US 12,304,871 B2
Open-celled gypsum core, gypsum acoustic panel, and method for making same
Yijun Sang, Oak Park, IL (US); Suman Sinha Ray, Chicago, IL (US); and Mark Hemphill, Hawthorn Woods, IL (US)
Assigned to KNAUF GIPS KG, Iphofen (DE)
Filed by KNAUF GIPS KG, Iphofen (DE)
Filed on Jan. 7, 2022, as Appl. No. 17/647,400.
Claims priority of provisional application 63/136,977, filed on Jan. 13, 2021.
Prior Publication US 2022/0220039 A1, Jul. 14, 2022
Int. Cl. C04B 38/00 (2006.01); B32B 5/02 (2006.01); B32B 5/18 (2006.01); B32B 5/24 (2006.01); B32B 13/02 (2006.01); B32B 15/04 (2006.01); B32B 15/12 (2006.01); B32B 29/00 (2006.01); C04B 14/42 (2006.01); C04B 24/38 (2006.01); C04B 28/14 (2006.01); C04B 38/10 (2006.01); G10K 11/165 (2006.01); G10K 11/168 (2006.01); C04B 111/00 (2006.01)
CPC C04B 38/0058 (2013.01) [B32B 5/022 (2013.01); B32B 5/18 (2013.01); B32B 5/245 (2013.01); B32B 13/02 (2013.01); B32B 15/046 (2013.01); B32B 15/12 (2013.01); B32B 29/007 (2013.01); C04B 14/42 (2013.01); C04B 24/38 (2013.01); C04B 28/14 (2013.01); C04B 38/10 (2013.01); G10K 11/165 (2013.01); G10K 11/168 (2013.01); B32B 2262/101 (2013.01); B32B 2266/049 (2016.11); B32B 2266/06 (2013.01); B32B 2307/102 (2013.01); B32B 2419/00 (2013.01); C04B 2111/00629 (2013.01)] 19 Claims
OG exemplary drawing
 
1. An open cell set gypsum core comprising:
a. an interlocking matrix of gypsum having air voids distributed therein, the air voids defining cells having cell walls formed by the interlocking matrix;
b. the interlocking matrix further having channels distributed therein, the channels interconnecting the air voids, the channels comprising openings in the cell walls formed by starch granules after dissolving, the starch granules being disposed in the cell walls of the set gypsum core before dissolving, wherein at least 30% of the air voids are interconnected to another of the air voids by at least one of the channels.