Compositions for the manufacture of gypsum boards, methods of manufacture thereof, and gypsum boards formed therefrom
AssigneeGeorgia-Pacific Corporation
InventorStuart Brandon Gilley
Life of this patent
Estimating the term…
Abstract
A composition for the manufacture of a gypsum board comprising hydrated pregelatinized starch, sulfonated styrene butadiene latex and stucco with 0.4 to 3 wt. % of starch based on the stucco weight is disclosed. The composition provides enhanced strength in the absence of other strengthening agents.
Claims20
A composition for the manufacture of a gypsum board, comprising a blend of at least one dry pregelatinized starch, at least one sulfonated styrene butadiene latex and stucco with about 0.4 to about 3 wt. % of starch and about 0.2 to about 10 wt. % of latex, based on the weight of the stucco.
A method for making a gypsum board, the method comprising:
- forming an aqueous solution containing at least water and at least one sulfonated styrene butadiene latex;
- forming a slurry from the aqueous solution and a dry blend of at least one pregelatinized starch and stucco;
- applying the slurry to lower facing sheet to form a core layer;
- applying an upper facing sheet to the upper surface of the gypsum slurry to form a “sandwich” of slurry and lower and upper facing sheets;
- and
- heating the core layer and the upper and lower facing sheets sufficiently to dry the core layer to form the gypsum board.
A gypsum board comprising a gypsum core that is faced on one or both faces with a facing, wherein the gypsum core comprises the setting product of a slurry of a hydrated blend of about 0.4 to about 3 wt. % of at least one pregelatinized starch and about 0.2 to about 10 wt. % of at least one sulfonated styrene butadiene latex based on the stucco weight.
Dependencies are inferred from the claim text.