Method of providing void spaces in gypsum wallboard and in a...

C - Chemistry – Metallurgy – 04 – B

Patent

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Details

C04B 38/10 (2006.01) C04B 24/16 (2006.01) C04B 28/14 (2006.01) C11D 1/29 (2006.01)

Patent

CA 2448888

The invention provides a method of providing void spaces in gypsum wallboard and in a gypsum core composition such that the weight of the gypsum product is reduced without deleteriously affecting its mechanical properties. More specifically, the invention provides a method of providing void spaces in a gypsum wallboard comprising the step of adding air bubbles having different relative stabilities to a gypsum slurry, wherein the less stable air bubbles are sufficiently unstable such that they coalesce on contact with each other in the slurry to form larger air bubbles, and the weight ratio of the less stable air bubbles to the more stable air bubbles initially added to the slurry is such that there are a sufficient number of more stable air bubbles to prevent a majority of the less stable air bubbles from becoming large enough to rupture before the slurry sets sufficiently to prevent the slurry from filling void spaces left by ruptured bubbles. The method further includes the steps of mixing the air bubble-containing gypsum slurry to distribute the air bubbles throughout the slurry to form a core composition of gypsum wallboard, depositing the core composition on a cover sheet, and, applying a second cover sheet over the core composition to form a gypsum wallboard.

L'invention porte sur un procédé de formation d'espaces vides dans des panneaux de plâtre et sur la composition de l'âme de plâtre desdits panneaux telle que sa réduction de poids n'en affecte pas les propriétés mécaniques. L'invention porte plus spécifiquement sur un procédé de formation d'espaces vides dans des panneaux de plâtre consistant: (i) à ajouter des bulles d'air de différentes stabilités relatives à un coulis de plâtre, les bulles les moins stables étant suffisamment instables pour de réunir en bulles plus grosses de manière à ce que le rapport pondéral entre les bulles les moins stables et les bulles les plus stables ajoutées initialement au coulis, soit tel que le nombre de bulles les plus stables soit suffisant pour empêcher la majeure partie des bulles les moins stables de se rompre avant la prise du coulis et l'occupation par le coulis des vides laissés par les bulles rompues; (ii) à mélanger le coulis de plâtre contenant du plâtre pour répartir les bulles d'air dans la masse du coulis destinée à former l'âme de la cloison; (iii) à déposer ledit coulis sur une plaque de couverture, puis (iv) puis à appliquer une deuxième plaque de couverture sur le coulis déposé pour former un panneau de plâtre.

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