Gypsum Wallboard Containing Acoustical Tile
AssigneeUnited States Cypsum Company
InventorsDavid Paul Miller, Michael Scott Cunningham, Patrick Desmond
Life of this patent
Estimating the term…
Abstract
Gypsum products and method for the preparation thereof are disclosed. The gypsum products comprise an interlocking matrix of set gypsum that is formed from a composition comprising calcined gypsum, water and acoustical tile.
Claims29
Gypsum wallboard comprising an interlocking matrix of set gypsum, said wallboard formed from a composition comprising calcined gypsum, water and acoustical tile, the wallboard having a nail pull resistance, a MOR in the machine direction, and a MOR in the cross direction, as related to the thickness of the wallboard, according to the following:
- (i) for ¼ inch wallboard, a nail pull resistance of at least 36 lbf, a MOR in the machine direction of at least 1288 psi, and a MOR in the cross direction of at least 448 psi;
- (ii) for ⅜ inch wallboard, a nail pull resistance of at least 56 lbf, a MOR in the machine direction of at least 958 psi, and a MOR in the cross direction of at least 324 psi;
- (iii) for ½ inch wallboard, a nail pull resistance of at least 77 lbf, a MOR in the machine direction of at least 749 psi, and a MOR in the cross direction of at least 252 psi;
- (iv) for ⅝ inch wallboard, a nail pull resistance of at least 87 lbf, a MOR in the machine direction of at least 659 psi, and a MOR in the cross direction of at least 206 psi;
- (v) for ¾ inch wallboard, a nail pull resistance of at least 97 lbf, a MOR in the machine direction of at least 520 psi, and a MOR in the cross direction of at least 174 psi;
- and
- (vi) for 1 inch wallboard, a nail pull resistance of at least 103 lbf, a MOR in the machine direction of at least 339 psi, and a MOR in the cross direction of at least 135 psi.
A method for preparing gypsum wallboard comprising an interlocking matrix of set gypsum, said method comprising:
- forming a mixture comprising water, calcined gypsum, and acoustical tile;
- and
- casting said mixture to form gypsum wallboard, the wallboard having a nail pull resistance, a MOR in the machine direction, and a MOR in the cross direction, as related to the thickness of the wallboard, according to the following:
- (i) for ¼ inch wallboard, a nail pull resistance of at least 36 lbf, a MOR in the machine direction of at least 1288 psi, and a MOR in the cross direction of at least 448 psi;
- (ii) for ⅜ inch wallboard, a nail pull resistance of at least 56 lbf, a MOR in the machine direction of at least 958 psi, and a MOR in the cross direction of at least 324 psi;
- (iii) for ½ inch wallboard, a nail pull resistance of at least 77 lbf, a MOR in the machine direction of at least 749 psi, and a MOR in the cross direction of at least 252 psi;
- (iv) for ⅝ inch wallboard, a nail pull resistance of at least 87 lbf, a MOR in the machine direction of at least 659 psi, and a MOR in the cross direction of at least 206 psi;
- (v) for ¾ inch wallboard, a nail pull resistance of at least 97 lbf, a MOR in the machine direction of at least 520 psi, and a MOR in the cross direction of at least 174 psi;
- (vi) for 1 inch wallboard, a nail pull resistance of at least 103 lbf, a MOR in the machine direction of at least 339 psi, and a MOR in the cross direction of at least 135 psi.
A composition comprising calcined gypsum, water and acoustical tile and optimally other additives wherein when said composition is cast in ¼ inch wallboard, said wallboard has a nail pull resistance of at least 36 lbf, a MOR in the machine direction of at least 1288 psi, and a MOR in the cross direction of at least 448 psi.
Dependencies are inferred from the claim text.