Gypsum hardened body, gypsum panel, method for manufacturing gypsum hardened body, and method for manufacturing gypsum board

Patent metadata

Field	Value
Publication number	US-9802867-B2
Application number	US-201415308947-A
Country	US
Kind code	B2
Filing date	May 23, 2014
Priority date	May 8, 2014
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

A gypsum hardened body including a gypsum slurry that has been hardened is provided. The gypsum slurry is obtained by mixing calcined gypsum, calcium hydrogen phosphate dihydrate, water, and foam. The specific gravity of the gypsum hardened body is greater than or equal to 0.3 and less than or equal to 0.8.

First claim

The invention claimed is:

1. A gypsum hardened body comprising:
a gypsum slurry that has been hardened;
wherein the gypsum slurry is obtained by mixing calcined gypsum, calcium hydrogen phosphate dihydrate, water, and foam; and
wherein a specific gravity of the gypsum hardened body is greater than or equal to 0.3 and less than or equal to 0.8.

2. The gypsum hardened body according to claim 1 , wherein
the gypsum slurry includes the calcium hydrogen phosphate dihydrate at an amount greater than or equal to 0.01 part by mass and less than or equal to 5 parts by mass with respect to 100 parts by mass of the calcined gypsum.

3. The gypsum hardened body according to claim 1 , wherein
the gypsum slurry includes the calcium hydrogen phosphate dihydrate at an amount greater than or equal to 0.05 parts by mass and less than or equal to 1 part by mass with respect to 100 parts by mass of the calcined gypsum.

4. The gypsum hardened body according to claim 1 , wherein the specific gravity of the gypsum hardened body is greater than or equal to 0.3 and less than or equal to 0.5.

5. The gypsum hardened body according to claim 1 , wherein the gypsum slurry further includes an organic carboxylic acid and/or an organic carboxylic acid salt.

6. The gypsum hardened body according to claim 5 , wherein
the organic carboxylic acid and/or the organic carboxylic acid salt includes at least one organic carboxylic acid selected from a group consisting of formic acid, acetic acid, propionic acid, butyric acid, valeric acid, acrylic acid, methacrylic acid, propiolic acid, oleic acid, maleic acid, fumaric acid, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, tartaric acid, citric acid, malic acid, gluconic acid, and lactic acid; and/or at least one salt of at least one organic carboxylic acid selected from the group.

7. The gypsum hardened body according to claim 5 , wherein
the gypsum slurry includes the organic carboxylic acid and/or the organic carboxylic acid salt at an amount greater than or equal to 0.005 parts by mass and less than or equal to 0.2 parts by mass with respect to 100 parts by mass of the calcined gypsum.

8. The gypsum hardened body according to claim 1 , wherein
the calcined gypsum includes β-calcined gypsum.

9. A gypsum panel including the gypsum hardened body according to claim 1 as a core material.

10. The gypsum panel according to claim 9 , wherein the gypsum panel is a gypsum board.

11. The gypsum panel according to claim 9 , wherein an amount of deflection of the gypsum panel is less than or equal to 100 mm.

12. A method for manufacturing a gypsum hardened body, comprising:
a gypsum slurry manufacturing step for manufacturing a gypsum slurry by mixing calcined gypsum, calcium hydrogen phosphate dihydrate, water, and foam;
a shaping step for shaping the gypsum slurry into a shaped body; and
a hardening step for hardening the shaped body obtained in the shaping step to obtain the gypsum hardened body;
wherein a specific gravity of the obtained gypsum hardened body is greater than or equal to 0.3 and less than or equal to 0.8.

13. A method for manufacturing a gypsum board, comprising:
a gypsum slurry manufacturing step for manufacturing a gypsum slurry by mixing calcined gypsum, calcium hydrogen phosphate dihydrate, water, and foam;
a shaping step for arranging the gypsum slurry between base paper and shaping the gypsum slurry into a shaped body; and
a hardening step for hardening the shaped body obtained in the shaping step to obtain the gypsum hardened body;
wherein a specific gravity of the obtained gypsum hardened body is greater than or equal to 0.3 and less than or equal to 0.8.

Assignees

• Yoshino Gypsum Co

Inventors

• Sudo Ushio
• Itano Hiroaki
• Sato Yosuke
• Sawada Tomoaki

Classifications

• C04B2201/20

  for the density · CPC title

• E04C2/043

  of plaster (E04C2/049 takes precedence) · CPC title

• C04B2103/12

  Set accelerators · CPC title

• C04B28/14 Primary

  containing calcium sulfate cements {(gypsum-paper plates E04C)} · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title