公开(公告)号：US11834375B2

公开(公告)日：2023-12-05

申请号：US17156258

申请日：2021-01-22

Applicant: United States Gypsum Company

Inventor： Qinghua Li ,  Mark K. Hemphill ,  Naveen Punati

IPC: B32B3/10 ,  C04B28/14 ,  C04B14/20 ,  B28B1/00 ,  B28B19/00 ,  B32B13/08 ,  C04B111/28 ,  C04B111/00

CPC classification number: C04B28/14 ,  B28B1/008 ,  B28B19/0015 ,  B28B19/0092 ,  B32B13/08 ,  C04B14/202 ,  B32B2264/102 ,  B32B2307/3065 ,  B32B2607/00 ,  C04B2111/00629 ,  C04B2111/285

Abstract: Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains a set gypsum core sandwiched between two cover sheets. The core is formed from a slurry containing stucco, water, and optional ingredients such as foaming agent, accelerator, retarder, polyphosphate, starch, and dispersant, and core intumescent material. The board also contains at least one skim coat and/or hard edges. A face skim coat layer can be included on one side of the core, facing a face cover sheet. A back skim coat layer can be included on the other side of the core, facing a back cover sheet. Hard edges are known in the art and can be formed, e.g., continuously from a stucco slurry for forming the face and/or back skim coats. Preferably, the back skim coat layer and/or the hard edges are formed from a slurry containing stucco, water, skim coat or edge intumescent material (which have the same desired characteristics), and other optional additives as desired. The skim coat or edge intumescent material can be composed of the same material as the core intumescent material, if desired, but the skim coat and/or edge intumescent material is present in a higher relative concentration in its respective slurry than the amount of core intumescent material in the core slurry. Examples of suitable intumescent materials include expandable vermiculite (e.g., No. 4 or No. 5 according to the US naming system, or combinations thereof), expandable graphite, perlite, or any combination thereof.

公开(公告)号：US11180412B2

公开(公告)日：2021-11-23

申请号：US16801083

申请日：2020-02-25

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Qinghua Li ,  Yanfei Peng

IPC: C04B7/19 ,  C04B7/42 ,  C04B14/06 ,  C04B14/10 ,  C04B14/20 ,  C04B14/28 ,  C04B14/36 ,  C04B18/08

Abstract: Aqueous cementitious slurries including predominantly Type I Portland cement containing an aluminate additive. The aluminate additive is an aluminate salt other than calcium aluminate or calcium sulfoaluminate, preferably sodium aluminate. Cementitious reactive powders of the slurry include the Type I Portland cement and 0.1-10 wt. % of the aluminate additive as an accelerator. The slurries may have a set time of about 10 minutes or less. Due to the short set time, the cementitious reactive powders may facilitate cement board fabrication by continuous manufacturing processes. Methods for making cement boards may include disposing the aqueous cementitious slurry including the cementitious reactive powders in a continuous layer, preferably upon a porous support, and setting the aqueous cementitious slurry with a set time of about 10 minutes or less.

公开(公告)号：US20210198148A1

公开(公告)日：2021-07-01

申请号：US16904779

申请日：2020-06-18

Applicant: United States Gypsum Company

Inventor： Qinghua Li ,  Mark K. Hemphill ,  Brian J. Christ ,  Curtis B. Loring

IPC: C04B28/14 ,  B32B13/08 ,  B32B43/00 ,  B32B38/00

Abstract: Disclosed are a composite gypsum board and a method of preparing gypsum board. The board contains at least one set gypsum layer sandwiched between face and back 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). The board and methods improve the bond between the gypsum layer(s) and at least one of the cover sheets (e.g., the back cover sheet). Also provided are methods and systems relating to drying gypsum board.

公开(公告)号：US11891336B2

公开(公告)日：2024-02-06

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 ,  B32B13/04 ,  B32B13/08 ,  E04C2/04 ,  C04B111/00

CPC classification number: C04B28/14 ,  B32B13/04 ,  B32B13/08 ,  C04B22/124 ,  E04C2/043 ,  E04C2/049 ,  B32B2307/718 ,  B32B2307/726 ,  B32B2309/105 ,  B32B2607/00 ,  C04B2111/0062

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：US20180119417A1

公开(公告)日：2018-05-03

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 ,  E04C2/04 ,  C04B14/02 ,  C04B14/20 ,  C04B28/14

CPC classification number: E04B1/942 ,  C04B14/024 ,  C04B14/202 ,  C04B28/14 ,  C04B2111/0062 ,  C04B2111/285 ,  E04C2/04 ,  E04C2/043 ,  C04B22/16 ,  C04B24/28 ,  C04B2103/20 ,  C04B2103/40 ,  C04B38/10 ,  C04B24/122

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.