Gypsum board having polyvinyl alcohol binder in interface layer and method for making the same

A polyvinyl alcohol and gypsum board technology, applied in the field of gypsum board, can solve the problems of reducing the bonding strength of the cured gypsum core and the paper surface material, and achieve the effect of light weight and good adhesion properties

Inactive Publication Date: 2008-11-26
GEORGIA PACIFIC GYPSUM LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

An unfavorable consequence of adding soap to gypsum slurries is that the bond strength between the cured gypsum core and the paper facestock is reduced

Method used

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  • Gypsum board having polyvinyl alcohol binder in interface layer and method for making the same
  • Gypsum board having polyvinyl alcohol binder in interface layer and method for making the same
  • Gypsum board having polyvinyl alcohol binder in interface layer and method for making the same

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0063] The following example illustrates the preparation of gypsum board according to the present invention having a paper facestock (70 lbs. / in.) tensile strength) and a pre-coated fiberglass mat facestock. The formulation described below was used as a thin coating applied to the paper facestock layer.

[0064] composition

lbs. / 1000 square feet

Burnt gypsum (CaSO 4 1 / 2H 2 O)

about 140

Celvol TM 203-24 (24% aqueous polyethylene

alcohol, 100% hydrolyzed)

2.2

glass fiber

≥4.3

Foaming agent

≤2.0

Potassium sulfate (accelerator)

≤1.5

Landplaster (Accelerator)

when needed

fluid blockers

when needed

[0065] The above formula is applied to paper face stock. Additional aqueous gypsum slurry was then applied to the coated paper facestock to form the core so that the total amount of calcined gypsum applied was about 1380 lbs. / MSF. Continuous length panels were produce...

Embodiment 2

[0068] This example illustrates the preparation of a gypsum board (70 lbs. / in. tensile strength) having a set gypsum core adhered to a paper facestock. In Examples 2A and 2B, polyvinyl alcohol was used in the slurry used to make the gypsum core. Example 2C is a control where no polyvinyl alcohol was used and starch and soap were used in the slurry.

[0069]

[0070] Figure 3 graphically illustrates the effect of polyvinyl alcohol on the compressive strength of gypsum board. The panel of Example 2A (represented by the blackened squares in Figure 3) exhibited the highest compressive strength and had 33.5 lbs. / ft at a water to gypsum (w / p) weight ratio of 90 / 1 3 density of. The panel of Example 2B using soap in the core (represented by the blacked out triangles in Figure 3) had 31.5 lbs. / ft at a w / p weight ratio of 90 / 1 3 density of. The board of Example 2C using starch and soap in the core (represented by the blackened circles in Figure 3) had 32 lbs. / ft at a w / p w...

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PUM

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Abstract

Paper and / or mat-faced gypsum board is prepared by applying a relatively thin coating of aqueous gypsum slurry containing a polyvinyl alcohol binder to one or two facer sheets. The polyvinyl alcohol binder provides adequate adhesion between the set gypsum core and the adjacent facer sheet(s) without the need for starch or other conventional binders. In one embodiment, polyvinyl alcohol is concentrated in one or more regions of the core adjacent to the facer sheet(s). In another embodiment, polyvinyl alcohol is applied to an aqueous gypsum slurry used to form the bulk core, such that the polyvinyl alcohol is present throughout the core.

Description

technical field [0001] The present invention relates to gypsum board, and more particularly, to gypsum board having a paper and / or fiber mat facestock adhered to a set gypsum core. Background technique [0002] Gypsum board panels with a set gypsum core sandwiched between two sheets of facing paper have long been used as structural members in building construction. The panels are often used to form partitions or walls in rooms, elevators, stairwells, ceilings, etc. Finishing papers provide the smooth surface especially needed for painting or wallpapering interior walls. Although paper is a relatively inexpensive facing material and is easy to use in the production of wallboard, it has certain disadvantages, especially in terms of moisture resistance. As an alternative to facing paper, fiber mats, such as fiberglass, are used as facing materials for gypsum wallboard. An example of such a wall panel is described in US Patent 3,993,822. Fibrous mats provide improved water r...

Claims

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Application Information

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Patent Type & Authority Patents(China)
IPC IPC(8): B32B29/00B28B1/30B28B3/12B32B13/04B32B13/08C04B24/26C04B28/14E04C2/04
CPCE04C2/043C04B2111/1006C04B2111/0062C04B28/14B32B13/04C04B2111/00413C04B24/2623B28B19/0092Y10T428/31996Y10T428/31993Y10T428/31909C04B24/2641B32B13/08B32B2607/00B32B13/14
Inventor H·C·弗朗西斯A·H·叶西翁什克F·E·埃斯格维拉
Owner GEORGIA PACIFIC GYPSUM LLC
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