Fire resistant building board

Patent metadata

Field	Value
Publication number	US-2025319689-A1
Application number	US-202519174368-A
Country	US
Kind code	A1
Filing date	Apr 9, 2025
Priority date	Apr 10, 2024
Publication date	Oct 16, 2025
Grant date	—

Abstract

A building board, particularly a gypsum board, can include a first cover sheet, a second cover sheet, and a core disposed between the first and second cover sheets. The core can include gypsum, microsilica, and an additive. The microsilica can no greater than 2.7 wt. % of the building board. The additive can include a polysiloxane material and be no greater than 0.25 wt. % of the building board.

First claim

What is claimed is:

1 . A building board, comprising:
a first cover sheet; a second cover sheet; a core between the first and second cover sheets, wherein the core comprises:
gypsum;
microsilica, wherein the microsilica is no greater than 2.7 wt. % of the building board; and
an additive, the additive comprising a polysiloxane material, wherein the additive is no greater than 0.25 wt. % of the building board.

2 . The building board of claim 1 , wherein the polysiloxane material is selected from the group consisting of silicone oil, polydimethylsiloxane (PDMS), polymethylhydrosiloxane (PMHS), or any combination thereof.

3 . The building board of claim 1 , wherein the additive is greater than 0 wt. %.

4 . The building board of claim 3 , wherein the additive is no greater than 0.20 wt. % of the building board.

5 . The building board of claim 1 , further comprising a second additive, wherein the second additive comprises a material selected from the group consisting of expandable graphite, vermiculite, perlite, mica, and a combination thereof.

6 . The building board of claim 1 , wherein the microsilica has a size of no greater than 500 microns.

7 . The building board of claim 1 , wherein the microsilica is no greater than 1.89 wt. % of the building board.

8 . The building board of claim 7 , wherein the microsilica is at least 0.108 wt. % of the building board.

9 . A building board, comprising:
a first cover sheet; a second cover sheet; a core between the first and second cover sheets, wherein the core comprises:
gypsum;
microsilica; and
additive, the additive comprising a polysiloxane material, wherein the building board has one of the following:
a linear shrinkage of less than 8.5%; or
a shrinkage improvement of at least 6%, wherein the shrinkage improvement is equal to a percentage the building board did not shrink as compared to an amount of shrinkage that a standard board without a combined polysiloxane material and microsilica.

10 . The building board of claim 9 , wherein the linear shrinkage is less than 7% after exposure to a temperature of at least 960° C. after exposure to a temperature of at least 960° C.

11 . The building board of claim 9 , wherein the linear shrinkage is less than 8% after exposure to a temperature of at least 1000° C.

12 . The building board of claim 9 , wherein the polysiloxane material is selected from the group consisting of silicone oil, polydimethylsiloxane (PDMS), polymethylhydrosiloxane (PMHS), or any combination thereof.

13 . The building board of claim 9 , wherein the additive is greater than 0 wt. %.

14 . The building board of claim 13 , wherein the additive is no greater than 0.22 wt. % of the building board.

15 . The building board of claim 9 , wherein the gypsum is no greater than 90 wt. % of the building board.

16 . The building board of claim 9 , further comprising a second additive, wherein the second additive comprises a material selected from the group consisting of expandable graphite, vermiculite, perlite, mica, and a combination thereof.

17 . The building board of claim 9 , wherein the microsilica has a size of no greater than 500 microns.

18 . The building board of claim 9 , wherein the microsilica is no greater than 2.7 wt. % of the building board.

19 . The building board of claim 9 , where the shrinkage improvement is at least 5%.

20 . A method of making a building board comprises:
forming a first layer comprising gypsum, microsilica, and an additive, wherein the microsilica is no greater than 2.7 wt. % of the building board, wherein the additive comprises a polysiloxane material, and wherein the additive is no greater than 0.25 wt. % of the building board; and rolling the first layer and formed interlayer between two cover sheets to form a building board.

Assignees

• Certainteed Gypsum Inc

Inventors

• Lespiat Remi
• Amato Dahlia
• Godefroid Julie
• Marzin Leana

Classifications

• B32B2607/00

  Walls, panels · CPC title

• B32B2307/3065

  Flame resistant or retardant, fire resistant or retardant · CPC title

• B32B2250/03

  3 layers · CPC title

• B32B2264/3065

  bimodal size distribution · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title