Gypsum panels, cores, and methods for the manufacture thereof

Patent metadata

Field	Value
Publication number	US-9938192-B2
Application number	US-201715456906-A
Country	US
Kind code	B2
Filing date	Mar 13, 2017
Priority date	Nov 17, 2014
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

Abstract

Gypsum panels, panel cores, and methods for the manufacture thereof are provided herein. A gypsum panel core includes gypsum and fiberglass, the fiberglass being present in the core in an amount of from about 1 lb/msf to about 6 lb/msf. The core has a thickness of about 1/2 inch, a weight of from about 1400 lb/msf to about 1750 lb/msf, and an ASTM E-119 wood stud fire test rating of at least 30 minutes.

First claim

We claim:

1. A gypsum panel core, comprising:
gypsum, pregelatinized starch, vermiculite, sodium trimetaphosphate, and fiberglass, the fiberglass being present in the core in an amount of from about 0.02lb/ft 3 to about 0.1 lb/ft 3 and the gypsum being present in the core in an amount of from 32 lb/ft 3 to 40 lb/ft 3 ,
wherein the core has a weight of from about 34 lb/ft 3 to about 42 lb/ft 3 , and
wherein the core has an ASTM E-119 wood stud fire test rating of at least 30 minutes.

2. The gypsum panel core of claim 1 , wherein the pregelatinized starch is present in the core in an amount of from about 0.02 lb/ft 3 to about 0.3 lb/ft 3 .

3. The gypsum panel core of claim 1 , wherein the pregelatinized starch is present in the core in an amount of from about 0.1 lb/ft 3 to about 0.2 lb/ft 3 .

4. The gypsum panel core of claim 1 , wherein the sodium trimetaphosphate is present in the core in an amount of from about 0.02 lb/ft 3 to about 0.3 lb/ft 3 .

5. The gypsum panel core of claim 1 , wherein the vermiculite is present in the core in an amount of from about 0.002 lb/ft 3 to about 1 lb/ft 3 .

6. The gypsum panel core of claim 1 , wherein the vermiculite is present in the core in an amount of from about 0.002 lb/ft 3 to about 0.7 lb/ft 3 .

7. The gypsum panel core of claim 1 , wherein the core has a weight of from about 35 lb/ft 3 to about 41 lb/ft 3 .

8. A method of using a gypsum panel comprising the gypsum panel core of claim 1 , wherein the gypsum panel forms an exterior wall of a building.

9. A gypsum panel, comprising:
a core having a weight of from about 34 lb/ft3 to about 42 lb/ft 3 , the core comprising gypsum, pregelatinized starch, vermiculite, sodium trimetaphosphate, and fiberglass, the fiberglass being present in the core in an amount of from about 0.02 lb/ft 3 to about 0.1 lb/ft 3 and the gypsum being present in the core in an amount of from 32 lb/ft 3 to 40 lb/ft 3 ; and
a facer disposed on at least one face of the core,
wherein the core has an ASTM E-119 wood stud fire test rating of at least 30 minutes.

10. The gypsum panel of claim 9 , wherein the core has a weight of from about 35 lb/ft 3 to about 41 lb/ft 3 .

11. The gypsum panel of claim 9 , wherein the pregelatinized starch is present in the core in an amount of from about 0.02 lb/ft 3 to about 0.3 lb/ft 3 .

12. The gypsum panel of claim 9 , wherein the pregelatinized starch is present in the core in an amount of from about 0.1 lb/ft 3 to about 0.2 lb/ft 3 .

13. The gypsum panel of claim 9 , wherein the sodium trimetaphosphate is present in the core in an amount of from about 0.02 lb/ft 3 to about 0.3 lb/ft 3 .

14. The gypsum panel of claim 9 , wherein the vermiculite is present in the core in an amount of from about 0.002 lb/ft 3 to about 1 lb/ft 3 .

15. The gypsum panel of claim 9 , wherein the vermiculite is present in the core in an amount of from about 0.002 lb/ft 3 to about 0.7 lb/ft 3 .

16. A method of using the gypsum panel of claim 9 , in construction, wherein the gypsum panel forms an exterior wall of a building.

17. A method of making a gypsum panel, comprising:
combining gypsum stucco, water, pregelatinized starch, vermiculite, sodium trimetaphosphate, and fiberglass to form a slurry; and
setting the slurry to form a core having a weight of from about 34 lb/ft 3 to about 42 lb/ft 3 , and comprising fiberglass in an amount of from about 0.02 lb/ft 3 to about 0.1 lb/ft 3 and gypsum in an amount of from 32 lb/ft 3 to 40 lb/ft 3 ,
wherein the core has an ASTM E-119 wood stud fire test rating of at least 30 minutes.

18. The method of claim 17 , wherein the core has a weight of from about 35 lb/ft 3 to about 41 lb/ft 3 .

19. The method of claim 17 , wherein the pregelatinized starch is present in the core in an amount of from about 0.1 lb/ft 3 to about 0.2 lb/ft 3 .

20. The method of claim 17 , wherein the sodium trimetaphosphate is present in the core in an amount of from about 0.02 lb/ft 3 to about 0.3 lb/ft 3 .

21. The gypsum panel core of claim 1 , wherein a ratio of gypsum to vermiculite in the core is 32:1 pcf or greater.

22. The gypsum panel of claim 9 , wherein a ratio of gypsum to vermiculite in the core is 32:1 pcf or greater.

23. The method of claim 17 , wherein a ratio of gypsum to vermiculite in the core is 32:1 pcf or greater.

Assignees

• Georgia Pacific Gypsum Llc

Inventors

• Moore Michael H
• Sanders Christopher J

Classifications

• E04C5/07

  Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal (metal elements with non-structural coatings E04C5/01) · CPC title

• E04C2/06

  reinforced · CPC title

• E04C2/043

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

• E04B9/001

  characterised by provisions for heat or sound insulation · CPC title

• C04B28/14 Primary

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