# US 10,245,755 B2 · Lightweight, reduced density fire rated gypsum panels

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- Number: US 10,245,755 B2
- Document ID: US10245755B2
- Status: Granted
- Kind: B2
- Application number: 15/457,466
- Filed: 2017-03-13
- Published: 2017-06-29
- Granted: 2019-04-02
- Earliest claimed: 2011-02-25
- Assignees: United States Gypsum Company
- Applicants: United States Gypsum Company
- Inventors: Qiang Yu; Srinivas Veeramasuneni; Weixin D. Song; Wenqi Luan
- Web page: https://patentgrep.com/patent/US10245755B2

## CPC

- B28B 1/50: specially adapted for producing articles of expanded material, e.g. cellular concrete (chemical aspects {or making expanded aggregate} C04B)
- B28B 11/12: for removing parts of the articles by cutting
- B28B 11/243: {Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence)}
- B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)}
- B32B 9/005: {comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 38/164: {Drying}
- C04B 20/06: Expanding clay, perlite, vermiculite or like granular materials
- C04B 28/14: containing calcium sulfate cements {(gypsum-paper plates E04C)}
- C04B 28/145: {Calcium sulfate hemi-hydrate with a specific crystal form}
- E04B 1/942: {slab-shaped}
- E04C 2/04: of concrete or other stone-like material; of asbestos cement; {of cement and other mineral fibres}(E04C2/26 takes precedence; material or manufacture B28, C04)
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2607/00: Walls, panels
- C04B 2111/0062: {Gypsum-paper board like materials}
- C04B 2111/28: Fire resistance, i.e. materials resistant to accidental fires or high temperatures
- C04B 2201/30: for heat transfer properties such as thermal insulation values, e.g. R-values
- Y10T 428/249968: Of hydraulic-setting material
- Y10T 428/249979: Specified thickness of void-containing component [absolute or relative] or numerical cell dimension
- Y10T 428/26: Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T 428/31971: Of carbohydrate
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.

## Claims

### Claim 1

A gypsum panel comprising a gypsum core disposed between cover sheets, the gypsum core formed from a mixture comprising:
stucco in an amount of about 1162 to about 1565 lbs/msf (about 5.7 to about 7.6 kg/m2), and
high expansion particles in an amount of up to about 10% by weight of stucco, said particles having a volume expansion of about 300% or more of their original volume after being heated for about one hour at about 1560° F. (850° C.);
the high expansion particles in an amount and distribution in the core effective to provide a High Temperature Shrinkage (S) in the X-Y direction of about 10% or less, and the panel having a density (D) of about 37 pounds per cubic foot (590 kg/m3) or less.

### Claim 2 (depends on 1)

The gypsum panel of claim 1, the high expansion particles in an amount and distribution in the core effective to provide an average High Temperature Thickness Expansion (TE) in the Z-direction of at least about −3%.

### Claim 3 (depends on 2)

The gypsum panel of claim 2, wherein the High Temperature Thickness Expansion (TE) in the Z-direction is about 2% or more.

### Claim 4 (depends on 1)

The gypsum panel of claim 1, the gypsum core effective to provide a Thermal Insulation Index (TI) of about 20 minutes or greater.

### Claim 5 (depends on 4)

The gypsum panel of claim 4, the gypsum core effective to provide a ratio of Thermal Insulation Index to density (TI/D) of about 0.6 minutes/pounds per cubic foot or more.

### Claim 6 (depends on 1)

The gypsum panel of claim 1, the high expansion particles in an amount and distribution in the core effective to provide a High Temperature Thickness Expansion (TE) of about 10% or more.

### Claim 7 (depends on 1)

The gypsum panel of claim 1, wherein the high expansion particles are high expansion vermiculite particles.

### Claim 8 (depends on 7)

The gypsum panel of claim 7, wherein at least about 50% of the high expansion vermiculite particles are greater than about 300 micrometers.

### Claim 9 (depends on 7)

The gypsum panel of claim 7, wherein at least about 50% of the high expansion vermiculite particles are greater than about 500 micrometers.

### Claim 10 (depends on 7)

The gypsum panel of claim 7, wherein between about 55% and about 95% of the high expansion vermiculite particles are greater than about 500 micrometers.

### Claim 11 (depends on 7)

The gypsum panel of claim 7, wherein between about 35% and 60% of the high expansion vermiculite particles are between about 500 micrometers and about 1000 micrometers.

### Claim 12 (depends on 7)

The gypsum panel of claim 7, wherein between about 20% and about 40% of the high expansion vermiculite particles are between about 1000 micrometers and about 1500 micrometers.

### Claim 13 (depends on 7)

The gypsum panel of claim 7, wherein at least 80% of the high expansion vermiculite particles are between 250 micrometers and 710 micrometers.

### Claim 14 (depends on 7)

The gypsum panel of claim 7, wherein at least 80% of the high expansion vermiculite particles are between 355 micrometers and 1000 micrometers.

### Claim 15 (depends on 1)

The gypsum panel of claim 1, wherein the mixture further comprises starch.

### Claim 16 (depends on 15)

The gypsum panel of claim 15, wherein the starch is in an amount from about 0.3% to about 3% by weight of stucco.

### Claim 17 (depends on 15)

The gypsum panel of claim 15, wherein the starch is a pregelatinized starch.

### Claim 18 (depends on 15)

The gypsum panel of claim 15, wherein the starch is a hydroxyethylated starch, an acid-modified starch or a non-pregelatinized starch.

### Claim 19 (depends on 1)

The gypsum panel of claim 1, the core effective to provide a core hardness of at least about 11 pounds (50 N).

### Claim 20 (depends on 19)

The gypsum panel of claim 19, wherein the core hardness is at least about 13 pounds (58 N).

### Claim 21 (depends on 20)

The gypsum panel of claim 20, wherein the core hardness is at least about 15 pounds (65 N).

### Claim 22 (depends on 1)

The gypsum panel of claim 1, the mixture further comprising mineral, carbon and/or glass fibers.

### Claim 23 (depends on 22)

The gypsum panel of claim 22, wherein the mineral, carbon, and/or glass fibers are in an amount from about 0.3% to about 0.9% by weight of stucco.

### Claim 24 (depends on 1)

The gypsum panel of claim 1, the high expansion particles in an amount and distribution in the core effective to provide a ratio of High Temperature Thickness Expansion to High Temperature Shrinkage (TE/S) of at least about −0.85.

### Claim 25 (depends on 1)

The gypsum panel of claim 1, wherein the High Temperature Thickness Expansion to High Temperature Shrinkage (TE/S) is about 0.2 or more.

### Claim 26 (depends on 24)

The gypsum panel of claim 24, at least one of the cover sheets having a basis weight from about 55 lbs/msf to about 65 lbs/msf.

### Claim 27 (depends on 1)

The gypsum panel of claim 1, wherein the high expansion particles are in an amount from about 4% to about 10% by weight of the stucco.

### Claim 28 (depends on 1)

The gypsum panel of claim 1, the panel having a density from about 32 pcf (510 kg/m3) to about 37 pcf (590 kg/m3).

### Claim 29 (depends on 1)

The gypsum panel of claim 1, the high expansion particles in an amount and distribution in the core effective to provide a High Temperature Thickness Expansion (TE) in the Z direction of about 20% or more.

### Claim 30 (depends on 1)

The gypsum panel of claim 1, wherein at a nominal thickness of about ⅝-inch, the gypsum core is effective to provide the panel with a nail pull resistance of at least about 70 lb, the nail pull resistance determined according to ASTM C473-09.

### Claim 31

A gypsum panel comprising a gypsum core disposed between cover sheets, the gypsum core formed from a mixture comprising:
stucco in an amount of about 1162 to about 1565 lb/msf (about 5.7 to about 7.6 kg/m2),
high expansion particles in an amount of up to about 10% by weight of stucco, said particles having a volume expansion of about 300% or more of their original volume after being heated for about one hour at about 1560° F. (850° C.),
starch in an amount of up to about 3% by weight of stucco, and
mineral, carbon and/or glass fibers;
the high expansion particles in an amount and distribution in the core effective to provide a High Temperature Shrinkage (S) in the X-Y direction of about 10% or less, the gypsum core effective to provide a Thermal Insulation Index (TI) of about 20 minutes or greater, and the panel having a density (D) of about 37 pounds per cubic foot (590 kg/m3) or less.

### Claim 32 (depends on 31)

The gypsum panel of claim 31, wherein at least about 50% of the high expansion particles are greater than about 300 micrometers.

### Claim 33 (depends on 31)

The gypsum panel of claim 31, wherein at least about 50% of the high expansion particles are greater than about 500 micrometers.

### Claim 34 (depends on 31)

The gypsum panel of claim 31, wherein between about 55% and about 95% of the high expansion particles are greater than about 500 micrometers.

### Claim 35 (depends on 31)

The gypsum panel of claim 31, wherein between about 35% and 60% of the high expansion particles are between about 500 micrometers and about 1000 micrometers.

### Claim 36 (depends on 31)

The gypsum panel of claim 31, wherein between about 20% and about 40% of the high expansion particles are between about 1000 micrometers and about 1500 micrometers.

### Claim 37 (depends on 31)

The gypsum panel of claim 31, wherein at least 80% of the high expansion particles are between 250 micrometers and 710 micrometers.

### Claim 38 (depends on 31)

The gypsum panel of claim 31, wherein at least 80% of the high expansion particles are between 355 micrometers and 1000 micrometers.

### Claim 39 (depends on 31)

The gypsum panel of claim 31,
wherein:
the high expansion particles are high expansion vermiculite particles,
the starch is a pregelatinized starch, and
the mineral, carbon, and/or glass fibers are in an amount from about 0.3% to about 0.9% by weight of stucco;
the gypsum core effective to provide a core hardness of at least about 11 pounds (50 N).

### Claim 40 (depends on 39)

The gypsum panel of claim 39, wherein the core hardness is at least about 15 pounds (65 N).

### Claim 41 (depends on 31)

The gypsum panel of claim 31, the high expansion particles in an amount and distribution in the core effective to provide a ratio of High Temperature Thickness Expansion to High Temperature Shrinkage (TE/S) of at least about −0.85.

### Claim 42 (depends on 41)

The gypsum panel of claim 41, wherein the High Temperature Thickness Expansion to High Temperature Shrinkage (TE/S) is about 0.2 or more.

### Claim 43 (depends on 31)

The gypsum panel of claim 31, wherein at least one of the cover sheets has a basis weight from about 55 lbs/msf to about 65 lbs/msf.

### Claim 44 (depends on 31)

The gypsum panel of claim 31, wherein the high expansion particles are in an amount from about 4% to about 10% by weight of the stucco.

### Claim 45 (depends on 31)

The gypsum panel of claim 31, the panel having a density of about 37 pcf (590 kg/m3) or less.

### Claim 46 (depends on 31)

The gypsum panel of claim 31, wherein at a nominal thickness of about %-inch, the gypsum core is effective to provide the panel with a nail pull resistance of at least about 70 lb, the nail pull resistance determined according to ASTM C473-09.

### Claim 47 (depends on 31)

The gypsum panel of claim 31, the gypsum core effective to provide a ratio of Thermal Insulation Index to density (TI/D) of about 0.6 minutes/pounds per cubic foot or more.