Gypsum slurries with linear polycarboxylate dispersants
AssigneeUnited States Gypsum Company
InventorsAnnamaria Vilinska, Alfred C. Li, Mario Dupuis, Iordana Triantafillu, Francis Loiseau
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Abstract
A gypsum slurry includes water, a hydraulic component including calcium sulfate hemihydrate and a linear polycarboxylate dispersant. The linear polycarboxylate anionic dispersant includes a first monomeric repeating unit and a second monomeric repeating unit. The first repeating unit of the linear polycarboxylate dispersant is an olefinic unsaturated carboxylic acid repeating unit or salt thereof. The second repeating unit of the linear polycarboxylate dispersant is a vinyl sulfonate. The slurry can be made into a gypsum panel. Methods of making gypsum slurry and a gypsum panel are also disclosed.
Claims20
A gypsum board comprising:
- a gypsum core material comprising
- calcium sulfate dihydrate and
- a linear polycarboxylate anionic dispersant comprising a first monomeric repeating unit A and a second monomeric repeating unit B, and an absence of polyvinyl acetate monomeric units;
- wherein the first monomeric repeating unit A is at least one carboxylic acid functional group containing olefinic moiety of formula I:
- wherein R is selected from the group consisting of —CH3, and —CH2—C(O)—OH, or a Na, K, or NH4+ salt thereof, wherein linear polycarboxylate anionic dispersant has an absence of acrylic acid monomer;
- and
- wherein the second monomeric repeating unit B is at least one vinyl sulfonate according to formula II:
- wherein X is NH or O;
- R1 is H or —CH3;
- R2 is a linear or branched alkylene group having the formula —(CnH2n)—, wherein n=2 to 6;
- M=H, Na, K, or NH4+;
- wherein the molar ratio of the first repeating unit A to the second repeating unit B is A is between 1:9 and 9:1;
- wherein the weight average molecular weight of the linear polycarboxylate anionic dispersant is 3000 to 100000 Daltons;
- wherein the gypsum core material has a total void volume of 10 to 92 volume percent,
- wherein the gypsum core material was made from a slurry comprising a mixture of the water, the linear polycarboxylate anionic dispersant, and a hydraulic component comprising hydraulic material, wherein the hydraulic material of the slurry comprises at least 80% calcium sulfate hemihydrate by weight based on the dry weight of the hydraulic component, wherein calcium sulfate anhydrite, synthetic gypsum or landplaster is less than 20% of the hydraulic material;
- wherein weight ratio of water to calcium sulfate hemihydrate of the slurry from which the gypsum core material was 0.2-1.5:1;
- wherein the board comprises the gypsum core sandwiched between cover sheets, wherein the dispersant is present in the slurry in an amount of from about 0.01% to about 2% by weight of the dry dispersant calculated as a percentage of the calcium sulfate hemihydrate.
Dependencies are inferred from the claim text.