Gypsum boards and methods of making them
AssigneeCertainTeed Gypsum, Inc.
InventorsDahlia N. AMATO, Patrick R. McGINLEY, Remi LESPIAT, Serge ADJOUA, Roger D. JONES, Michael P. FAHEY, David L. SERRECCHIA
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Abstract
A gypsum-based construction material may include a gypsum core. The gypsum core may have a core bubble median size (D50) of at least about 150 microns and not greater than about 600 microns, and a contacting bubble surface percentage of not greater than about 50%. The gypsum core may further have a water absorption of not greater than about 5.0%.
Claims20
A gypsum-based construction material comprising a gypsum core, wherein the gypsum core comprises:
- a core bubble median size (D50) of at least about 150 microns and not greater than about 600 microns,
- a contacting bubble surface percentage of not greater than about 50%, and
- a water absorption of not greater than about 5.0%.
A method of forming a gypsum-based construction material, wherein the method comprises:
- providing a stucco-based slurry composition comprising a surfactant at a content of at least about 0.10 wt. % and not greater than about 1.0 wt. % for a total weight of the stucco-based slurry composition, wherein the surfactant comprises an alkyl ether sulfate, an ethoxylated surfactant, a lauryl surfactant, an alcohol, or any combination thereof, and
- forming the stucco-based slurry composition into a gypsum-based construction material comprising a gypsum core, wherein the gypsum core comprises:
- a core bubble median size (D50) of at least about 150 microns and not greater than about 600 microns,
- a contacting bubble surface percentage of not greater than about 50%, and
- a water absorption of not greater than about 5.0%.
A gypsum-based construction material formed from a stucco-based slurry composition,
- wherein the stucco-based slurry composition comprises a dispersant component at a content of at least about 0.1 wt. % and not greater than about 1.0 wt. % for a total weight of the stucco-based slurry composition,
- wherein the gypsum-based construction material comprising a gypsum core, and wherein the gypsum core comprises:
- a core bubble median size (D50) of at least about 150 microns and not greater than about 600 microns,
- a contacting bubble surface percentage of not greater than about 50%, and
- a water absorption of not greater than about 5.0%.
Dependencies are inferred from the claim text.