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GYPSUM BOARD AND COMPOSITION

IP.com Disclosure Number: IPCOM000237186D
Publication Date: 2014-Jun-06

Publishing Venue

The IP.com Prior Art Database

Abstract

A gypsum board includes a coversheet and a gypsum layer disposed on the coversheet. The gypsum layer may include the reaction product of water and stucco. The gypsum layer may also include a glyoxal-urea oligomer having a weight average molecular weight (Mw) of less than 1,000 g/mol and comprising a weight ratio of urea:glyoxal of from 0.1:2 to 2:0.1. The gypsum board may be formed by a method that includes the step of combining the water, the stucco, and the glyoxal-urea oligomer to form a slurry. The method may also include the step of applying the slurry to the coversheet to form the gypsum layer disposed on the coversheet

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GYPSUM BOARD AND COMPOSITION

ABSTRACT OF THE DISCLOSURE

    A gypsum board includes a coversheet and a gypsum layer disposed on the coversheet. The gypsum layer may include the reaction product of water and stucco. The gypsum layer may also include a glyoxal-urea oligomer having a weight average molecular weight (Mw) of less than 1,000 g/mol and comprising a weight ratio of urea:glyoxal of from 0.1:2 to 2:0.1. The gypsum board may be formed by a method that includes the step of combining the water, the stucco, and the glyoxal-urea oligomer to form a slurry. The method may also include the step of applying the slurry to the coversheet to form the gypsum layer disposed on the coversheet.

SUMMARY OF THE DISCLOSURE

    A gypsum board includes a coversheet and a gypsum layer disposed on the coversheet. The gypsum layer may include the reaction product of water and stucco. The gypsum layer may also include a glyoxal-urea oligomer having a weight average molecular weight (Mw) of less than 1,000 g/mol and comprising a weight ratio of urea:glyoxal of from 0.1:2 to 2:0.1. The gypsum board may be formed by a method that includes the step of combining the water, the stucco, and the glyoxal-urea oligomer to form a slurry. The method may also include the step of applying the slurry to the coversheet to form the gypsum layer disposed on the coversheet.

BACKGROUND

    Gypsum board is a composite material typically made from two coversheets with a gypsum layer sandwiched therebetween. Gypsum boards are manufactured for use in a variety of applications with each application having specific performance requirements. Gypsum boards, for example, may be used as structural building panels on internal and external walls of a structure.

    Gypsum boards are typically manufactured by calcining gypsum into a plaster, making slurry or dispersion from the plaster, and passing the slurry/dispersion through machines which shape, set, and cut the plaster into a board. The coversheet(s) is then applied. Starch is typically added to the slurry/dispersion to reinforce a bond between the coversheet(s) and the gypsum

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layer. During formation of the gypsum board, i.e., during drying, the starch undergoes gelation and migrates to an interface between the gypsum layer and the coversheet(s) thereby bonding the coversheet(s) to the gypsum layer. Starch tends to limit penetration of the gypsum layer into the coversheet(s), resulting in a strong bond thereto. However, the use of starch can be expensive and difficult in certain conditions. Accordingly, there is an opportunity for improvement.

BRIEF DESCRIPTION OF THE DRAWINGS

    Other advantages of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

Figure 1A is a side view of one embodiment of a gypsum board according to this disclosure illustrating a coversheet and a...