公开(公告)号：US20230250019A1

公开(公告)日：2023-08-10

申请号：US17948710

申请日：2022-09-20

Applicant: United States Gypsum Company

Inventor： Qinghua Li ,  Mark Hemphill

IPC: C04B11/28

CPC classification number: C04B11/28 ,  C04B2111/0062

Abstract: This disclosure provides products useful as construction materials and containing set gypsum and ammonium-exchanged vermiculite, including a gypsum panel having a gypsum core comprising set gypsum and ammonium-exchanged vermiculite and characterized by decreased heat shrinkage and increased resistance to fire damage in comparison to the gypsum panel that comprises vermiculite that has not been ammonium-exchanged. The disclosure further relates to methods for producing the gypsum panel and constructing building assemblies with the gypsum panels, including walls and ceilings.

公开(公告)号：US11186067B2

公开(公告)日：2021-11-30

申请号：US16401719

申请日：2019-05-02

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Qinghua Li ,  Runhai Lu ,  Charles W. Cochran ,  Mark Hemphill

IPC: B32B13/08 ,  B32B29/06 ,  B32B29/00 ,  B32B3/26 ,  C04B28/14 ,  C04B111/00

Abstract: Gypsum boards formed from synthetic gypsum and other gypsum sources having high chloride salt concentrations. Gypsum boards may include a board core including set gypsum. A total concentration of the chloride anion in the board core ranges from about 500 ppm to about 3000 ppm, typically about 1000 ppm to about 3000 ppm, based on weight of the calcium sulfate hemihydrate. An inner surface of a front paper cover sheet contacts a first face of the board core. An inner surface of a back paper cover sheet contacts a second face of the board core. A starch layer coats the inner surface of at least one of the front and back cover sheet. Methods of making the gypsum board, and a wall system for employing the gypsum boards, are also provided.

公开(公告)号：US20250019307A1

公开(公告)日：2025-01-16

申请号：US18625937

申请日：2024-04-03

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Yanfei Peng ,  Ashish Dubey ,  Qinghua Li ,  Feng Peng ,  Richard Liu

IPC: C04B28/18 ,  C04B7/26 ,  C04B7/34 ,  C04B22/14 ,  C04B24/32 ,  C04B40/00 ,  C04B103/20 ,  C04B103/32 ,  C04B111/10

Abstract: A rapid setting, water durable binder composition includes a mixture of: a reactive powder including cement, at about 10-40 wt. % of the reactive powder, β-stucco at about 30-75 wt. % of the reactive powder, and pozzolanic material at about 5-30 wt. % of the reactive powder; a plasticizer in an amount equal to about 0.05-3 wt. %, preferably 0.1-3 wt. %, of the reactive powder, and water.

公开(公告)号：US11999658B2

公开(公告)日：2024-06-04

申请号：US17851709

申请日：2022-06-28

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Qinghua Li ,  Mark Hemphill

IPC: C04B28/14 ,  B28B19/00 ,  B32B5/02 ,  B32B5/18 ,  B32B5/24 ,  B32B7/02 ,  B32B13/04 ,  B32B13/08 ,  B32B29/00 ,  B32B37/15 ,  B32B38/00 ,  C04B11/26 ,  C04B14/04 ,  C04B18/04 ,  C04B18/06 ,  C04B22/00 ,  C04B22/06 ,  C04B22/10 ,  C04B22/16 ,  C04B103/00 ,  C04B111/00

CPC classification number: C04B28/14 ,  B28B19/0092 ,  B32B5/022 ,  B32B5/18 ,  B32B5/245 ,  B32B7/02 ,  B32B13/045 ,  B32B13/08 ,  B32B29/007 ,  B32B37/15 ,  B32B38/0004 ,  B32B38/164 ,  C04B11/266 ,  C04B14/047 ,  C04B18/0445 ,  C04B18/064 ,  C04B18/065 ,  C04B22/0093 ,  C04B22/064 ,  C04B22/10 ,  C04B22/16 ,  B32B2038/0084 ,  B32B2250/40 ,  B32B2262/101 ,  B32B2264/10 ,  B32B2264/30 ,  B32B2266/049 ,  B32B2305/022 ,  B32B2307/72 ,  B32B2307/732 ,  B32B2309/02 ,  B32B2315/00 ,  B32B2315/085 ,  B32B2317/12 ,  B32B2607/00 ,  C04B2103/0078 ,  C04B2111/00629

Abstract: A gypsum wallboard having a core with a central core layer and one or more densified layers is disclosed. At least one densified layer contains salt absorbent particles of zeolite and/or hydrotalcite to improve adhesion of the gypsum core to a cover sheet. Also, methods of making the gypsum wallboard and a wall system for employing the gypsum wallboard are disclosed.

公开(公告)号：US11993054B2

公开(公告)日：2024-05-28

申请号：US16904729

申请日：2020-06-18

Applicant: United States Gypsum Company

Inventor： Qinghua Li ,  Mark K. Hemphill

IPC: B32B13/04 ,  B32B9/02 ,  C04B28/14 ,  C04B111/00

CPC classification number: B32B13/04 ,  B32B9/02 ,  C04B28/14 ,  B32B2250/05 ,  B32B2250/40 ,  B32B2315/18 ,  B32B2317/20 ,  B32B2607/00 ,  C04B2111/0062

Abstract: Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains set gypsum layers sandwiched between two cover sheets. The set gypsum layers are formed from at least stucco and water. The set gypsum layers include a board core and one or more skim coat layers. The set gypsum core makes up a substantial thickness (e.g., at least about 90%, at least about 92%, at least about 95%, or at least about 97%) of the total thickness of all the gypsum layers. A first skim coat layer is included on one side of the core, facing a first (face) cover sheet. A second skim coat layer is included on the other side of the core, facing a second (back) cover sheet. At least the second skim layer is formed from a slurry that contains starch. The stucco material generally includes a high salt impurity content, for example, when the stucco is calcined from certain sources of low-quality synthetic gypsum. For example, in some embodiments, the salts are chloride salts, e.g., sodium chloride (NaCl), potassium chloride (KCl), magnesium chloride (MgCl2), and/or calcium chloride (CaCl2).

公开(公告)号：US11702373B2

公开(公告)日：2023-07-18

申请号：US16804936

申请日：2020-02-28

Applicant: United States Gypsum Company

Inventor： Qinghua Li ,  Naser Aldabaibeh ,  Mark Hemphill ,  Trevor Rische ,  Suman Sinha Ray

IPC: C04B41/50 ,  B28B19/00 ,  C04B28/14 ,  E04C2/04 ,  E04B1/94 ,  C04B41/45 ,  B28B11/14 ,  B28B11/04 ,  B28B11/24 ,  B32B13/08 ,  C04B18/08 ,  C04B111/00 ,  C04B111/28

CPC classification number: C04B41/5024 ,  B28B11/04 ,  B28B11/14 ,  B28B11/243 ,  B28B19/0092 ,  B32B13/08 ,  C04B28/14 ,  C04B41/4535 ,  E04B1/942 ,  E04C2/043 ,  C04B18/08 ,  C04B2111/0062 ,  C04B2111/28

Abstract: Disclosed are an organic binder-based coating; a composite gypsum board containing face and back cover sheets, an outside surface of the back cover sheet bearing the coating; and a method of preparing composite board where the back cover sheet contains the coating on its outer surface. The coating is formed from a composition comprising an alkaline silicate, a solid filler, and optionally, a borate. An enhancing layer can also be applied to the back cover sheet.

公开(公告)号：US11186066B2

公开(公告)日：2021-11-30

申请号：US16401675

申请日：2019-05-02

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Mark Hemphill ,  Qinghua Li ,  Charles W. Cochran

IPC: B32B13/08 ,  B32B29/06 ,  B32B29/00 ,  C04B28/14 ,  B32B3/26 ,  C04B111/00

Abstract: Gypsum boards formed from synthetic gypsum and other gypsum sources having high chloride salt concentrations. The gypsum boards may include a set gypsum board core layer between a front and back paper cover sheets. The back paper cover sheet has a plurality of perforations extending therethrough. Methods of making the gypsum boards, and a wall system for employing the gypsum boards, are also provided. The concentration of the chloride anion in aqueous gypsum slurry used to make the set gypsum board core layer and to perform the methods of the invention may range from about 500 ppm to about 3000 ppm, typically from about 500 ppm to about 2000 ppm per 1,000,000 parts by weight calcium sulfate hemihydrate, more typically from about 500 ppm to about 1500 ppm per 1,000,000 parts by weight calcium sulfate hemihydrate.

公开(公告)号：US20210155545A1

公开(公告)日：2021-05-27

申请号：US16904756

申请日：2020-06-18

Applicant: United States Gypsum Company

Inventor： Qinghua Li ,  Mark K. Hemphill

IPC: C04B28/14 ,  C04B22/12

Abstract: Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains at least one set gypsum layer sandwiched between two cover sheets. The set gypsum layer is formed from at least stucco and water. The stucco material generally includes a high salt impurity content, for example, when the stucco is calcined from certain sources of low-quality synthetic gypsum. For example, in some embodiments, the salts are chloride salts, e.g., sodium chloride (NaCl), potassium chloride (KCl), magnesium chloride (MgCl2), and/or calcium chloride (CaCl2)). At least one of the cover sheets is composed of high absorption paper, which enhances the bond between the set gypsum layer and the cover sheet.

公开(公告)号：US20210129490A1

公开(公告)日：2021-05-06

申请号：US16904729

申请日：2020-06-18

Applicant: United States Gypsum Company

Inventor： Qinghua Li ,  Mark K. Hemphill

IPC: B32B13/04 ,  B32B9/02 ,  C04B28/14

Abstract: Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains set gypsum layers sandwiched between two cover sheets. The set gypsum layers are formed from at least stucco and water. The set gypsum layers include a board core and one or more skim coat layers. The set gypsum core makes up a substantial thickness (e.g., at least about 90%, at least about 92%, at least about 95%, or at least about 97%) of the total thickness of all the gypsum layers. A first skim coat layer is included on one side of the core, facing a first (face) cover sheet. A second skim coat layer is included on the other side of the core, facing a second (back) cover sheet. At least the second skim layer is formed from a slurry that contains starch. The stucco material generally includes a high salt impurity content, for example, when the stucco is calcined from certain sources of low-quality synthetic gypsum. For example, in some embodiments, the salts are chloride salts, e.g., sodium chloride (NaCl), potassium chloride (KCl), magnesium chloride (MgCl2), and/or calcium chloride (CaCl2).

公开(公告)号：US10604929B2

公开(公告)日：2020-03-31

申请号：US15340767

申请日：2016-11-01

Applicant: United States Gypsum Company

Inventor： Qinghua Li ,  Naveen Punati ,  Mark Antosh ,  Weixin D. Song

IPC: E04B1/94 ,  C04B14/02 ,  C04B14/20 ,  C04B28/14 ,  E04C2/04 ,  C04B111/00 ,  C04B111/28

Abstract: Disclosed are a gypsum board, and related slurries and methods. The gypsum board comprises a gypsum layer disposed between two cover sheets. The gypsum layer comprises a crystalline matrix of set gypsum and expandable graphite. The expandable graphite exhibits volume expansion at high temperatures. Optionally, unexpanded vermiculite can also be included in the gypsum layer to provide an expansion component at even higher temperatures. Because of synergy between the expandable graphite and unexpanded vermiculite in accordance with some embodiments, less vermiculite can be included in the board than in conventional board that contained vermiculite. The board desirably can pass one or more fire-related tests, and is a fire-rated board in some embodiments.