Gypsum Panel Containing a Maleic Anhydride Polymer

Patent metadata

Field	Value
Publication number	US-2025361721-A1
Application number	US-202519209871-A
Country	US
Kind code	A1
Filing date	May 16, 2025
Priority date	May 24, 2024
Publication date	Nov 27, 2025
Grant date	—

Abstract

The present disclosure is directed to a gypsum panel and a method of making such gypsum panel. For instance, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core. The gypsum core includes gypsum and a maleic anhydride polymer comprising maleic anhydride repeating units present in an amount of more than 10 wt. % based on the weight of the maleic anhydride polymer. The method of the present disclosure is directed to making the aforementioned gypsum panel by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and a maleic anhydride polymer onto the first facing material and providing a second facing material on the gypsum slurry.

First claim

1 . A gypsum panel comprising:
a gypsum core comprising gypsum and a maleic anhydride polymer comprising maleic anhydride repeating units in an amount of more than 10 wt. % based on the weight of the maleic anhydride polymer, and a first facing material and a second facing material sandwiching the gypsum core.

2 . The gypsum panel of claim 1 , wherein the maleic anhydride repeating units constitute an amount of 25 wt. % or more of the maleic anhydride polymer based on the weight of the maleic anhydride polymer.

3 . The gypsum panel of claim 1 , wherein the maleic anhydride polymer comprises a maleic anhydride homopolymer.

4 . The gypsum panel of claim 1 , wherein the maleic anhydride polymer comprises a maleic anhydride copolymer.

5 . The gypsum panel of claim 1 , wherein the maleic anhydride polymer comprises maleic anhydride repeating units and repeating units of one or more ethylenically unsaturated monomers.

6 . The gypsum panel of claim 5 , wherein the one or more ethylenically unsaturated monomers comprise an acrylic acid or an ester thereof, a vinyl ether, a vinyl ester, a vinyl halide, a vinyl aromatic, or a mixture thereof.

7 . The gypsum panel of claim 5 , wherein the one or more ethylenically unsaturated monomers comprise an olefin.

8 . The gypsum panel of claim 7 , wherein the olefin comprises 2 or more to 10 or less carbon atoms.

9 . The gypsum panel of claim 1 , wherein the maleic anhydride polymer comprises maleic anhydride repeating units and 2,4,4-trimethyl-1-pentene repeating units.

10 . The gypsum panel of claim 5 , wherein the repeating units of one or more ethylenically unsaturated monomers constitute 1 wt. % or more to 90 wt. % or less of the maleic anhydride polymer based on the weight of the maleic anhydride polymer.

11 . The gypsum panel of claim 1 , wherein the maleic anhydride polymer comprises a metal salt.

12 . The gypsum panel of claim 11 , wherein the maleic anhydride polymer comprises a sodium salt.

13 . The gypsum panel of claim 1 , wherein the maleic anhydride polymer is present in an amount of 0.01 wt. % or more to 5 wt. % or less based on the weight of the gypsum core.

14 . The gypsum panel of claim 1 , wherein the maleic anhydride polymer is present in an amount of 0.1 wt. % or more to 3 wt. % or less based on the weight of the gypsum core.

15 . The gypsum panel of claim 1 , wherein the maleic anhydride polymer is present in an amount of 0.2 wt. % or more to 1 wt. % or less based on the weight of the gypsum core.

16 . The gypsum panel of claim 1 , wherein the gypsum is present in an amount of at least 60 wt. % based on the weight of the gypsum core.

17 . The gypsum panel of claim 1 , wherein the gypsum core comprises a further dispersant.

18 . The gypsum panel of claim 17 , wherein the further dispersant comprises naphthalene sulfonate, naphthalene sulfonate formaldehyde condensate, sodium naphthalene sulfonate formaldehyde condensate, lignosulfonate, melamine formaldehyde condensate, a polycarboxylate ether, a polycarboxylate ester, or a mixture thereof.

19 . The gypsum panel of claim 1 , wherein the gypsum panel exhibits a nail pull resistance of at least about 70 lb f when tested in accordance with ASTM C 1396 -17.

20 . The gypsum panel of claim 1 , wherein the gypsum panel exhibits a nail pull resistance of at least about 77 lb f when tested in accordance with ASTM C 1396 -17.

21 . A method for making a gypsum panel, the method comprising:
providing a first facing material; depositing a gypsum slurry comprising stucco, water, and a maleic anhydride polymer comprising maleic anhydride repeating units in an amount of more than 10 wt. % based on the weight of the maleic anhydride polymer onto the first facing material; 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

• Iyer Ratnasabapathy Gurunathan
• Cirignano Jillian
• Yang Xing
• Dong Ju
• Fenoli Christopher R

Classifications

• C04B2103/408

  Dispersants · CPC title

• B32B2607/00

  Walls, panels · CPC title

• B32B2250/40

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

• B32B2250/03

  3 layers · CPC title

• C04B2103/0039

  according to ASTM · CPC title