US 11,945,751 B2
Calcium aluminate cement and calcium sulfoaluminate cement catalysts in gypsum panels and use thereof
Qinghua Li, Rolling Meadows, IL (US); Ashish Dubey, Grayslake, IL (US); and Nicholas D′anna, Mundelein, IL (US)
Assigned to KNAUF GIPS KG, Iphofen (DE)
Filed by KNAUF GIPS KG, Iphofen (DE)
Filed on Apr. 30, 2021, as Appl. No. 17/245,862.
Claims priority of provisional application 63/128,270, filed on Dec. 21, 2020.
Prior Publication US 2022/0194856 A1, Jun. 23, 2022
Int. Cl. C04B 28/14 (2006.01); B28B 1/16 (2006.01); B28B 19/00 (2006.01); B32B 9/00 (2006.01); C04B 24/42 (2006.01); C04B 40/00 (2006.01); C04B 103/12 (2006.01); C04B 103/40 (2006.01); C04B 111/00 (2006.01); C04B 111/27 (2006.01)
CPC C04B 28/14 (2013.01) [B28B 1/16 (2013.01); B28B 19/0015 (2013.01); B32B 9/005 (2013.01); C04B 24/42 (2013.01); C04B 40/0046 (2013.01); B32B 2607/00 (2013.01); C04B 2103/12 (2013.01); C04B 2103/408 (2013.01); C04B 2111/0062 (2013.01); C04B 2111/27 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A gypsum panel having a core comprising:
interwoven matrices of calcium sulfate dihydrate crystals and a silicone resin, wherein the silicon resin is formed from polymerization of siloxane, wherein the interwoven matrices have dispersed throughout them a siloxane polymerization catalyst consisting of:
(a) 55 wt % to 100 wt % calcium aluminate cement and/or calcium sulfoaluminate cement,
wherein the calcium aluminate cement is 30 to 80 wt % Al2O3 wherein at least one phase of calcium aluminate in the calcium aluminate cement is monocalcium aluminate, dodecacalcium hepta-aluminate and/or calcium dialuminate, wherein at least a portion of the calcium aluminate cement is at least one calcium silicate compound, wherein at least a portion of the calcium aluminate cement is at least one calcium ferrite compound,
wherein the calcium sulfoaluminate cement is 30 to 80 wt % anhydrous calcium sulfoaluminate having formula 4CaO•3Al2O3•CaSO4, wherein at least 30 to 75 wt % of the calcium sulfoaluminate cement is Ca4(AlO2)6SO4, wherein at least a portion of the calcium sulfoaluminate cement is at least one of dicalcium silicate (2CaO•SiO2), gypsum (CaSO4•2H2O), and aluminoferrite (4CaO•Al2O3Fe2O3); and
(b) 0 wt % to 45 wt % and magnesium oxide;
wherein the weight ratio of the siloxane polymerization catalyst to the calcium sulfate dihydrate is 0.5-5:100, wherein the gypsum panel comprises at least 50 wt. % calcium sulfate dihydrate; and
at least one additive selected from the group consisting of: biocide, set retarder, set accelerator, starch, dispersant, foaming agent, filler, wax emulsion, thickener, fire retardant, latex binder, sugar, phosphates, phosphonates, borates and colorants,
wherein a water-resistance agent in the core consists of the silicon resin and optionally the wax emulsion.