Gypsum boards and methods of making them
AssigneeCertainTeed Gypsum, Inc.
InventorsDahlia N. AMATO, William C. REID, Serge ADJOUA, Amy M.L. LO, Remi LESPIAT, Sai Anudeep Reddy MADDI
Life of this patent
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Abstract
A gypsum-based construction material may include a gypsum core. The gypsum core may include a physically modified starch component, and a core bubble median size (D50) of at least about 80 microns and not greater than about 800 microns. The gypsum core may further have a thickness of not greater than about 27 mm, a board weight of at least about 1150 lbs/msf and not greater than about 2600 lbs/msf, a core hardness of at least about 60 N, and a nail pull of at least about 60 lbf.
Claims20
A gypsum-based construction material formed from a stucco-based slurry composition,
- wherein the stucco-based slurry composition comprises a physically modified starch component at a content of at least about 0.001 wt. % and not greater than about 10.0 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 80 microns and not greater than about 800 microns.
A gypsum-based construction material comprising a gypsum core, wherein the gypsum core comprises:
- a physically modified starch component,
- a core bubble median size (D50) of at least about 80 microns and not greater than about 800 microns,
- a thickness of not greater than about 27 mm,
- a board weight of at least about 1150 lbs/msf and not greater than about 2600 lbs/msf,
- a core hardness of at least about 60 N,
- a nail pull of at least about 60 lbf.
A method of forming a gypsum-based construction material, wherein the method comprises:
- providing a stucco-based slurry composition comprising a physically modified starch component, and
- forming the stucco-based slurry composition into a gypsum-based construction material,
- wherein the physically modified starch component comprises a Gel Formation Temperature of not greater than about 50° C.,
- wherein the stucco-based slurry composition comprises a slump size of at least about 5 inches when measured at a temperature of 35° C., and
- wherein the stucco-based slurry composition comprises a stiffening time of at least about 10 seconds when measured at a temperature of 35° C.
Dependencies are inferred from the claim text.