Back to results
US 12,162,803 B2Granted
Foam modifiers for gypsum slurries, methods, and products
AssigneeUnited States Gypsum Company
InventorsAnnamaria Vilinska, Weixin D. Song, Alfred C. Li
Life of this patent
Estimating the term…
Abstract
Disclosed is a foam modifier, e.g., useful for gypsum or cement slurries. The foam modifier comprises a fatty alcohol that is added to a gypsum or cement slurry that includes foaming agent, such as an alkyl sulfate surfactant. The fatty alcohol can be a C6-C16 fatty alcohol in some embodiments. The use of such a foam modifier can be used, for example, to stabilize the foam, reduce waste of foaming agent, improve void size control in the final product, and improve the gypsum board manufacturing process.
Claims17
A gypsum board comprising:
- (a) a set gypsum core disposed between two paper cover sheets;
- (b) the set gypsum core comprising a gypsum crystal matrix formed from at least water, stucco, and a foam;
- wherein:
- the foam is generated prior to mixing into a gypsum slurry forming the core by inserting air into a foaming agent comprising at least one alkyl sulfate and at least one alkyl ether sulfate and wherein the foam further comprises a fatty alcohol and water, wherein the fatty alcohol acts as a foam stabilizer, wherein the fatty alcohol is in the form of a single fatty alcohol, and wherein the fatty alcohol is a pure decanol;
- wherein the fatty alcohol is present in an amount of from about 0.0001% to about 0.010% by weight of the stucco.
2 more elements
A gypsum board comprising:
- (a) a set gypsum core disposed between two paper cover sheets;
- (b) the set gypsum core comprising a gypsum crystal matrix formed from at least water, stucco, and a foam;
- wherein:
- the foam is generated prior to mixing into a gypsum slurry forming the core by inserting air into a foaming agent, wherein the foaming agent consists of at least one alkyl sulfate and at least one alkyl ether sulfate, wherein the foam further comprises a fatty alcohol and water, wherein the fatty alcohol acts as a foam stabilizer, wherein the fatty alcohol is in the form of a single fatty alcohol, and wherein the fatty alcohol is a pure octanol, or a pure decanol;
- wherein the fatty alcohol is present in an amount of from about 0.0001% to about 0.010% by weight of the stucco;
- and
- wherein the water is present in an amount of about 69% by weight of the foam.
4 more elements
A gypsum board comprising:
- (a) a set gypsum core disposed between two paper cover sheets;
- (b) the set gypsum core comprising a gypsum crystal matrix formed from at least water, stucco, and a foam;
- wherein:
- the foam is generated prior to mixing into a gypsum slurry forming the core by inserting air into a foaming agent comprising at least one alkyl sulfate and at least one alkyl ether sulfate, wherein the foam further comprises a fatty alcohol and water, wherein the fatty alcohol is octanol, decanol, undecanol, nonanol, dodecanol, or any combination thereof;
- and
- wherein the fatty alcohol is present in an amount of from about 0.0001% to about 0.03% by weight of the stucco;
- wherein the foaming agent is present in an amount of from about 0.01% to about 0.05% by weight of the stucco;
- wherein the foaming agent is present relative to the fatty alcohol in a weight ratio of from about 5000:1 to about 100:1;
- and
- wherein the gypsum crystal matrix has a pore size distribution comprising air voids, wherein the air void size having greatest frequency is a diameter of about 100 microns or less.
7 more elements
Dependencies are inferred from the claim text.