# US 10,246,378 B2 · Building products composites and methods

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- Number: US 10,246,378 B2
- Document ID: US10246378B2
- Status: Granted
- Kind: B2
- Application number: 14/884,185
- Filed: 2015-10-15
- Published: 2016-04-21
- Granted: 2019-04-02
- Earliest claimed: 2014-10-16
- Assignees: Georgia-Pacific Gypsum LLC
- Applicants: Georgia-Pacific Gypsum LLC
- Inventors: Mianxue Wu; Jeffery T. Fields; Sara E. Endres
- Web page: https://patentgrep.com/patent/US10246378B2

## CPC

- C04B 38/0074: {expressed as porosity percentage}
- C04B 28/14: containing calcium sulfate cements {(gypsum-paper plates E04C)}
- E04C 2/043: {of plaster (E04C2/049 takes precedence)}
- C04B 2111/40: Porous or lightweight materials
- 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
- 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)

## Abstract

Methods of manufacturing composites are provided, including combining dihydrate calcium sulfate whiskers, hemihydrate calcium sulfate stucco, and water to form a slurry, and setting the slurry to form a composite having a natural porosity of about 60 volume percent or greater. Composites are also provided, including dihydrate calcium sulfate whiskers and dihydrate calcium sulfate crystals, and having a natural porosity of about 60 volume percent or greater.

## Claims

### Claim 1

A composite, comprising:
a nuclei seeding agent comprising dihydrate calcium sulfate whiskers; and
dihydrate calcium sulfate crystals formed about the dihydrate calcium sulfate whiskers, such that the composite has a natural porosity of about 60 volume percent or greater and a density of about 40 lb/ft3 or less,
wherein the composite does not contain a foaming agent or microspheres.

### Claim 2 (depends on 1)

The composite of claim 1, wherein the composite has a natural porosity of about 75 volume percent or greater.

### Claim 3 (depends on 1)

The composite of claim 1, wherein the composite has a natural porosity of about 90 volume percent or greater.

### Claim 4 (depends on 1)

The composite of claim 1, wherein the composite has a density of about 30 lb/ft3 or less.

### Claim 5 (depends on 1)

The composite of claim 1, wherein the composite comprises a gypsum board having a thickness of about 1 inch or less and an area density of about 1500 lb/msf or less.

### Claim 6 (depends on 1)

The composite of claim 1, wherein the composite comprises a gypsum board having a thickness of about 1 inch or less and an area density of about 1200 lb/msf or less.

### Claim 7

A composite, comprising:
a nuclei seeding agent comprising dihydrate calcium sulfate whiskers; and
dihydrate calcium sulfate crystals formed about the dihydrate calcium sulfate whiskers, such that the composite has a natural porosity of about 60 volume percent or greater,
wherein the composite does not contain a foaming agent or microspheres.

### Claim 8 (depends on 7)

The composite of claim 7, wherein the composite has a natural porosity of about 75 volume percent or greater.

### Claim 9 (depends on 7)

The composite of claim 7, wherein the composite has a natural porosity of about 90 volume percent or greater.

### Claim 10 (depends on 7)

The composite of claim 7, wherein the composite has a density of about 40 lb/ft3 or less.

### Claim 11 (depends on 7)

The composite of claim 7, wherein the composite has a density of about 30 lb/ft3 or less.

### Claim 12 (depends on 7)

The composite of claim 7, wherein the composite comprises a gypsum board having a thickness of about 1 inch or less and an area density of about 1500 lb/msf or less.

### Claim 13 (depends on 7)

The composite of claim 7, wherein the composite comprises a gypsum board having a thickness of about 1 inch or less and an area density of about 1200 lb/msf or less.