Gypsum board containing a polyol compound
The present invention is directed to a gypsum board and a method of making such gypsum board. For instance, the gypsum board comprises a gypsum core, a first facing material, and a second facing material wherein the first facing material and the second facing material sandwich the gypsum core. The gypsum core comprises a first gypsum core section and a second gypsum core section each comprising gypsum, wherein the first gypsum core section comprises a polyol compound and has a density higher than a density of the second gypsum core section.
1. A gypsum board comprising:
a gypsum core comprising a first gypsum core section and a second gypsum core section each comprising gypsum, wherein the first gypsum core section comprises a polyol compound and has a density higher than a density of the second gypsum core section; and
a first facing material and a second facing material, wherein the first facing material and the second facing material sandwich the gypsum core.
2. The gypsum board of claim 1 , wherein the polyol compound comprises a sugar, a sugar alcohol, a polyether, a polysaccharide, or a mixture thereof.
3. The gypsum board of claim 1 , wherein the polyol compound comprises a sugar alcohol.
4. The gypsum board of claim 3 , wherein the sugar alcohol comprises maltitol, sorbitol, mannitol, xylitol, erythritol, isomalt, threitol, arabitol, galactitol, fucitol, iditol, inositol, volemitol, lactitol, or a mixture thereof.
5. The gypsum board of claim 3 , wherein the sugar alcohol comprises glycerol.
6. The gypsum board of claim 1 , wherein the polyol compound comprises a sugar.
7. The gypsum board of claim 6 , wherein the sugar comprises glucose, sucrose, fructose, lactose, or a mixture thereof.
8. The gypsum board of claim 1 , wherein the polyol compound comprises a polyether.
9. The gypsum board of claim 8 , wherein the polyether comprises polyethylene glycol, polypropylene glycol, or a mixture thereof.
10. The gypsum board of claim 1 , wherein the polyol compound comprises a polysaccharide.
11. The gypsum board of claim 1 , wherein the polyol compound has a molecular weight of from 25 g/mol to 5,000 g/mol.
12. The gypsum board of claim 1 , wherein the polyol compound is present in an amount of from 0.001 lbs/MSF to 10 lbs/MSF based on the weight of the gypsum board.
13. The gypsum board of claim 1 , wherein the second gypsum core section does not include a polyol compound.
14. The gypsum board of claim 1 , wherein the gypsum board exhibits a gypsum content of 75% or more when determined based on the front of the gypsum board.
15. The gypsum board of claim 1 , wherein the gypsum board exhibits a gypsum content of 65% or more when determined based on the back of the gypsum board.
16. The gypsum board of claim 1 , wherein the gypsum board exhibits an edge hardness of 15 lb f to 50 lb f when measured according to ASTM C1396 and ASTM C473.
17. The gypsum board of claim 1 , wherein the gypsum board exhibits a nail pull resistance of 70 lb f or more when measured according to ASTM C1396, a core compressive strength of 300 psi or more when measured according to ASTM C1396, or both.
18. The gypsum board of claim 1 , wherein the second gypsum core section has a density that is 0.1% or more to 80% or less the density of the first gypsum core section.
19. The gypsum board of claim 1 , wherein the gypsum core comprises a third gypsum core section comprising gypsum and the polyol compound.
20. The gypsum board of claim 1 , wherein the gypsum core comprises a third gypsum core section and a fourth gypsum core section comprising gypsum and the polyol compound.
21. The gypsum board of claim 1 , wherein the gypsum core comprises a third gypsum core section, a fourth gypsum core section, and a fifth gypsum ore section comprising gypsum and the polyol compound.
22. A method for making the gypsum board of claim 1 , the method comprising:
providing a first facing material;
depositing a first gypsum slurry comprising stucco, a polyol compound, and water onto the first facing material;
depositing a second gypsum slurry comprising stucco and water onto the first gypsum slurry;
providing a second facing material on the second gypsum slurry; and
allowing the stucco to convert to calcium sulfate dihydrate.
23. A method for making the gypsum board of claim 1 , the method comprising
providing a first facing material;
depositing onto a first facing material
a first gypsum slurry comprising stucco, a polyol compound, and water,
a second gypsum slurry comprising stucco and water, and
a third gypsum slurry comprising stucco, a polyol compound, and water,
wherein the second gypsum slurry is deposited between the first gypsum slurry and the second gypsum slurry;
providing a second facing material on the first, second, and third gypsum slurries; and
allowing the stucco to convert to calcium sulfate dihydrate.
24. A method for making the gypsum board of claim 1 , the method comprising:
providing a first facing material;
depositing a first gypsum slurry comprising stucco, a polyol compound, and water onto the first facing material;
depositing onto the first gypsum slurry
a second gypsum slurry comprising stucco, a polyol compound, and water,
a third gypsum slurry comprising stucco and water, and
a fourth gypsum slurry comprising stucco, a polyol compound, and water,
wherein the third gypsum slurry is deposited between the second gypsum slurry and the third gypsum slurry;
providing a second facing material on the second, third, and fourth gypsum slurries; and
allowing the stucco to convert to calcium sulfate dihydrate.