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Composite light weight gypsum wallboard

一种石膏板、轻量的技术，应用在家用墙、纸/纸板层状产品、陶瓷制品等方向，能够解决粘结层难适用、减少成品墙板芯硬度等问题

Active Publication Date: 2009-09-09
USG CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Thinner bondlines are expected to be more difficult to apply and exhibit other disadvantages
However, using these thick bond coats will reduce the core stiffness in the finished wallboard

Method used

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  • Composite light weight gypsum wallboard
  • Composite light weight gypsum wallboard
  • Composite light weight gypsum wallboard

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0036] Example 1 Sample gypsum slurry formula

[0037] The gypsum slurry formula is shown in Table 1 below. All values ​​in Table 1 are expressed in weight percent based on the weight of dry stucco. Values ​​in parentheses are dry weight in pounds (lb / MSF).

[0038] Table 1

[0039] Component

Formulation A

Formulation B

[0040] Plaster (lb / MSF)

(732)

(704)

Sodium trimetaphosphate

0.20(1.50)

0.30(2.14)

Dispersant

(Naphthalene sulfonate)

0.18(1.35)

0.58 1 (4.05)

Pregelatinized starch

(Dry powder)

2.7(20)

6.4(45)

Plate starch

0.41(3.0)

0

Heat-resistant accelerator (HRA)

(15)

(15)

glass fiber

0.27(2.0)

0.28(2.0)

Paper fiber

0

0.99(7.0)

soap bar *

0.03(0.192)

0.03(0.192)

[0041] Total water volume (lb)

805

852

Water / stucco rat...

Embodiment 2

[0044] Example 2 Preparation of wallboard

[0045] Sample gypsum wallboards were prepared according to U.S. Patent Nos. 6,342,284 and 6,632,550 of Yu et al., which are incorporated herein by reference. The method involves separately generating foam and introducing the foam into the slurry of all other ingredients described in Example 5 of these patents.

[0046] The test results of the gypsum wallboard prepared by using the formula A and formula B of Example 1 and the common control board are shown in Table 2 below. In this example and other examples below, the nail pull resistance, core hardness, and flexural strength tests are all performed in accordance with ASTM C-473. In addition, it should be noted that the usual gypsum wallboard is about 1 / 2 Inches thick and weighs about 1600-1800 pounds per 1000 square feet of material, or lb / MSF. ("MSF" is the standard abbreviation for 1000 square feet in this field; it can be used for the area measurement of boxes, corrugated media a...

Embodiment 3

[0053] Example 3 1 / 2 inch gypsum wallboard weight reduction test

[0054] Further examples of gypsum wallboard (boards C, D and E), including slurry formulations and test results, are shown in Table 3 below. The slurry formulation in Table 3 includes the main components of the slurry. The values ​​in parentheses indicate weight percentages based on the weight of dry stucco.

[0055] table 3

[0056]

[0057]

[0058] ASTM standard: 77lb

[0059] 1 DILOFLO is 45% naphthalene sulfonate aqueous solution

[0060] As shown in Table 3, compared with the control plate, plates C, D, and E are made of a large amount of starch, DILOFLO dispersant and sodium trimetaphosphate (the percentage of starch and dispersant is approximately two-fold increase, trimetaphosphate The salt is increased by two to three times) while keeping the w / s ratio constant. However, the weight of the board was significantly reduced, and the strength measured by nail pull resistance was not significantly affecte...

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Abstract

The invention provides a lightweight composite gypsum board including a foamed low density set gypsum core, a top non-foamed (or reduced foamed) bonding high density layer and a bottom non-foamed (or reduced-foamed) bonding high density layer, a top cover sheet bonded to the foamed low density set gypsum core by the top non-foamed (or reduced-foamed) bonding high density layer, and a bottom cover sheet bonded to the foamed low density set gypsum core by the bottom non-foamed (or reduced-foamed) bonding high density layer. The foamed gypsum core and the non-foamed (or reduced-foamed) bonding layers are made from a gypsum slurry including stucco, pregelatinized starch, and preferably a naphthalenesulfonate dispersant and sodium trimetaphosphate. The foamed gypsum core has a density of less than about 30 pcf using soap foam in the gypsum-containing slurry. The gypsum board is lightweight with high strength. A method of making the gypsum board is also provided.

Description

Technical field [0001] The invention relates to a unique lightweight composite gypsum board with high strength. The present invention also relates to a method for manufacturing such a lightweight composite gypsum board using a unique gypsum-containing slurry to form a foamed low-density set gypsum board core and a non-foam (or low-foam) bonding high-density layer to produce such a lightweight composite gypsum board. The density layer bonds the top and bottom cover sheets to the core. Background technique [0002] Certain properties of gypsum (calcium sulfate dihydrate) make it popular in the manufacture of industrial and construction products (such as gypsum wallboard). Gypsum is an abundant, usually very cheap raw material, which can be cast, molded or otherwise formed into useful shapes through the process of dehydration and rehydration. The base material for gypsum wallboard and other gypsum products is the hemihydrate form of calcium sulfate (CaSO 4 ·1 / 2H 2 O), commonly calle...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B32B13/00B32B13/02
CPCB32B13/04B32B2250/40B32B2307/536B32B2607/00B32B2307/306B32B13/08B32B2419/04B32B13/14B32B29/00C04B28/145B32B2307/5825B32B13/02C04B2111/0062B32B2307/546Y10T428/24496Y10T428/249953Y02W30/91C04B14/42C04B18/241C04B22/16C04B24/226C04B24/38C04B38/106C04B2103/65B32B13/00C04B24/383
Inventor 于强卫新·戴维·宋
Owner USG CORP
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