Method for making a lightweight gypsum composition with internally generated foam and products made from same

US11414352B2 · kind B2 · utility

Assignee

• UNITED STATES GYPSUM COMPANY · US

Inventors

• David D. Pelot · Chicago, US
• Samar Emami · Chicago, US
• Robert H. Negri · Lake Villa, US
• Juan Carlos Ruiz Castaneda · Río Rico, MX
• Christopher R. Nelson · Grayslake, US
• John J. Roxburgh · Chicago, US
• Edgar R. De La Rosa Cruz · San Pedro Cholula, MX
• Jorge A. Garcia Torres · San Pedro Cholula, MX
• Miguel Gama Goicochea · Pedregal de Tepepan, MX
• Antonio Contreras · Aurora, US
• Juan Ignacio Huitzil · San Miguelito, MX

Key dates

• Filing date: Mar 5, 2019
• Grant date: Aug 16, 2022
• Expiry date: Feb 26, 2041

Classification

• Technology area (CPC C): Chemistry; Metallurgy
• CPC primary: C04B2111/72
• WIPO field: Materials, metallurgy
• WIPO sector: Chemistry

Abstract

Method of making foamed gypsum slurry having 15 to 90 volume percent gas bubbles including: passing first slurry including water and on dry basis 50 to 98 wt. % calcium sulfate hemihydrate, 1 to 50 wt. % calcium carbonate, and 0.1 to 10 wt. % cellulose thickener via a first hose to a Wye connector conduit first inlet opening at Rate C and passing alum solution via a second hose to a second inlet opening of the conduit at Rate D to create combined mixed stream passing from the conduit to a static mixer for mixing for Time 3 to activate at least a portion of the calcium carbonate and alum to generate CO2 and create the foamed gypsum slurry; transferring the slurry from the mixer to a cavity between two wall boards via a third hose. Allowing the slurry in the cavity to expand, harden and dry.