Gypsum Panel Containing an Intercalated Additive

1 . A gypsum panel comprising:

a gypsum core, the gypsum core comprising gypsum;

a fire resistance composition, the fire resistance composition comprising an intercalated additive, the intercalated additive comprising an intumescent material and one or more intercalated compounds and/or ions, the intercalated additive being present in the gypsum panel in an amount from about 0.0001 wt. % to about 5 wt. %; and

a first facing material and a second facing material sandwiching the gypsum core.

2 . The gypsum panel of claim 1 , wherein the one or more intercalated compounds and/or ions comprise one or more sulfates.

3 . The gypsum panel of claim 1 , wherein the one or more intercalated compounds and/or ions comprise one or more carbonates, one or more bicarbonates, or a combination thereof.

4 . The gypsum panel of claim 1 , wherein the intumescent material is expandable graphite.

5 . The gypsum panel of claim 1 , wherein the intumescent material is vermiculite.

6 . The gypsum panel of claim 1 , wherein the intercalated additive is formed by a process including milling a mixture comprising the intumescent material and one or more intercalating agents.

7 . The gypsum panel of claim 1 , wherein the intercalated additive is formed by a process including mixing an aqueous solution comprising the intumescent material and one or more intercalating agents.

8 . A gypsum panel comprising:

a gypsum core, the gypsum core comprising gypsum;

a fire resistance composition, the fire resistance composition comprising an intercalated additive, the intercalated additive comprising an intumescent material and one or more intercalated compounds and/or ions, wherein the intercalated additive is a multi-intercalated additive; and

a first facing material and a second facing material sandwiching the gypsum core.

9 . The gypsum panel of claim 8 , wherein the intercalated additive is present in the gypsum panel in an amount from about 0.0001 wt. % to about 5 wt. %.

10 . The gypsum panel of claim 8 , wherein the one or more intercalated compounds and/or ions comprise one or more sulfates.

11 . The gypsum panel of claim 8 , wherein the one or more intercalated compounds and/or ions comprise one or more carbonates, one or more bicarbonates, or a combination thereof.

12 . The gypsum panel of claim 8 , wherein the intumescent material is expandable graphite.

13 . The gypsum panel of claim 8 , wherein the intumescent material is perlite.

14 . The gypsum panel of claim 8 , wherein the intumescent material is vermiculite.

15 . The gypsum panel of claim 8 , wherein the intercalated additive is formed by a process including milling a mixture comprising the intumescent material and one or more intercalating agents.

16 . The gypsum panel of claim 8 , wherein the intercalated additive is formed by a process including mixing an aqueous solution comprising the intumescent material and one or more intercalating agents.

17 . The gypsum panel of claim 8 , wherein the intercalated additive is formed by the intercalation of two or more types of intercalated compounds and/or ions into the intumescent material sequentially, wherein a first intercalated compound and/or ion is intercalated into the intumescent material and a second intercalated compound and/or ion is intercalated into the intumescent material, the second intercalated compound and/or ion being intercalated into the intumescent material after the first intercalated compound and/or ion.

18 . A method for making a gypsum panel comprising:

providing a first facing material;

depositing a gypsum slurry comprising stucco and water onto the first facing material;

providing a second facing material on the gypsum slurry; and

allowing the stucco to convert to calcium sulfate dihydrate;

wherein the gypsum panel comprises a fire resistance composition, the fire resistance composition comprising an intercalated additive, the intercalated additive comprising an intumescent material and one or more intercalated compounds and/or ions, the fire resistance composition being present in the gypsum panel in an amount from about 0.0001 wt. % to about 5 wt. %.

19 . The method of claim 18 , wherein the intumescent material is expandable graphite.

20 . The method of claim 19 , wherein the intercalated additive is a multi-intercalated additive.