14-01-2016 дата публикации
Номер: US20160009598A1
Принадлежит:
A slurry for manufacturing gypsum board comprises calcined gypsum, water, a foaming agent, and a coalescing agent. The foaming agent imparts a plurality of bubbles in the slurry. Typically, a foam is pre-generated with the foaming agent and the foam is used to form the slurry such that the foam imparts the plurality of bubbles in the slurry. The coalescing agent coalesces the plurality of bubbles imparted by the foam. Typically, the coalescing agent coalesces a plurality of small and partially joined bubbles imparted by the foam to create larger and more discrete bubbles. A gypsum board and method of forming the slurry and the gypsum board are also disclosed. The gypsum board comprises a gypsum layer formed from the slurry. The gypsum layer defines a plurality of bubbles dispersed therein, which are imparted by the foam and coalescing agent of the slurry. 1. A gypsum board comprising a cover sheet and a gypsum layer disposed on said cover sheet , said gypsum layer defining a plurality of bubbles dispersed therein and comprising the reaction product of:calcined gypsum; andwater;{'sub': 1', '2, 'wherein an exothermic reaction occurs between said calcined gypsum and water, with said reaction product having a temperature ranging from an initial temperature (T) to a peak temperature (T) during formation;'}in the presence ofa foaming agent comprising a surfactant for creating a foam to impart a plurality of bubbles in said reaction product; and{'sub': CP', '1', '2, 'a coalescing agent comprising an alcohol alkoxylate and having a cloud point (T) from about 16.0 to about 60.0 C according to ADTM D2024 and that is between the initial temperature (T) and the peak temperature (T) of said reaction product, such that said coalescing agent coalesces the plurality of bubbles imparted by the foam thereby establishing the plurality of bubbles in said gypsum layer.'}2. (canceled)3. (canceled)4. A gypsum board as set forth in wherein said foaming agent and said coalescing agent are ...
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