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AssigneeCertainTeed Gypsum, Inc.
InventorsRobert J. Hauber, Gerald D. Boydston, Nathan Frailey, Severine Lamberet, Gaurav V. Pattarkine, Isaac K. Cherian, Sergio Centurione, Anirban Ghosh
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A composition and process for manufacture thereof used in hybrid inventive building materials comprising Syngenite (K2Ca(SO4)2.H2O) and Struvite-K (KMgPO4.6H2O). Starting constituents include magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate), mixed in predetermined ratios, cause reactions to proceed through multiple phases, which reactions variously are proceeding simultaneously and in parallel. Variables, e.g., water temperature, pH, mixing times and rates, have been found to affect resultant reaction products. Preferred ratios of chemical constituents and manufacturing parameters, including predetermined weight percent and specified ratios of Struvite-K and Syngenite are provided for building products used for specified purposes. Reactions are optimized in stoichiometry and additives to reduce the combined heat of formation to non-destructive levels. Various additives help control and guide reactions. Building products, such as board panels, include the resultant composition. A significant amount of the composition is disposed adjacent a building panel face.
A process for the continuous manufacture of a building product comprising:
A building board panel comprising at least one building composition disposed adjacent to at least one of the faces of the board panel, wherein the building composition comprises Struvite-K (KMgPO4.6H2O), Syngenite (K2Ca(SO4)2.H2O), and one or more of anhydrite gypsum, stucco (CaSO4.½H2O), hydrated gypsum (CaSO4.2H2O), and magnesium oxide (MgO).
A building board panel for use in building construction in which at least one of the faces comprises a composition comprising Struvite-K (KMgPO4.6H2O), Syngenite (K2Ca(SO4)2.H2O) and gypsum.
Dependencies are inferred from the claim text.