Lightweight, reduced density fire rated gypsum panels
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B28B-001/50
C04B-020/06
C04B-028/14
B32B-038/00
C04B-111/00
C04B-111/28
출원번호
US-0181590
(2014-02-14)
등록번호
US-9623586
(2017-04-18)
발명자
/ 주소
Yu, Qiang
Veeramasuneni, Srinivas
Song, Weixin D.
Luan, Wenqi
출원인 / 주소
United States Gypsum Company
대리인 / 주소
Leydig, Voit & Mayer, Ltd.
인용정보
피인용 횟수 :
0인용 특허 :
100
초록
A method of preparing a reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance that meet or exceed one or more industry standard fire tests.
대표청구항▼
1. A method for making a fire resistant gypsum panel, the method comprising: (A) preparing a gypsum slurry having vermiculite particles dispersed therein, the vermiculite particles expandable from a first unexpanded volume to a second average expanded volume of about 300% or more of the original une
1. A method for making a fire resistant gypsum panel, the method comprising: (A) preparing a gypsum slurry having vermiculite particles dispersed therein, the vermiculite particles expandable from a first unexpanded volume to a second average expanded volume of about 300% or more of the original unexpanded volume when heated for one hour at about 1560° F.;(B) disposing the gypsum slurry between a first cover sheet and a second cover sheet to form an assembly comprising a set gypsum core with the expandable 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 has a density (D) of about 40 pounds per cubic foot or less and a core hardness of at least about 11 pounds, a nominal panel thickness of about ⅝-inch, and a gypsum core and distribution of the expandable vermiculite particles therein effective to inhibit the transmission of heat through a single-layer assembly of said panels prepared pursuant to the procedures of UL U305, where surfaces of the panels on one side of the assembly are exposed to a heat source and surfaces of the panels on the opposite, unheated side of the assembly are provided with a plurality of temperature sensors pursuant to ASTM standard E119-09a, such that the maximum single value of the temperature sensors on the unheated side of the assembly is less than about 500° F. after about 60 minutes when the assembly is heated in accordance with the time-temperature curve of ASTM standard E119-09a. 2. The method of claim 1, the gypsum core and amount and distribution of the vermiculite particles within the core are effective to provide a Thermal Insulation Index (TI) of about 20 minutes or greater. 3. The method of claim 1, the gypsum core and the vermiculite particles are effective to provide the panel with a High Temperature Shrinkage (S) of about 10% or less and a ratio of High Temperature Thickness Expansion to High Temperature Shrinkage (TE)/S of about 0.2 or more. 4. The method of claim 1, wherein the set gypsum core is effective to provide the panel with a ratio of TI/D of about 0.6 minutes/pounds per cubic foot or more. 5. The method of claim 1, wherein the set gypsum is a crystalline matrix and comprises walls defining air voids, the air voids with an average equivalent sphere diameter of about 100 μm or greater. 6. The method of claim 1, wherein the set gypsum is a crystalline matrix and comprises walls defining and separating air voids within the gypsum core, the walls having an average thickness of about 25 μm or greater. 7. The method of claim 1, wherein the panel exhibits an average shrink resistance of about 75% or greater when heated at about 1800° F. for one hour. 8. The method of claim 1, wherein the gypsum core is formed from a slurry comprising water, stucco, the vermiculite 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. 9. The method of claim 1, wherein at a nominal panel thickness of about ⅝-inch, the panel has a nail pull resistance of at least about 70 lb, the nail pull resistance determined according to ASTM standard C473-09. 10. The method of claim 1, wherein the set gypsum core comprises walls defining air voids with an average equivalent sphere diameter from about 100 μm to about 350 μm with a standard deviation from about 100 μm to about 225 μm. 11. The method of claim 10, wherein the walls have an average thickness from about 25 μm to about 75 μm with a standard deviation from about 5 μm to about 40 μm. 12. The method of claim 1, wherein the gypsum core is formed from a slurry comprising water, stucco, the vermiculite particles in an amount up to about 10% by weight based on the weight of the stucco, and mineral, glass or carbon fibers, or combinations thereof. 13. The method of claim 12, wherein the slurry further comprises a starch in an amount from about 0.3% to about 3.0% by weight based on the weight of the stucco and a dispersant in an amount from about 0.1% to about 1.0% by weight based on the weight of the stucco. 14. The method of claim 12, wherein the slurry further includes a phosphate-containing component in an amount from about 0.03% to about 0.4% by weight based on the weight of the stucco. 15. The method of claim 1, wherein the panel satisfies the one hour fire-rated panel standards of ASTM standard E119-09a when prepared pursuant to the procedures of UL U305. 16. The method of claim 1, wherein the panel satisfies the one hour fire-rated panel standards of ASTM standard E119-09a when prepared pursuant to the procedures of UL U419. 17. The method of claim 1, wherein the panel satisfies the one hour fire-rated panel standards of ASTM standard E119-09a when prepared pursuant to the procedures of UL U423. 18. A method for making a fire resistant gypsum panel, the method comprising: (A) preparing a gypsum slurry having vermiculite particles dispersed therein, the vermiculite particles expandable from a first unexpanded volume to a second average expanded volume of about 300% or more of the original unexpanded volume when heated for one hour at about 1560° F.;(B) disposing the gypsum slurry between a first cover sheet and a second cover sheet to form an assembly comprising a set gypsum core with the expandable 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 has a density of about 40 pounds per cubic foot or less and a core hardness of at least about 11 pounds, the panel has a nominal panel thickness of about ⅝-inch, and a gypsum core and distribution of the expandable vermiculite particles therein effective to inhibit the transmission of heat through a single-layer assembly of said panels prepared to the procedures of UL U423, where surfaces of the panels on one side of the assembly are exposed to a heat source and surfaces of the panels on the opposite, unheated side of the assembly are provided with a plurality of temperature sensors pursuant to ASTM standard E119-09a, such that the a maximum single value of the temperature sensors on the unheated side of the assembly is less than about 500° F. after about 60 minutes when the assembly is heated in accordance with the time-temperature curve of ASTM standard E119-09a. 19. The method of claim 18, the gypsum core and amount and distribution of the vermiculite particles within the core are effective to provide a Thermal Insulation Index (TI) of about 20 minutes or greater. 20. The method of claim 18, the gypsum core and the vermiculite particles are effective to provide the panel with a High Temperature Shrinkage (S) of about 10% or less and a ratio of High Temperature Thickness Expansion to High Temperature Shrinkage (TE)/S of about 0.2 or more. 21. The method of claim 18, wherein the set gypsum core is effective to provide the panel with a ratio of TI/D of about 0.6 minutes/pounds per cubic foot or more. 22. The method of claim 18, wherein the set gypsum is a crystalline matrix and comprises walls defining air voids, the air voids with an average equivalent sphere diameter of about 100 μm or greater. 23. The method of claim 18, wherein the set gypsum is a crystalline matrix and comprises walls defining and separating air voids within the gypsum core, the walls having an average thickness of about 25 μm or greater. 24. The method of claim 18, wherein the panel exhibits an average shrink resistance of about 75% or greater when heated at about 1800° F. for one hour. 25. The method of claim 18, wherein the gypsum core is formed from a slurry comprising water, stucco, the vermiculite 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. 26. The method of claim 18, wherein at a nominal panel thickness of about ⅝-inch, the panel has a nail pull resistance of at least about 70 lb, the nail pull resistance determined according to ASTM standard C473-09. 27. The method of claim 18, wherein the set gypsum core comprises walls defining air voids with an average equivalent sphere diameter from about 100 μm to about 350 μm with a standard deviation from about 100 μm to about 225 μm. 28. The method of claim 27, wherein the walls have an average thickness from about 25 μm to about 75 μm with a standard deviation from about 5 μm to about 40 μm. 29. The method of claim 18, wherein the gypsum core is formed from a slurry comprising water, stucco, the vermiculite particles in an amount up to about 10% by weight based on the weight of the stucco, and mineral, glass or carbon fibers, or combinations thereof. 30. The method of claim 29, wherein the slurry further comprises a starch in an amount from about 0.3% to about 3.0% by weight based on the weight of the stucco and a dispersant in an amount from about 0.1% to about 1.0% by weight based on the weight of the stucco. 31. The method of claim 29, wherein the slurry further includes a phosphate-containing component in an amount from about 0.03% to about 0.4% by weight based on the weight of the stucco. 32. The method of claim 18, wherein the panel satisfies the one hour fire-rated panel standards of ASTM standard E11909a when prepared pursuant to the procedures of UL U305. 33. The method of claim 18, wherein the panel satisfies the one hour fire-rated panel standards of ASTM standard E119-09a when prepared pursuant to the procedures of UL U419. 34. The method of claim 18, wherein the panel satisfies the one hour fire-rated panel standards of ASTM standard E119-09a when prepared pursuant to the procedures of UL U423.
연구과제 타임라인
LOADING...
LOADING...
LOADING...
LOADING...
LOADING...
이 특허에 인용된 특허 (100)
Song, W. David; Englert, Mark H.; Yu, Qiang; Brown, Martin W.; Stevens, Richard B., Acoustical gypsum board panel and method of making it.
Englert, Mark H.; Stevens, Richard B.; Sucech, Steven W.; Fults, Therese A.; Porter, Michael J.; Petersen, Bruce L.; Dombeck, Russell A., Acoustical panel comprising interlocking matrix of set gypsum and method for making same.
Englert,Mark H.; Stevens,Richard B.; Sucech,Steven W.; Fults,Therese A.; Porter,Michael J.; Petersen,Bruce L.; Dombeck,Russell A., Acoustical panel comprising interlocking matrix of set gypsum and method for making same.
Albrecht, Gerhard; Hübsch, Christian; Leitner, Hubert; Grassl, Harald; Kern, Alfred, Copolymers based on unsaturated mono-or dicarboxylic acid derivatives and oxyalkylene glycol alkenyl ethers, method for the production and use thereof.
Richards Turner W. (Conyers GA) Francis Hubert C. (Lithonia GA) Fowler George F. (Norcross GA), Firedoor constructions including gypsum building product.
Blackburn, David R.; Lu, Runhai; Tracy, Sharon L.; Liu, Qingxia; Wittbold, James R.; Petersen, Bruce Lynn; Li, Alfred; Fall, John L.; Shake, Michael P.; Lee, Chris, Foamed slurry and building panel made therefrom.
Francis, Hubert C.; Ksionzyk, Anne H.; Esguerra, Fabio E., Gypsum board having polyvinyl alcohol binder in interface layer and method for making the same.
Selbe Rexford L. (Palatine IL) Waropay Vincent M. (Naperville IL) Quigg Paul S. (Barrington IL) Reily William S. (Des Plaines IL), Gypsum fire barrier for cable fires.
Garvey Chad E. (Ball Ground GA) Hutchings David A. (Tucker GA) McVay Ted McC. (Stone Mountain GA) Pennock Richard F. (Decatur GA), Gypsum microfiber sheet material.
Liu, Qingxia; Shake, Michael P.; Blackburn, David R.; Wilson, John W.; Randall, Brian; Lettkeman, Dennis M., Gypsum products utilizing a two-repeating unit dispersant and a method for making them.
Qiang Yu ; Steven W. Sucech ; Brent E. Groza ; Raymond J. Mlinac ; Frederick T. Jones ; Paul J. Henkels, Gypsum-containing product having increased resistance to permanent deformation and method and composition for producing it.
Yu, Qiang; Sucech, Steven W.; Groza, Brent E.; Mlinac, Raymond J.; Jones, Frederick T.; Boehnert, Frederick M., Gypsum-containing product having increased resistance to permanent deformation and method and composition for producing it.
Hutchings David A. ; Qureshi Shahid P. ; Foucht Millard E. ; Sampson Richard D. ; McVay Ted M., High performance intumescent system for imparting heat/flame resistance to thermally unstable substrates.
Sucech Steven W. (Lake Villa IL) Hinshaw Stewart E. (Sweetwater TX) Nemeth Bradley S. (Bedford IN) Buster Kip R. (Burlington IA), Method for preparing uniformly foamed gypsum product with less foam agitation.
Tonyan, Timothy D.; Ullett, James M.; Reicherts, James E., Non-combustible reinforced cementitious lightweight panels and metal frame system for a fire wall and other fire resistive assemblies.
Tonyan, Timothy D.; Ullett, James M.; Reicherts, James E., Non-combustible reinforced cementitious lightweight panels and metal frame system for building foundations.
Tonyan, Timothy D.; Ullett, James M.; Reicherts, James E., Non-combustible reinforced cementitious lightweight panels and metal frame system for flooring.
Tonyan, Timothy D.; Ullett, James M.; Reicherts, James E., Non-combustible reinforced cementitious lightweight panels and metal frame system for roofing.
Tonyan, Timothy D.; Ullett, James M.; Reicherts, James E., Non-combustible reinforced cementitious lightweight panels and metal frame system for shear walls.
Schlatter Reinhard (Schaffhausen CHX) Gabi Urs (Wrenlos CHX) Ehrat Rainer (Schaffhausen CHX), Process for the production of a flame resistant to nonflammable composite panel and apparatus for carrying out the proce.
Dillenbeck, Robert L.; Heinold, Thomas; Rogers, Murray J.; Bray, Windal S., Ultra low density cementitious slurries for use in cementing of oil and gas wells.
Lehnert Charles W. (Stone Mountain GA) Randall Brian G. (Stone Mountain GA) Fowler ; Jr. George F. (Norcross GA) Hinkel Ray W. (Stone Mountain GA), Use of fibrous mat-faced gypsum board in shaft wall assemblies and improved fire resistant board.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.