Method of forming a gypsum panel including a starch layer
AssigneeGold Bond Building Products, LLC
InventorsGene Whittington, Robert Piercy, Tom Griffith, Al Flanders
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Abstract
In the present disclosure, a method of forming a gypsum panel is disclosed. The method comprises: providing a first facing material, forming a starch slurry by combining starch and water at a shear rate of 3,000 rpm or more, providing the starch slurry onto the first facing material, depositing a gypsum slurry comprising stucco and water onto the starch slurry on the first facing material, providing a second facing material on the gypsum slurry, and allowing the stucco to convert to calcium sulfate dihydrate.
Claims22
A method of forming a gypsum panel, the method comprising:
- providing a first facing material;
- providing a starch slurry onto the first facing material, the starch slurry covering 98% or less of a deposition surface of the first facing material, the starch slurry being formed by combining starch and water at a shear rate of 4,500 rpm or more, the starch being present in the starch slurry in an amount of 1 wt. % or more based on the weight of the starch slurry, the starch being a solid;
- depositing a gypsum slurry comprising stucco and water onto the starch slurry on the first facing material;
- providing a second facing material on the gypsum slurry;
- and
- converting the stucco to calcium sulfate dihydrate.
A method of forming a gypsum panel, the method comprising:
- providing a first facing material;
- providing a starch slurry onto the first facing material, the starch slurry covering 98% or less of a deposition surface of the first facing material, the starch slurry being formed by combining starch, water, and gypsum at a shear rate of 4,500 rpm or more, the gypsum to starch weight ratio in the starch slurry being from 0.001 to 1, the starch being present in the starch slurry in an amount of 1 wt. % or more based on the weight of the starch slurry, the starch being a solid;
- depositing a gypsum slurry comprising stucco and water onto the starch slurry on the first facing material;
- providing a second facing material on the gypsum slurry;
- and
- converting the stucco to calcium sulfate dihydrate.
Dependencies are inferred from the claim text.