Low Density Gypsum Panel
AssigneeGold Bond Building Products, LLC
InventorsR. G. Iyer, Terry Moser, Bradley J. Busche, Eli Stav, Michael N. Blades, Joseph J. Bailey, Craig Robertson, Daisha Holloman
Life of this patent
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Abstract
The present invention is directed to a gypsum panel and a method of making a gypsum panel. The gypsum panel comprises a gypsum core and a facing material. The gypsum core includes gypsum, a foaming agent, and optionally starch in an amount of less than 4 wt. % based on the weight of gypsum. The gypsum core includes air voids having an average void size of 50 microns or more. The gypsum panel has a density of 33 pcf or less, a weight of 1,800 lbs/MSF or less, and an NRC value of 0.2 or more.
Claims23
1-30. (canceled)
A gypsum panel comprising a gypsum core and a facing material,
- the gypsum core comprising gypsum, a foaming agent, and optionally starch in an amount of less than 4 wt. % based on the weight of gypsum,
- wherein the gypsum core includes air voids having an average void size of microns or more,
- wherein the gypsum panel has a density of 33 pcf or less, a weight of 1,800 lbs/MSF or less, and an NRC value of 0.2 or more.
A method of making a gypsum panel, the method comprising:
- providing a first facing material,
- providing a gypsum slurry comprising stucco, a foaming agent, optionally starch in an amount of less than 4 wt. % based on the weight of stucco, and water onto the first facing material,
- providing a second facing material onto the gypsum slurry, and
- allowing the stucco to set;
- wherein the gypsum panel has a density of 33 pcf or less, a weight of 1,800 lbs/MSF or less, and an NRC value of 0.2 or more.
A gypsum panel comprising a gypsum core and a facing material,
- the gypsum core comprising gypsum, a foaming agent, and optionally starch in an amount of less than 4 wt. % based on the weight of gypsum,
- wherein the gypsum panel has a density of 33 pcf or less, a weight of 1,800 lbs/MSF or less, and an NRC value of 0.2 or more.
Dependencies are inferred from the claim text.