Composite material and method of producing

C - Chemistry – Metallurgy – 04 – B

Patent

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25/111, 261/77

C04B 11/024 (2006.01) C04B 16/02 (2006.01) C04B 28/14 (2006.01)

Patent

CA 2003046

An improved composite material is produced by mixing gypsum and host particles of a stronger substance, such as wood fibers, in a dilute slurry; heating the slurry, under pressure, to convert the gypsum to calcium sulfate alpha hemihydrate; and substantially dewatering the hot slurry before rehydrating the hemihydrate back to gypsum. The resulting material is a homogoneous mass comprising gypsum crystals physically interlocked with the discrete host particles. According to a further aspect of the invention, an improved wallboard, having fire resistance, dimensional stability and excellent strength properties, is produced by compressing the composite mass before hydrating it to a final set.

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