Compositions for the manufacture of gypsum boards, methods of manufacture thereof, and gypsum boards formed therefrom
AssigneeGeorgia-Pacific Gypsum LLC
InventorsStuart Brandon Gilley, Hubert C. Francis, Carla Greaves Jones, Fabio E. Esguerra
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Abstract
A composition for the manufacture of a gypsum board comprising hydrated pregelatinized starch 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 dry pregelatinized starch and stucco with 0.4 to 3 wt. % of starch, based on the weight of the stucco.
A method for making a gypsum board, the method comprising:
- forming a slurry from a dry blend of a 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.
The method of claim 11, wherein the pregelatinized starch is a hydroxyethylated corn starch.
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 0.4-3 wt. % pregelatinized starch based on the stucco weight.
Dependencies are inferred from the claim text.