Granted Patent B2

US 12,612,334 · App. 17/807,966 · Granted Apr 28, 2026

Inventors: Annamaria Vilinska (Chicago, IL); Alfred C. Li (Naperville, IL)

Assignee: KNAUF GIPS KG

C04B14/365C04B24/16C04B2103/40C04B2111/0062

Abstract

Claims (39)

1 . A gypsum board, comprising:

a set gypsum core disposed between two cover sheets;

said set gypsum core comprising a gypsum crystal matrix formed from at least water, stucco, and a foam; and

said foam is formed from a blend of a first surfactant, a second surfactant and a third surfactant and water,

wherein each of said first surfactant, said second surfactant and said third surfactant are separately supplied for blending and is a distinct composition from the other surfactants,

wherein said first surfactant is at least one of an alkyl sulfate and an octyl sulfate,

wherein said second surfactant is an alkyl ether sulfate, and

wherein said third surfactant is at least one of octyl sulfate, cocamidopropyl betaine and decyl glucoside.

2 . The gypsum board of claim 1 , wherein said third surfactant has at least one of a different head group chemistry and a different carbon chain length than said first surfactant and said second surfactant.

3 . The gypsum board of claim 1 , wherein said first surfactant is one of Polystep® B25M surfactant, Polystep® B29M surfactant, Vinapor® Gyp 80 surfactant and Hyonic® 25AM/FM surfactant.

4 . The gypsum board of claim 1 , wherein said second surfactant is one of Steol® FA 403M surfactant, Steol® CS 230 surfactant and Hyonic® 33 PFM surfactant.

5 . The gypsum board of claim 1 , wherein said third surfactant or soap is an alkyl sulfate.

6 . The gypsum board of claim 1 , wherein said third surfactant is one of alkyl sulfate, alkyl ether sulfate, alkyl ether carboxylate, alkylbenzene sulfonate, alkyl sulfosuccinate, alkyl phosphate, alkyl ether phosphate, fatty alcohol ethoxylate, alkylphenol ethoxylate, fatty acid ethoxylate, fatty amine ethoxylate, fatty amine ethoxylate, alkyl glucoside, sorbitan alkanoate, alkyl quat, dialkyl quat, ester quat, betaine, amidobetaine, and imidazoline.

7 . A gypsum board, comprising:

a set gypsum core disposed between two cover sheets;

said set gypsum core comprising a gypsum crystal matrix formed from at least water, stucco, and a foam;

said foam is formed from a blend of a first surfactant, a second surfactant and a third surfactant and water, wherein each said surfactant is independently supplied and is controlled via a designated user-operated control valve for blending and has a distinct composition from the other surfactants;

said first surfactant is an alkyl sulfate;

said second surfactant is an alkyl ether sulfate; and

said third surfactant is an alkyl sulfate distinct from said first surfactant and having one of a head group chemistry and a carbon chain length different from said first surfactant and said second surfactant.

8 . The gypsum board of claim 7 , wherein said third surfactant is octyl sulfate, cocamidopropyl betaine or decyl glucoside.

9 . A process for producing low density gypsum wallboard panels, comprising:

providing a first surfactant;

providing a second surfactant;

providing a third surfactant;

wherein each of said first surfactant, said second surfactant and said third surfactant is a distinct composition from the other surfactants;

each of said first surfactant, said second surfactant and said third surfactant are delivered independently by separate delivery tubes using user-operated control valves for each surfactant into a soap mixing tube;

blending said first surfactant, said second surfactant and said third surfactant with water in said mixing tube to form foam; and

blending said foam with a wallboard slurry for forming a low density gypsum wallboard.

10 . The process of claim 9 , further including:

laying a sheet of face paper on a moving conveyor;

applying said slurry and foam upon said face paper; and

laying a sheet of backing paper upon said slurry and foam.

11 . The gypsum board of claim 7 , wherein said first surfactant is at least one of an alkyl sulfate and an octyl sulfate,

wherein said second surfactant is an alkyl ether sulfate, and

wherein said third surfactant is at least one of octyl sulfate, cocamidopropyl betaine and decyl glucoside.

12 . The process of claim 9 , wherein said first surfactant is at least one of an alkyl sulfate and an octyl sulfate,

wherein said second surfactant is an alkyl ether sulfate, and

wherein said third surfactant is at least one of octyl sulfate, cocamidopropyl betaine and decyl glucoside.

Assignments (2)

Continuity (2)

References Cited (32)