Gypsum Panel Containing a Magnetic Additive
AssigneeGold Bond Building Products, LLC
InventorsBradley J. Busche, Joseph J. Bailey, Ratnasabapathy Gurunathan Iyer, Richard P. Weir
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Abstract
The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, in one embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and one or more magnetic additives. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and one or more magnetic additives onto the first facing material, and providing a second facing material on the gypsum slurry.
Claims21
A gypsum panel comprising:
- a gypsum core comprising gypsum and one or more magnetic additives and having a concentration gradient of the one or more magnetic additives over a portion of the thickness of the gypsum core;
- and
- a first facing material and a second facing material, the first facing material and the second facing material sandwiching the gypsum core.
A gypsum panel comprising:
- a gypsum core comprising gypsum and one or more magnetic additives;
- and
- a first facing material and a second facing material, the first facing material and the second facing material sandwiching the gypsum core, wherein at least a portion of the one or more magnetic additives penetrates a portion of the thickness of the first facing material, the second facing material, or both.
A method for making a gypsum panel comprising:
- providing a first facing material;
- depositing a gypsum slurry comprising stucco, water, and one or more magnetic additives onto the first facing material;
- providing a second facing material on the gypsum slurry;
- and
- allowing the stucco to convert to calcium sulfate dihydrate
- wherein the method further comprises generating at least one magnetic field with one or more magnets before providing the second facing material on the gypsum slurry and/or after the step of providing the second facing material on the gypsum slurry, the at least one magnetic field moving at least a portion of the one or more magnetic additives in the gypsum slurry toward the first facing material, the second facing material, or both.
A system for forming a gypsum panel containing one or more magnetic additives:
- one or more magnets;
- a conveyor assembly;
- and
- a gypsum slurry comprising one or more magnetic additives.
Dependencies are inferred from the claim text.