Gypsum panel containing a polyol compound and/or an alkoxylated compound
The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, in one embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and an alkoxylated compound. In another embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and a polyol compound and wherein the gypsum panel exhibits a humidified deflection of greater than 0 inches to 0.05 inches. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and the respective compound onto the first facing material, and providing the second facing material on the gypsum slurry.
1 . A gypsum panel comprising:
a gypsum core; and
a first facing material and a second facing material sandwiching the gypsum core;
wherein the gypsum core comprises:
gypsum;
at least one alkoxylated compound, present in an amount of 0.001 to 150 lbs/MSF;
at least one foaming agent, present in an amount 0.5 to 25 lbs/ft 3 ; and
a void structure of air voids generated by the foaming agent;
wherein the at least one alkoxylated compound provides an improved wall strength in the void structure, as indicated by wall thickness;
wherein the at least one alkoxylated compound comprises at least one alkoxylated polyol compound, which comprises at least one alkoxylated sugar alcohol, which comprises alkoxylated maltitol, alkoxylated sorbitol, alkoxylated mannitol, alkoxylated xylitol, alkoxylated erythritol, alkoxylated isomalt, alkoxylated threitol, alkoxylated arabitol, alkoxylated galactitol, alkoxylated fucitol, alkoxylated iditol, alkoxylated inositol, alkoxylated volemitol, alkoxylated lactitol, alkoxylated glycerol, or a mixture thereof; and
wherein the at least one foaming agent comprises an alkyl sulfate, an alkyl ether sulfate, or a mixture thereof.
2 . The gypsum panel of claim 1 , wherein the at least one alkoxylated compound comprises a compound having an —(O—R 1 ) n -functionality wherein R 1 is an alkylene having from 1 to 5 carbon atoms and n is an integer of 1 or more.
3 . The gypsum panel of claim 2 , wherein R 1 is an alkylene having from 2 to 3 carbon atoms.
4 . The gypsum panel of claim 1 , wherein the at least one alkoxylated compound comprises a compound having an —(O—R 1 ) n —R 2 functionality wherein R 1 is an alkylene having from 1 to 5 carbon atoms, n is an integer of 1 or more, and R 2 is hydroxyl, alkoxy, or alkyl.
5 . The gypsum panel of claim 4 , wherein R 1 is an alkylene having from 2 to 3 carbon atoms.
6 . The gypsum panel of claim 4 , wherein n is from 1 to 30.
7 . The gypsum panel of claim 1 , wherein the at least one alkoxylated compound comprises at least two alkoxylated polyol compounds, which comprises at least one alkoxylated sugar alcohol, which comprises alkoxylated maltitol, alkoxylated sorbitol, alkoxylated mannitol, alkoxylated xylitol, alkoxylated erythritol, alkoxylated isomalt, alkoxylated threitol, alkoxylated arabitol, alkoxylated galactitol, alkoxylated fucitol, alkoxylated iditol, alkoxylated inositol, alkoxylated volemitol, alkoxylated lactitol, alkoxylated glycerol, or a mixture thereof.
8 . The gypsum panel of claim 1 , wherein the at least on alkoxylated compound comprises at least one alkoxylated polyol compound, which comprises at least one alkoxylated sugar alcohol, which comprises alkoxylated maltitol, alkoxylated sorbitol, alkoxylated mannitol, alkoxylated xylitol, alkoxylated erythritol, alkoxylated isomalt, alkoxylated threitol, alkoxylated arabitol, alkoxylated galactitol, alkoxylated fucitol, alkoxylated iditol, alkoxylated inositol, alkoxylated volemitol, alkoxylated lactitol, or a mixture thereof.
9 . The gypsum panel of claim 1 , wherein the at least one alkoxylated compound comprises at least one alkoxylated polyol compound, which comprises at least one alkoxylated sugar alcohol, which comprises alkoxylated glycerol.
10 . The gypsum panel of claim 9 , wherein the alkoxylated glycerol is ethoxylated glycerol.
11 . The gypsum panel of claim 1 , wherein the at least one alkoxylated compound comprises an ethoxylated compound, a propoxylated compound, or a mixture thereof.
12 . The gypsum panel of claim 1 , wherein the air voids comprise air voids having a diameter of less than 150 microns, or less in an amount of from 0.01% to less than 50% of the total air voids.
13 . The gypsum panel of claim 1 , wherein the air voids comprise air voids having a diameter of less than 100 microns, in an amount of from 0.01% to less than 50% of the total air voids.
14 . The gypsum panel of claim 1 , wherein the air voids have an average air void size of 150 microns er mere to 1,500 microns.
15 . The gypsum panel of claim 1 , wherein the air voids have an average air void size of 400 microns to 1,500 microns.
16 . The gypsum panel of claim 1 , wherein the air voids have an average wall thickness of from 0.05 mm to 0.4 mm.
17 . The gypsum panel of claim 16 , wherein the air voids have an average wall thickness of 0.1 mm to 0.4 mm.
18 . The gypsum panel of claim 1 , wherein the gypsum panel has a nail pull resistance of about 70 lb f to about 400 lb f .
19 . The gypsum panel of claim 1 , wherein the gypsum panel has a core compressive strength of from 200 psi to 1500 psi.
20 . The gypsum panel of claim 1 , wherein the gypsum core is formed from a gypsum slurry comprising stucco, water, the at least one alkoxylated compound, and the at least one foaming agent.
21 . The gypsum panel of claim 1 , wherein the gypsum core further comprises a dispersant.