Low-density, low-weight gypsum boards with fire-resistance rating

专利摘要:
FIRE RESISTANT PLASTER PANELS OF LOW WEIGHT AND DENSITY . A light weight, reduced density gypsum board that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire resistant gypsum boards with higher gypsum content, weight and density.
公开号:BR112013021559B1
申请号:R112013021559-3
申请日:2012-02-24
公开日:2021-08-31
发明作者:Qiang Yu；Wenqi Luan；Weixin David Song；Srinivas Veeramasuneni；Alfred Li
申请人:United States Gypsum Company；
IPC主号:

专利说明:

CROSS REFERENCE TO RELATED ORDERS
[01] This patent application claims and the benefit of priority to US Temporary Patent Application No. 61/446,941, filed February 25, 2011 and entitled "Low Density, Low Weight Plaster Panels with Resistance Rating Rating fire”, which is incorporated into the present in its entirety and by this reference. FUNDAMENTALS
[02] This disclosure generally pertains to gypsum panels of reduced density and weight with improved thermal insulation properties, resistance to heat shrinkage and fire resistance.
[03] Gypsum boards commonly used in construction and other building applications (such as plasterboard or ceiling panels) comprise a gypsum core with backing sheets of paper, fiberglass or other suitable materials. Gypsum boards are typically manufactured by mixing calcined gypsum or "stucco" with water and other ingredients to prepare a slurry that is used to form the core of the boards. As generally understood in the art, stucco predominantly comprises one or more forms of calcined gypsum, i.e. gypsum subjected to dehydration (usually by heating) to form anhydrous gypsum or hemidrated gypsum (CaSO4% H2O). Calcined gypsum can include beta hemidrated calcium sulfate, alpha hemidrated calcium sulfate, water soluble calcium sulfate anhydrite, or mixtures of any or all of these, from natural or synthetic sources. When introduced into the slurry, the calcined gypsum begins a hydration process, which is completed during the formation of the gypsum panels. This hydration process, when properly filled, generates a generally continuous crystalline matrix of hardened gypsum dihydrate in different crystalline forms (ie, CaSO42 H2O forms).
[04] During the formation of the panels, the cladding sheets are normally supplied as continuous nets. The gypsum slurry is deposited as a flux or tape onto the first of the facing sheets. The slurry is spread along the entire length of the first facing sheet to a predetermined approximate thickness to form the core of the panel. A second facing sheet is then placed on top of the slurry, leaving the plaster core between the sheets and forming a continuous panel.
[05] The continuous panel is normally transported along a mat to allow the core to continue the hydration process. When the core is sufficiently hydrated and hardened, it is cut to one or more desired sizes to form individual plasterboards. The panels are then transferred to and through an oven at temperatures sufficient to dry the panels to a desired free moisture level (usually a relatively low free moisture content).
[06] Depending on the process employed and the expected use of the panels and other such considerations, additional layers of slurry, strips or tapes comprising plaster and other additives may be applied to the first or second sheet to provide specific properties for the finished panels such as such as hardened edges or a hardened face of the panel. Likewise, foam may be added to gypsum core slurry or strips and/or tapes of other slurry at one or more locations in the process to provide a distribution of air voids within the gypsum core or core portions. of the finished panels.
[07] The resulting panels can be further cut and processed for use in a variety of applications depending on the desired panel size, cladding layer composition, core compositions, etc. Gypsum panels typically range in thickness from approximately % of an inch to approximately one inch, depending on their expected use and application. The panels can be applied to a variety of structural elements used to form walls, ceilings and other similar systems using one or more fasteners such as screws, nails and/or adhesives.
[08] If finished gypsum boards are exposed to relatively high temperatures, such as those produced by flames or high temperature gases, parts of the gypsum core may absorb enough heat to initiate the release of water from hydrated gypsum core crystals. The heat absorption and water release from the dihydrate gypsum may be sufficient to retard heat transfer through or within the panels for a while. Gypsum board can act as a barrier to prevent high temperature flames from passing directly through the wall system. The heat absorbed by the gypsum core may be sufficient to essentially burn off parts of the core, depending on heat source temperatures and exposure time. At certain temperature levels, heat applied to a panel can also cause phase changes in the gypsum core anhydrite and the rearrangement of crystal structures. In some instances, the presence of salts and impurities can reduce the melting point of the gypsum core crystal structures.
[09] Gypsum panels can experience shrinkage of panel dimensions in one or more directions as a result of some or all of these high temperature heating effects, and such shrinkage can cause failures in the structural integrity of the panels. When panels are attached to wall, ceiling or other structure assemblies, panel shrinkage can lead to separation of panels from other panels mounted in the same sets and their supports and, in some cases, collapse of panels or supports ( or both). As a result, gases or flames at high temperatures can pass directly into or through a wall or ceiling structure.
[010] Gypsum panels have been produced to resist the effects of relatively high temperatures for a period of time, which can inherently delay the passage of high heat levels through or between panels and in (or through) systems. using. Gypsum panels referred to as fire resistant or "fireproof" are typically formulated to increase the ability of the panels to delay the passage of heat, however, wall or ceiling structures and play an important role in controlling the spread of fire in the buildings interior. As a result, building code authorities and other relevant public and private entities typically set stringent standards for the strength performance of fireproof gypsum boards.
[011] The ability of gypsum panels to resist fire and associated extreme heat can be assessed by performing generally accepted tests. Examples of such tests are routinely used in the construction industry, such as those published by Underwriters Laboratories ("UL"), such as the UL U305, U419, and U423 test procedures and protocols, as well as the procedures described in the E119 specification published by American Society for Testing and Materials (ASTM). Such tests can include building test sets using the plasterboards, typically a single-layer application of the panels on each face of a wall structure formed of wood or steel beams. Depending on the test, the assembly may or may not be subjected to load forces. The front of one side of the assembly, such as an assembly constructed in accordance with UL U305, U419 and U423, for example, is exposed to rising temperatures over a period of time in accordance with a heating curve such as those discussed in the procedures ASTM E119.
[012] The temperatures near the heated side and the surface temperatures of the unheated side of the assembly are monitored during testing to assess the temperatures experienced by the exposed gypsum panels and the heat transmitted through the assembly to the unexposed panels. Tests are terminated upon one or more structural failures of the panels and/or when temperatures on the unexposed side of the assembly exceed a predetermined limit. Typically, these threshold temperatures are based on the maximum temperature in any of these sensors and/or the average of the temperature sensors on the unheated side of the assembly.
[013] Testing procedures, such as those set forth in UL U305, U419, and U423, and ASTM E119 are intended for the resistance of the assembly to transmit heat through the assembly as a whole. The tests also provide, in one aspect, a measure of the resistance of the gypsum panels used in the assembly to shrink in the x-y direction (width and length) as the assembly is subjected to high temperature heating. Such tests also provide a measure of the resistance of panels to losses in structural integrity that result in the opening of gaps or spaces between panels in a wall assembly, with the passage resulting from high temperatures in the interior cavity of the assembly. In another aspect, the tests provide a measure of the ability of gypsum boards to resist heat transmission through the boards and the assembly. Such tests are believed to reflect the ability of the specified system to provide building occupants and fire/fire control systems with a window of opportunity to escape or deal with fire conditions.
[014] In the past, various strategies have been used to improve the fire resistance of gypsum panels rated for fire resistance. For example, thicker, denser panel cores that used more gypsum compared to lower density gypsum panels were provided and therefore include an increased amount of chemically bonded water within the gypsum (hydrated calcium sulfate) to act as a heat sink, reduce panel shrinkage and increase the structural stability and strength of the panels. Alternatively, various ingredients, including fiberglass and other fibers, have been incorporated into the gypsum core to improve the fire resistance of the gypsum panels, increasing the core tensile strength and distributing shrinkage stresses throughout the core matrix. Likewise, quantities of certain clays, such as those less than approximately one micrometer in size and colloidal silica or alumina additives, such as those less than one micrometer in size, have been used in the past to provide greater fire resistance. (and high temperature shrinkage resistance) in a gypsum panel core. It was recognized, however, that reducing the weight and/or core density of gypsum panels by reducing the amount of gypsum in the core would negatively affect the structural integrity of the panels and their resistance to fire and high temperature conditions.
[015] Another approach has been to add unexpanded vermiculite (also referred to as vermiculite ore) and glass or mineral fibers to the core of gypsum panels. In such approaches, vermiculite is expected to expand under heated conditions to compensate for shrinkage of the gypsum core components. It was believed that the glass/mineral fibers would hold parts of the plaster matrix together.
[016] This approach is described in US Patents No. 2,526,066 and 2,744,022, which discuss the use of vermiculite and unexfoliated mineral and glass fibers divided into parts in sufficient proportions to inhibit shrinkage of gypsum panels under conditions of high temperature. Both references, however, were based on a high-density core to provide enough plaster to act as a heat sink. They disclose the preparation of % inch thick gypsum panels with a weight of 2 to 2.3 pounds per square foot (2,000 to 2,300 pounds per thousand square feet ("lb/msf")) and board densities approximately 50 pounds per cubic foot ("pcf") or greater.
[017] The '066 patent reported that cut sections of such panels (with 2% mineral fiber and 7.5% minus 28 mesh vermiculite) evidenced up to 19.1% expansion in thickness when heated to 1400°F (760 °C) for 30 minutes, but did not provide any information about the shrinkage of the xy direction of these samples. The '066 patent further cautioned that, depending on the panel formulation and vermiculite content, expansion of vermiculite can cause panel damage due to protruding panels and/or cracks and openings in the panels.
[018] The '022 patent was aimed at increasing the gypsum content (and therefore density and weight) of the panels disclosed in the '066 patent and, by reducing the fiberglass/mineral content of those panels, providing a greater capacity for dissipating heat from gypsum References such as the '022 patent further acknowledge that the expansive properties of vermiculite, unless contained, would have resulted in the separation (ie, fragmentation, peeling or flaking) of the core and destruction of a wall assembly in a relatively short time under high temperature conditions.
[019] In another example, U.S. Patent No. 3,454,456 describes the introduction of unexpanded vermiculite to the core of fire resistant plasterboard gypsum panels to resist shrinkage of the panels. The '456 patent also relies on relatively high gypsum content and density to provide a desired heat sink capability. The '456 patent discloses board weights for % inch finished gypsum panels with a minimum weight of approximately 192 lb/msf and a density of approximately 46 pcf. This density is comparable to the thicker and much heavier 5/8 inch (approximately 2400lb/msf) gypsum boards currently available commercially for fire resistant applications.
[020] The '456 patent also discloses that the use of vermiculite in a gypsum panel core to increase the fire resistance of the panel is subject to significant limitations. For example, the '456 patent notes that expansion of vermiculite within the core can cause the core to disintegrate due to separation and other destructive effects. The '456 patent also discloses that unexpanded vermiculite particles can weaken the core structure so much that the core becomes brittle, weak and soft. The '456 patent proposes to address such significant inherent limitations with the use of vermiculite in gypsum panels by employing a "single" unexpanded vermiculite with a relatively small particle size distribution (over 90% of unexpanded particles smaller than a mesh size #50 (approximately 0.117 inch (0.297 mm) openings), with less than 10% slightly larger than mesh size #50). This approach supposedly inhibited the adverse effects of vermiculite expansion in the panel, as explained in col. 2, ll. 52-72 of the '456 patent.
[021] The '456 patent further explains that unexpanded vermiculite with the particle size distribution described above corresponds to a product known commercially as "Classification No. 5" unexpanded vermiculite. Grade No. 5 unexpanded vermiculite has been used in commercial fire resistance/fire resistance grading panels with gypsum cores of conventional board densities (eg approximately 45 pcf to in excess of approximately 55 pcf) since at least the 1970s. For the reasons discussed above, the use of unexpanded vermiculite which comprises a significant distribution of particles with sizes larger than those typical of the No. 5 Classification of unexpanded vermiculite has been considered potentially destructive to panels. fire resistance due to the aforementioned splitting and other effects caused by expansion of vermiculite within a gypsum core under high temperature conditions.
[022] In another approach, U.S. Patent No. 3,616,173 is directed to fire resistant gypsum panels with a gypsum core characterized by the '173 patent as a lower weight or a lower density. The '173 patent distinguished its prior art 1/2 inch panels that weigh approximately 2000 lb/msf or more and which have core densities in excess of approximately 48 pcf. Thus, the 173 patent discloses % inch thick panels having a density equal to or greater than approximately 35 pcf and preferably approximately 40 pcf to approximately 50 pcf. The '173 patent achieves its disclosed core core densities by incorporating significant amounts of small particle size inorganic material of clay, colloidal silica or colloidal aluminum into its gypsum core, as well as glass fibers in the quantities required to prevent shrinkage. of its gypsum panels under high temperature conditions.
[023] The '173 patent further discloses the additional option of unexpanded vermiculite to its gypsum core composition, along with the required amounts of its disclosed small particle size inorganic materials. Even with these additives, however, the disclosed test of each of the panels in the '173 patent showed that they had significant shrinkage. This shrinkage occurred despite the fact that each of the tested and reported panels had core densities of approximately 43 pcf or greater.
[024] For 1/2 inch thick gypsum panels, the disclosed panels of the '173 patent have a shrink strength of approximately 60% to approximately 85%. "Shrunk strength" as used in the '173 patent is a measure of the proportion or percentage of the area x-y (width-length) of a segment of the core that remains after the core is heated to a defined temperature for a defined period of time as described in the '173 patent. See, for example, col. 12, ll. 41-49.
[025] Other efforts have also been made to increase the strength and structural integrity of gypsum panels and reduce panel weight by various means. Examples of such lightweight gypsum boards include, U.S. Patent Nos. 7,731,794 and 7,736,720 and Patent Application Publication Nos. 2007/0048490 A1, 2008/0090068 A1 and 2010/0139528 A1.
[026] Finally, it is noted that, in the absence of water-resistant additives, when immersed in water, the hardened plaster can absorb up to 50% of its weight. And when plasterboards, including fire-resistant plasterboards, absorb water, they can swell, deform and lose strength, which can degrade their fire-resistant properties. Lightweight fire resistant panels have much more air and/or water voids than conventional heavier fire resistant panels. These voids would be expected to increase the rate and extent of water absorption, and it is expected that such light weight fire resistant panels would be more water absorbent than heavier conventional fire resistant panels.
[027] Many attempts have been made in the past to improve the water resistance of gypsum boards in general. Various hydrocarbons including wax, resins and asphalt were added to the slurries used to make the panels to impart water resistance to the panels. Siloxanes have also been used in slurries to impart water resistance to gypsum boards through the formation of silicone resins in situ. However, siloxanes would not be expected to sufficiently protect panels of low weight and density. Thus, there is a need in the art for a method of producing fire resistant, low weight and density gypsum panels with improved water resistance at a reasonable cost, increasing the water resistance normally imparted by siloxanes. SUMMARY
[028] In some embodiments, the present disclosure describes a reduced weight, reduced density gypsum panel — and methods for making such panels — with fire resistance properties comparable to the heavier and denser gypsum panels typically used for applications in construction where a fire resistance rating is required. In some embodiments, panels formed in accordance with the principles of the present disclosure comprise a hardened gypsum core having a density of less than approximately 40 pounds per cubic foot ("pcf") disposed between two core sheets. In embodiments of such panels that are 5/8 inches thick, the weight is approximately less than approximately 2100 lb/msf.
[029] In some embodiments, high expansion particles such as high expansion vermiculite, for example, can be incorporated into the gypsum core in effective amounts to provide fire resistance in terms of shrinkage resistance comparable to commercial type gypsum panels X and other much heavier and denser gypsum panels. Highly expanding particles can have an unexpanded first phase and an expanded second phase when heated. Such panels can also provide fire resistance, in terms of thermal insulation property and High Temperature Shrinkage in the xy (width-length) direction, as well as High Temperature Thickness Expansion properties in the z-direction (thickness), which is comparable or significantly larger than commercial type X gypsum panels and other much heavier and denser commercial gypsum panels, including commercial gypsum panels containing Grade No. 5 vermiculite. In still other embodiments, panels formed in accordance with the principles of present disclosure can provide fire performance on parts such as those subjected to standard industrial fire tests comparable to at least Type X commercial gypsum panels and other heavier and denser commercial panels. Such industry standard fire tests include, but are not limited to, those set forth in UL U305, U419, and U423 full scale fire test specifications and procedures and fire tests that are equivalent to those.
[030] In other embodiments, reduced density and weight reduced gypsum panels formed in accordance with principles of the present disclosure and the methods for making the same can provide High Temperature Shrinkage (at temperatures of approximately 1560 °F (850 °C)) of less than approximately 10% in xy directions and expansion in the z direction greater than approximately 20%. In some modes, the z-direction ratio of High Temperature Thickness Expansion is greater than approximately 0.2 in some modes, greater than approximately 2 in other modes, in some modes greater than approximately 3, in other modes greater than approximately 7, in still other embodiments more than approximately 17, and still in new embodiments approximately 2 to approximately 17. In other embodiments, the reduced weight and density gypsum panels formed in accordance with current disclosure principles and methods for making they can provide shrink strength more than approximately 85% in xy directions at temperatures of more than approximately 1800°F (980°C).
[031] In yet other embodiments, a fire resistant gypsum panel formed in accordance with principles of the present disclosure, and methods for making the same, may include a gypsum core disposed between two facing sheets. The gypsum core can comprise a crystalline matrix of hardened gypsum and high expansion particles expandable to approximately 300% or more of their original volume after heating for approximately one hour at approximately 1560°F (approximately 850°C). Gypsum core can have a density (D) of approximately 40 pounds per cubic foot or less and a core hardness of at least approximately 11 pounds (5 kg). The gypsum core can be effective in providing a Thermal Insulation Index (TI) of approximately 20 minutes or more.
[032] In other embodiments, assemblies made using light weight and 5/8 inch thick density gypsum panels formed in accordance with the principles of the present disclosure may provide fire resistance comparable to (or better than) assemblies using gypsum panels denser and heavier when tested in accordance with UL U305, U419, and U423 fire test procedures. The fire resistance of panels formed in accordance with the principles of the present disclosure may be reflected by the maximum single sensor temperature or the average sensor temperature on the unexposed surface of such assemblies, performed in accordance with UL U305 fire testing procedures , U419 and U423 (and equivalent fire test procedures). In some embodiments, assemblies made using panels formed in accordance with the principles of the present disclosure and tested in accordance with UL U419 provide a maximum single sensor temperature of less than approximately 500°F (260°C) and/or an average temperature less than approximately 380°F (195°C) at approximately 60 minutes of elapsed time. In some embodiments, assemblies made using panels formed in accordance with the principles of the present disclosure and tested in accordance with UL U419 provide a maximum single sensor temperature of less than approximately 206°F and/or an average sensor temperature of less than approximately 250 °F at approximately 50 minutes of elapsed time. In other embodiments, assemblies made using panels formed in accordance with the principles of the present disclosure in such UL U419 tests can provide a maximum single sensor temperature of less than about 410°F and/or an average sensor temperature of less than about 320 °F at approximately 50 minutes. In still other embodiments, assemblies made using panels formed in accordance with the principles of the present disclosure in such tests can provide a maximum single sensor temperature of less than approximately 300°F and/or an average sensor temperature of less than approximately 280° F at approximately 55 minutes of elapsed time.
[033] In other embodiments, an assembly made of panels formed in accordance with the principles of the present disclosure may show fire resistance under test in accordance with UL U419 procedures reflected by a maximum single sensor temperature of less than approximately 500°F and /or an average sensor temperature of less than approximately 380°F at approximately 60 minutes of elapsed time. In yet other embodiments, assemblies made using panels formed in accordance with the principles of the present disclosure may in such tests show a maximum single sensor temperature of less than about 415°F and/or an average sensor temperature of less than about 320° F at approximately 60 minutes of elapsed time. In certain such embodiments, gypsum panels formed in accordance with principles of the present disclosure may have a core with a density less than approximately 40 pcf which meets the requirements for a fire panel with a 60 minute fire resistance rating according to one or more of the UL U305, U419, and U423 fire test procedures and other fire test procedures that are equivalent to any of those.
[034] In still other embodiments, the formula for reduced weight and density gypsum panels in accordance with the principles of the present disclosure and the methods for making them can provide gypsum panels with the aforementioned fire resistance properties, a density less than approximately 40 pcf and a nail tensile strength that can meet ASTM C 1396/C 1396/M-09 standards. More particularly, such panels, when nominally 5/8-inch thick, can have a nail tensile strength of at least 87 lbs. Furthermore, in other embodiments, such panels offer essentially the same sound transmission characteristics as much heavier and denser panels. In some embodiments, 5/8 inch thick panels formed in accordance with the principles of the present disclosure may have sound transmission class ratings of at least approximately 35 when mounted to a steel beam assembly in accordance with ASTM tests and procedures E90-99.
[035] In still other embodiments, a gypsum core composition hardened by a nominal 5/8 inch fire rated panel is provided using gypsum containing slurry comprising at least water, stucco and high expansion vermiculite. In one embodiment, the hardened gypsum core has a density of approximately 30 pcf to approximately 40 pcf, and the core is composed of stucco in an amount of approximately 1162 lbs/msf to approximately 1565 lbs/msf, high expansion vermiculite of approximately 5% to approximately 10% by weight of stucco, and mineral or glass fiber from approximately 0.3% to approximately 0.9% by weight of stucco. (Unless otherwise noted, gypsum core component percentages are stated by weight based on the weight of stucco used to prepare the core slurry). In another embodiment, the hardened gypsum core has a density of approximately 30 pcf to approximately 40 pcf, and the core is composed of stucco in an amount of approximately 1162 lbs/msf to approximately 1565 lbs/msf, high expansion vermiculite of approximately 5% to approximately 10% by weight of stucco, starch from approximately 0.3% to approximately 3% by weight of stucco, mineral or glass fiber from approximately 0.3% to approximately 0.9% by weight of stucco, and phosphate from approximately 0.03% to approximately 0.4% by weight of stucco.
[036] In other embodiments, the gypsum core of 5/8 inch thick panels formed in accordance with principles of the present disclosure may have a density of approximately 32 to approximately 38 pounds per cubic foot and a gypsum core weight of approximately 1500 to approximately 1700 lb/msf. In some embodiments, the gypsum core may include approximately 5.5% to approximately 8% high expansion vermiculite, approximately 0.4% to 0.7% mineral or glass fiber, and approximately 0.07% to approximately 0.25% phosphate. In other embodiments, the gypsum core may include approximately 5.5% to approximately 8% high expansion vermiculite, approximately 0.5% to approximately 2.5% starch, approximately 0.4% to approximately 0.7% of mineral or glass fiber, and approximately 0.07% to approximately 0.25% phosphate. In still other embodiments, each of the gypsum core components, such as starch, fiber and phosphate content, can then be adjusted to provide desired panel properties and, in view of the composition and weight of the facing sheets, other additives the core of the panel and the quality of the gypsum stucco.
[037] Each of the gypsum core components described in this document may also vary appropriately for panels of different thickness, as will be appreciated by one skilled in the art. For example, 1/2 inch panels may have lb/msf plaster values at approximately 80% of the stated values, and 3/4 inch panels may have lb/msf values at approximately 120% of the stated values. In some embodiments, these proportions may vary depending on physical property specifications for panels of different thickness. Other aspects and variations of panels and core formulations in accordance with current disclosure principles are discussed below.
[038] Other conventional additives may also be employed in core slurries and gypsum core compositions disclosed herein, in customary amounts, to impart desirable core properties and to facilitate the manufacturing process. Examples of such additives are setting accelerators, setting retarders, dewatering inhibitors, binders, adhesives, dispersing aids, leveling or non-levelling agents, thickeners, bactericides, fungicides, pH adjusters, dyes, water-impermeable, fillers, aqueous foams and mixtures thereof.
[039] In panels formed in accordance with the principles of the present disclosure and the methods of producing them, aqueous foam can be added to the core slurry in an amount effective to provide the desired gypsum core densities, using methods discussed in more detail below. In some embodiments, addition of the foam component to the core slurry can result in a distribution of voids and void sizes in the presence of the vermiculite core component that contributes to one or more strength properties of the panel and/or core. Likewise, additional layers of slurry, strips or tapes comprising plaster and other additives (which can increase density relative to other parts of the core) can be applied to the first or second facing sheet to provide specific properties to the finished panels , like harder edges.
[040] In still other embodiments, a fire resistant gypsum panel formed in accordance with principles of the present disclosure, and methods for making the same, may include a gypsum core disposed between two facing sheets. The hardened gypsum core can have a density (D) of approximately 40 pounds per cubic foot (approximately 640 kg/m 3 ) or less and comprises a crystalline matrix of hardened gypsum and high expansion particles. High expansion particles are swellable to approximately 300% or more of their original volume after heating for approximately one hour at approximately 1560°F (approximately 850°C).
[041] In other embodiments, the present disclosure describes a method of making a fire resistant gypsum panel. A gypsum slurry with high expansion particles dispersed therein is prepared. The slurry is disposed between a first coating sheet and a second coating sheet to form an assembly. The set is cut into a panel of predetermined dimensions. The panel is dry. The hardened gypsum core has a density (D) of approximately 40 pounds per cubic foot (approximately 640 kg/m 3 ) or less and comprises a crystalline matrix of gypsum set and high expansion particles. High expansion particles are swellable to approximately 300% or more of their original volume after heating for approximately one hour at approximately 1560°F (approximately 850°C).
[042] In other embodiments, the present disclosure describes a method of classification of fireproof gypsum panels, where the hardened gypsum core component is formed from the aqueous slurry containing calcined gypsum. In some embodiments, the slurry may include high expansion vermiculite, starch, dispersants, phosphates, fiberglass/mineral, foam, other additives in amounts described above, stucco and water at a water/stucco weight ratio of approximately 0. 6 to about 1.2, preferably about 0.8 to about 1.0 and most preferably about 0.9. The core slurry can be deposited as a continuous tape on and distributed along a continuous web of the first overlay sheet. A web of a second liner sheet may be placed over the slurry deposited on the web of the first liner sheet to form a general continuous gypsum panel of a desired approximate thickness. The general continuous gypsum board can be cut into individual panels of a desired length after the slurry containing calcined gypsum has hardened (by hydrating the calcined gypsum to form a continuous matrix of hardened gypsum) sufficiently for cutting and the resulting panels. plaster can be dried.
[043] As will be noted, the principles related to gypsum panels disclosed in this document are capable of being carried out in other and different modalities and capable of being modified in several aspects. Alternative aspects and additional features of the disclosed principles will be noted from the following detailed description and accompanying drawings. Therefore, it should be understood that the above general summary and the following detailed description are only exemplary and explanatory and do not restrict the scope of the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS
[044] The figures listed and discussed below, unless expressly indicated, are examples of, and not limitations on, the invention disclosed in this document.
[045] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[046] FIGURE 1 is a two-dimensional image developed by an X-ray CT micro scanner, as discussed below, of a core section of a sample of nominal 5/8 inch thickness, exemplary panel of approximately 1880 lb/ msf formed according to current disclosure principles.
[047] FIG. 2 is a three-dimensional image developed by an X-ray CT micro scanner, as discussed below, of a core section of the sample shown in FIG. 1.
[048] FIG. 3 is a three-dimensional volume image developed by an X-ray CT micro scanner, as discussed below, of a core section of the sample shown in FIG. 1.
[049] FIG. 4 is a two-dimensional image developed by an X-ray CT micro scanner, as discussed below, of a core section of a sample of nominal 5/8 inch thickness, exemplary panel of approximately 1860 lb/msf formed according to principles. of the current release.
[050] FIG. 5 is a three-dimensional image developed by an X-ray CT micro scanner, as discussed below, of a core section of the sample shown in FIG. 4.
[051] FIG. 3 is a three-dimensional volume image developed by an X-ray CT micro scanner, as discussed below, of a core section of the sample shown in FIG. 4.
[052] FIG. 7 is a perspective view of one embodiment of a representative assembly constructed in accordance with UL U305, UL U419, UL U423 and/or equivalent fire test and including gypsum panels formed in accordance with the principles of the present disclosure, the panels plaster being shown fragmented and common tape and composite removed for illustrative purposes.
[053] FIG. 8 is a profile view of the assembly of FIG. 7 of the unexposed surface which includes a plurality of temperature sensors in accordance with UL U305, UL U419, UL U423 and/or the equivalent fire test.
[054] FIG. 9 is a graph of the maximum single sensor temperature on the unexposed surface of each of the assemblies made with panels of Sample Runs 1 through 17 and 21 described in this document and subjected to testing under the condition of UL U419 (as discussed below), 0 minute elapsed to completion of testing, and a graph of the ASTM E119 temperature curve used for the blast furnace temperatures in the tests.
[055] FIG. 10 shows a graph of the average sensor temperatures on the unexposed surface of each of the UL U419 fire test kits that are the subject of FIG. 9, from 0 minute to the end of the tests and the ASTM E119 temperature curve used for the blast furnace temperatures in such tests.
[056] FIG. 11 is an expanded graph of the maximum single-sensor temperatures from the U419 fire tests that are the subject of FIG. 9 for sets using Sample Runs 1 to 17 and 21 panels, 40 to 65 minutes elapsed time.
[057] FIG. 12 is an expanded graph of average sensor surface temperatures from the UL U419 fire tests which are the subject of FIG. 10 for sets using Sample Runs 1 to 17 and 21 panels, 40 to 65 minutes elapsed time.
[058] FIG. 13 is a graph of the data in FIG. 11 for assemblies that use the Execution Samples 5, 14, and 21 panels.
[059] FIG. 14 is a graph of the data in FIG. 12 for assemblies using the Execution Samples 5, 14, and 21 panels.
[060] FIG. 15 is an expanded graph of the maximum single sensor temperatures on the unexposed surface of each of the assemblies using the Run Sample 18 and 22 panels that have been fire tested under the conditions of UL U423 (as discussed below) , 40 to 65 minutes of elapsed time.
[061] FIG. 16 is an expanded graph of the average sensor temperatures on the unexposed surface of each of the assemblies using the Sample Runs 18 and 22 panels of the UL U423 fire tests which should be the subject of FIG. 15, 40 to 65 minutes of elapsed time.
[062] FIG. 17 is an expanded graph of the maximum single sensor temperatures on the unexposed surface of each of the assemblies using the Run Sample 19 and 20 panels that have been fire tested under the conditions of UL U305 (as discussed below) , tests from 40 to 65 minutes of elapsed time.
[063] FIG. 18 is an expanded graph of the average sensor temperatures on the unexposed surface of each of the assemblies using the Sample Runs 19 and 20 panels of the UL U305 tests which are the subject of FIG. 17, 40 to 60 minutes of elapsed time.
[064] FIG. 19 is a table (Table I) of exemplary formulations for gypsum panels formed in accordance with the principles of the present disclosure.
[065] FIG. 20 is a table (Table II) of weight loss and density change with vermiculite temperature of Classification No. 5.
[066] FIG. 21 is a table (Table III) of weight loss and density change with high expansion vermiculite temperature.
[067] FIG. 22 is a table (Table IV) with statistical information on the air void distributions for Specimens 1-4.
[068] FIG. 22 is a table (Table IV) with statistical information on the wall thickness distributions of Specimens 1-4.
[069] FIG. 24 is a table (Table VI) of shrink strength test results.
[070] FIGS. 25a-b is a table (Table VII) of the main components of the formulations (average of values from each run, unless otherwise noted) for sample panels referenced in Example 4
[071] FIGS. 26a-b is a table (table VIII) of High Temperature Shrinkage and High Temperature Thickness Expansion tests of the specimens from the sample runs referenced in Table VII and Example 4B.
[072] FIG. 27 is a table (Table IX) of predicted minimum Thermal Insulation Index values for desired fire resistance in 50, 55 and 60 minutes together using panels formed in accordance with the principles of the present disclosure.
[073] FIGS. 28a-b is a table (Table X) of high temperature thermal insulation testing of specimens from sample runs referenced in Table VII and Example 4D.
[074] FIGS. 29a-c is a table (Table XI) of the fire test data for specimens from the sample runs referenced in Table VII and Example 4E.
[075] FIG. 30 is a table (Table XII) of nail tensile strength test data for specimens from the sample runs referenced in Table VII and Example 5.
[076] FIG. 31 is a table (Table XIII) of curvature testing data for specimens from sample runs 17, 18, and 19.
[077] FIGS. 32a-c is a table (Table XIV) of core, tip, and edge hardness testing data for specimens from sample runs 17, 18, and 19.
[078] FIG. 33 is a table (Table XV) of sound transmission loss test data of examples of gypsum boards formed in accordance with the principles of the present disclosure and commercial Type X fire-resistance rated gypsum boards.
[079] FIGS. 34a-b are a table (Table XVI) of the laboratory evaluation of siloxane/starch treated panels.
[080] FIG. 35 is a table (table XVIII) of High Temperature Shrinkage and High Temperature Thickness Expansion tests of the laboratory sample specimens referenced in Example 10.
[081] FIG. 36 is a table (Table XVII) of High Temperature Thermal Insulation Index tests of the laboratory sample specimens referenced in Example 10.
[082] FIG. 37 is a table (Table XIX) of formulations for laboratory samples with varying amounts of vermiculite.
[083] FIGS. 38a-c are tables (Table XXa-c) of High Temperature Insulation Index, High Temperature Shrinkage, and High Temperature Thermal Expansion tests from Annex 11 A, Samples 1-9, with varying amounts of aluminum trihydrate (ATH) .
[084] FIG. 39 is a graph of the amount of ATH as a percent weight by weight of stucco versus the High Temperature Insulation Index taken from the test data in Table XXb of FIG. 38a to Annex 11A, Samples 3-9.
[085] FIGS. 40a-c are tables (Table XXIa-c) of testing the High Temperature Insulation Index, High Temperature Shrinkage, and High Temperature Thermal Expansion of Example 11B, Samples 10-17, with varying amounts of (ATH).
[086] FIGS. 41a-b are tables (Table XXIIa and XXIIb) of High Temperature Insulation Index, High Temperature Shrinkage, and High Temperature Thermal Expansion tests from Annex 11C, Samples 18-20 with ATH. DETAILED DESCRIPTION
[087] The embodiments described below are not intended to be complete or to limit the appended claims of compositions, assemblies, methods and operations disclosed herein. Rather, the aspects and modalities described were chosen to explain the principles of the invention and its application, operation and use in order to better enable those skilled in the art to follow its teachings.
[088] The present disclosure provides modalities using combinations of stucco, high expansion particles such as high expansion vermiculite, in an unexpanded condition and other observed ingredients, examples of which are mentioned in Table I in FIG 19. These formulations provide fire resistant reduced density and reduced weight gypsum panels that provide desired fire resistant properties that were previously not considered feasible for gypsum panels of such reduced weights and densities. Panels formed in accordance with principles of the present disclosure may also have nail tensile strength and sound transmission characteristics suitable for a variety of construction effects and, in some embodiments, such properties are comparable to commercial fire resistance rated panels heavier and denser. The unique formulations and methods of making panels formed in accordance with the principles of the present disclosure make it possible to produce such low weight and density and high performance fire resistant gypsum panels with High Temperature Shrinkage of less than approximately 10% in the xy directions. (width-length) and High Temperature Thickness Expansion in the z direction (thickness) of more than approximately 20% when heated to approximately 1560 °F (850 °C). In still other embodiments, when used in wall or other assemblies, such assemblies have comparable fire test performance to assemblies made from commercial fire resistant plasterboards of greater weight and density.
[089] In still other embodiments, a fire resistant gypsum panel formed in accordance with principles of the present disclosure, and methods for making the same, may include a gypsum core disposed between two facing sheets. The gypsum core can comprise a crystalline matrix of hardened gypsum and high expansion particles expandable to approximately 300% or more of their original volume after heating for approximately one hour at approximately 1560°F (approximately 850°C). Gypsum core can have a density (D) of approximately 40 pounds per cubic foot or less and a core hardness of at least approximately 11 pounds (5 kg). The gypsum core can be effective in providing a Thermal Insulation Index (TI) of approximately 20 minutes or more. The plaster core can be effective in providing the panel with a TI/D ratio of approximately 0.6 minutes/lbs per cubic foot (0.038 minutes / (kg/m3)) or more.
[090] In some embodiments, a fire resistant gypsum panel formed in accordance with the principles of the present disclosure and the methods for making the same can provide a panel that exhibits an average shrinkage strength of approximately 85% or greater when heated to approximately 1800°F (980°C) for one hour. In other embodiments, the panel exhibits an average shrinkage strength of approximately 75% or greater when heated to approximately 1800°F (980°C) for one hour.
[091] In some embodiments, the present disclosure provides 5/8 inch thick gypsum panels with a gypsum core density of less than approximately 40 pcf. In other preferred embodiments, gypsum panel core densities are from approximately 30 pcf to approximately 40 pcf; approximately 32 pcf to approximately 38 pcf or approximately 35 to approximately 37 pcf. Such panels formed in accordance with the principles of the present disclosure provide fire resistance properties comparable to much heavier and denser gypsum panels such as Type X commercial fire-rated gypsum panels (fire-rated) , which typically have a core density of at least approximately 42 pcf (and a 5/8 inch thick panel weight of at least approximately 2200 lb/msf), such as SHEETROCK® BrandFIRE CODE® Type X panels.
[092] In other embodiments, methods are provided for fabricating fire resistant gypsum panels by preparing a calcined gypsum containing an aqueous fluid slurry with the components discussed below in this document, where the calcined gypsum (also known as stucco) and water are used to create an aqueous slurry at a preferred water/stucco weight ratio of approximately 0.6 to approximately 1.2 in some embodiments, approximately 0.8 to approximately 1.0 in other embodiments, and approximately 0.9 in still other modalities. The slurry is deposited as a continuous ribbon onto a continuous liner sheet web of paper, non-woven fiberglass, or other fibrous materials or combination of fibrous materials. A second web of continuous cladding sheet is then placed over the deposited slurry tape to form a continuous gypsum panel of desired thickness and width. The continuous gypsum board is cut to a desired length after the slurry containing calcined gypsum has hardened (through hydration of the calcined gypsum to form a continuous matrix of the hardened gypsum) sufficiently to cut, and the resulting gypsum panels are dried. The dry panels, moreover, can be subjected to subsequent cutting, shaping and finishing steps.
[093] In other embodiments, a layer of higher density gypsum may be formed on or around the first facing sheet and/or along the peripheral edges of the facing sheet. The higher density layer typically provides beneficial properties to the board surfaces, such as increased hardness, improved nail tensile strength, etc. Higher density along the outer edges of the facing sheet typically provides improved edge hardness and other beneficial properties. In still other embodiments, a higher density layer is applied to either or both of the cladding sheets or equivalent portions of the core/cladding sheet construction.
[094] Typically, higher density layers are applied using conventional techniques, such as coating one or both coating layers upstream or in close proximity to deposition of the core layer on the first coating sheet or applying the second sheet coating on the core slurry layer. Similarly, the higher density peripheral layer is typically applied as a narrow strip or tape of gypsum slurry (with a density differing from the core slurry) to the peripheral edges of the first cladding sheet upstream or very close to the deposition of the core slurry on the first sheet. In some such embodiments, the higher density layers comprise approximately 3% to approximately 4% of the board weight.
[095] Likewise, in some embodiments, a fire resistant gypsum panel with reduced weight and density suitable for use as drywall, ceiling board or other types of applications (such as exterior cladding, roofing material etc.) is provided. In certain such embodiments, gypsum panels have a nominal thickness suitable for use in construction applications, such as approximately 5/8 inches, approximately 1/2 inches and/or approximately 1/4 inches, which are typical thicknesses used for many indoor and outdoor applications of buildings. Cladding sheets can also be covered with water-resistant or wear-resistant coatings or, in some applications, plaster, cementitious materials, acrylic materials or other coatings suitable for specific building needs. Panels can also be formed to a variety of dimensions suitable for standard, non-standard or custom applications. Examples of such panels are four-foot-wide nominal panels having a nominal length of eight, ten, and twelve feet typical of those used for building construction purposes.
[096] The core density of lightweight fire resistant panels is a significant contributor to the total weight of the panels relative to conventional panels of similar dimensions. Thus, in the aforementioned core density embodiments, typical skin sheet panel densities may include approximately 30 pcf to approximately 39.5 pcf; approximately 32.7 pcf to approximately 38.5 pcf and approximately 35.6 pcf to approximately 37.5 pcf. For 5/8-inch thick, four-foot by eight-foot panels, with such panel densities, panel weights can be approximately 1600 lb/msf to approximately 2055 lb/msf, approximately 1700 lb/msf to approximately 2000 lb/msf msf and 1850 lb/msf to approximately 1950 lb/msf, respectively. For other panel thicknesses and dimensions, the weight of panels can be varied proportionately. For example, in the case of panels with similar densities but with a nominal 1/2 inch thickness, the weight of the panel would be approximately 80% of the aforementioned weight of the 5/8 inch thick panel. Similarly, for panels of comparable densities and dimensions, but with a nominal thickness of 3/4 inch, the panel weights can be approximately 120% of the 5/8 inch thick panels.
[097] In embodiments where the hardened gypsum core has a density of about 30 pcf to about 40 pcf, the core of 5/8 inch thick panels can be formed from slurry formulations comprising stucco in an amount of from about 1162 lbs/msf to about 1565 lbs/msf, high expansion vermiculite from about 5% to about 10% by weight of stucco, starch from about 0.3% to about 3% by weight of stucco; glass or mineral fiber from about 0.3% to about 0.5% by weight of stucco, and phosphate from about 0.03% to about 0.4% by weight of stucco. As mentioned below, other conventional additives may be employed in practicing the principles of the present disclosure in customary amounts to impart desirable properties, to facilitate fabrication, and to obtain the desired core density. In other embodiments, the gypsum core of 5/8 inch thick panels formed in accordance with the principles of the present disclosure can have a density of about 32 to about 38 pounds per cubic foot and a gypsum core weight. from about 15,000 to about 17,000 lb/msf. In some such embodiments, the gypsum core also comprises about 5.5% to about 8% high-swelling vermiculite, about 0.5% to about 2.5% starch, about 0.4 % to about 0.7% fiberglass or mineral, and about 0.07% to about 0.25% phosphate. As mentioned above, each component of the gypsum core, such as starch, fiber and phosphate, can be further adjusted to provide the desired properties of the panel, and taking into account the composition and weight of the facing sheets, the nature and the quantity of other additives for the panel core and the quality of the gypsum plaster.
[098] In the exemplary embodiments mentioned in Table I in FIG. 19, the combination of stucco, high-expansion particles in the form of high-expansion vermiculite, and other observed ingredients provides light weight gypsum panels with the desired fire resistance, and also provides panels that satisfy the tensile strength of nail and the desired sound transmission properties. This combination of ingredients (and others within the scope of the invention) enables the production of such fire resistant, light weight and high performance gypsum panels with xy area shrinkage resistance and z direction expansion properties comparable to, if not better, much denser and heavier gypsum panels. In embodiments such as set forth in Table I in FIG. 19, High Temperature Shrinkage of panels is typically less than about 10% in xy (width-length) directions and High Temperature Expansion of panel thickness in z direction (thickness) is typically greater than about 20% in about 1560°F (850°C) as discussed in Example 4B below. In some embodiments, the ratio of the z-direction High Temperature Expansion and the High Temperature Shrinkage of xy is at least about 2 to above about 17 at 1570°F (855°C) as also discussed in the Example 4B.
[099] Another measure of heat resistance is discussed in Example 3 below. In this test, shrinkage strength at temperatures greater than about 1800°F (980°C) was evaluated. Using panels formed in accordance with the principles of the present disclosure, such as those set forth in Table I of Fig. 19, the reduced weight and density gypsum panels demonstrated shrink strength greater than about 85% in the x-y directions. Values expressed in Table I as lb/msf are for 5/8 inch nominal thickness panels.
[0100] Other conventional additives may be employed in practicing the principles of the present disclosure in customary amounts to impart desirable properties and to facilitate manufacturing. Examples of such additives are aqueous foams, setting accelerators, setting retarders, dehydration inhibitors, binders, adhesives, dispersing aids, leveling or non-levelling agents, thickeners, bactericides, fungicides, pH adjusters, dyes, water-impermeable , fills and mixtures of these. In some embodiments, gypsum panels formed in accordance with the principles of the present disclosure can incorporate inorganic materials such as clay, colloidal silica or colloidal alumina in their gypsum core. In most such embodiments, such inorganic materials are not in amounts that would significantly affect the shrinkage strength of gypsum panels under high temperature conditions.
[0101] In some embodiments using one or more formulations within those disclosed in Table I in FIG. 19, panels, and methods for making them, are provided, which are configured as 5/8 inch thick reduced weight and density gypsum panels that will meet or exceed the “one hour” fire resistance in accordance with the fire containment and structural integrity requirements of UL U305, U419, U423 and/or equivalent fire testing procedures and standards. In still other embodiments using the formulations in Table I, the present disclosure provides 0/2 inch thickness reduced weight and density gypsum panels, and methods for making them, which are capable of satisfying at least one fire resistance by % of hour in accordance with U419 fire containment and structural integrity standards and procedures. Similar results can be achieved using other formulations consistent with the principles described in this document.
[0102] The combination of light weight, fire resistance and the structural and strength characteristics mentioned above is believed to be due to the unexpected results of the various combinations of the above components. Components useful in calcined gypsum slurry formulations following the principles of the present disclosure are discussed in more detail below.
[0103] Stuccoes - The stucco (or calcined gypsum) component used to form the crystalline matrix of the gypsum panel core typically comprises a beta hemidrated calcium sulfate, water soluble calcium sulfate anhydrite, alpha hemidrated calcium sulfate, or mixtures from any or all of these, from natural or synthetic sources. In some embodiments, the stucco may include non-gypsum minerals such as small amounts of clays or other components that are associated with the gypsum source or are added during calcining, processing and/or distribution of the stucco to the mixer.
[0104] By way of example, the amounts of plaster referred to in Table I in FIG. 19 conclude that the gypsum source is at least about 95% pure. In this regard, the components and their relative amounts, such as those mentioned in Table I above, used to form the core slurry can be varied or modified depending on the source, purity and content of the stucco. For example, the composition of the gypsum core slurry and the amount of high expansion vermiculite used can be modified for different stucco compositions depending on the purity of the gypsum, the natural or synthetic source of the gypsum, the water content of the stucco , the clay content of the stucco, etc.
[0105] High Expansion Particles - Gypsum panels with reduced weight and density formed in accordance with the principles of the present disclosure can achieve unique and unexpected results in terms of fire resistance and associated extreme thermal conditions, without relying on larger amounts of hemihydrates of gypsum typical of conventional fire resistant gypsum panels or rely predominantly on conventional relatively low expansion vermiculite, such as termed “Grade No. 5” unexpanded vermiculite (with a typical particle size of less than 0.0157 inches (0.40mm) )). As mentioned above, panels formed in accordance with the principles of the present disclosure can use high expansion particles in the form of vermiculite with a high volume of expansion relative to Grade No. 5 vermiculite (US classification system) and other low vermiculites expansion that have been used in commercial fire resistant gypsum panels.
[0106] Vermiculites referred to herein as “high expansion vermiculite” have an expansion volume after heating at around 1560°F (about 850°C) of about 300% or more of their original volume. In contrast Grade No. 5 unexpanded vermiculite typically has a volume expansion at about 1560°F (about 850°C) of about 225%. Other particles with properties comparable to high expansion vermiculite may also be used in panel arrangements formed in accordance with the principles of the present disclosure. In some embodiments, high expansion vermiculites can be used that have a volume expansion of about 300% to about 380% their original volume after being placed for one hour inside a chamber with a temperature of about 1560°F ( about 850°C).
[0107] Another such high expansion vermiculite is often termed Grade No. 4 unexpanded vermiculite (US classification system) (such high expansion vermiculites were rejected as useful ingredients in fire resistant plasterboards in US Patent No. 3,454,456 discussed above). In some embodiments, at least about 50% of the particles in the high expansion vermiculite used in panels formed in accordance with the principles of the present disclosure will be larger than 50 mesh (i.e., openings greater than about 0.0117 inches ( 0.297 mm)). In other embodiments, at least about 70% of the particles will be larger than about 70 meshes (i.e., openings greater than about 0.0083 inches (0.210mm)).
[0108] In other modalities, high expansion vermiculites that are classified in different classification systems and/or foreign may be used. Such high expansion vermiculites should have substantially similar expansion and/or thermal resistance characteristics typical of those discussed in this document. For example, in some disciplines, a vermiculite classified as European, South American or South African Rank 0 (micron) or Rank 1 (superfine) may be used.
[0109] In some embodiments, a high-expansion vermiculite can be used that includes particle size in which up to about 50% of the vermiculite particles are less than about 500 microns, up to about 60% of the vermiculite particles are between about about 500 microns. 500 microns and about 1000 microns, up to about 40% of the vermiculite particles are between about 1000 microns and about 1500 microns, and up to about 20% of the vermiculite particles are between about 1500 microns and about 3000 microns . In some embodiments, the high expansion vermiculite can include vermiculite particles according to the following distribution: between about 25% and about 45% of the particles are less than about 500 microns, between about 40% and 60% of the particles are between about 500 microns and about 1000 microns, up to about 20% of the particles are between about 1000 microns and about 1500 microns, and up to about 10% of the particles are between about 1500 microns and about 3000 microns. In still other embodiments, a high expansion vermiculite can include vermiculite particles according to the following distribution: between about 5% and about 20% of the particles are less than about 500 microns, between about 35% and 60% of the particles are between about 500 microns and about 1000 microns, between about 20% and about 40% of the particles are between about 1000 microns and about 1500 microns, and up to about 20% of the particles are between about 1500 microns and about 3000 microns.
[0110] In still other embodiments, vermiculites that have been chemically treated or otherwise modified in such a way that they exhibit volume expansion behavior under heat similar to the high expansion vermiculites discussed herein may also be used. High expansion vermiculite useful in panels formed in accordance with the principles of the present disclosure may also include other vermiculites, vermiculite mixtures and/or compositions containing vermiculite (and other particle sizes and size distribution), as well as other particulate materials with properties of comparable expansion that provide panel shrinkage and expansion characteristics typical of the panels disclosed herein. Other suitable high expansion vermiculites and other particulate materials may also differ from those disclosed herein in aspects that are not important to the provision of the reduced density and weight fire resistant gypsum panels disclosed herein.
[0111] In some embodiments, the high expansion vermiculite used in fire resistant gypsum panels of reduced density and weight formed in accordance with the principles of the present disclosure may include commercially available US Grade No. 4 vermiculite. Each of the commercial producers can provide specifications for high expansion vermiculite physical properties such as Mohs hardness, total moisture, free moisture, bulk density, specific ratio, aspect ratio, cation exchange capacity, solubility, pH (in distilled water), expansion rate, expansion temperature, and melting point, for example. It is considered that in different modalities using different sources of high expansion vermiculite, these physical properties will vary.
[0112] In some embodiments, high-expansion vermiculite particles are normally distributed throughout the core part of gypsum panels. In other embodiments, the high expansion vermiculite particles are normally distributed evenly throughout the core of the gypsum boards.
[0113] High expansion vermiculite can normally be randomly distributed to all parts with reduced density of the panel core. In some embodiments, it may be desirable to have a different vermiculite distribution in denser parts of the panel, such as in the higher density gypsum layer mentioned above adjacent to the panel surface(s) or in higher density core parts along the edges of the panel. In other embodiments, high expansion vermiculite can be substantially excluded from such denser parts of the panels, such as hardened surfaces and edges of the panels. Such variations in content and distribution of vermiculite particles in the denser parts of the panels may be a result of the removal of slurry from the core of the core slurry mixer for use in such parts of the panels by introducing the vermiculite into the slurry by other means suitable for the core parts of the panel with reduced density, using edge mixers or other means known to those skilled in the art.
[0114] There may be considerable variation in the amount of high expansion particles distributed throughout the core, and in the specific distribution of particles in some modalities of panels formed in accordance with the principles of the present disclosure in relation to the distribution of particles in other panels so formed. Such variations in the amount and distribution of high expansion particles will depend on the amount and type of vermiculite or other particles incorporated into the slurry, the size and size distribution of the high expansion particles, the core slurry composition and mixing procedures and core slurry distribution, among other factors. Similarly, the specific particle distribution, particle properties and particle size within the core may vary and may depend on similar factors during the mixing and distribution of the core slurry during the panel forming process.
[0115] In some embodiments, the distribution of high expansion particles prevents cases of high concentrations of high expansion particles in parts of the panel core that reduce the strength and structural integrity of the core during normal use of the panels or during high conditions. temperature and/or fire. This would not include minor variations found in typical commercial production. The distribution of high expansion particles can also be modified in terms of particle concentration in one or more parts of the core for specific desired applications of the panels.
[0116] In some embodiments, the distribution of the aforementioned high expansion particles in the reduced density core of the panels occurs during mixing of the gypsum slurry, passage of the slurry to the first facing sheet and/or slurry distribution fluid by the extension of the coating sheet. In some embodiments, the high expansion particles can be added to the core slurry mixer with other dry or semi-dry materials during the mixing and preparation of the gypsum slurry. Alternatively, in other embodiments, the high expansion particles can be added in other procedures, steps or stages that generally distribute the high expansion particles into the desired parts of the gypsum core of the panel.
[0117] As reflected in FIGURES 1-6, discussed in more detail below, vermiculite particles are often distributed near or adjacent to voids formed in the reduced density portion of the gypsum core, as well as in crystalline portions of the core that someone of average knowledge in the art I would expect it to contribute to the structural strength of the core. Such a distribution in a reduced density crystalline core structure (which is considered relatively fragile) would lead one of ordinary skill in the art to believe that significant expansion of vermiculite particles would disturb the core and cause fragmentation, core fractures and core failures. known to those of ordinary skill in the art and discussed in the references discussed above. This would be particularly true in embodiments of a gypsum panel formed in accordance with the principles of the present disclosure where the core of the panel has a relatively low density and therefore a relatively high void volume, and a significantly reduced crystalline gypsum content. . It would be expected that reducing the crystalline gypsum content of the core would reduce the strength and structural heat sink capacity of gypsum boards. As discussed below, this was surprisingly not the case for panels formed in accordance with the principles of the present disclosure.
[0118] Starches — As will be appreciated by one of skill in the art, core slurry formulation modalities for use in preparing panels formed in accordance with the principles of the present disclosure may include a starch. In some embodiments of panels formed in accordance with principles of the present disclosure and methods for preparing such panels, the core slurry formulation, as mentioned in Table I of Fig. 19, includes a pregelatinized starch or a starch functionally equivalent. Raw starch can be pregelatinized by cooking the starch in water at temperatures of at least 185°F or by other known methods to cause gel formation in the starch used in the core of the panel. Starch can be incorporated into the core slurry in a dry form, a pre-dispersed liquid form, or in combinations of both. In a dry form, the starch can be added to the core slurry mixer with other dry ingredients or in a separate addition procedure, step or stage. In pre-dispersed form, it can be added with other liquid ingredients, such as calibration water, for example, or in a separate addition procedure, step or stage.
[0119] Some examples of readily available pregelatinized starches that can be used in the practice of the present disclosure are pregelatinized yellow cornmeal starch available for sale from Cargill, Inc. or Archer Daniels Midland Co. In some embodiments, the starch component includes at least pregelatinized corn starch, such as pregelatinized corn flour available from Bunge Milling, St. Louis, Missouri. Such pregelatinized starches have the following typical characteristics: moisture around 7.5%, protein around 8.0%, oil around 0.5%, crude fiber around 0.5%, ash in about 0.3%; having a green strength of about 0.48 psi; and, having a density of about 35lb/ft3. In yet other embodiments, the core slurry formulation can include one or more commercially available hydroxyethylated starches suitable for purposes of disclosure herein.
[0120] In other embodiments, other useful starches can be used, including acid-modified starches such as acid-modified corn flour available from HI-BOND from Bunge Milling, St. Louis, Missouri. This starch has the following typical characteristics: moisture at about 10.0%, oil at about 1.4%, soluble in cold water at about 17.0%, alkaline fluidity at about 98.0%, bulk density of about 30 lb/ft3 and about 20% slurry producing a pH of about 4.3. Another useful starch is non-pregelatinized wheat starch, such as ECOSOL-45, available from ADM/Ogilvie, Montreal, Quebec, Canada.
[0121] Fibers -In some embodiments incorporating the fibers, such as mentioned in Table I in FIG. 19, and methods for preparing such panels, the fibers can include mineral fibers, carbon and/or glass fibers and blends of such fibers, as well as other comparable fibers, providing comparable benefits to the panel. In some embodiments, the glass fibers are incorporated into the gypsum core slurry and the resulting crystalline core structure. Glass fibers in some such embodiments can have an average length of about 0.5 to about 0.75 inches and a diameter of about 11 to about 17 microns. In other embodiments, such glass fibers can have an average length of about 0.5 to about 0.675 inches and a diameter of about 13 to about 16 microns. In still other embodiments, E-glass fibers are used with a softening point greater than about 800°C and such fiber type is Advantex® glass fibers (available from Owens Corning) with a softening point greater than the pile. minus about 900°C. Mineral or carbon wool fibers, such as those known to those skilled in the art, can be used in place of or in combination with glass fibers such as those mentioned above.
[0122] Phosphates - In some embodiments of panels formed in accordance with the principles of the present disclosure and the methods for preparing such panels, a phosphate salt or other source of phosphate ions as mentioned in Table I in FIG. 19 is added to the gypsum slurry used to produce the gypsum core of the panel. The use of such phosphates can contribute to providing a gypsum core with increased strength, resistance to permanent deformation (eg, resistance to bending), and dimensional stability compared to hardened gypsum formed from a non-phosphate-containing mixture. In some such embodiments, the phosphate source is added in amounts to provide dimensional stability to the panel and panel core, while the gypsum hemidrate in the core hydrates and forms the crystalline core structure of the gypsum dihydride (eg, during the time between the forming plate and the oven section of the forming process). Additionally, it is noted that to the extent that the added phosphate acts as a retarder, an appropriate accelerator can be added at the level necessary to overcome any adverse retarding effects of the phosphate. Phosphates are generally added in a dry form and/or a liquid form, with the dry ingredients normally added to the core slurry mixer and the liquid ingredients added to the mixer or in other steps or procedures.
[0123] Phosphate-containing components useful in the present disclosure include water-soluble components and may be in the form of an ion, a salt, or an acid, i.e. condensed phosphoric acids, each of which comprises two or more units of phosphoric acid; condensed salts or phosphate ions, each of which comprises two or more phosphate units; and monobasic salts or monovalent ions of orthophosphates, such as described, for example, in US Patent Nos. 6,342,284; 6,632,550; and 6,815,049, the disclosures all of which are incorporated herein by reference. Suitable examples of such classes of phosphates will be apparent to those skilled in the art. For example, any suitable monobasic orthophosphate-containing compound can be used to practice the principles of the present disclosure, including, but not limited to, monoammonium phosphate, monosodium phosphate, monopotassium phosphate, and combinations thereof. A preferred monobasic phosphate salt is monopotassium phosphate.
[0124] Similarly, any suitable water-soluble polyphosphate salt may be used in accordance with the present disclosure. Polyphosphate can be cyclic or acyclic. Exemplary cyclic polyphosphates include, for example, trimetaphosphate salts and tetrametaphosphate salts. The trimetaphosphate salt can be selected, for example, from sodium trimetaphosphate (also referred to herein as STMP), potassium trimetaphosphate, lithium trimetaphosphate, ammonium trimetaphosphate and the like, or combinations thereof.
[0125] Also, any suitable water-soluble acyclic polyphosphate salt may be used in accordance with the present disclosure. The acyclic polyphosphate salt has at least two phosphate units. By way of example, suitable acyclic polyphosphate salts in accordance with the present disclosure include, but are not limited to, pyrophosphates, tripolyphosphates, sodium hexametaphosphate having from about 6 to about 27 repeating phosphate units, sodium hexametaphosphate. potassium having from about 6 to about 27 repeating phosphate units, ammonium hexametaphosphate having from about 6 to about 27 repeating phosphate units, and combinations thereof. A preferred acyclic polyphosphate salt, in accordance with the present disclosure, is commercially available as CALGON.RTM. of LP Performance Products ICL, St. Louis, Missouri, which is a sodium hexametaphosphate having from about 6 to about 27 repeating phosphate units.
[0126] Preferably, the phosphate-containing compound is selected from the group consisting of sodium trimetaphosphate having the molecular formula (NaPO3)3, sodium hexametaphosphate having from 6 to about 27 repeated phosphate units and having the molecular formula Nan+2PnO3n+ 1 where n=6-27, tetrapotassium pyrophosphate having the molecular formula K4P2O7, trisodium dipotassium tripolyphosphate having the molecular formula Na3K2P3O10, sodium tripolyphosphate having the molecular formula Na5P3O10, tetrasodium pyrophosphate having the molecular formula Na4P2O7, aluminum trimetaphosphate the molecular formula Al(PO3)3, sodium acid pyrophosphate having the molecular formula Na2H2P2O7, ammonium polyphosphate having 10003000 repeated phosphate units and having the molecular formula (NH4)n+2PnO3n+1 where n=1000-3000, or polyphosphoric acid having 2 or more repeating phosphoric acid units and having the molecular formula Hn+2PnO3n+1 where n is 2 or more. Sodium trimetaphosphate is most preferred and is commercially available from LP Performance Products ICL, St. Louis, Missouri.
[0127] Dispersants - In other embodiments of fire resistant panels of reduced weight and density formed in accordance with the principles of the present disclosure and the methods for preparing such panels, dispersants such as those mentioned in Table I in FIG. 19 can be included in the gypsum core slurry. Dispersants can be added in dry form with other dry ingredients and/or in liquid form with other liquid ingredients in the core slurry mixer, or in other steps or procedures.
[0128] In some embodiments, such dispersants can include naphthalenesulfonates, such as polynaphthalenesulfonic acid and its salts (polynaphthalenesulfonates) and derivatives, which are condensation products of naphthalenesulfonic acids and formaldehyde. Such desirable polynaphthalene sulfonates include sodium and calcium naphthalene sulfonate. The average molecular weight of naphthalenesulfonates can range from about 3,000 to 27,000, although it is preferred that the molecular weight be about 8,000 to 10,000. In an aqueous solution with a specified percentage of solids, a higher molecular weight dispersant has a higher viscosity and generates a greater demand for water in the Formulation than a lower molecular weight dispersant.
[0129] Useful naphthalene sulfonates include DILOFLO, available from GEO Specialty Chemicals, Cleveland, Ohio; DAXAD, available from Hampshire Chemical Corp., Lexington, Massachusetts; and LOMAR D, available from GEO Specialty Chemicals, Lafayette, Indiana. Naphthalenesulfonates are preferably used as aqueous solutions in the range of 35% to about 55% by weight of solids content, for example. It is preferred to use the naphthalene sulfonates in the form of an aqueous solution, for example, in the range of from about 40 to about 45% by weight solids content. Alternatively, where appropriate, naphthalene sulfonates can be used in dry solid or powder form, such as LOMAR D, for example.
[0130] Alternatively, in other embodiments, dispersants known to those skilled in the art are useful to improve the fluidity in gypsum slurries may be used, such as polycarboxylate dispersants. A number of polycarboxylate dispersants, specifically polycarboxylic ethers, are preferred types of dispersants. A preferred class of dispersants used in the slurry includes two repeating units and is described in more detail in U.S. Patent 7,767,019 entitled "Gypsum Products Utilizing a Two-Repeating Unit System and Process for Making Them", and incorporated herein by reference. Examples of such dispersants are products of BASF Construction Polymers, GmbH (Trostberg, Germany) and are supplied by BASF Construction Polymers, Inc. (Kennesaw, GA) (future “BASF”) and are hereinafter referred to as the “Dispersants Type PCE211”. A particularly useful dispersant of the PCE211 Type Dispersants is designated PCE211 (future “211”). Other polymers in this series useful in the present disclosure include PCE111. Type PCE211 dispersants are more fully described under no. Serial No. 11/827,722 (Publication No. US 2007/0255032A1) filed July 13, 2007, and entitled "Polyether-Containing Copolymer," incorporated herein by reference.
[0131] The molecular weight of one type of such PCE211 type dispersants can be from about 20,000 to about 60,000 Daltons. Lower molecular weight dispersants have been found to cause less delay in setting time than dispersants having a molecular weight greater than 60,000 Daltons. Generally, the longer side chain length, which results in an increase in total molecular weight, provides better dispensability. However, tests with gypsum indicate that dispersant effectiveness is reduced at molecular weights above 50,000 Daltons.
[0132] Another class of polycarboxylate compounds that are useful as dispersants in this disclosure is disclosed in U.S. Patent No. 6,777,517, incorporated herein by reference and hereinafter referred to as "Type 2641 Dispersant". Examples of Type PCE211 and Type 2641 dispersants are manufactured by BASF Construction Polymers, GmbH (Trostberg, Germany) and marketed in the United States by BASF Construction Polymers, Inc. (Kennesaw, Ga.). Preferred Type 2641 Dispersants are sold by BASF as MELFLUX 2641F, MELFLUX 2651F and MELFLUX 2500L dispersants.
[0133] Yet another preferred dispersant family is sold by BASF and referred to as "Type 1641 Dispersants". Type 1641 dispersant is more fully described in U.S. Patent No. 5,798,425, incorporated herein by reference. One such Type 1641 Dispersant is marketed as MELFLUX 1641F dispersant by BASF. Other dispersants that can be used include other polycarboxylate ethers, such as COATEX Ethacryl M, available from Coatex, Inc. of Chester, SC and lignosulfonates or sulfonated lignin. Lignosulfonates are water-soluble anionic polyelectrolyte polymers, by-products of wood pulp production using sulfite pulp formation. An example of a lignin useful in practicing the principles of the present disclosure is Marasperse C-21 available from Reed Lignin, Inc., Greenwich, Connecticut.
[0134] High Efficiency Heat Sink Additives ("HEHS Additives") — In some embodiments of panels formed in accordance with the principles of the present disclosure and methods for preparing such panels, the core of the panel may include one or more additives referred to herein as High Efficiency Heat Sink Additives (“HEHS Additives”). Such additives have a heat dissipation capability that exceeds the heat dissipation capability of comparable amounts of dehydrated gypsum over the temperature range causing dehydration and water vapor release from the dehydrated gypsum component of the panel core. Such additives are typically selected from compositions, such as aluminum trihydrate or other metal hydroxide, which decompose, releasing water vapor in temperature ranges equal or similar to gypsum dihydrate. While other HEHS additives (or combinations of HEHS additives) with increased heat dissipation efficiency relative to comparable amounts of gypsum dihydrate can be used, preferred HEHS additives provide a sufficiently increased heat dissipation efficiency relative to gypsum dihydrate to compensate for any increase in weight or other unwanted properties of HEHS Additives when used in a gypsum panel intended for fire resistant or other high temperature applications.
[0135] For example, in preferred embodiments, one or more HEHS additives undergo an endothermic reaction to absorb heat when exposed to significant increases in temperature. In some such embodiments, the heat of decomposition (which may be a dehydration reaction) per unit mass of the HEHS additive(s) consumes at least about 685 Joules/gram, in other embodiments at least about 1000 Joules /gram, and in still other modes it consumes from about 1100 to about 1400 Joules/gram. In such embodiments, the HEHS additive(s) may have a heat of decomposition per unit mass in the relevant temperature range that is significantly greater than that of the gypsum dihydrate in the gypsum board. Likewise, the HEHS additive consumes more energy (Joules/gram) during heating than what is consumed by dehydrating gypsum dihydrate.
[0136] In some embodiments, the lowest decomposition temperature of the HEHS additive(s) is about 40°C or more. In other embodiments, decomposition temperatures of the HEHS additive(s) range from approximately 40°C to about 1000°C; in other embodiments, from about 150°C to about 450°C; and, in other embodiments, from about 150°C to about 300°C. In another embodiment, the HEHS additive(s) begins endothermic thermal decomposition at approximately 150°C and is(are) substantially or entirely decomposed at a temperature of about 980°C, which is the typical 1-hour endpoint temperature on the aforementioned ASTM E119 temperature curve used in the aforementioned fire test.
[0137] As mentioned above, a preferred HEHS additive comprises aluminum trihydrate (ATH) containing crystallized or otherwise bound or complexed water. ATH is normally very stable at room temperature. At temperatures above between about 180°C and 205°C, ATH normally undergoes endothermic decomposition, releasing water vapor. The heat of decomposition for such ATH additives is greater than about 1000 Joule/gram, and in a preferred embodiment is about 1170 Joule/gram. Without being bound by theory, it is believed that the ATH additive decomposes to release approximately 35% of the water of crystallization as water vapor when heated above 205°C as follows: AL(OH)3 ^ Al2O3-3H2O. In a modality using ATH as an HEHS additive, any ATH can be used. In modalities, ATH from commercial suppliers such as Akrochem Corp. from Akron, OH, can be used. Any suitable ATH classification can be used. An example is ATH Classification No. SB-36. ATH Classification No. SB-36 can have an average particle size of about 25 microns and a surface area of about 1 m2 /g. In other modalities, another suitable ATH classification with adequate mean particle size and surface area may be used.
[0138] In other embodiments, the HEHS additive(s) may comprise magnesium hydroxide. In such embodiments, the magnesium hydroxide HEHS additive preferably has a heat of decomposition greater than 1000 Joules/gram, such as about 1350 Joules/gram, at or above 180°C to 205°C. In such embodiments, any suitable magnesium hydroxide can be used, such as those commercially available from suppliers, including Akrochem Corp. from Akron, OH.
[0139] The greater heat dissipation capacity of the preferred HEHS Additives can be used to increase the thermal insulation properties of the gypsum panels disclosed in this document compared to panels formed without the HEHS additive. The amount and composition of HEHS additives incorporated in the gypsum boards disclosed herein may vary depending on the desired weight and density of the boards, the purity of the plaster used to form the boards, the formulation of the board core, the presence of other additives and other similar considerations. Examples of preferred gypsum board formulations incorporating preferred HEHS additives are summarized in Table I in FIG. 19. The HEHS additive can be added in a dry form and/or liquid form, with the dry ingredients normally added to the core slurry mixer and the liquid ingredients added to the mixer at other stages of the process.
[0140] In some such preferred embodiment, the core of the panel incorporates an HEHS additive such as aluminum trihydrate in an amount of from about 2% to about 5% by weight of the stucco in some embodiments from about 2% to about of 7% by weight of the stucco in other embodiments, and in amounts up to about 10% by weight of the stucco in still other preferred embodiments. In some such preferred embodiments, the incorporation of HEHS additives into the core formulation allows for the reduction of the stucco content of the formulation to reduce the weight and density of the core of the panel. In an example of using the HEHS additive, the ratio between the HEHS additive and the plaster removed on a weight basis is about 1 to about 2. In such an example, in other words, about 40-50 lbs/ msf of the HEHS additive can be incorporated into the core formulation and about 80-100 lbs/msf of stucco can be removed from the formulation. Likewise, savings of around 40-50 lbs/msf in weight can be achieved in this example without a significant change in the thermal insulation properties of the panel.
[0141] The relationship between HEHS additive and stucco removed from a core formulation can be varied depending on the HEHS additive used, its heat dissipation properties, the heat dissipation properties of the specific stucco, the gypsum core formulation, the desired thermal insulation properties of the panel, the desired weight reduction and physical properties of the panel and related issues. In some preferred embodiments using aluminum trihydrate, the ratio of HEHS additive to removed plaster can be about 2:1 in some embodiments, in other embodiments about 3:1, and in still other embodiments about 4:1. The relationship between HEHS additive(s) and removed plaster may be different for different compositions and applications of HEHS additive.
[0142] Retarders/Accelerators - Set retarders (up to about 2 lb/MSF (approx. 9.8 g/m2) in 5/8 inch thick panels) or dry accelerators (up to about 35 lb/MSF (approx. 170 g/m2) in 5/8-inch thick panels) can be added to some modalities of core slurry to modify the rate at which stucco hydration reactions occur. "CSA" is an example of a preferred setting accelerator including about 95% calcium sulfate dihydrate co-ground with about 5% sugar and heated to 250°F (1-21°C) to caramelize the sugar. CSA is available from the USG Corporation, Southard, Oklahoma factory, and may be made in accordance with U.S. Patent No. 3,573,947, incorporated herein by reference. Potassium sulphate is another example of a preferred accelerator. "HRA", which is another example of a preferred accelerator, is calcium sulfate dihydrate freshly ground with sugar at a ratio of about 5 to about 25 pounds of sugar per 100 pounds of calcium sulfate dihydrate. HRA is further described in U.S. Patent No. 2,078,199, incorporated herein by reference.
[0143] Another accelerator, known as wet gypsum accelerator or "WGA", is also a preferred accelerator. A description of the use and of a method for making the wet gypsum accelerator is disclosed in U.S. Patent No. 6,409,825, incorporated herein by reference. This accelerator includes at least one additive selected from the group consisting of an organic phosphonic compound, a phosphate-containing compound or mixtures thereof. This particular accelerator has substantial longevity and maintains its effectiveness over time, such that the wet gypsum accelerator can be made, stored and even transported over long distances before use. The wet gypsum accelerator can be used in amounts ranging from about 5 to about 80 pounds per thousand square feet (approx. 24.3 to 390 g/m2) of the 5/8 thick plasterboard product inch.
[0144] Foams - Foam can be introduced into the core slurry in amounts that provide the aforementioned reduced core density and panel weight. The introduction of foam into the core slurry in the proper amounts, formulations, and processes can produce a desired network and distribution of air voids, and walls between air voids, within the core of the final dry panels. In some embodiments, the sizes, distribution of air voids and/or wall thickness between the air voids provided by the foam composition and the foam introduction system are as discussed below, as well as those providing density, strength and related properties comparable to the panel. The air void structure allows for the reduction of gypsum and other core constituents and core density and weight, while substantially maintaining (or improving in some cases) the strength properties of the panel, such as core compression stress and the stiffness, flexural strength and tensile strength of the panel nail, among others.
[0145] In some embodiments, at a nominal panel thickness of about 5/8 inch, a gypsum panel formed in accordance with the principles of the present disclosure and the methods for making so provides a panel that has a resistance to wear. Nail pull, determined in accordance with ASTM C473-09, of at least about 70 lbs. In other embodiments, the panel may have a nail tensile strength, determined in accordance with ASTM C473-09, of at least about 85 lbs.
[0146] In some such embodiments, the mean equivalent sphere diameter of the air voids may be at least about 75 µm, and in other embodiments, at least about 100 µm. In other embodiments, the mean equivalent sphere diameter of the air voids can be from about 75 µm to about 400 µm. In still other embodiments, the average equivalent sphere diameter of the air voids can be from about 100 µm to about 350 µm with a wax standard deviation of 100 to about 225. In other embodiments, the average equivalent sphere diameter of air voids can be from about 125 µm to about 325 µm with a standard deviation of about 100 to about 200.
[0147] In some embodiments, about 15% to about 70% of air voids have an equivalent sphere diameter of about 150 µm or less. In other embodiments, about 45% to about 95% of the air voids have an equivalent sphere diameter of about 300 µm or less, and about 5% to about 55% of the air voids have a sphere diameter. equivalent of about 300 µm or more. In other embodiments, about 45% to about 95% of the air voids have an equivalent sphere diameter of about 300 µm or less, and about 5% to about 55% of the air voids have a sphere diameter. equivalent of about 300 µm to about 600 µm. In the discussion of average air void sizes in this document, gypsum core voids that are about 5 µm or less are not considered when calculating the number of air voids or the average air void size.
[0148] In those and other modalities, the thickness, distribution and positioning of the walls between the voids in such modalities, only and/or in conjunction with the desired air void size distribution and positioning, also allows for the reduction in density and in the weight of the panel's core, while substantially maintaining (or improving, in some cases) the strength properties of the panel. In some such embodiments, the average thickness of the walls separating the air voids can be at least about 25 µm. In some embodiments, the walls defining and separating air voids within the plaster core may have an average thickness of from about 25 µm to about 200 µm, from about 25 µm to about 75 µm in other embodiments, and from about from 25 µm to about 50 µm in still other modalities. In still other embodiments the walls defining and separating air voids within the plaster core can have an average thickness of from about 25 µm to about 75 µm with a standard deviation of from about 5 to about 40. In still other embodiments, the walls defining and separating air voids within the plaster core can have an average thickness of about 25 µm to about 50 µm with a standard deviation of about 10 to about 25.
[0149] Without being limited by theory, it is believed that modalities with the placements and sizing of air voids discussed above, and the wall thickness and placements, aid in improving the high temperature properties of the panel when used with the high expansion vermiculite disclosed in this document. Foam void and wall thickness are believed to aid in reducing or substantially resist the creation of significant flaws in the gypsum core structure when high expansion vermiculite expands under high temperature conditions.
[0150] Examples of the use of foaming agents to produce the desired voids and wall structures include those discussed in U.S. Patent No. 5,643,510, the disclosure of which is incorporated herein by reference. In some embodiments, the combination of a more stable first foaming agent and a less stable second foaming agent can be used in core slurry blends. In other embodiments, only one type of foaming agent is used, as long as the desirable density and strength requirements of the panel are met. Approaches for adding foam to core slurry are known in the art and examples of such an approach are discussed in U.S. Patent Nos. 5,643,520 and 5,683,635, the disclosures of which are incorporated herein by reference.
[0151] Overlay Sheets - In some embodiments of a panel formed in accordance with the principles of the present disclosure, the first overlay sheet comprises a low porosity manila paper, over which the gypsum slurry is distributed (which is usually the exposed face of the board when used in a construction application). Newsprint can be used as the second facing sheet placed over the gypsum core slurry during the forming process (which is usually the hidden back surface of the panels when used in construction applications). In other applications, non-woven fiberglass mats, sheet materials of other fibrous or non-fibrous materials, or combinations of paper and other fibrous materials may be used as one or both of the overlay sheets. As will be appreciated by one of skill in the art, in other embodiments, other overlay sheets can be used that are suitable for the purpose of the panel.
[0152] In embodiments using paper overlay sheets or the like, the first overlay sheet may have a higher density and basis weight than the second overlay sheet. For example, in some embodiments, the first overlay sheet can have a basis weight of about 55 to about 65 lb/msf, and the second overlay sheet can have a basis weight of about 35 to about 45 lb/msf. In still other embodiments, different types of paper liner sheets, having different weights and comprising different materials, for example, can be used. Similarly, cladding sheets may incorporate, and may have added to their exposed surfaces, sheathing materials providing surfaces suitable for specific construction applications such as external cladding, roofing, tile backing, etc.
[0153] Siloxane — In some embodiments, the water resistance of gypsum panels formed in accordance with the principles of the present disclosure can be improved by adding a polymerizable siloxane to the slurry used to make the panels. Preferably, the siloxane is added in the form of an emulsion. The slurry is then molded and dried under conditions that promote polymerization of the siloxane to form a highly cross-linked silicone resin. A catalyst, which promotes the polymerization of the siloxane to form a highly cross-linked silicone resin, can be added to the gypsum slurry.
[0154] Preferably, the siloxane is generally a linear fluid hydrogen-modified siloxane, but may also be a hydrogen-modified cyclic siloxane. Such siloxanes are capable of forming highly cross-linked silicone resins. Such fluids are well known to those skilled in the art and are commercially available and are described in the patent literature. Typically, hydrogen-modified linear siloxanes useful in practicing the principles of the present disclosure comprise those having a repeating unit of the general formula:
wherein R represents a saturated or unsaturated monovalent hydrocarbon radical. In preferred embodiments, R represents an alkyl group and more preferably R is a methyl group. During polymerization, the end groups can be removed by condensation and the siloxane groups are bonded together to form the silicone resin. Chain crosslinking can also occur. The resulting silicone resin imparts water resistance to the plaster matrix as it forms.
[0155] Preferably, a solvent-free methyl hydrogen siloxane fluid, sold under the name SILRES BS 94 by Wacker-Chemie GmbH (Munich, Germany), will be used as the siloxane. The manufacturer indicates that this product is a siloxane fluid that does not contain water or solvents. It is contemplated that about 0.3 to about 1.0% siloxane BS 94 can be used, based on the weight of dry ingredients. It is preferable to use from about 0.4% to about 0.8% siloxane, based on the weight of dry plaster.
[0156] The siloxane can be formed into an emulsion or a stable suspension with water. A number of siloxane emulsions are contemplated for use in this slurry. Siloxane-in-water emulsions are also available for purchase, but these can include emulsifying agents that tend to modify the properties of gypsum articles, such as the binding of paper in gypsum board products. Stable emulsions or suspensions prepared without the use of emulsifiers are therefore preferred. Preferably, the suspension will be formed in situ by mixing the siloxane fluid with water. The siloxane suspension is kept in a stable condition until used and remains well dispersed under the slurry conditions. The siloxane suspension or emulsion is maintained in a well-dispersed condition in the presence of optional additives, such as setting accelerators, that may be present in the slurry. The siloxane suspension or emulsion is maintained so that it remains stable through the steps in which the gypsum panels are formed. Preferably, the suspension is stable for more than 40 minutes. Most preferably, it remains stable for at least an hour. In the discussion and claims that follow, the term "emulsion" is intended to include true emulsions and suspensions that are stable at least until the plaster is about 50% set.
[0157] The siloxane polymerization reaction proceeds slowly, requiring the panels to be stored long enough to develop water resistance before shipping. Catalysts are known to speed up the polymerization reaction, reducing or eliminating the time required to store plasterboards as water resistance develops. The use of dead-burned magnesium oxide for the polymerization of siloxane is described in U.S. Patent No. 7,892,472 entitled "Method of Making Water-Resistant Gypsum-Based Article", incorporated herein by reference. Deeply calcined magnesium oxide is insoluble in water and interacts less with the other components of the slurry. It accelerates siloxane healing and, in some cases, causes the siloxane to heal more completely. It is commercially available with a consistent composition. A particularly preferred source of dead-burned magnesium oxide is BAYMAG 96. This has a BET surface area of at least 0.3 m2 /g. Loss on ignition is less than about 0.1% by weight. Magnesium oxide is preferably used in amounts from about 0.1 to about 0.5%, based on the weight of dry plaster.
[0158] There are at least three classes of magnesium oxide on the market, depending on the calcination temperature. "Deeply calcined" magnesium oxide is calcined between 1500°C to 2000°C, eliminating most, if not all, of the reactivity. MagChem P98-PV (Martin Marietta Magnesia Specialties, Bethesda, Md.) is an example of a “deep-burned” magnesium oxide. BayMag 96 (Baymag, Inc. of Calgary, Alberta, Canada) and MagChem 10 (Martin Marietta Magnesia Specialties, Bethesda, Md.) are examples of “heavily calcined” magnesia. “Heavily calcined” magnesium oxide is calcined at temperatures from 1000°C to about 1500°C. This has a narrow range of reactivity, a high density and is typically used in application where slow degradation or chemical reactivity is required, such as in animal feed and fertilizer. The third class is "lightly burned" or "caustic" magnesia produced by calcining at temperatures from about 700°C to about 1000°C. This type of magnesia is used in a wide range of applications including plastics, rubber, paper and pulp processing, steel boiler additives, adhesives and acid neutralization. Examples of lightly calcined magnesia include BayMag 30, BayMag 40 and BayMag 30 (-325 Mesh) (BayMag, Inc. of Calgari, Alberta, Canada).
[0159] As mentioned in US Patent No. 7,803,226, incorporated herein by reference, preferred catalysts are made of a mixture of magnesium oxide and Class C fly ash. When combined in this manner, any of the classes of magnesium oxide is helpful. However, deep calcined and heavily calcined magnesium oxides are preferred due to reduced reactivity. The relatively high reactivity of magnesium oxides can lead to crack reactions that can produce hydrogen. As hydrogen is generated, the product expands, causing cracks where the plaster has settled. Expansion also causes the molds into which the plaster is poured to collapse, resulting in loss of detail and product deformation in one or more dimensions. Preferably, BayMag 96, MagChem P98-PV and MagChem 10 are preferred magnesium oxide headphones. Preferably, magnesium oxide and fly ash are added to the plaster before adding it to the calibration water. Dry components such as these are often added to the plaster as it moves along a conveyor to the mixer.
[0160] A preferred fly ash is a Class C fly ash. Class C hydraulic fly ash or its equivalent is the most preferred fly ash component. A typical composition of a Class C fly ash is shown in Table 1 of U.S. Patent No. 7,803,226. Fly ash with a high lime content, greater than about 20% lime by weight, which is obtained from the processing of certain coals. The ASTM C-618 designation, incorporated herein by reference, describes the characteristics of Class C fly ash. A preferred Class C fly ash is supplied by Bayou Ash Inc., Big Cajun, II, Louisiana. Preferably, fly ash is used in amounts from about 0.1% to about 5%, based on the weight of dry plaster. More preferably, fly ash is used in amounts of from about 0.2% to about 1.5%, based on the weight of the dry plaster.
[0161] The catalysis of siloxane results in faster and more complete polymerization and crosslinking of the siloxane to form the silicone resin. The hydration of the plaster forms an interconnected matrix of calcium sulfate dihydrate crystals. While the gypsum matrix is forming, the siloxane molecules are also forming a matrix of the silicone resin. Since these are formed simultaneously, at least in part, the two matrices become intertwined with each other. Excess water and slurry additives, including fly ash, magnesium oxide, and the additives described below, which have been dispersed throughout the slurry, become dispersed by the matrices in the interstitial spaces to achieve water resistance to slurry. along the core of the panel. In some embodiments, adequate amounts of a pregelatinized starch, or starch with equivalent function, can work in conjunction with the siloxane to retard water ingress along the most vulnerable edges of the panel.
[0162] In some embodiments, core slurry formulation modalities for use in preparing panels formed in accordance with the principles of the present disclosure may include a combination of pregelatinized starch (or starch with equivalent functionality) in a higher amount to about 2% by weight based on the weight of the stucco and siloxane in an amount of at least about 0.4% and preferably at least about 0.7% by weight based on the weight of the stucco, which can produce gypsum panels with less than about 5% water absorption. This water resistance property can be particularly useful, as a low density panel has much more of its total volume made up of air and/or water voids than a conventional panel. It would be expected that the increase in void volume would make the light weight panels much more water absorbent. While not wishing to be bound by theory, it is believed that water resistance develops when the siloxane cures within the formed panels and that pregelatinized starch of at least about 2.0% by weight works in conjunction with siloxane to retard water ingress through micropores at the panel edges first blocking water ingress and then after water absorption by the starch, by forming a highly viscose starch/water combination. In other embodiments, a hydroxyethylated starch or a starch that is functionally equivalent to a pregelatinized starch can be used in combination with the siloxane.
[0163] Referring to FIGURES 7 and 8, an exemplary embodiment of an assembly 100 is shown that includes plaster panels 102 formed in accordance with the principles of the present disclosure. Gypsum panels 102 are applied to both opposing surfaces 104, 105 of set 100. Set 100 is a representation of an assembly constructed to UL Underwriters Laboratories specifications U305, U419, and U423 and any other fire testing procedure that is equivalent to any of these fire test procedures. It should be understood that the reference made in this document to a specific Underwriters Laboratories fire test procedure, such as, UL U305, U419, and U423, for example, also includes a fire test procedure, such as one promulgated by any other. entity, which is equivalent to the specific UL standard in question.
[0164] Mount 100 includes 110 wood beams that are nominally 2 inches thick by 4 inches wide and are spaced 16 inches center apart. The mount also includes a pair of strut plates 112 and a top plate 114 made of nominal 2 inches by 4 inches of wood. In some embodiments, the wood beams 110 and the boards 112, 114 may be number two kiln dried wood beams. The assembly 100 effectively ceases fire with the appropriate lock 116 disposed between the beams 110. It should be understood that while the exemplary assembly 100 includes the wooden beams 110, the assembly may include metal beams and loading parameters to suit to the particular specification, according to which it is constructed.
[0165] Plasterboard 102 in assembly 100 are 5/8 inches thick and include paper backing sheets with tapered edges and square edges. Plasterboard 102 is applied horizontally to beams 110 with horizontal joints 122 between adjacent plasterboard 102 aligned on opposing surfaces 104, 105 of assembly 100.
[0166] In other embodiments, the plaster panels 102 can be applied vertically to the beams 110. The horizontal joints of the vertically applied panels do not need to be supported by the beams 110.
[0167] The horizontal joints 122 between the adjacent plasterboards 102 are covered with the paper tape 130 and the joint compound 132. The joint compound and paper tape can be omitted when square edge boards are used . In other embodiments, a nominal 3/32 inch thick gypsum veneer plaster may be applied to the entire surface of gypsum panels classified as veneered skirting with the joints reinforced with paper tape.
[0168] Gypsum panels 102 can be secured to beams 110 using a suitable nail or screw ratio. For example, gypsum panels can be secured to the wood beams with 6d cement-coated nails (1-7/8 inches long, 0.0915 inches rod diameter and 15/64 inches head diameter) nailed to 7 inches in center. The nail heads are covered with joining compound 134 (see FIG. 8). In other embodiments, the nail heads can be left exposed. In other embodiments, the nail ratio can be different and the screws can be used with an appropriate screw ratio.
[0169] In the illustrated embodiment, the space between adjacent beams 110 is left empty. In other embodiments, fiberglass or mineral wool insulation blankets can be placed to completely or partially fill the beam cavities. In still other embodiments, as an alternative to insulation blankets, a spray-applied cellulose insulation material may be used. Sprayed insulation material can be applied with water to fill the enclosed beam cavity in accordance with application procedures specific to the product used.
[0170] Gypsum panels 102 formed in accordance with the present disclosure are effective to inhibit heat transmission through assembly panels 100 prepared in accordance with UL U305 procedures wherein the first surface 104 is exposed to a heat source and the opposite surface 105 is not heated. The assembly 100 is subjected to load forces, in accordance with UL U305, while being subjected to heating. The heat source follows a time-temperature curve in accordance with ASTM standard E119-09a. Referring to FIG. 8, the unheated surface 105 includes temperature sensors 138 applied thereto. The 138 sensors are arranged in a pattern in accordance with U305 UL procedures. The gypsum panels 102 are effective to inhibit heat transmission from the heated surface 104 to the unheated surface 105 such that the maximum single temperature of the sensors 138 on the unheated surface 105 is less than about 415°F and the average temperature of the sensors 138 on the unheated surface 105 is less than about 340°F in approximately 50 minutes of elapsed time when measured in accordance with UL U305. Gypsum panels 102 are effective to inhibit heat transmission from heated surface 104 to unheated surface 105 to qualify for a one hour fire rating for assembly 100.
[0171] Gypsum 102 panels formed in accordance with the present disclosure are effective to withstand hose flow testing also performed as part of UL U305 procedures. Conforming to UL U305, an assembly constructed similarly to FIG. 7 is subjected to fire resistance test in accordance with U305 for 30 minutes, at which time it is removed from the heating environment and moved to another location for the hose flow test in accordance with U305. The assembly is subjected to a stream of water from a fire hose equipped to draw water to approximately 30 psi of water pressure for a duration of sixty seconds.
[0172] Consequently, gypsum panels formed in accordance with the principles of the present disclosure can be used in assemblies that are effective to inhibit heat transmission to meet the one-hour fire resistance rating to be classified as Type X board under ASTM 1396/C 1396M-06. In other embodiments, assemblies can be constructed using gypsum panels formed in accordance with the principles of the present disclosure that conform to the specification of other UL assemblies, such as UL U419 and U423, for example. In yet other embodiments, gypsum panels formed in accordance with the principles of the present disclosure can be used in other assemblies that are substantially equivalent to at least one of U305, U419, and U423. These assemblies can pass the one-hour fire evaluation and hose flow test applicable to U305, U419, U423 and other equivalent fire test procedures.
[0173] The following embodiments further illustrate aspects of the present invention but, of course, should not be interpreted in any way as limiting its scope.
[0174] In one embodiment, a fire-resistant gypsum panel comprises a gypsum core disposed between two facing sheets, the gypsum core comprising a crystalline matrix of hardened gypsum and high expansion particles having a volume expansion of approximately 300 % or more of its original volume after heating for approximately one hour at approximately 1560°F, the plaster core having a density (D) of approximately 40 pounds per cubic feet or less and core hardness of at least approximately 11 pounds, and the gypsum core being efficient to provide a Thermal Insulation Index (TI) of approximately 20 minutes or more.
[0175] In another embodiment, the fire resistant gypsum panel comprising the gypsum core is efficient to provide the panel with a TI/D ratio of approximately 0.6 minutes/pounds per cubic feet (about 0.04 min /kg/m3) or more.
[0176] In another embodiment, the fire-resistant gypsum panel comprises the crystalline matrix of hardened gypsum comprises walls defining air voids, the air voids having an average equivalent sphere diameter of approximately 100 µm or greater.
[0177] In another embodiment, the fire-resistant gypsum panel comprises the crystalline matrix of hardened gypsum comprises walls defining and separating air voids within the gypsum core, the walls with an average thickness of approximately 25 μm or greater.
[0178] In another embodiment, fire-resistant gypsum panel exhibits an average shrinkage strength of approximately 75% or more when heated to approximately 1800°F (approximately 980°C) for one hour.
[0179] In another modality, the fire-resistant gypsum panel comprises the gypsum core, where the gypsum core is formed from a fluid paste composed of water; stucco; the high expansion particles; and a heat sink additive in an amount effective to provide a thermal insulation index (TI) that is greater than a gypsum core formed from the slurry without the heat sink additive.
[0180] In another embodiment, the fire resistant gypsum panel comprises the high expansion particles comprise unexpanded vermiculite particles, the amount and distribution of vermiculite particles in the gypsum core being efficient to provide the panel with IT of approximately 20 minutes or more.
[0181] In another modality, the fire-resistant gypsum panel comprises the gypsum core is formed from a fluid paste composed of water; stucco; vermiculite particles in amounts up to about 10% by weight, based on the weight of the plaster; and mineral, glass or carbon fibers or combinations thereof.
[0182] In another embodiment, fire resistant gypsum panel meets at least UL U305 one-hour standards for fire resistant panel.
[0183] In another embodiment, fire resistant gypsum panel at a nominal panel thickness of approximately 5/8 inches, the panel has a nail tensile strength of at least about 70 lbs, the nail tensile strength being determined in accordance with ASTM C473-09 standard.
[0184] In another embodiment, fire resistant gypsum panel meets at least UL U419 one-hour standards for fire resistant panel.
[0185] In another embodiment, the fire-resistant gypsum panel comprises a gypsum core disposed between two cladding sheets, the gypsum core, composed of a crystalline matrix of hardened gypsum and high expansion particles having a volume expansion of approximately 300% or more of its original volume after being heated for approximately one hour at approximately 1560°F distributed within the gypsum core; the panel, having a panel density of approximately 40 pounds per cubic feet or less and a core hardness of at least about 11 pounds, and the gypsum core and high expansion particles efficient to provide the panel with a Shrinkage at High Temperature (S) of approximately 10% or less and a High Temperature Thickness Expansion to High Temperature Shrink (TE)/S ratio of approximately 0.2 or more.
[0186] In another embodiment, the fire-resistant gypsum panel comprises the crystalline matrix of hardened gypsum comprises walls defining air voids with an average equivalent sphere diameter of about 100 μm to about 350 μm with a standard deviation of about from 100 to about 225.
[0187] In another embodiment, fire resistant gypsum panel walls have an average thickness of about 25 µm to about 75 µm with a standard deviation of about 5 to about 40.
[0188] In another embodiment, the fire-resistant gypsum panel comprises the high-expansion particles comprise high-expansion vermiculite particles.
[0189] In another embodiment, the fire-resistant gypsum panel is formed from the slurry, where the slurry further comprises starch in an amount of from about 0.3% to about 3.0% by weight, with based on the weight of the stucco and dispersant in an amount of from about 0.1% to about 1.0% by weight, based on the weight of the stucco.
[0190] In another embodiment, the fire resistant gypsum panel is formed from the slurry, where the slurry additionally includes a phosphate-containing component in an amount of about 0.03% to about 0.4% in weight based on stucco weight.
[0191] In another embodiment, fire resistant gypsum panel meets at least UL U419 one-hour standards for fire resistant panel.
[0192] In another modality, the fire-resistant gypsum panel comprises a gypsum core disposed between two cladding sheets, the hardened gypsum core composed of a crystalline matrix of hardened gypsum and expandable particles distributed in the crystalline gypsum matrix, the hardened gypsum core having a density of about 40 pounds per cubic foot or less, and a core hardness of at least about 11 pounds, the panel having a nominal panel thickness of about 5/8 inches, the expandable particles having an unexpanded first phase and an expanded second phase when heated, the panel effective in inhibiting heat transmission through an assembly of said panels prepared and heated in accordance with the procedures of UL U419, where the panel surfaces of one side of the mount are exposed to a heat source and the panel surfaces on the unheated opposite side of the mount are provided with multiple temperature sensors. temperature in accordance with UL U419, so that the maximum single value of the temperature sensors on the non-heating side of the assembly is less than about 500°F after about 60 minutes when the assembly is heated in accordance with the time-curve. ASTM E119-09a standard temperature.
[0193] In another embodiment, the fire-resistant gypsum panel is effective in inhibiting heat transmission through the assembly, so that the average value of the temperature sensors on the unheated side of the assembly, measured in accordance with UL U419, is less than about 380°F after about 60 minutes of heating according to the time-temperature curve of ASTM standard E119-09a.
[0194] In another embodiment, the fire-resistant gypsum panel is effective in inhibiting heat transmission through the assembly, so that the single maximum value of temperature sensors on the non-heating side of the assembly, measured in accordance with UL U419 , is less than about 410°F after about 55 minutes of heating according to the time-temperature curve of the ASTM E119-09a standard.
[0195] In another embodiment, the fire-resistant gypsum panel is effective in inhibiting heat transmission through the assembly, so that the average value of temperature sensors on the non-heating side of the assembly, measured in accordance with UL U419, is less than about 320°F after about 55 minutes of heating according to the ASTM E119-09a standard time-temperature curve.
[0196] In another embodiment, the fire resistant gypsum panel is effective in inhibiting heat transmission through the assembly, so that the single maximum value of temperature sensors on the non-heating side of the assembly, measured in accordance with UL U419 , is less than about 260°F, and the average value of temperature sensors on the non-heating side of the assembly, measured in accordance with UL U419, is less than about 250°F, after about 50 minutes of heating accordingly with the time-temperature curve of the ASTM E119-09a standard.
[0197] In another embodiment, fire resistant gypsum panel is effective in inhibiting heat transmission through assembly, so that the panel meets UL U419 one hour fire resistant panel.
[0198] In another embodiment, the fire resistant gypsum panel comprises the expandable particles comprise high expansion vermiculite particles, the high expansion vermiculite particles expanding at an average of about 300% or more of their original volume when heated for one hour at approximately 1560 °F (about 850 °C).
[0199] In another embodiment a method is presented for making a fire resistant gypsum panel, the method comprising: (A) preparing a slurry of gypsum that has high expansion particles dispersed therein, wherein the high expansion particles have a volume expansion of about 300% or more of their original volume after being heated for about one hour at about 1560°F; (B) removing slurry of gypsum between a first cover sheet and a second cover sheet to form an assembly comprising a gypsum core together with the high expansion particles generally distributed throughout the gypsum core; (C) cutting the assembly into a panel of predetermined dimensions; and (D) drying the panel; such that the gypsum core assembly has a density (D) of about 40 pounds per cubic foot or less and a core hardness of at least about 11 pounds, and the gypsum core is effective to provide an Index of thermal insulation (TI) of about 20 minutes or more.
[0200] In another embodiment the method for making a fire resistant gypsum panel is presented, wherein the gypsum core assembly is effective to provide the panel with a TI/D rate of about 0.6 minutes/lbs. per cubic foot or more.
[0201] In another embodiment, the method for making a fire-resistant gypsum panel is presented, in which the gypsum assembly is a crystalline matrix and comprises walls that define air gaps, air gaps with an average equivalent sphere diameter of about 100 µm or more.
[0202] In another embodiment, the method for making a fire-resistant gypsum panel is presented, in which the gypsum assembly is a crystalline matrix and comprises walls that define and separate air gaps within the gypsum core, the walls with a average thickness of about 25 µm or more.
[0203] In another embodiment, the method for making a fire-resistant gypsum panel is presented, wherein the panel has an average shrinkage strength of about 75% or more when heated to about 1800°F for one hour.
[0204] In another embodiment, the method for making a fire-resistant gypsum panel is presented, in which the gypsum core is formed from a slurry comprising water, stucco, high expansion particles, and a heat sink additive in an amount effective to provide a Thermal Insulation Index (TI) that is greater than a gypsum core formed from the slurry without the heat sink additive.
[0205] In another embodiment the method for making a fire resistant gypsum panel is presented, wherein the high expansion particles comprise unexpanded vermiculite particles, the amount and distribution of vermiculite particles in the gypsum core effective to provide the dashboard with IT of about 20 minutes or more.
[0206] In another embodiment, the method for making a fire-resistant gypsum panel is presented, in which the gypsum core is formed from a slurry comprising water, stucco, vermiculite particles in an amount of up to about 10% by weight based on the weight of the stucco, and mineral, glass or carbon fibers, or combinations thereof.
[0207] In another embodiment, the method for making a fire-resistant gypsum panel is presented, wherein the thickness of a nominal panel of about 5/8-inches, the panel has a nail tensile strength of at least about of 70 pounds, the nail tensile strength determined in accordance with ASTM C473-09 standard.
[0208] In another embodiment the method for making a fire resistant gypsum panel is presented, wherein the panels meet at least the standard of one hour fire rated panel UL U305, U419 UL, and UL U423.
[0209] In another embodiment a method is presented for making a fire-resistant gypsum panel, the method comprises: (A) preparing a slurry of gypsum that has high expansion particles dispersed therein, wherein the high expansion particles have a volume expansion of about 300% or more of their initial volume after being heated for about one hour at about 1560°F; (B) removing slurry of gypsum between a first cover sheet and a second cover sheet to form an assembly comprising a crystalline matrix of gypsum with the high expansion particles generally distributed throughout the gypsum core; (C) cutting the assembly into a panel of predetermined dimensions; and (D) drying the panel; such that the panel comprises a density of about 40 pounds per cubic foot or less and a core hardness of at least about 11 pounds, and the gypsum assembly crystalline matrix and high expansion particles are effective to provide the panel with a high temperature shrinkage (S) about 10% or less and a high temperature Expansion Thickness High Temperature Shrinkage (TE)/S ratio of about 0.2 or more.
[0210] In another embodiment, the method for making a fire-resistant gypsum panel is presented, in which the crystalline matrix of the defined gypsum comprises walls that define air gaps with an equivalent average sphere diameter, from about 100 μm at about 350 µm with a standard deviation of about 100 to about 225.
[0211] In another embodiment, the method for making a fire-resistant gypsum panel is presented, in which the walls have an average thickness of about 25 µm to about 75 µm with a standard deviation of about 5 to about 40 .
[0212] In another embodiment is presented the method to make a fire resistant gypsum panel, in which the high expansion particles comprise high expansion vermiculite particles.
[0213] In another embodiment, the method for making a fire-resistant gypsum panel is presented, wherein the slurry further comprises a starch in an amount of from about 0.3% to about 3.0% by weight with based on the weight of the stucco and a dispersant in an amount of from about 0.1% to about 1.0%, by weight, based on the weight of the stucco.
[0214] In another embodiment, the method for making a fire-resistant gypsum panel is presented, wherein the slurry further includes a phosphate-containing component in an amount of from about 0.03% to about 0.4% by weight , based on the weight of the stucco.
[0215] In another embodiment the method for making a fire-resistant gypsum panel is presented, wherein the thickness of a nominal panel of about 5/8-inches, the panel has a nail tensile strength of at least about of 70 pounds, the nail tensile strength determined in accordance with ASTM C473-09 standard.
[0216] In another embodiment the method for making a fire resistant gypsum panel is presented, wherein the panel meets the one hour fire rated panel standard of UL U305.
[0217] In another embodiment the method for making a fire resistant gypsum panel is presented, wherein the panel meets the one hour fire rated panel standard of UL U419.
[0218] In another embodiment, a method for manufacturing a fire-resistant gypsum panel is presented, the method comprising: (A) preparing a slurry of gypsum having high expansion particles dispersed therein; (B) deposition of the slurry of plaster between the first cladding sheet and the second cladding sheet to form an assembly comprising a hardened plaster core with expandable particles generally distributed throughout the plaster core; (C) cutting the assembly into a panel of predetermined dimensions; and (D) curing the panel; so that the hardened gypsum core has a density (D) of approximately 40 pounds per cubic foot and a core hardness of at least approximately 11 pounds, the panel has a nominal panel thickness of 5/8-inch, the particles of high expansion having an unexpanded first phase and an expanded second phase when heated, and the panel is efficient to inhibit heat transmission through an assembly of such prepared and heated panels per UL U419 procedures, where panel surfaces in one side of the mount are exposed to a heat source and panel surfaces on the opposite unheated side of the mount are provided with a plurality of temperature sensors referring to UL U419, such that the maximum single value of the temperature sensors on the unheated side of the mount is less than approximately 500 °F (approximately 260 °C) after approximately 60 minutes when the mount is heated according to the temperature curve. po-temperature of ASTM standard E119-09a.
[0219] In another embodiment, a method is presented to manufacture a fire-resistant gypsum panel, where the panel is efficient to inhibit heat transmission through an assembly such that the average value of the temperature sensors on the unheated side of the assembly measured relative to UL U419, is less than approximately 380°F after approximately 60 minutes of heating per ASTM standard E119-09a time-temperature curve.
[0220] In another embodiment, a method is presented to manufacture a fire-resistant gypsum panel, where the panel is efficient to inhibit heat transmission through an assembly such that the maximum single value of the temperature sensors on the unheated side of the As measured to UL U419, it is less than approximately 410°F after approximately 55 minutes of heating per ASTM standard E119-09a time-temperature curve.
[0221] In another embodiment, a method is presented to manufacture a fire-resistant gypsum panel, where the panel is efficient to inhibit heat transmission through an assembly such that the average value of the temperature sensors on the unheated side of the assembly measured against UL U419, is less than approximately 320°F after approximately 55 minutes of heating per ASTM standard E119-09a time-temperature curve.
[0222] In another embodiment, a method is presented to manufacture a fire-resistant gypsum panel, where the panel is efficient to inhibit heat transmission through an assembly such that the maximum single value of the temperature sensors on the unheated side of the mount measured referring to UL U419 is less than approximately 260°F and the average value of the temperature sensors on the unheated side of the mount measured referring to UL U419 is less than approximately 250°F after approximately 50 minutes of heating. according to the time-temperature curve of ASTM standard E119-09a.
[0223] In another embodiment a method is presented to manufacture a fire resistant gypsum panel, where the panel is efficient to inhibit heat transmission through an assembly, such that the panel meets at least one of the standards of UL U305, UL U419 and UL U423 One Hour Fire Resistant Panel.
[0224] In another embodiment, a method is presented to manufacture a fire-resistant gypsum panel, where the expandable particles comprise high-expansion vermiculite particles, the high-expansion vermiculite particles expandable to approximately 300% or more of their original volume after heating for about an hour to approximately 1560 °F.
[0225] In another embodiment, the fire-resistant gypsum panel comprises a gypsum core disposed between two facing sheets, the gypsum core comprising a crystalline matrix of hardened gypsum, the gypsum core having a panel density of approximately 40 pounds per cubic feet) or less and a core hardness of at least about 11 pounds, and the panel with a High Temperature Shrinkage of (S) of about 10% or less.
[0226] In another embodiment, fire resistant gypsum panel has an average High Temperature Shrinkage of (S) of approximately 10% or less.
[0227] In another embodiment, the fire resistant gypsum panel has a ratio (TE) /S of High Temperature Thickness Expansion (TE) to High Temperature Shrinkage (S) of approximately 2 or more.
[0228] In another embodiment, fire resistant gypsum panel has a ratio (TE) /S of High Temperature Thickness Expansion (TE) to High Temperature Shrinkage (S) of approximately 2 to approximately 17 or more.
[0229] In another embodiment, the fire resistant gypsum panel has a ratio (TE) /S of High Temperature Thickness Expansion (TE) to High Temperature Shrinkage (S) of approximately 17 or more.
[0230] In another embodiment, the fire-resistant gypsum panel comprises the gypsum core, where the gypsum core comprises unexpanded vermiculite particles, the quantity and distribution of vermiculite particles in the gypsum core being efficient to provide the panel with a High Temperature (TE) Thickness Expansion (TE) to High Temperature (S) Shrinkage (TE) ratio of approximately 1 or more.
[0231] In another embodiment, the fire-resistant gypsum panel comprises the gypsum core, where the gypsum core comprises expandable high expansion particles of about 300% or more of its original volume after it has been heated for about one hour at about 1560 °F (850 °C) in an amount and distributed within the crystalline matrix of hardened gypsum such that the panel has a Thermal Insulation Index (TI) of about 20 minutes or more.
[0232] In another embodiment, the fire resistant gypsum panel comprises the high expansion particles where the high expansion particles are high expansion vermiculite particles.
[0233] In another embodiment, fire resistant gypsum panel has an average shrinkage strength of approximately 85% or more when heated to approximately 1800°F (980°C) for one hour.
[0234] In another embodiment, the fire-resistant gypsum panel comprises the crystalline matrix of hardened gypsum, where the crystalline matrix of hardened gypsum comprises (a) walls defining air gaps, air gaps with an average equivalent sphere diameter of approximately 100 µm or more or (b) walls defining and separating air gaps within the plaster core, the walls having an average thickness of approximately 25 µm or more.
[0235] In another embodiment, the fire-resistant gypsum panel comprises walls, where the walls have an average thickness of approximately 25 μm to approximately 75 μm with a standard deviation of approximately 5 to approximately 40.
[0236] In another embodiment, the fire resistant gypsum panel has a nominal panel thickness of 5/8-inches, the hardened gypsum core comprises high expansion particles have an unexpanded first phase and an expanded second phase when heated , and the panel is effective in inhibiting heat transmission by mounting such prepared and heated panels per UL U419 procedures, where panel surfaces on one side of the assembly are exposed to a heat source and panel surfaces on the opposite unheated side of the mount are provided with a plurality of temperature sensors referring to UL U419, such that the maximum single value of the temperature sensors on the unheated side of the mount is less than approximately 500°F after approximately 60 minutes when the assembly is heated in accordance with the time-temperature curve of ASTM standard E119-09a.
[0237] In another embodiment, the fire-resistant gypsum panel comprises the gypsum core, where the gypsum core is formed from a fluid paste comprising water; stucco; vermiculite particles in an amount up to approximately 10% by weight based on the weight of the plaster; and mineral, glass or carbon fibers or combinations thereof.
[0238] In another embodiment, the fire resistant gypsum panel comprises mineral, glass or carbon fibers or combinations thereof in an amount of approximately 0.3% to approximately 0.9% by weight based on the weight of the stucco.
[0239] In another embodiment, the fire resistant gypsum panel comprises the overlay sheets, wherein at least one of the overlay sheets comprises a paper overlay sheet having a weight of from about 40 to about 65 lb/MSF .
[0240] In another embodiment, fire resistant gypsum panel meets at least the one-hour fire rated panel standard of UL U305, UL U419, and UL U423.
[0241] In another embodiment, the fire resistant gypsum panel is effective in inhibiting heat transmission through the assembly such that (a) the average value of the temperature sensors measured on the unheated side of the assembly referring to UL U419 is lower than (i) approximately 380 °F (approximately 195 °C) after approximately 60 minutes of heating, or (ii) approximately 320 °F (approximately 160 °C) after approximately 55 minutes of heating; (b) the maximum single value of temperature sensors measured on the unheated side of the mount referring to UL U419 is less than (i) approximately 500°F (approximately 260°C) after approximately 60 minutes of heating, or (ii) approximately 410 °F (approximately 210 °C) after approximately 55 minutes of warm-up, or (c) the maximum single value of temperature sensors measured on the unheated side of the mount referring to UL U419 is less than approximately 260 °F (approximately 125 °C) and the average value of the temperature sensors measured on the unheated surface of the mount referring to UL U419 is less than approximately 250 °F (approximately 120 °C) after approximately 50 minutes of heating; each heating according to the time-temperature curve of the ASTM E119-09a standard.
[0242] In another embodiment, a wall system comprises at least one fire resistant plasterboard as discussed in the preceding paragraphs and at least one fastening element.
[0243] In another embodiment, a wall system comprises the fastening element, wherein the at least one fastening element is a screw, a nail, or an adhesive.
[0244] In another embodiment a method for fabricating a fire resistant gypsum panel as discussed in any of the preceding paragraphs comprises (A) preparing a slurry of gypsum; (B) depositing the gypsum slurry between the first liner sheet and the second liner sheet to form an assembly; (C) cutting the assembly into a panel of predetermined dimensions; and (D) curing the panel.
[0245] In another embodiment, a method is presented to manufacture a fire resistant gypsum panel, where the gypsum core comprises high expansion particles expandable to about 300% or more of its original volume after being heated for about one hour at about 1560 °F (850 °C) in an amount and distributed within the crystalline matrix of hardened gypsum such that the panel has a Thermal Insulation Index (TI) of about 20 minutes or more.
[0246] In another embodiment a method for fabricating a fire resistant gypsum panel is presented, where the panel meets at least the one hour fire rated panel standard of UL U305, UL U419 and UL U423.
[0247] In another embodiment, the fire resistant gypsum panel comprises a gypsum core disposed between two facing eyes, the panel has a density (D) of about 40 pounds per cubic foot or less and a core hardness of at least about 11 pounds, and the gypsum core is effective to provide a Thermal Insulation Index (TI) of about 20 minutes or more.
[0248] In another embodiment, the fire resistant gypsum panel comprises the core of gypsum disposed between two cladding eyes, the panel has a density (D) of about 40 pounds per cubic foot or less, a High Temperature Shrinkage of (S) average of approximately 10% or less and the panel inhibits heat transmission through an assembly such that the panel meets at least one of the UL U305, UL U419, and UL U423 One-Hour Standards for Weather Resistant Panel fire.
[0249] In another embodiment, the fire-resistant gypsum panel comprises the gypsum core disposed between two cladding sheets, the gypsum core comprising a crystalline matrix of hardened gypsum with the high expansion particles and the gypsum core has a density (D) of about 40 pounds per cubic foot or less.
[0250] In another embodiment, a wall mount comprises nails, a fire resistant plasterboard having a density (D) of about 35 pounds per cubic foot or less, and a cavity between the two adjacent wall nails comprising insulation , where the wall mount meets at least one of the UL U305, UL U419, and UL U423 One-Hour Fire Resistant Panel standards.
[0251] In another embodiment, the fire resistant gypsum panel comprises a gypsum core disposed between two facing sheets, the gypsum core having a density (D) of about 40 pounds per cubic foot or less and a layer of high density between cladding sheet and gypsum core.
[0252] In another embodiment, the fire resistant gypsum panel comprises a gypsum core disposed between a first and second facing sheet, the gypsum core having a density (D) of about 40 pounds per cubic foot or less and a high density layer formed on the first overlay sheet and/or along the peripheral edge of the overlay sheet.
[0253] In another embodiment, the fire resistant gypsum panel comprises a gypsum core disposed between two facing sheets, the gypsum core comprising a crystalline matrix of hardened gypsum and high expansion particles having a density (D) of about 40 pounds per cubic foot or less.
[0254] It should be noted that the foregoing are merely examples of embodiments. Other exemplary embodiments are evident from the description here. It will also be understood by one of skill in the art that each of these embodiments can be used in various combinations with the other embodiments provided herein. EXAMPLES
[0255] The following examples further illustrate aspects of the invention, but, of course, should not be interpreted in any way as limiting its scope. Example 1
[0256] The expansion characteristics of relatively low expansion vermiculite often used in conventional fireproof gypsum panels such as Grade No. vermiculite. 5, with respect to high expansion vermiculite used in panels and methods, following the principles of the present disclosure, were evaluated under substantially identical heating conditions. In this study, 50 gram samples of exemplary unexpanded Grade 5 (relatively low expansion) vermiculite and exemplary high expansion vermiculite (here Grade 4) vermiculite were placed in three crucibles and heated in an oven for one hour at setting temperatures constants of about 212°F (100°C), about 390°F (200°C), about 750°F (400°C), about 1,110°F (600°C) and about 1470° F (800°C). After one hour of heating, the samples were weighed and their respective densities were measured. Comparisons of average weight loss and resulting densities for each test sample are listed in Tables II and III, in FIGS. 20 and 21, respectively.
[0257] Bulk density of Grade No. 5 unexpanded and unexpanded high expansion vermiculite in this study were nearly equal (66.1 vs. 66.9 lb/ft3). Vermiculite volume showed no appreciable change below about 390°F (200°C), but began to expand above about 390°F (200°C) and bulk density decreased with increasing temperature. High expansion vermiculite expanded significantly more than Grade No. 5 relatively low expansion vermiculite at the same temperatures, producing corresponding differences in bulk density. It should also be noted that, during heating of the No. 5 vermiculite from ambient temperature to about 1470°F (800°C), which approximates the temperatures experienced in fire and fire test conditions, it produced an expansion volume of about 290% relative to the original unheated volume. Heating the high expansion vermiculite from room temperature to 1470°F (800°C) produced a volume expansion significantly greater than about 390% over the original unheated volume.
[0258] This study confirmed, among other observations, that for a given weight and density of vermiculite, the amount of additional expansion volume produced by the high expansion vermiculite far exceeded that of the vermiculite used in conventional fireproof plates. These results also confirmed that a person skilled in the art would not find it obvious to use such high expansion vermiculite in any significant amount on gypsum panels with the reduced weights and densities of panels formed in accordance with the principles of the present disclosure. The expansion properties of such high expansion vermiculite would be expected to seriously damage and reduce the structural integrity and stability of such gypsum panels when exposed to high temperature conditions, such as those experienced under fire conditions and under conditions of fire test. Example 2
[0259] As mentioned above, fire resistant gypsum panels of low weight and densities with paper backing sheets were made in accordance with the principles of the present disclosure and subjected to micro computed tomography (CT) ray scanning -X. The panels were samples of Sample Run 2 and one of Sample Runs 3, 4, or 5, discussed below in Example 4. Each of the samples of Sample Runs 2, 3, 4, and 5 were made with about 1280 lb/msf of stucco; about 75-100 lb/msf of Grade #4 vermiculite; about 20 lb/msf of pregelatinized starch; about 32 lb/msf of HRA accelerator, about 7.5 lb/msf of fiberglass, about 2 lb/msf of dispersant; about 1.5 lb/msf of phosphates, and foam in an amount and composition sufficient to provide the desired panel weights and densities. The panel's first overlay sheet was approximately 61 lb/msf of manila paper and the second overlay sheet was about 41 lb/msf of newsprint. The finished board is approximately 5/8 inches thick. The completed panels were sampled on different dates, with a nominal weight of about 1860 lb/msf (Sample Runs 3, 4 and 5) and about 1880 lb/msf (Sample Run 2). Core densities were about 37 pcf and 36.5 pcf, respectively.
[0260] The core samples from each of the two sets of samples were analyzed, using a cone beam x-ray micro CT scanning technique with micron resolution, as generally discussed in Lin, Videla, Yu and Miller , "Characterization and Analysis of Porous, Brittle Solid Structures by X-Ray Micro CT", JOM, Vol. 62, No. 12, pp. 91-94 (Mineral, Metals and Materials Society, 12/2010) (“Lin's Micro CT X-Ray article”), which is incorporated herein by reference. Data from the scans were analyzed and used to produce the images shown in FIGS. 1-6. FIGS. 1 and 4 are two dimensional slices of the core samples from the 1880 lb/msf and 1860 lb/msf samples, respectively. FIGS. 2 and 5 are three-dimensional images of the same samples, respectively, consisting of 1626x1020x1024 voxels, where the size of each voxel is 5.07 x 5.07 x 5.07 μm. FIGS. 3 and 6 present plotted three-dimensional volume images of the 1880 lb/msf and 1860 lb/msf samples, respectively showing the distribution of spaces and high-expansion vermiculite (and other particulates).
[0261] A sample of 5/8 inch thick fire resistant gypsum panels formed in accordance with the principles of the present disclosure shown in FIGS. 1-6 includes a gypsum handle core comprising a gypsum crystal matrix with walls defining the air spaces within the gypsum core. The size distribution of the three-dimensional air space was determined using high-resolution micro X-ray tomography (HRXMT) based on a 3D watershed algorithm discussed in the Lin X-Ray Micro CT article (see also, A. Videla, CL Lin, and JD Miller, Part. Part. Syst. Charact., 23 (2006), pp. 237-245). Three-dimensional HRXMT image analysis with 5.07 µm voxel resolution was used with the three-dimensional watershed algorithm to calculate an equivalent sphere diameter for the counted air spaces. Table IV in FIG. 22 presents the results for the three-dimensional air space size distribution measured by number and volume for Sample Runs 2 and 3, Samples 1 and 2, respectively, and two additional samples of gypsum panels formed according to the principles of the present disclosure, using the same analytical procedures.
[0262] Referring to FIG. 22, in different embodiments, gypsum panels formed in accordance with the principles of the present disclosure may include a variety of air gap sizes, size distributions and different arrangements within the gypsum crystal matrix of the gypsum handle core. For example, the total airspaces for a given sample size can range from less than about a thousand to about 7000 and the average equivalent sphere diameter of the airspaces can range from about 100 µm to about 350 µm with a standard deviation of about 100 to about 225. As mentioned above, such air space structures and arrangements allow for reduction of core density and weight while maintaining desired slab strength and structural properties.
[0263] The gypsum core wall thickness distribution of the samples shown in FIGS. 1-6 was determined, using HRXMT based on erosion, dilation, and skeletonization operations discussed in Lin's X-Ray Micro CT article (see also, WB Lindquist et al., J. Geophys. Res., 101B (1996) ), pp. 8297-8310). Three-dimensional HRXMT image analysis used the three-dimensional skeletonization procedure to calculate gypsum core wall thicknesses between air spaces. The wall thickness between adjacent air spaces was obtained by a medial axis operation and is equal to the diameter of an equivalent sphere touching both sides of the wall. Table V in FIG. 23 presents the results for the measured wall thickness for Sample Runs 2 and 3, Samples 1 and 2, respectively, and two additional samples of gypsum panels formed in accordance with the principles of the present disclosure, using the same analytical procedure.
[0264] Referring to FIG. 23, in different embodiments, gypsum panels formed in accordance with the principles of the present disclosure may include a variety of different wall configurations within the gypsum crystal matrix of the gypsum handle core. For example, the total number of walls for a given sample size can range from about 20 million to about 35 million in some embodiments, and the average wall thickness within the gypsum core can be at least about 25 µm . In the samples, the walls defining and separating the air spaces within the gypsum core can have an average thickness of about 25 µm to about 50 µm with a standard deviation of about 10 to about 25. As mentioned above, such wall structures and their arrangement allow for reduction of core density and weight while maintaining desired slab strength and structural properties. In some embodiments, the gypsum panel core can employ the combined benefits of the size distribution and arrangement of air spaces mentioned above, and the wall thickness distribution and arrangement to achieve substantial weight and density reduction, while provides acceptable strength and related properties.
[0265] As indicated in FIGS. 1 and 2, and 4 and 5, the high expansion vermiculite particles are shown in their unexpanded form, as the white or gray particles generally distributed throughout the core material. Many of the vermiculite particles are located near or adjacent to the structures of the spaces in the core sample, as well as interspersed by all structural elements of the cores in the panel. In FIGS. 3 and 6, vermiculite particles are shown as large colored particles in various orientations suspended in the core structure, again dispersed throughout the core crystal matrix, often close to or adjacent to core spaces. FIGS. 1-6 also reflect variations in sizes and distributions of vermiculite particles that can occur in the core structure of gypsum panels formed in accordance with the principles of the present disclosure.
[0266] As mentioned above in this document, FIGS. 1-6 are indicative of the relatively high content of spaces, complex distribution of spaces, and typical reduced gypsum core density of panels formed in accordance with the principles of the present disclosure. This structure is further complicated by the variation in crystal structures in the walls of spaces and in the structure of the intermediate core adjacent between spaces. This crystal structure may include needle-like crystallites, plate-like crystallites and/or combinations thereof and other crystalline and amorphous elements. Such embodiments of panels formed in accordance with the principles of the present disclosure rely on the integrity of such relatively fragile core structures to provide fire resistance and/or other panel structure and strength properties such as nail tensile strength, strength. curvature and flexural strength.
[0267] In this sense, as illustrated in FIGS. 1-6, the incorporation of high-expansion vermiculite particles in such structures would be expected to lead to fragmentation, fracture and disruption of the walls of spaces and areas of the intermediate core when the panel is exposed to high temperatures due to too much expansion. resulting from volumes of vermiculite particles (eg, resulting in volumes of about 290% more than about 390% of the original volumes of unheated vermiculite). One would expect to severely weaken the core structure, causing failures, premature cracking or collapse of the panels. In addition, because the high degree of expansion of vermiculite occurs at temperatures where the gypsum core is losing volume and potentially integrity, because of water loss and other losses and/or changes in crystal morphology, the high degree of expansion of vermiculite into the wall of spaces and mid-core structures would be expected to accelerate the loss of panel integrity. Thus, it would be expected that substantial amounts of added gypsum or other shrink resistant additives would be required to provide the structural strength necessary for the fire resistance and strength properties of the board. As discussed above, and further illustrated in the examples in this document, reduced weight and density panels formed in accordance with the principles of the present disclosure, in contrast, provide fire resistance capabilities comparable to panels of higher gypsum content and very high density. taller. Example 3
[0268] The xy panel shrinkage strength test (width and length, respectively), as discussed in the aforementioned reference, US Patent No. 3,616,173 (the "'173 patent"), was investigated as a way to characterize the properties of fire resistance of gypsum panels formed in accordance with the principles of the present disclosure. As explained in the '173 patent, to the extent that the xy dimensions of a section selected from a gypsum panel shrink when the section is subjected to heating, it is an indication of the panel's resistance to shrinkage, cracking and spacing of the beams and supports of the structural assemblies, using the panels.
[0269] A set of approximately 3 inch by 9 inch 5/8 inch thick gypsum board specimens used in this study was tested, generally following the procedures described in the '173 patent. Samples were cut from a complete sheet of gypsum plaster formed from Sample Run 13 mentioned below. (In the '173 patent, samples were molded to a thickness of about % inch from a laboratory mix, using water instead of foam to control density). The samples were placed in a muffle, placing them vertically on their long edge (and in this case 5/8 inches thick) on a piece of insulating material, with insulating blocks positioned between the samples to prevent the core samples from fall. The initial x-y surface area of one or both sides of each sample was measured.
[0270] The oven and the sample were at room temperature when the samples were placed in the muffle. The muffle was heated to 1800°F and then held for an hour, after which the heat was cut off and the oven left to cool with its door slightly open. After the oven and the sample had cooled to room temperature, the samples were removed and the x-y surface area of the samples was measured. The surface area of the sample remaining after heating was divided by the surface area of the initial preheat sample and multiplied by 100 to give the percent surface area remaining after heating. This number, the percent surface area remaining, is referred to in this document as the "shrink strength" value as that term is used in this document.
[0271] Specimens from three different plasterboard samples were tested in a first run. In this first run, three specimens of a sample were cut from a 5/8 inch thick plasterboard prepared in accordance with the present disclosure from Sample Run 13 discussed in Example 4 below. These specimens were tested simultaneously with three specimens from each of two commercial board samples cut from a commercial 5/8-inch Type-X board sold under the designation "5/8'' Type-X Core Board Sheetrock Brand Firecode®” commercially available from the United States Gypsum Company. Type X samples had a core density of about 43.5 pcf and a plate weight of about 2250 lb/msf.
[0272] The first sample panel, from Sample Run 13 discussed in Example 4, was prepared in accordance with the present disclosure and was about 5/8 inches thick and weighed about 1850 lb/msf, with a density of 35.5 pcf core. The panel was made from about 1311 lb/msf of stucco, about 27 lb/msf of HRA, about 30 lb/msf of pregelatinized starch, about 100 lb/msf of high expansion vermiculite, about 7 .5 lb/msf of fiberglass, about 1.5 lb/msf of sodium trimetaphosphate and about 2.5 lb/msf of naphthalenesulfonate dispersant, as well as foam in an amount and formulation necessary to produce density of desired core. The panel's physical test established that it demonstrated a nail tensile strength of about 103 lbs using ASTM test procedures.
[0273] In a second embodiment, three specimens each of a second commercial 5/8-inch Type-X plate sold under the designation "Sheetrock Brand Firecode Type-X 5/8" Plate" are commercially available from the United States Gypsum Company. The Type X samples had a core density ranging from about 41.73 pcf and a plate weight of about 2250 lb/msf. Three specimens were also cut from each of the commercial 5/8-inch and %-inch Firecode® C core plates, sold under the designation "%'' and 5/8'' Firecode® C-core of the Brand Sheetrock”, respectively. These boards are also commercially available from the United States Gypsum Company. Firecode® C boards incorporate low-expansion vermiculite. The core density of the % and 5/8 inch samples range from about 48.12 pcf and about 46.86, respectively, and plate weight from about 2025 lb/msf and about 2550 lb/msf, respectively. .
[0274] The mean values of the shrink strength test results are found in Table VI in FIG. 24. The above data demonstrates that the fireproof board formed in accordance with the principles of the present disclosure had significantly higher shrinkage strength, at a much lower weight and density, using this test. The average shrinkage strength was about 88% compared to the shrinkage strength of the much heavier and denser commercial Type X board samples of about 77% and about 61%. Similar results were seen for significantly denser and heavier commercial Firecode® C panels, which demonstrated shrink strength using this test of about 74%. There was no appreciable difference in shrinkage strength using this test between the % inch and /8 inch C Firecode® samples.
[0275] For comparison purposes, the '173 patent reported that each of the % inch tested samples in its examples (unless otherwise noted) had a core density of about 43 pcf. The '173 patent further reported that at this density, the 63 samples tested showed a reported shrinkage strength of 54% (gypsum panels without small particle size inorganic material or added vermiculite) to about 85% (gypsum with clay panels and glass fibers at 0.45 weight percent of all dry core ingredients).
[0276] The '173 patent samples with only glass fibers added (0.45 weight percent of all dry core ingredients) reported a shrinkage strength of less than 60% (eg, 53.7% at 61.5%). With the vermiculite and fiberglass added, and without the small particle size inorganic material added, the samples reported shrink strength values of about 60.8% (vermiculite at 1.0 weight percent of all ingredients of dry core) and about 64.1% (vermiculite and fiberglass at 1.0 and 0.45 weight percent, respectively, of all dry core ingredients). Samples with reported shrinkage strength values of about 80% or more had a substantial clay content of 5.0 by weight of all dry core ingredients, including those samples with added fiberglass and vermiculite. In most, if not all, of the examples, little or no benefit was evidenced from the added vermiculite used, when the amount of added clay was kept constant. Therefore, it is surprising that in gypsum panel embodiments formed in accordance with the principles of the present disclosure that do not incorporate significant amounts of small particle size inorganic material, nor clay, colloidal silica or colloidal alumina in their gypsum core to resist shrinkage under high temperature conditions, these modalities, however, exhibited shrinkage strength at least comparable to, if not better than, conventional Type X gypsum panels and commercial panels using low-expansion vermiculite such as Firecode® C panels .
[0277] Thus, the formulations and methods to manufacture fire resistant gypsum panels following the principles of the present disclosure can provide gypsum panels with shrink-resistant properties, under this test, that outperform very heavy and heavier gypsum panels. dense and meet or surpass such panels with significant added ingredients, such as clay, that were needed to provide the desired shrinkage strength. Example 4
[0278] Several test runs on different days were made to produce nominal 5/8 inch thick examples of reduced weight and density gypsum panels formed in accordance with the principles of the present disclosure made using the formulation approach discussed in this document , and examples of which are shown in Table I in FIG. 19. Test run samples are further described, in part, in Table VII in FIGS. 25a-b, which also gives component quantities, plate weights, and plate densities (approximate quantities). Exemplary panels formed in accordance with the principles of the present disclosure were subjected to the tests discussed in Examples 4A through 4E below. Samples of commercially available Type X fireproof gypsum panels and glass mat gypsum panels were also obtained for comparison purposes. Commercial samples referred to as Type X panels were 5/8 inch thick SHEETROCK® brand Type X FIRECODE® gypsum panels commercially available from the United States Gypsum Company (evaluated with fire for one hour) (Sample Run 21). Commercial samples referred to as glass-mat panels were taken from commercially available 5/8 inch thick SECUROCK® brand SECUROCK® brand Glass-Mat gypsum gypsum commercially available from the United States Gypsum Company (evaluated with fire for one hour).
[0279] The specimens for the densities, shrinkage strength, z-direction High Temperature Thickness Expansion and insulation test that were taken from the gypsum panels discussed in these Examples, from the examples of the principles of the present disclosure and those panels commercial plasterboards, were taken at least six inches from the panel edges at one or more locations in the "field" of the panels, unless otherwise indicated. Example 4A
[0280] Specimens from Sample Runs 1 to 20 of reduced weight and density fire resistant gypsum panels formed in accordance with the principles of the present disclosure were subjected to the high temperature core cohesion test in accordance with EN 520 Gypsum Plasterboards - Definitions, Requirements and Test Method, which is commonly used in Europe as a standard for certain fireproof plasterboards. Procedures for this test are also discussed in ASTM report WK25392 - Revision of C473 - 09 Standard Test Methods for Physical Testing of Gypsum Panel Products (hereinafter “ASTM Pub. WK25392”) available at www.astm.org /DATABASE.CART/WORKITEMS/WK25392.htm or ASTM International in other forms or formats.
[0281] This test evaluates the ability of gypsum panels to withstand the deflection and mechanical stresses encountered when assemblies, using the panels, are exposed to high temperatures, such as those found in fires. Under high temperature conditions, for example, structural elements of assemblies, such as wall beams, can be deformed or compromised by their exposure to high temperatures. As a result, assemblies can deflect toward or away from the heat source, imposing compression and/or expansion forces on the panels.
[0282] In these tests, a test specimen of about 1.75 inches by about 12 inches (24 mm by 100 mm) is mounted horizontally with a length of a cantilever structure of about 10 inches (254 mm). A shear stress and bending moment are imposed by a weight hanging from the free end of the specimen. The weight is suspended about 0.39 inches (10 mm) above a platform. Weight mass is based on the thickness of the test specimen, ranging from about 10.6 ounces (300 g) to about 25.9 ounces (450 g), for gypsum board thicknesses of about % inches (12.7 mm) to about % inches (19.1 mm). The test specimen is exposed to flame by two horizontally opposed Meker nozzles located about 3.9 inches (100 millimeters) from the fixed end of the specimen.
[0283] The mouth of each nozzle is positioned about 1.0 inch (25.4 mm) from the adjacent face of the test specimen and adjusted so that a thermocouple is inserted about 0.2 cm (5 mm) from of specimens poured at about 1830 °F (1000 °C). If the specimen weakens and/or flexes, but remains intact, without breaking into separate pieces when the weight contacts the platform, then it is considered to have passed the test. At least six of the seven replicates must pass for the plasterboard sample to pass. Test results are expressed in terms of "pass" or "fail".
[0284] Testing for specimens from all Sample Runs used a weight of 25.9 ounces (450g). Specimens from each of the Sample Runs passed the high temperature core cohesion test despite the reduced weight and densities of the gypsum panels. Example 4B
[0285] As mentioned above, in addition to core cohesion issues, gypsum core shrinkage, due to exposure to high temperatures, also contributes to the loss of physical integrity of an assembled panel structure such as a wall unit and/or the fire barrier. A test to measure “High Temperature Shrinkage” was developed and reported in ASTM Pub. WK25392 to provide a quantitative measure of the shrinkage characteristics of gypsum panels under high temperature conditions. This test procedure reflects the fact that the High Temperature Shrinkage that gypsum board can experience under fire conditions is influenced by factors in addition to calcination reactions that can occur in gypsum board cores under high temperature conditions. The test protocol likewise uses an unventilated blast furnace so that there is no airflow from outside the blast furnace that could cool the samples. The blast furnace temperature is also approximately 1560 °F (850 °C) to account for the shrinkage that can occur in the anhydrite phases of gypsum core structures, as well as calcination and other high temperature effects when exposed to conditions of fire from high temperatures. “High Temperature Shrinkage”, as used in this document, refers to a measure of the shrinkage characteristics of gypsum panels under test and sample conditions at high temperatures consistent with those described in this document.
[0286] Panel specimens from Sample Runs 1 through 20 formed in accordance with the principles of the present disclosure were tested for the amount of x-y High Temperature Shrinkage they experienced under the high temperature conditions specified in ASTM Pub. WK25392. Specimens were also evaluated for their loss or gain in thickness in these tests. The test specimens were discs of diameter about 4 inches (100 mm) cut from the plasterboard samples using an orthopedic drill with a hole saw blade. Six specimens were needed for each test and placed in the oven side by side without touching each other. The test specimens were also placed on small pedestals to allow for uniform heating and ventilation on both sides so that they remained relatively flat, cylindrical discs.
[0287] In order to avoid thermal shock to test samples, which can produce invalid test results due to fragmentation and breakage, the testing protocol has been modified to place the samples in the blast furnace before it is heated to fence. 1560°F (850°C). The samples were placed at this temperature for a minimum of approximately 20 minutes before the blast furnace was turned off. The blast furnace door remained closed while the blast furnace cooled. Samples were not removed for measurement until after the temperature had dropped to approximately room temperature.
[0288] As gypsum board is anisotropic, the amount of shrinkage will vary slightly in the length and width directions. Therefore, two orthogonal measurements were taken and averaged to calculate the average disc diameter. In these tests, two measurements were taken at 90 degrees to each other, as this approach was found to provide a consistent measurement of average diameter from sample to sample. It has been found that the orientation of the samples in terms of “machine direction” and “cross machine direction” is not important for the purposes of this test. Typically, if the two measurements for a disk differ by more than 0.01 inch (0.25 mm), the disk would be rejected and the measurements excluded from the reported results. High temperature shrinkage was calculated as the percent change in mean diameter after exposure to heat, and denoted "S", typically to the nearest 0.1% for the group of six samples.
[0289] Data from this test are reported in Table VIII in FIGS. 26a-b and demonstrate that the core structure of exemplary panels formed in accordance with the principles of the present disclosure are significantly more resistant to High Temperature Shrinkage, (S from approximately 2% to approximately 4%), than would be expected given the reduced core density and the lack of gypsum content, which is normally considered necessary to reduce gypsum panel shrinkage.
[0290] In addition, the samples show a thickness expansion, or "High Temperature TE Thickness Expansion," in the z-direction of about 11% to more than about 30% from their initial thickness, prior to heating to its final thickness after heating. "High Temperature Thickness Expansion", as used in this document, refers to a measure of the thickness expansion characteristics of gypsum panels in the z-direction under high temperature test and sample conditions consistent with those described in this document. The ratio of High Temperature Thickness Expansion (z-direction) to High Temperature Shrinkage (ie, TE/S) provides a measure of the overall benefit of the following principles of the present disclosure, and was about 3 more 17 in Sample Runs 1 through 20.
[0291] For comparison purposes, High Temperature Shrinkage, High Temperature Thickness Expansion, and the typical expansion to shrinkage ratio of commercial 5/8 inch thick gypsum boards are also included. in Table VIII in FIG. 26b. The data, and typical weight and density data, are from the testing of commercial SHEETROCK® brand Type X FIRECODE® gypsum panels, SHEETROCK® brand Type C FIRECODE® gypsum panels, and Glass-coated gypsum panels. SECUROCK® brand treadmill, all commercially available from the United States Gypsum Company. As can be seen, the relatively low High Temperature Shrinkage in exemplary panels formed in accordance with the principles of the present disclosure is comparable, if not better, to commercial fireproof panels. Furthermore, the amount of High Temperature Thickness Expansion in the exemplary panels formed in accordance with the principles of the present disclosure is unexpectedly substantially greater than the heavier, denser conventional fireproof gypsum board, with no other effects adverse effects.
[0292] The unexpected benefit of panels formed in accordance with the principles of the present disclosure is also reflected in their High Temperature Thickness Expansion (z-direction) substantially greater at the High Temperature Shrinkage Ratio (TES) relative to panels at commercial fireproof. The relatively small High Temperature Shrinkage and substantially large High Temperature Thickness Expansion of the exemplary panels formed in accordance with the principles of the present disclosure indicate that they provide unexpected fire resistance for their weight and density at reflective temperatures from those found under conditions of structural fire. Similar results are also obtained with panels produced from other combinations of the constituent materials within the scope of the invention. Example 4C
[0293] A useful indicator of the performance of gypsum panels in assemblies, eg those using wooden beam structures, loaded as requested in ASTM E119 fire tests, is discussed in the article Shipp, PH, and Yu, Q., “Thermophysical Characterization of Type X Special Fire Resistant Gypsum Board”, Proceedings of the Fire and Materials 2011 Conference, San Francisco, January 31 - February 2, 2011, Interscience Communications Ltd., London, UK, pp. 417-426. This article discusses an extensive series of load-bearing E119 fire tests loading load-bearing wood-framed wall mounts and a correlation between the High Temperature Shrinkage and thermal insulation characteristics of commercial Type X gypsum panels and the expected performance in the scope of fire test procedures E119.
[0294] A multivariate linear regression analysis was conducted on test data with FR fire resistance (in minutes) as the dependent variable. Independent variables were percent SH shrinkage (as measured by the High Temperature Shrinkage test in Example 4B), Thermal Insulation Index TI (as measured by the test discussed below in Example 4D), wood moisture content MC (as per percent by weight), and the installation of the laboratory for testing LAB = {0, 1}. The resulting linear regression analysis established the following relationship (with an error pattern for the regression of 2.55 minutes): FR = 18.3 - 1.26 SH + 1.60 TI + 0.42 MC + 6.26 LAB (1)
[0295] Assuming tests conducted in a single laboratory (laboratory 1) and a typical wood moisture content of 13.5%, the above relationship can be expressed as follows: FR = 30.23 - 1.26*SH + 1.60*T/ (2)
[0296] Equation 2 can be rearranged to indicate a predicted minimum Thermal Insulation Index for a typical commercial Type X panel in a loaded, loaded wood beam assembly required to provide fire test performance under the E119 test procedures using data High Temperature Shrink test test. The resulting ratio can be expressed as: TI> (FR - 30.23) / 1.60 + 1.26 / 1.60*SH (3)
[0297] For fire resistance in 50, 55 and 60 minutes. The desired TI would be greater than or equal to the following: TI > 12.36 + 0.78*SH (4a) TI > 15.48 + 0.78*SH (4b) TI > 18.60 + 0.78*SH ( 4c)
[0298] As shown in Table IX in Figure 27, the above relationships expressed in equations 4a to 4c indicate that the approximate minimum IT values listed would be required to provide acceptable fire resistance under E119 conditions at about 50, 55, and 60 minutes. High Temperature SH Shrinkage values for the Sample Run panels and commercial panels are given in Table X in Figures 28a-b, as discussed in Example 4B above.
[0299] For exemplary panels of Sample Runs 1 to 20 formed in accordance with the principles of the present disclosure, the minimum IT values derived from the ratios (equations 4(a) to 4(c)) would be equal to or greater than from about 13.8 to 15.8 in 50 minutes, from about 16.6 to about 19 in 55 minutes and from about 20 to 22 in 60 minutes. These calculated IT values comparable to, if not greater than, the calculated IT values of Type X, Type C (with grade 5 vermiculite) and commercial glass faced gypsum panels are also reported in Table IX in Figure 27. The values IT costs calculated for commercial panels, at much heavier weights and densities, would be equal to or greater than about 13.9 to about 16.6 in 50 minutes, about 17 to about 19.7 in 55 minutes, and about 20.2 to about 23 in 60 minutes.
[0300] As discussed below in Example 4D, the measured IT values for samples of exemplary panels formed in accordance with the principles of the present disclosure, Sample Runs 1 to 20, equaled or exceeded these predicted minimum IT values, notwithstanding their significantly reduced weights and densities relative to Type X gypsum boards and were comparable to the measured TI values of the Type X gypsum board sample. Furthermore, under comparable testing using the U305 procedures discussed in Example 4E below, boards formed from according to the principles of the present disclosure actually provided greater fire resistance than expected when subjected to fire tests. Without being bound by theory, it is believed that the surprising increased fire resistance of panels formed in accordance with the principles of the present disclosure demonstrated in actual fire tests is attributable, in part, to the degree of High Temperature Thickness Expansion achieved by the panels and methods of the present disclosure. Furthermore, without being bound by theory, it is believed that the benefits of such significant High Temperature Thickness Expansion cannot be reflected in the above relationships when they are based on tests with Type X gypsum panels that typically exhibit a shrinkage during heating (see Table VIII in Figure 26b, Type X tests). 4D example
[0301] High Temperature Thermal Insulation Index tests in accordance with procedures discussed in ASTM Pub. WK25392 were also evaluated. This procedure provides a representative, simple test of the high temperature thermal insulation characteristics of gypsum boards. The heat transfer conditions reflected in this test can be described by the energy equation for a one-dimensional unstable heat conduction across the plate thickness: Δ/Δx (k (ΔT/Δx)) + q = pcp (ΔT/Δt) ( 5) where T is the temperature at a given time t and depth x on the plate. Thermal conductivity (k), density (p), and specific heat (cp) are non-linear temperature dependent functions at elevated temperatures. The rate of heat generation q represents a variety of endothermic and exothermic reactions, for example, phase changes of gypsum and combustion of covering paper, which occur at different temperatures and, correspondingly, at different times.
[0302] In order to assess the total heat conduction through the gypsum panel and therefore its thermal insulation performance, it is usually not necessary to measure and describe each variable separately. It is enough to assess its net cumulative effect on heat transfer. To this end, the High Temperature Thermal Insulation Index test discussed in ASTM Pub. WK25392 was developed. “High Temperature Thermal Insulation Index” as used in this document refers to a measurement of the thermal insulation characteristics of gypsum panels under high temperature testing and sample conditions consistent with those described in this document. Each test specimen consists of two 4-inch (100 mm) diameter discs that are secured by G-type horn head screws. A thermocouple is placed in the center of the specimen. The sample is then edge mounted in a rack designed to ensure uniform heating across its surface and placed in an oven preheated to approximately 930°F (500°C). The temperature rise at the center of the test sample is recorded and a thermal insulation index, TI, calculated as the time, in minutes, required for the sample to be heated from about 105°F (40°C) to about 390 °F (200 °C). The thermal insulation index of the test sample is calculated as: TI = t200°C — t40°C (6)
[0303] A temperature profile developed from data collected by this procedure often shows the transition from gypsum to hemihydrate at about 212°F (100°C) and the conversion from hemihydrate to first phase anhydrite at close to approx. 285 °F (140 °C). These data also often show that once these phase transitions are completed, the temperature rises rapidly in a linear fashion as no further significant chemical or phase change reactions typically occur below the furnace temperature of about 930°F ( 500°C). By waiting until the sample core temperature reached approximately 105 °F (40 °C) to start timing, reproducibility and acceptable repeatability were achieved.
[0304] The Thermal Insulation Index tests of samples from Sample Runs 1 to 20 are reported in Table X in Figures 28a-b. The Thermal Insulation Index (TI) data for the examples from the Sample Runs show that the core structure of low weight, low density gypsum panels formed in accordance with the principles of the present disclosure provides surprisingly thermal insulation properties. effective given its density and gypsum content. As indicated in Table X, Thermal Insulation Index values ranged from about 22 minutes to about 25 minutes for samples from Sample Runs 1 to 20. This indicates that a core composition formed in accordance with the principles of the present disclosure is a more effective heat insulator than expected, taking into account core density for purposes of withstanding the high temperatures experienced under fire and fire test conditions. These examples also show that the ratio of Thermal Insulation Index to density ranged from about 0.60 to about 0.68 minutes/pcf for the samples from Sample Runs 1 to 20. For comparison, the Insulation Index ratio Thermal to density was from about 0.55 to about 0.59 minutes/pcf for samples from Sample Runs 1 through 20 of denser commercial SHEETROCK® branded Type X FIRECODE® gypsum panels, and heavier, commercial gypsum panels. SHEETROCK® brand FIRECODE® Type C plaster, and SECUROCK® brand Glass-Mat cladding gypsum.
[0305] As indicated by these data, exemplary panels formed according to the principles of the present disclosure have somewhat lower Thermal Insulation Index values than much heavier and denser commercial panels. This can be taken as an indication that exemplary panels formed in accordance with the principles of the present disclosure would have lower fire resistance performance. However, when the density of exemplary panels formed in accordance with the principles of the present disclosure is taken into account, their thermal insulation capabilities (as reflected by IT reasons for density) are similar to or better than heavier commercial panels, denser. Furthermore, as indicated in Example 4E, exemplary panels formed in accordance with the principles of the present disclosure demonstrated unexpected fire resistance as compared to heavier, denser commercial panels when they were used in assemblies subjected to scale fire tests. complete. Example 4E
[0306] Sample Runs 1 to 20 Samples of fire resistant, low weight, low density panels formed in accordance with the principles of the present disclosure have been subjected to full scale fire testing in accordance with the procedures set forth in UL procedures of U419, U423 and U305. These test procedures describe the assembly of a test frame comprising a wall mount frame of wood or steel beams (typically beams of about 10 feet vertical, mounted between the base plate and a top plate of the same material ). Assemblies using samples of panels formed in accordance with the principles of the present disclosure from Sample Runs 1 to 17 were fire tested under the procedures of U419; an assembly using samples of panels formed in accordance with the principles of the present disclosure of Sample Run 18 was subjected to U423 fire test procedures; and assemblies using samples of panels formed in accordance with the principles of the present disclosure from Sample Runs 19 and 20 were subjected to U305 fire test procedures.
[0307] In addition, samples of SHEETROCK® brand 5/8 inch thick fireproof, one-hour fireproof Type X FIRECODE® gypsum boards for one hour commercial, (Sample Run 21), and Glass cladding gypsum panels -Securock® brand fireproof mat for one hour commercials (Sample Run 22), were subjected to procedures of U419 and U423, respectively, for comparison purposes. Sample Run 21 Type X panels weighed approximately 2250 lb/msf, with a core density of about 43.5 pcf. The Securock® panels from Sample Run 22 weighed about 2630 lb/msf, with a core density of about 51 pcf.
[0308] In tests U419 and U423, the beams were commercially available light gauge steel beams formed from steel having a thickness of about 0.015 inches to about 0.032 inches, and having dimensions of about 35/8" or 3 -1/2” inches wide by about 1-%” inches thick. The steel beams, Viper 25 steel beams (Marino/Ware, Div of Ware Industries Inc), were spaced about 24 inches apart in the assembly. The U305 test used 2 x 4 beams (approximately 3.5 inches wide by 1.5 inches thick) of #2 Douglas fir wood, spaced about 16 inches apart.
[0309] The U419 test procedures are considered some of the most stringent of the UL test types as light gauge steel beams often undergo heat deformation (usually pushing exposed panels towards the gas jet flames) due to transfer through the panels and into the gap of the assembly between the exposed and unexposed panels. This deformation often causes separation of panel joints, or other failures, on the exposed and heated side of the assembly, allowing penetration of the gas jet flame and/or high heat into the assembly span and on the unexposed and unheated side of the assembly. set. It is expected that the lighter the gauge of the steel beams, the greater the probability of heat deformation of the beams and the assembly.
[0310] The plaster panels were fixed horizontally, that is, perpendicular to the vertical beams, on each side of the set. Typically, two panels approximately 10 feet by 4 feet and one panel approximately 10 feet by 2 feet were used on each side of the structure. The 10 ft by 2 ft panel was placed on top of the set, which makes testing more difficult for the set than if the thinner panel were placed in the middle between the wider panels or at the bottom of the set. Horizontal edge joints and butt joints on opposite sides of the beams were not staggered. The panels were secured to the frame with one-inch S-type high/low screws on each side of the assembly, eight inches off center. The panels were positioned so that the seams between the panels on each side of the structure were aligned with one another. Then the seams were sealed with paper joint tape and joint putty.
[0311] The type of test, the type of beam and the results expressed in time (minutes and seconds) until the end of the test are indicated in Table XI in FIGURES 29a-c. In tests following the U419 procedures, the steel used to form the light gauge beams was 0.015 inches or 0.018 inches thick. Testing subsequent to the U423 procedures used commercially available steel beams made of steel about 0.032 inches thick. Under U419 procedures, the assembly is not subject to external load. In the U419 test, the samples failed by exceeding the prescribed temperature limits. Under the U423 and U305 procedures, a total external load of approximately 9,520 lb (U423) and 17,849 lb (U305) was applied to the top of the assembly. In the U 423 and U 305 tests, the samples failed by breaking under load rather than exceeding the prescribed temperature limits.
[0312] In each of the tests, the completed panel assembly and structure were positioned so that one side of the assembly, the exposed side, was subjected to a series of gas jet blast furnace flames that heated the exposed side assembly at temperatures and at a rate specified by ASTM ASTM E119 in accordance with procedures U305, U419, and U423. Examples of the ASTM E119 heating curve are shown in FIGURES 9 and 10. In accordance with these ASTM and UL procedures, a series of approximately 14 sensors were positioned in spaced relationship between the exposed heated side of the assembly and each of the gas jets. to monitor the temperatures used to heat the exposed side of the assembly. Also in compliance with these ASTM and UL procedures, the sensor array has been arranged in spaced relationship on the unexposed heated opposite side of the assembly. Typically 12 sensors have been applied to the unexposed surface of the assembly in a standard conforming to UL and/or ASTM specifications. In accordance with these procedures, each sensor was also covered by an insulating pad.
[0313] During the fire test procedures, the blast furnace temperatures used followed the ASTM E119 heating curve, starting at room temperature and increasing on the exposed side of the assembly to over 1600°F in approximately one hour, with the faster temperature change occurring at the beginning of the test and near the completion of the test. The test was terminated when there was a catastrophic failure of the assembly structure, the average temperature of the sensors on the unexposed side of the assembly exceeded the preselected temperature, or when a single sensor on the unexposed side of the assembly exceeded a second preselected temperature. selected.
[0314] The fire test data are plotted in FIGURES 9-16. FIG. 9 shows the graph of a single sensor maximum temperature on the unexposed surface of each of the paneled assemblies from Sample Runs 1 to 17 and commercial samples 21, from the start of each test to the end of the test. As mentioned above, FIG. 9 also shows the graph of the ASTM E 119 temperature curve used for the blast furnace temperatures on the exposed side of the assemblies. FIG. 10 shows a graph of the average unexposed surface temperatures of each of the paneled sets of Sample Runs 1 through 17 from the beginning to the end of each test, as well as the ASTM E 119 temperature curve used for the high temperatures -oven on the exposed side of the sets. As indicated by the data graphs, the unexposed side, maximum single sensor and average sensor temperatures for all sets were closely aligned during the test, despite the very significant differences in density and gypsum content between the panels of Sample Runs 1-20 and the much denser and heavier commercial Type X glass-faced gypsum panels, Sample Runs 21 and 22.
[0315] As indicated in FIGURES 9 and 10, in addition, there is an inflection in the graphs between about 50 to 55 minutes elapsed and after the inflection point the maximum single sensor and average sensor temperatures not exposed for each test show a sharp increase in slope. It is believed, without limitation by such theory, that the inflection point indicates a point where the exposed heated panels of the assembly are close to or beyond the limits of their thermal insulation and heat sink capabilities and thus the transfer of heat. heat across the assembly rapidly increases with the completion of the test. This transmission can be through the panels themselves or through one or more openings in the joints between the panels. Regardless of the specific reasons for the inflection points shown by the data, it was unexpected that the temperatures transmitted through the panels and assembly spans and the temperature transmission rates were comparable for panels with reduced weight and density formed in accordance with the principles of the present disclosure and heavier panels with higher core density.
[0316] FIGURES 11 and 12 are graphs of the maximum single sensor and average sensor temperatures, respectively, on the unexposed surface of each of the assemblies in the U419 fire tests using Sample Runs 1 to 17 and Sample Type X panels commercial 21. FIGURES 11 and 12 show an expanded plot of data from 40 minutes elapsed to 65 minutes elapsed (all tests were terminated before 65 minutes). These data graphs show in more detail the approximate correspondence of the fire resistance of panels formed in accordance with the principles of the present disclosure, and assemblies made using such panels, and much denser and heavier Type X panels, and assemblies using the panels Type X up to between about 50 to 55 minutes.
[0317] Measured temperatures for assemblies using panels from sample runs of panels formed in accordance with the principles of the present disclosure continued to closely match those of commercial panels from about 55 minutes to over 60 minutes. FIGURES 13 and 14 show a plot of the data of FIGURES 9 and 10, respectively, for sets using the exemplary panels formed in accordance with the principles of the present disclosure of Sample Runs 5, 14 and Sample 21 (the Type panel example X commercial). These data show that panels formed in accordance with the principles of the present disclosure, and assemblies made using such panels, are capable of providing panels with a fire resistance comparable, if not better, to much heavier and denser commercial panels under the condition of UL U419 fire test for at least 60 minutes. Similar results are also obtained with panels produced from other combinations of constituent materials within the scope of the invention.
[0318] It was also noted that, after about 50 minutes, the temperatures for assemblies using panels from Sample Runs 6, 7, and 9 increased somewhat faster than assemblies using panels from other Sample Runs. As seen in Table VII in FIG. 25b, Sample Run 6 panels have the lowest weight and density, and Sample Runs 7 and 9 panels may be subject to excessive drying. Likewise, temperatures for sets using panels from Sample Runs 8 and 15 also increased slightly faster than the remaining sets. As also indicated in Table VII, the panels in Sample Runs 8 and 15 may also have been affected by excessive drying or impurities in the gypsum source. Without being bound by theory, it is believed that these fabrication conditions and materials contributed substantially to the differences between the temperature profiles of assemblies using the panels and those of assemblies using panels from other Sample Runs.
[0319] Taking into account these considerations and the difficulty of the U419 test patterns, the data from such tests show that panels formed according to the principles of the present disclosure nevertheless presented surprisingly effective fire resistance, considering their weights and densities . Collected together, data from assemblies using panels formed in accordance with the principles of the present disclosure further show that the methods and panels of the present disclosure can provide robust fire resistant assemblies that offer the average person of skill in the art considerable flexibility to adjust the vermiculite and stucco content of the panels to compensate for significant variations, manufacturing conditions and raw material quality.
[0320] FIGS. 15 and 16 are graphs of the maximum single sensor temperature and average sensor temperature on the unexposed surface of each of the assemblies in the U423 fire tests of the assemblies, using the panels in Sample Runs 18 and 22. FIGS. 15 and 16 show an expanded graph of data from 40 minutes of elapsed time to 65 minutes of elapsed time (all tests ended before 65 minutes). This data plot shows in more detail the comparable heat resistance of assemblies using panels formed in accordance with the principles of the present disclosure and the heavier and denser commercial glass-mat-faced gypsum panels (Sample Run 22) , even though the panels' glass cladding sheets would be expected to provide additional fire resistance in this test. These data, specifically data after 50 minutes of elapsed time, confirm that panels formed in accordance with the principles of the present disclosure, and the assemblies that use them, are capable of providing fire resistance comparable to (and in some cases potentially better than) much heavier and denser commercial panels under the U423 fire test conditions.
[0321] The data presented in Table XI in FIGS. 29a-c give the maximum temperatures reached by any sensor and the average of all sensors on the unexposed surface of the mount over the 50, 55, and 60 minute elapsed time. Table XI also reports the maximum temperature reached by any sensor and the average of all sensors on the unexposed surface of the assembly at the end of the test. In the tests of Sample Runs 6, 7 and 8, the test ended in 58 minutes (Samples 6 and 7) or 59 minutes (Sample Run 8) and thus the maximum temperature of the single sensor and the average of the sensor, in the closing, are the same.
[0322] For U419 tests, a maximum single sensor temperature of less than about 260°F on the unexposed surface of the mount and/or an average sensor temperature of less than about 250°F on such an unexposed surface, the approx. 50 minutes of elapsed time was considered an indication of a successful test and an indication that the core formulation of the gypsum panel tested and the manufacturing process, and the assemblies using the panels formed in accordance with the principles of the present disclosure are able to meet or exceed the requirements for a “one hour” fire assessment under the appropriate UL testing procedures. Similarly, a maximum single sensor temperature less than about 410°F on the unexposed surface of the mount, at about 55 minutes, and/or an average sensor temperature less than about 320°F on such an unexposed surface , at about 55 minutes, on the U419 was yet another indication that the panels and methods of the present disclosure could be used to provide a fire resistant assembly suitable for use in fireproof applications. This was confirmed by results showing temperatures less than 300°F on the unexposed surface of the mount at about 55 minutes and/or an average sensor temperature less than about 280°F on such unexposed surface at about 55 minutes for many of the mounts under the U419 test conditions.
[0323] The fact that assemblies using panels formed in accordance with the principles of the present disclosure have demonstrated a single sensor maximum temperature, at about 60 minutes of elapsed time, less than about 500°F on the unexposed surface of the assembly and/or an average sensor temperature of less than about 380°F on such an unexposed surface has also demonstrated the surprising fire resistance of panels formed in accordance with the principles of the present disclosure, and the assemblies utilizing them, under the U419 standards, gave the panels reduced weight and density. Many of the assemblies that have experienced a maximum single sensor temperature, at about 60 minutes of elapsed time, less than about 415 °F on the unexposed surface of the assembly and/or an average sensor temperature of less than about 320 °F at such unexposed surface demonstrated that panels formed in accordance with the principles of the present disclosure, and assemblies utilizing them, under the U419 test standards could qualify for a 60 minute fire assessment under those standards.
[0324] Regardless of the sensor-specific maximum and average temperatures at 50, 55, and 60 minutes, the results of assemblies using the panels from Sample Runs 1 to 17 were still surprising when compared to Type X gypsum and glass-faced panels commercial samples from Sample Runs 21 and 22. Given the very significant differences in weight and density between Sample Runs 1 through 17 and the much heavier and denser commercial samples, one would expect to see much greater differences in maximum sensor temperatures and average sensor temperatures over each of the 50, 55, and 60 minute elapsed time periods. The average sensor temperatures for the unexposed surface of panels from most Sample Runs 1 to 17 also do not reflect the considerably lower weight and density of those panels relative to commercial panels from Sample Runs 21 and 22.
[0325] As also reflected in Table XI in FIGS. 29a-c, the single sensor maximum temperature and the sensor average on the unexposed side of the assemblies using the Sample Runs 18, 19, and 20 panels were very similar, and in some cases better than the weatherproof plate. commercial fire in the assemblies tested under the procedures of U423 and U305, both of which use wooden beams and impose weight loading on the assemblies. For example, the panels from the Sample 18 Run proved that an assembly with the unexposed side temperatures was very similar in 50, 55 and 60 minutes to those of Sample 22 of the commercial fireproof panel in assemblies using 0.032 inch steel beams. steel tested under U423 procedures. For assembly using panels formed in accordance with the principles of the present disclosure from Sample Run 18 in these tests, the maximum single sensor temperatures were less than about 255°F, 270°F, and 380°F, at about 50, 55 and 60 minutes of elapsed time, respectively. The average sensor temperatures were less than about 220°F, 235°F, and 250°F, at about 50, 55, and 60 minutes of elapsed time, respectively. Exemplary panels formed in accordance with the principles of the present disclosure from Sample Run 18, in fact, surprisingly evidenced a single sensor temperature comparable, in 60 minutes, to the commercial Sample Run 22, a much more gypsum panel. heavy and much denser with fiberglass coating sheets. This result is particularly notable since the fiberglass cladding sheets in the panels of Sample Run 22 are believed to improve the fire resistance of the panels over the same panels with paper cladding sheets.
[0326] Similarly, panels from Sample Runs 19 and 20 tested in assemblies using wooden beams under the procedures of U305 demonstrated maximum single sensor temperatures less than about 250 °F, 260 °F and 265°F , at about 50, 55 and 60 minutes of elapsed time, respectively. Average sensor temperatures in these mounts were less than about 230°F, 240°F, and 245°F, at about 50, 55, and 60 minutes of elapsed time, respectively.
[0327] In addition, under commonly accepted UL standards, the data in Table XI in FIGS. 29a-c indicate that reduced weight and densities gypsum panels formed in accordance with the principles of the present disclosure were capable of meeting or exceeding the standards required for approval as a commercial "one hour" fireproof gypsum panel under the procedures of U419. For example, fire testing the assembly using panels formed in accordance with the principles of the present disclosure from Sample Run 17 reported in Table XI, among others of the assemblies using the panels of the present disclosure, would qualify under the commercial "one hour" fireproof panel standards of U419 specifications. Mounting made according to U419 using Sample Run 17 panels evidenced a single sensor maximum temperature, on the unexposed side, lower than the ambient temperature at the start of the test plus 325°F and an average sensor temperature less than ambient temperature plus 250 °F. In this fire test, the single sensor maximum was below the required temperature until 60 minutes and 18 seconds elapsed, and the average sensor temperature was below its limit until 60 minutes and 8 seconds elapsed. Consequently, this test confirmed that the formulation and procedures used to make the Sample Run 17 panels could qualify for one hour fireproof panels under U419 standards.
[0328] Similar results were observed for the sample panels of Sample Runs 18, 19, and 20, which were tested under test procedures U423 and U305. The temperature limits used for sensors on the unexposed surfaces of these assemblies were calculated in the same way (single sensor maximum ambient temperature plus 325°F and an average sensor temperature less than ambient temperature plus 250°F). For Sample Run 18, the single sensor temperature threshold and the mid-sensor threshold were reached at about 62 minutes, 27 seconds and 62 minutes, 35 seconds, respectively. For Sample Runs 19 and 20, tests were completed before any threshold was reached in more than 63 minutes, 40 seconds for Sample Run 19, and more than 64 minutes, 35 seconds for Sample Run 20. This established that panels formed in accordance with the principles of the present disclosure would qualify as fireproof for one hour under these tests.
[0329] The above data from Examples 4A to 4E thus demonstrates that reduced weight and density panels formed in accordance with the principles of the present disclosure, and the assemblies utilizing them, provide structural integrity, heat dissipation, and heat dissipation properties. insulation (or a combination thereof) comparable to much heavier and denser commercial panels, without the significantly higher gypsum content of those commercial panels. In addition, the fact that light-gauge, reduced-density gypsum panels formed in accordance with the principles of the present disclosure demonstrate such structural integrity, heat dissipation and insulating properties in assemblies using light gauge steel beams (considered among those most likely to deform and be adversely affected by high temperatures) would not be anticipated by a person skilled in the art. Similar results are also obtained with panels produced from other combinations of the constituent materials within the scope of the invention.
[0330] A concern during testing, furthermore, was that the panels from Sample Run 1, 6 through 10, and 15 were subject to issues during manufacture that could affect their resistance to high temperatures in the fire tested assemblies. Such issues were potential problems with core plaster hydration (Sample Run 1), potential over drying (Sample Runs 7 to 10) and increased levels of impurities in the gypsum source (Sample Runs 8 and 15). Fire test results indicate that such manufacturing issues may have affected some of the exemplary panels formed in accordance with the principles of the present disclosure (eg, Sample Runs 6, 7, 9, and 15). The results also demonstrate that such issues can be overcome and/or compensated for by the formulation of the core and the methods for producing the panels, following the principles of this disclosure. In addition, the test results confirm that any necessary adjustments to the fire performance of the reduced weight and density panels of the present disclosure can be made by adjusting the relative amounts of high expansion vermiculite and gypsum to achieve the desired fire performance. Example 5
[0331] In this example, the panel samples from Sample Runs 1 to 20 were subjected to a nail tensile strength test to determine the strength properties of the panel under this commonly used criterion. The nail tensile strength test is a measure of a combination of the strengths of a gypsum board core, its cladding sheets, and the bond between the cladding sheets and plaster. The test measures the maximum force required to pull a nail with a head through the panel until large tile cracks occur. In the tests in this Example, the nail tensile strength tests were performed in accordance with Method B of ASTM C473-95.
[0332] Briefly summarized, the tested samples were conditioned at approximately 70°F and 50% relative humidity for 24 hours prior to testing. A 7/64 inch drill bit was used to drill pilot holes through the thickness of the samples. The samples were then placed on a sample backing plate with a three inch diameter hole in the center, which was perpendicular to the path of the test nail. The pilot hole was aligned with the tip of the nail shank. Load was applied at a strain rate of one inch per minute until maximum load was reached. At 90% of the peak load, after passing the peak load, the test was stopped and the peak load was recorded as resistant to nail pull.
[0333] Nail tensile strength results are summarized in Table XII in figure 30 for Sample Runs 1 to 20. As indicated in Table XII, four additional samples, Sample Runs 23 to 26, were also subjected to the nail test. Nail tensile strength. Sample Runs 23 to 25 were examples of low weight and low density gypsum panels following the principles of the present invention and made in accordance with the formulation of Table I in Figure 19 and Sample Runs 1 to 20 of Table VII in figures 25a-b, with the variations in weight and density as indicated in Table XII in Figure 30. Sample Run 26 was a Type X FIRECODE® SHEETROCK® brand gypsum panel rated for 5/8 commercial “one hour” commercially available inches thick with a weight of about 2250 lb/msf and density of about 43 pcf.
[0334] Average nail tensile strength values for exemplary lightweight and low-density panels formed in accordance with the principles of the present disclosure ranged from about 73 lb-f to about 107 lb-f. This indicates that, despite the low density and high expansion use of vermiculite in panels formed in accordance with the principles of the present disclosure, panels of the present disclosure can obtain a minimum nail tensile strength value comparable to proof plaster panels of heavier and denser fire. Furthermore, it has been indicated that panels formed in accordance with the principles of the present disclosure can obtain satisfactory nail tensile strength values for commercial purposes, which for 58 inch gypsum panels with liner paper sheets is approximately 96 lb-f. Similar results are also obtained with panels produced from other combinations of constituent materials within the scope of the invention. Example 6
[0335] Exemplary panels formed in accordance with the principles of the present disclosure and made in accordance with Table I in Figure 19 and Sample Runs 17 to 19 of Table VII in Figures 25a-b were subjected to the flexural strength test for determine the strength properties of the panel under this commonly used criterion. Flexural strength testing can generally include a procedure to assess the ability of gypsum panel products to resist bending stresses during material handling or use. This test method evaluates the bending properties of gypsum panel products by supporting the specimen near the edges and applying a transverse load at an intermediate point between the supports. In particular, flexural strength testing was performed on sample panels from Sample Runs 17,18, and 19 in accordance with Method B of ASTM C473-95.
[0336] Briefly summarized, the tested samples were conditioned at approximately 70°F and 50% relative humidity for 24 hours prior to testing. Four pieces of the sample, each 12 inches (305 mm) by approximately 16 inches (406 mm), are cut from each gypsum board sample, two having a 16-inch dimension parallel to the edge and two having a 16-inch dimension perpendicular to the edge. An apparatus with parallel sample holders spaced 14 inches (357 mm) apart at the centers, measured at the surface contact points with the sample, and attached to a plate that is rigidly attached to the test apparatus is used to support each sample centrally on the fixed parallel supports. A load is applied at an intermediate point of similar support between the supports. For samples with the long dimension parallel to the edge, test one sample of each plasterboard product facing up and the other facing down. For samples with the long dimension perpendicular to the edge, test one sample of each plasterboard product facing up and one facing down. Calculate and report the average breaking load in pounds-force (lb-f) or Newtons (N) for each test condition. The test conditions are: (1) parallel, facing up; (2) parallel, facing down; (3) perpendicular, facing up; and, (4) perpendicular, facing downwards.
[0337] The flexural strength test results are summarized in Table XIII in Figure 31 for samples from Sample Runs 17, 18, and 19. As indicated in Table XIII, gypsum panels formed in accordance with the principles of the present disclosure meets or exceeds the flexural strength standards set forth in ASTM specification C 1396 / C 1396M-06 for 5/8” thick gypsum panels (ie, 147 lb-f (654 N) with support edges perpendicular to length of panel, and 46 lb-f (205 N) with support edges parallel to panel length). Example 7
[0338] Exemplary panels formed in accordance with the principles of the present disclosure and made in accordance with Table I in Figure 19 and Sample Runs 17, 18, and 19 of Table VII in figures 25a-b were subjected to hardness testing of core, edge, and edge to determine panel strength properties under these commonly used criteria. Hardness tests can generally include a procedure for evaluating the ability of the gypsum panel product's core, edges, and edges to resist crushing during handling or use of the material. This test method evaluates the hardness of gypsum panel products by determining the force required to propel a steel punch into the test area. In particular, core, tip, and edge hardness testing was performed on sample panels from Sample Runs 17, 18, and 19 in accordance with Method B of ASTM C473-95.
[0339] Briefly summarized, the tested samples were conditioned at approximately 70°F and 50% relative humidity for 24 hours prior to testing. A portion of the core hardness test sample of not less than 12 inches by 3 inches (305 mm by 76 mm) was cut from the center of each gypsum panel sample. A portion of the sample for the edge hardness test of not less than 12 inches by 3 inches (305 mm by 76 mm) was cut from one end cut by grinding each gypsum panel sample. The 12-inch (305-mm) dimension for the core hardness and edge hardness samples is perpendicular to the edges of the plasterboard sample. A portion of the edge hardness test sample of not less than 12 inches by 3 inches (305 mm by 76 mm) was cut from both edges of each gypsum panel sample. The 12-inch (305-mm) dimension of the edge hardness samples is parallel to the edges of the plasterboard sample.
[0340] A means for securing the sample to the base of the testing apparatus is provided so that the face of the sample is perpendicular to the base of the testing apparatus and parallel to the movement of the steel punch. The steel drill is positioned so that its central axis is parallel to the path line. The specimen is held in a fixed vertical position on its 12 inch (305 mm) dimension edge. Three tests, spaced approximately 4 inches (102 mm) apart, are performed on each specimen, with the first test area 2 ±1/2 inches (51 ±13 mm) from one edge of the specimen. The steel drill is positioned over the test area and the load is applied. The core, tip, or edge hardness measurement is reported as the load in pounds-force (lb-f) or newtons (N) required to propel the steel drill a distance of 1/2 inch (13 mm) on the core of the sample. The core, tip, and edge hardness of the sample is reported as the average of the three sample measurements.
[0341] Core, edge, and edge hardness test results are summarized in Table XIV in Figures 32a-c for samples from Sample Runs 17, 18, and 19. As indicated in Table XIV, gypsum panels formed following the principles of the present disclosure meet or exceed the core, edge, and edge hardness standards set forth in ASTM specification C 1396 / C 1396M-06 for gypsum panels (ie, 11 lb-f (49 N)). Example 8
[0342] Exemplary panels formed in accordance with the principles of the present disclosure and made in accordance with Table I in Figure 19 and Sample Runs 17 to 19 of Table VII in Figures 25a-b were tested for sound transmission and a value transmission class (“STC”). Panels from Sample Runs 17, 18, and 19 were tested on two basic wall mounts prepared in accordance with UL test procedures U305 and U419. The U305 type mount was made of wood beams approximately 2 x 4 inches, spaced approximately 16 inches off center. Type U419 mounts were made from 3 5/8 inch 25 gauge (about 0.015 inch thick) steel beams arranged 24 inches off center. Both types of beams were arranged in an 8’x8’ frame.
[0343] All assemblies consisted of a single layer of plaster on each face of the assembly. The mounts, in addition, have been tested with and without approximately 3 %” of fiberglass insulation in the wall cavities. Exemplary low weight, low density gypsum panels formed in accordance with the principles of the present disclosure had an average weight of about 1900 lb/msf, and a core density of about 36 pcf.
[0344] Panel assemblies and sound transmission test results including STC values determined in accordance with ASTM E90/ASTM E413 Specification are summarized XV in Figure 33. Assemblies made of steel beams and using panels formed from in accordance with the principles of the present disclosure have demonstrated STC values of about 1 to 2 points lower than typically found with corresponding steel beam assemblies constructed with the higher density, commercial Type X panels. In wooden structures, however, assemblies using panels formed in accordance with the principles of the present disclosure obtained STC values very similar to typical values for comparable assemblies using commercial type X panels. It is generally understood that any STC difference of less than 3 points is not noticeable to the untrained human ear and therefore the general differences of 1 to 2 points between the STC values of the example panels formed according to the principles of the present advertising and commercial Type X panels should not be noticeable to most listeners. As demonstrated by these tests, the low-weight, low-density gypsum examples of the panels surprisingly have sound transmission characteristics very similar to much heavier and denser gypsum panels, in addition to their other benefits discussed in this document. Similar results are also obtained with panels produced from other combinations of constituent materials within the scope of the invention. Example 9
[0345] Test cubes were made from the gypsum board formulations of Table XVI in Figures 34a-b to examine the effect of adding siloxane to the slurry used to make gypsum board following the principles of the present disclosure.
[0346] A high shear mixer running at about 7500 RPM 2.5 minutes was used to make the siloxane emulsion. The siloxane emulsion was mixed with stucco and additives to make a slurry with 10 seconds of immersion plus 10 seconds mixing at high speed of a Waring mixer. The slurry was converted into 2" x 2" x 2 cubes and dried at 115°F overnight. Densities were adjusted by varying the water/stucco ratio. The ASTM C1396 water absorption test method was performed by placing dry cubes in water at 70°F for 2 hours and determining the percent weight gain.
[0347] The test results are set out in the final row of Table XVI. These data show that water absorption below about 5% was achieved using siloxane from about 8 to about 12 lb/MSF and about 2.15% pregelatinized starch at cube densities as low as about 30 lb/ft3. This example, therefore, establishes that the presence of more than about 2% pregelatinized starch works in conjunction with the siloxane to achieve unexpected, improved water resistance. Example 10
[0348] The amount-altering effects of vermiculite with thermal properties, including High Temperature Shrinkage, High Temperature Thickness Expansion, and thermal insulation characteristics of high expansion vermiculite used in panels and methods in accordance with the principles of the present disclosure were evaluated under substantially identical heating conditions. In this study, laboratory samples were prepared using 1000 grams of stucco, 11 grams of heat resistant accelerator, 15 grams of pregelatinized starch, 6 grams of fiberglass, and 2000 ml of water at 70°F. These laboratory samples were prepared using different amounts and types of high expansion vermiculite according to the formulations set out in Table XVII in Figure 35.
[0349] Laboratory samples differ only in the type and amount of high expansion vermiculite used in sample preparation. Polabora micron and superfine (Ratings 0 and 1, respectively) are commercially available from South Africa. As shown in Figure 19, these South African classifications of vermiculite are comparable to Grade 4 of vermiculite using the grading system. USA. The Polabora Classification 0 has a particle size distribution that substantially corresponds to the commercially available classification 4 of vermiculite in the US classification system. The Polabora Classification 1 has a particle size distribution that includes a larger portion of larger particles, but which overlaps with the classification 4 of vermiculite samples using the US classification system.
[0350] Laboratory samples were evaluated using the High Temperature Shrinkage test protocol described in ASTM Pub. WK25392 and discussed in Example 4B. ASTM Pub. WK25392 and the preceding discussion thereof are incorporated in this document. Data from this test are reported in Table XVII in Figure 35. For each sample run, six test samples were evaluated using the High Temperature Shrinkage and High Temperature Thickness Expansion (z direction) test described in ASTM Pub. WK25392 . An average of the results of the six test samples is found in Table XVII. Testing demonstrates that the ratio (TE/S) of High Temperature Thickness Expansion (z direction) to High Temperature Shrinkage generally increases with increasing amounts of high expansion vermiculite. This performance change reduced or diminished once the use of vermiculite reached about 10% by weight of stucco. These results are consistent between the two different types of high expansion vermiculite used.
[0351] Laboratory samples were evaluated using the High Temperature Thermal Insulation Index test protocol described in ASTM Pub. WK25392 and discussed in Example 4D. ASTM Pub. WK25392 and the preceding discussion thereof are incorporated into this document. Data from this test is reported in Table XVIII in Figure 36. For each sample run, two test samples were evaluated using the High Temperature Thermal Insulation Index test described in ASTM Pub. WK25392. An average of the results of the two test samples is found in Table XVIII. The test demonstrates that the high temperature Thermal Insulation Index of laboratory samples increases somewhat with increasing amounts of high expansion vermiculite. This performance change was reduced or diminished as the use of vermiculite reached about 10% by weight of stucco. These results are consistent between the two different types of high expansion vermiculite used. Example 11
[0352] Laboratory studies were conducted regarding the effectiveness of an HEHS additive, aluminum trihydrate (ATH), used in gypsum core formulations following principles of the present disclosure. The properties of sample panels made using those formulations were evaluated in terms of High Temperature Thermal Insulation Index ("TI"), and High Temperature Shrinkage ("% SH") and High Temperature Thickness Expansion ("% of TE”). In Examples 11A, 11B and 11C discussed below, core formulations were prepared using varying amounts of stucco, high expansion vermiculite, ATH, heat resistant accelerator ("HRA"), pregelatinized starch, trimetaphosphate, fiberglass, naphthalenesulfonate dispersant, and water according to the formulations discussed in each Example for Core Formulation Samples 1 to 20.
[0353] Quantities of each component are given in "parts" by weight, which can be pounds, grams, or other units of measure. Where a value for a component in a core formulation is expressed as a percentage, this refers to the amount of the component relative to the stucco component as a percentage by weight. Where component quantity is expressed in terms of pounds per thousand square feet (lb/msf), the reported value is a calculated, approximate equivalent to the component weight quantity in thousand square feet of panel approximately 58 inches thick ( approximately 0.625 inch, 15.9 mm), based on the amount by weight of the component in the formulation.
[0354] For each of the sample formulations, the dry ingredients were combined with water in a Waring blender to provide consistent, well-mixed gypsum slurry. Then two panels approximately 12 inches by 12 inches (30.5 cm by 30.5 cm), approximately 58 inches thick (approximately 0.625 inches, 15.9 mm), were formed with each of the sample formulations. . To form the panels, the slurries of each sample formulation were hand molded between a top paper of about 48 pounds per msf and a bottom layer paper of about 42 pounds per msf.
[0355] Each of the molded panels was allowed to set until hydration of the plaster was substantially complete and then dried at about 350°F (about 177°C) for about 20 minutes and about 110°F ( about 40°C) for about 48 hours. The water content of the formulation was used to provide the indicated weight and mounting density, hand molded dry samples. Foam was not added to sample formulations. The following approximate values are reported in Figures 38, 40, and 41, Tables XXa through XXIIb, for panels formed from Formulation Samples 1 to 20: panel density (pounds per cubic foot), high expansion vermiculite , the approximate plaster weight in lb/msf, approximate ATH and the approximate ATH weight in lb/msf.
[0356] From each panel, ten four-inch disks were cut. Two assemblies (four discs of ten discs) were used for the High Temperature Thermal Insulation Index tests. The remaining six discs were used for the High Temperature Shrinkage and High Temperature Thickness Expansion tests. The High Temperature Thermal Insulation Index results are the average of two readings (that is, the average of the readings for each of the two assemblies). The High Temperature Shrinkage and High Temperature Thickness Expansion percentages reported are an average of six reads (that is, the average of the six disk reads). The High Temperature Thermal Insulation Index test (reported in minutes as mentioned above) was performed using the protocol described in ASTM Pub. WK25392 and discussed in Example 4D. The High Temperature Shrinkage and High Temperature Thickness Expansion tests (reported in the change in dimensions, as mentioned above) were done using the protocols described in ASTM Pub. WK25392 and discussed in Example 4B. The data from these tests is reported in the tables in Figures 38, 40, and 41 in terms of the average of the results of each disk mount tested (that is, the average of the two disk mounts tested for IT and the average of the six disk mounts tested for shrinkage and expansion).
[0357] The High Temperature Thermal Insulation Index ("TI") test discussed in Examples 11A to 11C demonstrates that a given amount of ATH by weight is more efficient in increasing the High Temperature Thermal Insulation Index than an amount stucco equivalent in weight. With or without the presence of high-expansion vermiculite, these test results show that generally about 40 to 50 lbs/msf of ATH can provide similar thermal insulation protection, such as about 100 lbs/msf of stucco or more (this amount of stucco may vary by stucco source and purity). This test also demonstrates that ATH can be used with high expansion vermiculite without any significant adverse effect on the High Temperature Shrinkage and High Temperature Thickness Expansion properties of the panels. The panels of Examples 11A through 11C generally continued to exhibit High Temperature Shrinkage values of about 10 or less and a ratio (TES) of High Temperature Thickness Expansion (z direction) to High Temperature Shrinkage of about 0. 2 or more. In some formulations, data also indicate that the ATH additive improves the High Temperature Shrinkage and High Temperature Thickness Expansion properties of the panels. Although these tests have been performed on samples created in the laboratory, it is expected that comparable results will be achieved using full production and process formulations that include the addition of foam to the core formulation to produce air voids in the gypsum core of the assembly. dry panels. Example 11A
[0358] In this example, a stucco (stucco A) prepared from a synthetic gypsum source was used to prepare the core formulations for Samples 1 to 9. Gypsum panels produced with this synthetic gypsum stucco typically show shrinkage on High Temperature Higher in relation to panels formed from high purity natural plaster. The base core formulation was made using the following approximate amounts by weight: 600 parts (Samples 1 to 8) or 579 parts (Sample 9) of stucco A; 6 parts of HRA; 4.2 parts of pregelatinized starch; 0.84 piece of trimetaphosphate; 0 parts (Sample 1) or 42 parts (Samples 2 to 9) of high expansion vermiculite (0% or 7% by weight of stucco, respectively); 3 parts of glass fibers; 0.8 part naphthalenesulfonate dispersant; 0 parts (Sample 1), 12 parts (Sample 4), 21.1 parts (Samples 2, 5 and 9), 30 parts (Sample 6), 42.2 parts (Sample 7) and 60 parts (Sample 8) of ATH (2%, 4%, 5%, 7% and 10% by weight of stucco, respectively); and 1290 parts of water.
[0359] Each of the Core formulation Samples 1 through 9 were molded into panels and tested for High Temperature Thermal Insulation Index, High Temperature Shrinkage and High Temperature Thickness Expansion, as mentioned above. The molded and dried panels of each of the sample formulations had the approximate values for density, high expansion vermiculite content, stucco, ATH and TI reported in Tables XXa and XXb, Figures 38A and 38B, respectively. Table XXa also reports the difference between core formulations having no ATH (Sample 1), and having 4% ATH with a reduced stucco content (Sample 2), both without high expansion vermiculite. Table XXb similarly reports the difference between a core formulation having no ATH (Sample 3) and the TI values for core formulations having increasing amounts of ATH with decreasing amounts of stucco (Samples 4 to 9) , which contained 7% high expansion vermiculite. Table XXc, Figure 38, reports the results of approximate density, % high-expansion vermiculite, % ATH, % High Temperature Shrink, and % High Temperature Thickness Expansion for panels made from each of the Core formulation samples 1 to 9.
[0360] Table XXa shows that ATH can be added in an amount (here 4% by weight of stucco) that is effective to increase the IT of the panels for about one minute, despite a stucco reduction of about 20 pounds /msf. This benefit was achieved without the use of high expansion vermiculite. Table XXb shows the effect of core formulations, Samples 3 to 9, with increasing amounts of ATH in relation to stucco content, from 0% to as high as 10%, in conjunction with the use of high expansion vermiculite in 7 % by weight of stucco.
[0361] Sample formulations 3 through 9 provided an increase in IT from about 23 to about 26 minutes. The effect of adding ATH to these formulations is further summarized in Figure 39, which plots ATH versus TI in minutes of panels made with Sample 3 to 9 formulations. As shown in Figure 39 and Table XXb, with up to about 5% ATH, the TI of Sample formulations 3 through 6 increased up to about two minutes, despite reducing the amount of stucco in the core formulation by about 25 lb/msf in Samples 5 and 6. Similarly, the TI increased as much as about 3.3 minutes in the Sample 8 formulation, with 10% ATH and a reduction of about 15 lbs/msf of stucco. The test results of each of the Sample assemblies with the same approximate stucco content — Samples 5 and 6, and 7 and 8 — also show that increasing the amount of ATH provides an increase in TI values.
[0362] Formulation Samples 3 to 9 with ATH also show improvements in High Temperature Shrinkage and High Temperature Thickness Expansion results. Formulation Sample 1 without ATH and without high expansion vermiculite had High Temperature Shrinkage of about 19% and a High Temperature Thickness Expansion of about -24%. With the addition of 4 ATH in Sample 2, High Temperature Shrinkage is improved to about 9%, and High Temperature Thickness Expansion to about -11.5%. Addition of about 7% high expansion vermiculite from Samples 3 to 9 shows an improvement in High Temperature Shrinkage by about 5% and High Temperature Thickness Expansion by about 18%, notwithstanding a significant reduction in stucco (eg Sample 8).
[0363] In addition, the Sample 9 formulation shows that it is possible to achieve a desired TI of 23 minutes or more, while reducing the stucco content of the formulation by at least about 75 lb/msf, using about 4% of ATH and about 7% high expansion vermiculite. Formulation Sample 9 also shows that a core formulation with a reduced stucco content can improve the High Temperature Shrinkage properties by reducing the percentage shrinkage by at least 12% and High Temperature Thickness Expansion properties by increasing the percentage of expansion by about 30% or more. A comparison of panels made with formulation Samples 3 and 9, and Samples 4 and 5 shows that ATH can be substituted for stucco in a ratio of about 1 part ATH to at least 1.7 to about 2 parts stucco, while retaining similar IT properties. Replacement ratios can vary considerably depending on the stucco source and core formulations. Furthermore, for a given stucco formulation, replacement ratios can be increased if a reduction in IT is desired or decreased if higher IT properties are desired. Example 11B
[0364] In this example, a stucco (stucco B) prepared from a natural gypsum source of high relative purity (at least about 90% gypsum) was used to prepare the core formulations for Samples 10 to 17. A Base core formulation was made using the following approximate values by weight: 1000 parts stucco B; 10 parts of HRA; 7 parts of pregelatinized starch; 1.4 part of trimetaphosphate; 70 parts of high expansion vermiculite (about 7% by weight of stucco); 5 parts of glass fibers; 1.4 part naphthalenesulfonate dispersant; 0 part (Sample 10), 17.6 parts (Sample 11), 35.2 parts (Samples 12 and 17) and 70.4 parts (Samples 13 to 16) of ATH (2%, 4% and 7% by weight of stucco, respectively); and 1800 parts (Samples 10 to 14), 1900 parts (Sample 15) and 2150 parts (Samples 16 and 17) of water.
[0365] Each of the core formulation Samples 10 through 17 were molded into panels and tested for High Temperature Thermal Insulation Index, High Temperature Shrinkage, and High Temperature Thickness Expansion, as mentioned above. The molded and dried panels of each of the Sample formulations had the approximate values for density, high expansion vermiculite content, stucco, ATH, TI reported in Figures 40A and 40B, Tables XXIa and XXIb, respectively. Table XXIa reports the difference between a core formulation made using stucco B with no ATH (Sample 10) and the TI values for core formulations with increasing amounts of ATH and no change in stucco content (Samples 11 to 14). Each of these formulations contained about 7% high expansion vermiculite. Table XXIb reports the differences in IT results between core formulations with about 7% (Samples 15 and 16) and 4% (Sample 17) ATH. The equivalent of about 100 lb/msf of stucco was taken from formulation Samples 16 and 17, and all samples contained 7% high expansion vermiculite. Table XXIc, Figure 40, reports the density, high expansion vermiculite content, ATH, and High Temperature Shrinkage and High Temperature Thickness Expansion results for panels made from each of the 10 core formulation samples to 17.
[0366] Table XXIa shows the benefit of adding an amount of ATH (here 2%, 4% and 7%) that is effective to result in an IT increase with a constant stucco content, here of about 0. 1 to about 1.5 minutes. Table XXIb shows the effect of Core Formulation Samples 15 and 16, where ATH is held constant and 100 pounds of stucco is removed. This produced a TI reduction of 1.3 minutes, but with a TI greater than about 24 minutes, both Samples 15 and 16 would be acceptable for fireproof applications. Sample 17 similarly shows that the amount of ATH can be reduced to about 4%, and the amount of stucco in the core formulation can be reduced the equivalent of about 100 lb/msf, keeping the TI of about 23 minutes. This is also considered acceptable for fireproof applications. The results in Table XXIb show that an effective amount of ATH can be used to maintain TI at a predetermined level (eg, about 23 minutes) in addition to reducing the amount of stucco used in the formulation.
[0367] Table XXIc, Figure 40, shows the High Temperature Shrinkage and High Temperature Thickness Expansion results for panels made with Core formulation Samples 10 to 17. These results show that using stucco B and the Samples from formulations 10 to 17, the High Temperature Shrinkage and High Temperature Thickness Expansion results are materially unchanged with the addition in ATH. This is true even for formulas with a reduction in stucco that is the equivalent of about 100 lb/msf (see Samples 16 and 17). Example 11C
[0368] In this example, a stucco (stucco C) prepared from a natural gypsum source of low relative purity (approximately 80% gypsum, the remaining clays and other impurities) was used to prepare the core formulations for Samples 18 to 20. The base core formulation was made using the following approximate amounts by weight: 1000 parts (Samples 18 and 20) or 975 parts (Sample 19) of stucco C; 10 parts of HRA; 10 parts of pregelatinized starch; 2 parts of trimetaphosphate; 100 parts of high expansion vermiculite (about 10% by weight of stucco); 5 parts of glass fibers; 5 parts of naphthalenesulfonate dispersant; 0 parts (Sample 18), and 25 parts (Samples 19 and 20) ATH (0% and 3% by weight of stucco, respectively); and 1750 parts (Sample 18), 1725 parts (Sample 19) and 1700 parts (Sample 20) of water.
[0369] Each of the core formulation Samples 18 through 20 were molded into panels and tested for High Temperature Thermal Insulation Index, High Temperature Shrinkage, and High Temperature Thickness Expansion, as mentioned above. The molded and dried panels of each of the Sample formulations had the approximate values for density, high expansion vermiculite content, stucco, ATH and TI reported in XXIIa and XXIIb, Figures 41A and 41B, respectively. Table XXIIa reports the difference between a core formulation, made using stucco C, without any ATH (Sample 18) and the TI values for core formulations with about 3% ATH by weight of stucco, where the amount of stucco C increased from the equivalent of about 1450 lb/msf (Sample 19) to about 30 pounds to about 1480 lb/msf (Sample 20). Each of the formulations contained about 10% high expansion vermiculite by weight of stucco. Table XXIIb reports the density, high expansion vermiculite content, ATH, and High Temperature Shrinkage and High Temperature Thickness Expansion results for panels made from each of the core formulation Samples 18 to 20.
[0370] Table XXIIa shows the benefit of adding an amount of ATH (here about 3% by weight of stucco) that is effective to increase TI in panels made with these formulations for about one minute (compare Sample 18 with Samples 19 and 20). Table XXIIa also shows that the TI of the panels was not improved with the addition of about 30 lb/msf of Stucco C to the formulation (Sample 20), adding a significant amount of filler material (impurities) to the core. Table XXIIb shows that, in some formulations, the addition of about 3 ATH by weight of stucco preserves acceptable values for High Temperature Shrinkage (S), such as at about 10% or less and High Temperature Thickness Expansion, such as a positive expansion. In some cases, the addition of about 25 parts ATH by weight of stucco can improve High Temperature Shrinkage (compare Sample 18 to Sample 19).
[0371] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent, as if each reference were individually and specifically indicated to be incorporated by reference and established in its entirety in this document.
[0372] The use of the terms "a" and "a" and "the" and similar references in the context of the description of the invention (especially in the context of the claims below) is to be interpreted in the sense of covering both the singular and the plural, unless otherwise indicated in this document or clearly contradicted by the context. The recitation of the ranges of values in this document is only intended to serve as a summary method of referring to each individually. separate value within range, unless otherwise indicated in this document, and each separate value is incorporated into the descriptive report as if it were individually referenced in this document. All methods described herein may be performed in any appropriate order, unless otherwise indicated in this document, or otherwise clearly contradicted by the context. The use of any and all examples, or exemplary language (eg, "as") presented herein, is only intended to il further clarify the invention and does not represent a limitation on the scope of the invention, unless stated otherwise. No language in the descriptive report should be interpreted as indicating any element not claimed as essential to the practice of the invention.
[0373] Preferred aspects and embodiments of this invention are described in this document, including the best mode known to the inventors to carry out the invention. It is to be understood that the illustrated embodiments are exemplary only and are not to be viewed as limiting the scope of the invention.

权利要求:
Claims (26)
[0001]
1. Fire resistant gypsum panel, CHARACTERIZED in that it comprises a gypsum core disposed between two facing sheets, the gypsum core comprising a crystalline matrix of hardened gypsum and high expansion particles having a volume expansion of 300% or more of its original volume after heating for one hour at 1560 °F (850 °C), the gypsum core having a density (D) of 40 pounds per cubic feet (640 kg/m3) or less and a hardness of core of at least 11 pounds (5 kg), and where the gypsum core provides a Thermal Insulation Index (TI) of 20 minutes or more, where the high expansion particles are vermiculite, in grades between 3 and 10% by weight based on the weight of the stucco, and the gypsum core is formed from a slurry comprising water, stucco and vermiculite, in addition to mineral fibers, carbon fibers, and/or glass fibers.
[0002]
2. Fire resistant gypsum panel according to claim 1, CHARACTERIZED by the fact that the gypsum core provides the panel with a TI/D ratio of 0.6 minutes/lbs per cubic feet (0.04 min /kg/m3) or more.
[0003]
3. Fire-resistant gypsum panel according to claim 1 or 2, CHARACTERIZED by the fact that the crystalline matrix of hardened gypsum comprises walls defining air voids, the air voids having an average equivalent sphere diameter of 100 μm or greater.
[0004]
4. Fire-resistant gypsum panel according to any one of claims 1 to 3, CHARACTERIZED by the fact that the crystalline matrix of hardened gypsum comprises walls defining and separating air voids within the gypsum core, the walls with a thickness average of 25 µm or greater.
[0005]
5. Fire-resistant gypsum panel according to any one of claims 1 to 4, CHARACTERIZED by the fact that the panel has an average shrinkage strength of 75% or more when heated to 1800°F (980°C) during one hour.
[0006]
6. Fire-resistant gypsum panel, according to any one of claims 1 to 5, CHARACTERIZED by the fact that the gypsum core is formed from a fluid paste comprising water; stucco; the high expansion particles; and a heat sink additive, wherein the gypsum core formed from the slurry with the heat sink additive has a thermal insulation index (TI) that is higher than a gypsum core formed from the slurry without the heat sink additive.
[0007]
7. Fire resistant gypsum panel according to any one of claims 1 to 6, CHARACTERIZED by the fact that the high expansion particles comprise unexpanded vermiculite particles, and that the panel has a TI of 20 minutes or more .
[0008]
8. Fire-resistant gypsum panel as claimed in any one of claims 1 to 7, CHARACTERIZED by the fact that the panel meets at least one hour UL U305 standards for fire-rated panel.
[0009]
9. Fire resistant gypsum panel according to any one of claims 1 to 8, CHARACTERIZED by the fact that at a nominal panel thickness of 5/8 inches, the panel has a nail tensile strength of at least 70 lb, nail tensile strength being determined in accordance with ASTM C473-09 standard.
[0010]
10. Fire resistant gypsum panel as claimed in any one of claims 1 to 7, CHARACTERIZED by the fact that the panel meets at least UL U419 one-hour fire panel standards.
[0011]
11. Fire resistant gypsum panel according to claim 1, CHARACTERIZED by the fact that the gypsum core and high expansion particles provide the panel with a High Temperature Shrinkage of (S) of 10% or less and a High Temperature Thickness Expansion to High Temperature Shrink (TE)/S ratio of 0.2 or more.
[0012]
12. Fire resistant gypsum panel according to claim 11, CHARACTERIZED by the fact that the crystalline matrix of hardened gypsum comprises walls defining air voids with an average equivalent sphere diameter of 100 μm or greater.
[0013]
13. Fire resistant gypsum panel according to claim 11 or 12, CHARACTERIZED by the fact that the crystalline matrix of hardened gypsum comprises walls defining air voids with an average equivalent sphere diameter of 100 μm up to 350 μm with a standard deviation from 100 to 225.
[0014]
14. Fire resistant gypsum panel according to any one of claims 11 to 13, CHARACTERIZED by the fact that the crystalline matrix of hardened gypsum comprises walls defining and separating air voids within the gypsum core, the walls having a thickness average of 25 µm or more.
[0015]
15. Fire-resistant plasterboard according to any one of claims 11 to 14, CHARACTERIZED by the fact that the walls have an average thickness of 25 μm to 75 μm with a standard deviation of 5 to 40.
[0016]
16. Fire resistant gypsum panel according to claim 1, CHARACTERIZED by the fact that the slurry further comprises a starch in an amount of 0.3% to 3.0% by weight, based on the weight of the plaster and a dispersant in an amount of 0.1% to 1.0% by weight, based on the weight of the plaster.
[0017]
17. Fire resistant gypsum panel according to claim 1, CHARACTERIZED by the fact that the slurry additionally includes a phosphate-containing component in an amount of 0.03% to 0.4% by weight based on weight of the stucco.
[0018]
18. Fire resistant plasterboard according to any one of claims 11 to 17, CHARACTERIZED by the fact that at a nominal panel thickness of 5/8 inches, the panel has a nail tensile strength of at least 70 lb, nail tensile strength being determined in accordance with ASTM C473-09 standard.
[0019]
19. Fire resistant gypsum panel as claimed in any one of claims 11 to 18, CHARACTERIZED by the fact that the panel meets at least UL U305 one-hour fire panel standards.
[0020]
20. Fire resistant gypsum panel according to any one of claims 11 to 18, CHARACTERIZED by the fact that the panel meets at least UL U419 one-hour fire panel standards.
[0021]
21. Fire resistant gypsum panel according to claim 1, CHARACTERIZED by the fact that the panel having a nominal panel thickness of 5/8 inches, the high expansion particles having an unexpanded first phase and a second phase expanded when heated, wherein the panel inhibits heat transmission through an assembly of said prepared and heated panels in accordance with UL U419, wherein the panel surfaces on one side of the assembly are exposed to a heat source and the surfaces of the panels on the unheated opposite side of the mount are provided with various temperature sensors in accordance with UL U419, so the maximum single value of the temperature sensors on the unheated side of the mount is less than 500°F (260°C) after 60 minutes when the assembly is heated in accordance with the time-temperature curve of ASTM standard E119-09a.
[0022]
22. Fire-resistant gypsum panel according to claim 21, CHARACTERIZED by the fact that the panel inhibits heat transmission through the assembly, so that the average value of the temperature sensors on the non-heating side of the assembly, measured per UL U419, it is less than 380°F (180°C) after 60 minutes of heating according to the time-temperature curve of ASTM standard E119-09a.
[0023]
23. Fire-resistant gypsum panel according to claim 21 or 22, CHARACTERIZED by the fact that the panel inhibits heat transmission through the assembly, so that the single maximum value of temperature sensors on the non-heating side of the assembly, measured in accordance with UL U419, is less than 410°F (210°C) after 55 minutes of heating per ASTM standard E119-09a time-temperature curve.
[0024]
24. Fire-resistant gypsum panel according to any one of claims 21 to 23, CHARACTERIZED by the fact that the panel inhibits heat transmission through the assembly, so that the average value of temperature sensors on the unheated side assembly temperature, measured in accordance with UL U419, is less than 320°F (160°C) after 55 minutes of heating per ASTM standard E119-09a time-temperature curve.
[0025]
25. Fire-resistant gypsum panel according to any one of claims 21 to 24, CHARACTERIZED by the fact that the panel inhibits heat transmission through the assembly, so that the single maximum value of temperature sensors on the side without mounting heating, measured in accordance with UL U419, is less than 260°F (125°C), and the average value of temperature sensors on the non-heating side of the mounting, measured in accordance with UL U419, is less than 250° F (120 °C), after 50 minutes of heating according to the time-temperature curve of the ASTM E119-09a standard.
[0026]
26. Fire-resistant gypsum panel according to any one of claims 21 to 25, CHARACTERIZED by the fact that the panel inhibits heat transmission through assembly, so that the panel meets UL standard U419 from one hour to fire resistant panel.

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法律状态:
2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-07-16| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|

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2020-02-27| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2020-09-01| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2021-02-09| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-06-08| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-08-31| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 24/02/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201161446941P| true| 2011-02-25|2011-02-25|

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US61/446,941|2011-02-25|

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PCT/US2012/026613|WO2012116325A1|2011-02-25|2012-02-24|Lightweight, reduced density fire rated gypsum panels|BR122015003966-5A| BR122015003966A2|2011-02-25|2012-02-24|LOW-WEIGHT DENSITY PLASTER PANELS WITH FIRE RESISTANCE CLASSIFICATION, WALL SYSTEM AND METHOD FOR MANUFACTURING A FIRE RESISTANT PLASTER PANEL|