GMT+0000 (Coordinated Universal Time) (A1). Legal status and post-grant events are not shown on this page.
- What related patents are in patentsdb?
- We list 8 related publications on this page (citations in our corpus or others sharing the same primary CPC).