Method Of Forming A Gypsum Panel Including A Starch Layer

Patent metadata

Field	Value
Publication number	US-2025333357-A1
Application number	US-202519262287-A
Country	US
Kind code	A1
Filing date	Jul 8, 2025
Priority date	Apr 2, 2020
Publication date	Oct 30, 2025
Grant date	—

Abstract

In the present disclosure, a method of forming a gypsum panel is disclosed. The method comprises: providing a first facing material, forming a starch slurry by combining starch and water at a shear rate of 3,000 rpm or more, providing the starch slurry onto the first facing material, depositing a gypsum slurry comprising stucco and water onto the starch slurry on the first facing material, providing a second facing material on the gypsum slurry, and allowing the stucco to convert to calcium sulfate dihydrate.

First claim

1 . A method of forming a gypsum panel, the method comprising:
providing a first facing material; depositing a gypsum slurry comprising stucco and water onto the first facing material; providing a second facing material on the gypsum slurry; and converting the stucco to calcium sulfate dihydrate; wherein a starch slurry is provided onto the first facing material, the second facing material, or both, the starch slurry covering less than 100% of a deposition surface of the first facing material, the second facing material, or both, the starch slurry being formed by combining a starch and water at a shear rate of from 3,000 rpm to 6,000 rpm, the starch being present in the starch slurry in an amount of 1 wt. % or more based on the weight of the starch slurry, the starch being a solid.

2 . The method of claim 1 , wherein the starch slurry is further provided on the gypsum slurry and the second facing material is provided on the starch slurry on the gypsum slurry.

3 . The method of claim 1 , wherein the first facing material is a paper facing material and the second facing material is a paper facing material.

4 . The method of claim 1 , wherein the starch slurry covers at least 50% of the deposition surface of the first facing material.

5 . The method of claim 1 , wherein the starch slurry includes starch in an amount of 50 wt. % or more based on a solids content of the starch slurry.

6 . The method of claim 1 , wherein the starch slurry comprises gypsum, wherein the gypsum to starch weight ratio in the starch slurry is from 0.001 to 10.

7 . The method of claim 1 , wherein the shear rate is 5,000 rpm or less.

8 . The method of claim 1 , wherein the gypsum slurry further comprises a starch in an amount of 0.0001 wt. % to 10 wt. %.

9 . The method of claim 1 , wherein the gypsum panel has a weight of from 1,000 lbs/MSF to 4,000 lbs/MSF.

10 . The method of claim 1 , wherein the gypsum panel has a nail pull resistance of at least 70 lb f .

11 . The method of claim 1 , wherein the starch is present in the starch slurry in an amount of 5 wt. % or more based on the weight of the starch slurry.

12 . The method of claim 1 , wherein gypsum is present in the starch slurry in an amount of 0.1 wt. % or more to 10 wt. % or less.

13 . The method of claim 1 , wherein the starch has a peak gelling temperature of 120° F. or more.

14 . The method of claim 1 , wherein:
the starch slurry covers at least 50% of the deposition surface of the first facing material; the starch has a peak gelling temperature of 120° F. or more; and the gypsum panel has a weight of from 1,000 lbs/MSF to 4,000 lbs/MSF.

15 . A gypsum panel made according to the method of claim 1 .

16 . A method of forming a gypsum panel, the method comprising:
providing a first facing material; depositing a gypsum slurry comprising stucco and water onto the first facing material; providing a second facing material on the gypsum slurry; and converting the stucco to calcium sulfate dihydrate; wherein a starch slurry is provided onto the first facing material, the second facing material, or both, the starch slurry covering less than 100% of a deposition surface of the first facing material, the second facing material, or both, the starch slurry being formed by combining a starch and water at a shear rate of 6,000 rpm or less, the starch being present in the starch slurry in an amount of 1 wt. % or more based on the weight of the starch slurry, the starch having a peak gelling temperature of 120° F. or more and a peak viscosity of 150 BU or more, the starch being a solid.

17 . The method of claim 16 , wherein the starch slurry comprises gypsum, wherein the gypsum to starch weight ratio in the starch slurry is from 0.001 to 10.

18 . The method of claim 16 , wherein the starch slurry covers at least 50% of the deposition surface of the first facing material.

19 . The method of claim 16 , wherein the starch slurry comprises starch in an amount of 50 wt. % or more based on the solids content of the starch slurry,

20 . The method of claim 16 , wherein the starch is present in the starch slurry in an amount of 5 wt. % or more based on the weight of the starch slurry.

21 . The method of claim 16 , wherein the gypsum panel has a nail pull resistance of at least 70 lb f .

22 . The method of claim 16 , wherein the starch has a peak gelling temperature of 190° F. or less and a peak viscosity of 1,300 BU or less.

23 . The method of claim 16 , wherein the shear rate is 1,500 rpm or more.

24 . A gypsum panel made according to the method of claim 16 .

Assignees

• Gold Bond Building Products Llc

Inventors

• Whittington Gene
• Piercy Robert
• Griffith Tom
• Flanders Al

Classifications

• C04B41/009

  characterised by the material treated · CPC title

• B28B19/0092 Primary

  to webs, sheets or the like, e.g. of paper, cardboard · CPC title

• C04B41/65

  with inorganic materials · CPC title

• C04B41/63

  Macromolecular compounds · CPC title

• C04B2111/00629

  the covering sheets being made of material other than paper · CPC title