Abstract:
A composition comprising a mixture of a calcium sulfate material, water, and a tetrametaphosphate compound is disclosed. Desirably, the inclusion of the tetrametaphosphate compound (e.g., salt or ion) in a pre-set treatment of a calcium sulfate material enhances the resistance to permanent deformation (e.g., sag), dimensional stability, and/or compressive strength of the composition while also preferably avoiding any significant retardive effect on the rate of hydration of calcined gypsum to calcium sulfate dihydrate. A set gypsum-containing product and a method for producing a set gypsum-containing product having increased resistance to permanent deformation are also disclosed.
Abstract:
A composition and method for treating a set gypsum-containing material are disclosed. The composition is formed from at least water at least one trimetaphosphate salt, at least one monobasic phosphate salt, and at least one acyclic polyphosphate salt having at least three phosphate units. The method comprises applying to a set gypsum material at least two of the following inorganic phosphates: at least one monobasic phosphate salt, at least one trimetaphosphate salt, and at least one acyclic polyphosphate salt having at least three phosphate units. The method can be for inhibiting re-calcination of a set gypsum containing material, and/or for enhancing the strength, surface hardness, paintability, abrasion resistance, and/or water erosion resistance of a set gypsum-containing material. Also disclosed is a method of making a set gypsum-containing material.
Abstract:
A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.
Abstract:
A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.
Abstract:
In a first embodiment of the invention, aged brushite is combined with calcium sulfate hemihydrate and water to make a gypsum slurry. Aged brushite slurry behaves similarly to calcium sulfate dihydrate to act as a seed crystal and rapidly initiate crystallization. The brushite slurry does not require the addition of a coating to maintain its activity over time compared to calcium sulfate dihydrate set accelerators. A gypsum-based product made using brushite slurry as the set accelerator is a second embodiment. The product has the brushite molecules integrated as part of the calcium sulfate dihydrate matrix and is distributed throughout the matrix.
Abstract:
The invention generally provides gypsum-containing slurries including stucco, a hydroxyethylated starch, naphthalenesulfonate dispersant, and sodium trimetaphosphate. The naphthalenesulfonate dispersant is present in an amount of about 0.1 % - 3.0% by weight based on the weight of dry stucco. The hydroxyethylated starch is present in an amount of from about 0.5% by weight to about 10% by weight based on the weight of dry stucco in the formulation. The sodium trimetaphosphate is present in an amount of about 0.1 % - 0.4% by weight based on the weight of dry stucco. Other slurry additives can include accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, lightweight gypsum wallboard, and a method of making lightweight gypsum wallboard.
Abstract:
This invention provides gypsum wallboards with a unique microstructure where the walls between voids are enhanced in thickness and strength to substantially improve the strength and handling properties of the wallboards. A method of making lightweight gypsum wallboards is also provided.