Green gypsum board prepared using low water to solids ratio

Abstract

Disclosed are gypsum boards and methods of board preparation. The board comprises a set gypsum core, with a cover sheet disposed on either side of the core. The core is formed from a mixture containing water, stucco, uncalcined gypsum, and optional additives, the mixture having a low water-to-solids ratio. A hydration reaction occurs between water and stucco. The water amount can be, e.g., 0% to 30%, such as 1% to 25% or 1% to 20%, higher than the stoichiometric amount for hydration. For board preparation, an industrial press (e.g., hydraulic or pneumatic) or rollers can be used to form designated board thickness. Green technology is deployed since less energy is consumed to calcine the gypsum into stucco (inasmuch as some solids content need not be calcined because of the uncalcined gypsum content in the mixture) and for board drying. Improved production efficiencies and high-quality product with strength are achieved.

Dependencies are inferred from the claim text.