Gypsum Panel Having Enhanced Water Resistance

Patent metadata

Field	Value
Publication number	US-2025326691-A1
Application number	US-202519175017-A
Country	US
Kind code	A1
Filing date	Apr 10, 2025
Priority date	Apr 19, 2024
Publication date	Oct 23, 2025
Grant date	—

Abstract

The present invention is directed to gypsum panels containing a water resistance enhancement composition and a method of making such gypsum panels. In one embodiment, the gypsum panel comprises a gypsum core, a first facing material, and a second facing material. Notably, the gypsum core may be formed by a gypsum slurry comprising a water resistance enhancement composition including an alkali salt, an ammonium salt, or a combination thereof. The methods of the present invention are directed to making the aforementioned gypsum panels.

First claim

1 . A gypsum panel comprising:
a gypsum core comprising gypsum, the gypsum core being formed by a gypsum slurry, the gypsum slurry comprising a water resistance enhancement composition and a siloxane composition, the water resistance enhancement composition being an alkali salt, an ammonium salt, or a combination thereof, the siloxane composition being a siloxane, wherein the weight ratio of the water resistance enhancement composition to the siloxane composition in the gypsum slurry is from about 40:1 to about 1:40; and a first facing material and a second facing material sandwiching the gypsum core.

2 . The gypsum panel of claim 1 , wherein the water resistance enhancement composition comprises the alkali salt, the alkali salt being an alkali carbonate, an alkali bicarbonate, or a combination thereof.

3 . The gypsum panel of claim 2 , wherein the alkali salt comprises an alkali carbonate, wherein the alkali carbonate is sodium carbonate.

4 . The gypsum panel of claim 2 , wherein the alkali salt comprises an alkali bicarbonate, wherein the alkali bicarbonate is sodium bicarbonate.

5 . The gypsum panel of claim 1 , wherein the water resistance enhancement composition comprises an ammonium salt.

6 . The gypsum panel of claim 5 , wherein the ammonium salt is ammonium carbonate, ammonium bicarbonate, or a combination thereof.

7 . The gypsum panel of claim 1 , wherein the gypsum slurry has a pH of less than about 10.

8 . The gypsum panel of claim 1 , wherein the gypsum slurry has a pH of less than about 9.

9 . The gypsum panel of claim 1 , wherein the weight ratio of the water resistance enhancement composition to the siloxane composition in the gypsum slurry is from about 20:1 to about 1:20.

10 . The gypsum panel of claim 1 , wherein the weight ratio of the water resistance enhancement composition to the siloxane composition in the gypsum slurry is from about 10:1 to about 1:5.

11 . The gypsum panel of claim 1 , wherein the gypsum panel exhibits a water absorption of less than about 10%.

12 . The gypsum panel of claim 1 , wherein the gypsum panel exhibits a water absorption of less than about 7%.

13 . The gypsum panel of claim 1 , wherein the water resistance enhancement composition is present in the gypsum slurry in an amount of 3 wt. % or less by weight of the gypsum slurry.

14 . The gypsum panel of claim 1 , wherein:
the gypsum slurry has a pH of less than about 9; the weight ratio of the water resistance enhancement composition to the siloxane composition in the gypsum slurry is from about 20:1 to about 1:20; and the water resistance enhancement composition is present in the gypsum slurry in an amount of 3 wt. % or less by weight of the gypsum slurry.

15 . A gypsum panel comprising:
a gypsum core comprising gypsum; a siloxane composition, the siloxane composition being a siloxane; and a first facing material and a second facing material sandwiching the gypsum core; wherein a water resistance enhancement composition is present in or applied to a gypsum slurry, the first facing material, the second facing material, or a combination thereof during a process of making the gypsum panel, the water resistance enhancement composition being an alkali salt, an ammonium salt, or a combination thereof; wherein the weight ratio of the water resistance enhancement composition to the siloxane composition in the gypsum panel is from about 40:1 to about 1:40.

16 . The gypsum panel of claim 15 , wherein the water resistance enhancement composition comprises the alkali salt, the alkali salt being an alkali carbonate, an alkali bicarbonate, or a combination thereof.

17 . The gypsum panel of claim 16 , wherein the alkali salt comprises an alkali carbonate, wherein the alkali carbonate is sodium carbonate.

18 . The gypsum panel of claim 16 , wherein the alkali salt comprises an alkali bicarbonate, wherein the alkali bicarbonate is sodium bicarbonate.

19 . The gypsum panel of claim 15 , wherein the water resistance enhancement composition comprises an ammonium salt.

20 . The gypsum panel of claim 19 , wherein the ammonium salt is an ammonium carbonate, an ammonium bicarbonate, or a combination thereof.

21 . The gypsum panel of claim 15 , wherein the gypsum slurry has a pH of less than about 9.

22 . A method for making a gypsum panel comprising:
providing a first facing material; depositing a gypsum slurry comprising stucco, water, a water resistance enhancement composition, and a siloxane composition onto the first facing material, the water resistance enhancement composition being an alkali salt, an ammonium salt, or a combination thereof, the weight ratio of the water resistance enhancement composition to the siloxane composition in the gypsum slurry being from about 40:1 to about 1:40; providing a second facing material on the gypsum slurry; and allowing the stucco to convert to calcium sulfate dihydrate.

Assignees

• Gold Bond Building Products Llc

Inventors

• Yang Xing
• Iyer Ratnasabapathy Gurunathan

Classifications

• C04B28/145

  Calcium sulfate hemi-hydrate with a specific crystal form · CPC title

• B32B2607/00

  Walls, panels · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• B32B2307/712

  Weather resistant · CPC title

• B32B2250/40

  Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA · CPC title