AU2012101707A4 - Composite Light Weight Gypsum Wallboard - Google Patents

Abstract

Abstract A composite gypsum board comprising: a set gypsum core having a dry density; the set gypsum core adjacent to a bonding layer having a dry density, the set gypsum core dry density being less than the bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board having a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the set gypsum core has an average core hardness of at least about 11 pounds (about 5 kg) as determined in accordance with ASTM C473.

Description

WO 2008/042060 PCT/US2007/018978 COMPOSITE LIGHT WEIGHT GYPSUM WALLBOARD FIELD OF THE INVENTION [00011 This invention pertains to unique light weight composite gypsum boards having high strength. It also pertains to a method of making such light weight composite gypsum boards using a unique gypsum-containing slurry to form a foamed low density set gypsum core and non-foamed (or reduced-foamed) bonding high density layers that bond the top and bottom cover sheets to the core. BACKGROUND OF THE INVENTION 100021 Certain properties of gypsum (calcium sulfate dihydrate) make it very popular for use in making industrial and building products, such as gypsum wallboard. Gypsum is a plentiful and generally inexpensive raw material which, through a process of dehydration and rehydration, can be cast, molded or otherwise formed into useful shapes. The base material from which gypsum wallboard and other gypsum products are manufactured is the hemihydrate form of calcium sulfate (CaSO 4 1/2H 2 0), commonly termed "stucco," which is produced by heat conversion of the dihydrate form of calcium sulfate (CaSO 4 2H20), from which 1-1/2 water molecules been removed. [00031 Conventional gypsum-containing products such as gypsum wallboard have many advantages, such as low cost and easy workability. Various improvements have been achieved in making gypsum-containing products using starches as ingredients in the slurries used to make such products. Pregelatinized starch, for example, can increase flexural strength and compressive strength of gypsum-containing products including gypsum wallboard. Known gypsum wallboard contains board starch at levels of less than about 10 lbs/MSF. [0004] It is also necessary to use substantial amounts of water in gypsum slurries containing pregelatinized starch in order to ensure proper flowability of the slurry. Unfortunately, most of this water must eventually be driven off by drying, which is expensive due to the high cost of the fuels used in the drying process. The drying step is also time-consuming. It has been found that the use of naphthalenesulfonate dispersants can increase the fluidity of the slurries, thus WO 2008/042060 PCT/US2007/018978 overcoming the water demand problem. In addition, it has also been found that the naphthalenesulfonate dispersants, if the usage level is high enough, can cross-link to the pregelatinized starch to bind the gypsum crystals together after drying, thus increasing dry strength of the gypsum composite. Trimetaphosphate salts have not in the past been recognized to affect gypsum slurry water requirements. However, the present inventors have discovered that increasing the level of the trimetaphosphate salt to hitherto unknown levels in the presence of a specific dispersant makes it possible to achieve proper slurry flowability with unexpectedly reduced amounts of water, even in the presence of high starch levels. This, of course, is highly desirable because it in turn reduces fuel usage for drying as well as the process time associated with subsequent water removal process steps. Thus the present inventors have also discovered that the dry strength of gypsum board can be increased by using a naphthalenesulfonate dispersant in combination with pregelatinized starch in the slurry used to make the wallboard. [00051 Conventional gypsum wallboards have adequate strength for working, and meet standard test requirements such as nail pull (77 lb) and core hardness (11 lb). However, conventional wallboards are heavy, typically weighing up to 1600-1700 lb/MSF. If a way could be found to produce a high strength gypsum wallboard in which board weight (and density) is significantly reduced, without adversely affecting nail pull and hardness characteristics, this would represent a useful contribution to the art. [0006] It is also known in making gypsum wallboard that bonding layers can be used to promote adherence or bonding of the paper cover sheets to the set gypsum core. Typically, these bonding layers are relatively thick, ranging from about 7 mils to about 25 mils, even up to 50 mils. Thinner bonding layers would be expected to be more difficult to apply and to present other drawbacks. Unfortunately, the use of these thick bonding layers can decrease the core hardness in the finished wallboard. Finished densities in these dried bonding layers range from greater than about 70 pcf to about 90 pcf. The term 'pcf is defined as pounds per cubic foot (lb/ft 3 ). If a way could be found to make a low density set gypsum board using thinner, lighter bonding layers, without sacrificing core hardness or other important board properties, this would represent a useful contribution to the art. 2 3 [0007] According to a first aspect of the present invention, there is provided a composite gypsum board including: a set gypsum core having a dry density; the set gypsum core adjacent to a first bonding layer having a dry density, the set gypsum core dry density being less than the first bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board having a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the set gypsum core has an average core hardness of at least about 11 pounds (about 5 kg) as determined in accordance with ASTM C473. [0008] According to a second aspect of the present invention, there is provided a composite gypsum board including: a set gypsum core having a dry density; the set gypsum core adjacent to a first bonding layer having a dry density, the set gypsum core dry density being less than the first bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board having a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the board has a ratio of dry density (pcf) to average core hardness (lb) of less than about 3.2, wherein the core hardness is determined in accordance with ASTM C473. [0008a] According to a third aspect of the present invention, there is provided a composite gypsum board including: a set gypsum core having a dry density; the set gypsum core adjacent to a first bonding layer having a dry density, the set gypsum core dry density being less than the first bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3

);

3a the board having a dry density of about 35 pef (about 560 kg/m 3 ) or less; and "A the board, when at a thickness of about % iUh (about 1,3 um), has a nail pull resistance to ;: average core hardness ratio from about 4 to about 8, each as determined in accordance with ASTM C473. 'A [0008b] Preferably, the set gypsum core has an average core hardness of at least C C about 11 pounds (about 5 kg) as determined in accordance with ASTM C473; and the first bonding layer and set gypsum core are formed from one or more scurries, the amount of slurry used to form the first bonding layer including from about 4% to about 9% by weight of the total amount of slurry used to form the set gypsum core and the first bonding layer. [0008c] Preferably, the amount of slurry used to form the first bonding layer including from about 4% to about 6% by weight of the total amount of slurry used to form the set gypsum core and the first bonding layer. [0008d] Preferably, the amount of slurry used to form the first bonding layer including from about 6% to about 9% by weight of the total amount of slurry used to form the set gypsum core and the first bonding layer. [0008e] Preferably, the set gypsum core is disposed between the first bonding layer and a second bonding layer, the set gypsum core dry density being less than the second bonding layer dry density by a differential of at least about 10 pef (about 160 kg/in 3 ), aud the second bonding layer having a thickness of about 2 mils (about 0.05 mm) to less than about 7 mils (about 0.2 mm). [0008f] Preferably, at least one of the first and second bonding layers has a dry density from about 60 pcf (about 960 kg/m 3 ) to about 70 pcf (about 1100 kg/r 3 ). [0008g] Preferably, at least one of the first and second bonding layers has a dry density from about 45 pcf (about 720 kg/m 3 ) to about 60 pcf (about 960 kg/rn 3

).

3b [0008h] Preferably, the first and second bonding layers are formed from one or more slurries, the amount of slurry used to form the first and second bonding layers including from about 10% to about 16% by weight of the total amount of slurry used to form the set gypsum core and the first and second bonding layers. [0008i] Preferably, the board dry density is from about 24 pcf (about 380 kg/m 3 ) to about 35 pcf (about 560 kg/m ). f) [0008j] Preferably, the set gypsum core formed from a slurry including water, stucco, foam, and (i) starch present in an amount from about 0.5% to about 10% by weight based on the weight of the stucco, the starch effective to increase the core hardness of the gypsum board relative to the core hardness of the gypsum board without the starch, (ii) a trimetaphosphate compound chosen from the group consisting of sodium trimetaphosphate, potassium trimetaphosphate, lithium trimetaphosphate, and ammonium trimetaphosphate, the trimetaphosphate compound being present in an amount from about 0.12% to about 0.4% by weight based on the weight of the stucco, (iii) naphthalenesulfonate dispersant present in an amount from about 0.1% to about 3.0% by weight based on the weight of the stucco, or (iv) any combination of (i) - (iii). [0008k) Preferably, the starch is a pregelatinized starch. [00081] Preferably, the board, when at a thickness of about /2 inch (about 1.3 cm), has (i) a dry weight up to about 1400 Ib/MSF (about 6.8 kg/SQM), (ii) a nail pull resistance of at least 65 lb (29 kg), as determined in accordance with ASTM C473, (iii) an average flexural strength of at least 36 lb (16 kg) in a machine direction and/or 107 lb (48.5 kg) in a cross-machine direction, as determined in accordance with ASTM C473, or (iv) any combination of (i) - (iii). [0008m] According to a fourth aspect of the present invention, there is provided a method of making a composite gypsum board, the method including: (a) mixing at least water and stucco, and optionally foam, to form a first slurry; (b) depositing a portion of the first slurry of (a) on a first cover sheet to form a first bonding layer having a thickness of about 2 mils (about 0.05 mm) to less than about 7 3c mils (about 0.2 mm); (c) adding foam to at least a portion of the first slurry of (a) and mixing to form a second slurry, wherein the second slurry includes a greater amount of foam than the first slurry and has a lower wet density than the first slurry; (d) depositing the second slurry of (c) onto the first bonding layer to form a panel; (e) cutting the panel into a board of predetermined dimensions; and (f) drying the board; wherein the set gypsum core dry density is less than the first bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board has a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the dry slurry of (c) has an average core hardness of at least about 11 pounds (about 5 kg) as determined in accordance with ASTM C473. [0008n] According to a fifth aspect of the present invention, there is provided a method of making a composite gypsum board, the method including: (a) mixing at least water and stucco, and optionally foam, to form a first slurry; (b) depositing a portion of the first slurry of (a) on a first cover sheet to form a first bonding layer; (c) adding foam to at least a portion of the first slurry of (a) and mixing to form a second slurry, wherein the second slurry includes a greater amount of foam that the first slurry and has a lower wet density that the first slurry; (d) depositing the second slurry of (c) onto the first bonding layer to form a panel; (e) cutting the panel into a board of predetermined dimensions; and (f) drying the board; wherein the set gypsum core dry density is less than the first bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/mi 3 ); the board has a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the board has a ratio of dry density (pcf) to average core hardness (lb) of less than about 3.2, wherein the core hardness is determined in accordance with ASTM C473.

3d [00080] According to a sixth aspect of the present invention, there is provided a method of making a composite gypsum board, the method including: (a) mixing at least water and stucco, and optionally foam, to form a first slurry; (b) depositing a portion of the first slurry of (a) on a first cover sheet to form a first bonding layer; (c) adding foam to a portion of the first slurry of (a) and mixing to form a second slurry, wherein the second slurry includes a greater amount of foam than the first slurry and has a lower wet density than the first slurry; (d) depositing the second slurry of (c) onto the first bonding layer to form a panel; (e) cutting the panel into a board of predetermined dimensions; and (f) drying the board; wherein the set gypsum core dry density is less than the first bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board has a dry density of about 35 pef (about 560 kg/m 3 ) or less; and the board, when at a thickness of about % inch (about 1.3 cm), has a nail pull resistance to average core hardness ratio from about 4 to about 8, each as determined in accordance with ASTM C473. [0008p] Preferably, the dry slurry of (c) has an average core hardness of at least about 11 pounds (about 5 kg) as determined in accordance with ASTM C473; and the amount of slurry used to form the first bonding layer of the panel includes from about 4% to about 9% by weight of the total amount of slurry used to form the second slurry of (c) and the first bonding layer of the panel. [0008q] Preferably, the method includes depositing a portion of the first slurry of (a) on a second cover sheet to form a second bonding layer having a thickness of about 2 mils (about 0.05 mm) to less than about 7 mils (about 0.2 mm) and placing the slurry-covered surface of the second cover sheet on the deposited second slurry of (c), the set gypsum core dry density being less than the second bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3

).

3e [0008r] Proforably, the amount of slurry used to form the first and second boudiur layers of the panel includes from about 10% to about 16% by weight of the total amount of slurry used to form the second slurry of (c) and the first and second bonding layers of the panel. o [0008s] Preferably, wherein the board dry density is from about 24 pcf (about 380 NI kg/m 3 ) to about 35 pcf (about 560 kg/m 3 ). n DETAILED DESCRIPTION OF THE INVENTION [0009] It has now unexpectedly been found that the preparation of a foamed low density set gypsum core using thinner, lighter top and bottom non-foamed (or reduced foamed) bonding high density layers to attain good bonding of a heavy top WO 2008/042060 PCT/US2007/018978 (face) cover sheet and a bottom (back) cover sheet, can provide a composite gypsum board having nail pull resistance, core hardness, and board strength. [0010] The composite gypsum board of the present invention includes a foamed low density set gypsum core having a top surface and a bottom surface, a top non foamed (or reduced-foamed) bonding high density layer covering the top surface of the foamed low density set gypsum core, a top (or face) cover sheet having a foamed low density set gypsum core-facing surface, the top cover sheet bonded to the foamed low density set gypsum core by the top non-foamed (or reduced foamed) bonding high density layer, a bottom non-foamed (or reduced-foamed) bonding high density layer covering the bottom surface of the foamed low density set gypsum core, and a bottom (or back) cover sheet having a foamed low density set gypsum core-facing surface, the bottom cover sheet bonded to the foamed low density set gypsum core by the bottom non-foamed (or reduced-foamed) bonding high density layer. Preferably the top cover sheet will be paper having a weight of about 60 lb/MSF (thickness about 18 mils). Additionally, the top (face) cover sheet and bottom (back) cover sheet are substantially parallel with respect to the foamed low density set gypsum core. The foamed low density set gypsum core is made from a foamed gypsum slurry containing stucco, and includes pregelatinized starch, and preferably a naphthalenesulfonate dispersant, and also preferably, sodium trimetaphosphate. The top and bottom non-foamed (or reduced-foamed) bonding high density layers can comprise from about 10% to about 16% of the of the total amount of gypsum slurry. [00111 According to one embodiment of the present invention, there are provided finished composite gypsum board from gypsum-containing slurries containing stucco, pregelatinized starch, a naphthalenesulfonate dispersant, and sodium trimetaphosphate. The naphthalenesulfonate dispersant is present in an amount of about 0.1% - 3.0% by weight based on the weight of dry stucco. The pregelatinized starch is present in an amount of at least about 0.5% by weight up to about 10% by weight based on the weight of dry stucco in the formulation. The sodium trimetaphosphate is present in an amount of about 0.12% - 0.4% by weight based on the weight of dry stucco in the formulation. Other ingredients that may be used in the slurry include binders, paper fiber, glass fiber, and accelerators. A soap 4 WO 2008/042060 PCT/US2007/018978 foam which introduces air voids is added to the newly formulated gypsum containing slurries to help reduce the density of the foamed low density set gypsum core in the final gypsum-containing product, for example, gypsum wallboard or composite gypsum board. [00121 The combination of from about 0.5% by weight up to about 10% by weight pregelatinized starch, from about 0.1% by weight up to about 3.0% by weight naphthalenesulfonate dispersant, and a minimum of at least about 0.12% by weight up to about 0.4% by weight of trimetaphosphate salt (all based on the weight of dry stucco used in the gypsum slurry) unexpectedly and significantly increases the fluidity of the gypsum slurry. This substantially reduces the amount of water required to produce a gypsum slurry with sufficient flowability to be used in making gypsum-containing products such as gypsum wallboard. The level of trimetaphosphate salt, which is at least about twice that of standard formulations (as sodium trimetaphosphate), is believed to boost the dispersant activity of the naphthalenesulfonate dispersant. [0013] The air voids can reduce the bonding strength between a foamed low density set gypsum core and the cover sheets. Since greater than half of the composite gypsum boards by volume may consist of air voids due to foam, the foam can interfere with the bond between the foamed low density set gypsum core and the paper cover sheets. This is addressed by providing a non-foamed (or reduced foamed) bonding high density layer on the gypsum core-contacting surfaces of both the top cover sheet and the bottom cover sheet prior to applying the cover sheets to the core. This non-foamed, or alternatively, reduced-foamed, bonding high density layer formulation typically will be the same as that of the gypsum slurry core formulation, except that either no soap will be added, or a substantially reduced amount of soap (foam) will be added. Optionally, in order to form this bonding layer, foam can be mechanically removed from the core formulation, or a different foam-free formulation can be applied at the foamed low density set gypsum core/ face paper interface. [0014) Soap foam is required to introduce and to control the air (bubble) void sizes and distribution in the foamed set gypsum core, and to control the density of 5 WO 2008/042060 PCT/US2007/018978 the foamed set gypsum core. A preferred range of soap in the set gypsum core is from about 0.2 Ib/MSF to about 0.7 lb/MSF; a more preferred level of soap is about 0.3 lb/MSF to about 0.5 lb/MSF. Although preferably no soap will be used in the non-foamed bonding high density layers, if soap is used in reduced-foamed bonding high density layers, the amount will be about 5% by weight or less of the amount of soap used to make the foamed low density set gypsum core. [00151 The non-foamed or reduced-foamed, that is. high density portion of the gypsum-containing slurry used in the bonding layer will be from about 10 - 16% by weight of the (wet) slurry used in making the final board. In a preferred embodiment, 6 - 9% by weight of the slurry can be used as the top non-foamed (or reduced-foamed) bonding high density layer, and 4 - 7% by weight of the slurry can be used as the bottom non-foamed (or reduced-foamed) bonding high density layer. The presence of the top and bottom non-foamed (or reduced-foamed) bonding high density layers provides an improved bond between the top and bottom cover sheets and the foamed low density set gypsum core. The wet density of the non-foamed bonding high density layer can be about 80-85 pcf. The dry (finished) density of the non-foamed (or reduced-foamed) bonding high density layer can be about 45-70 pcf. Additionally, the thickness of the non-foamed (or reduced-foamed) bonding high density layers of the present invention will range from about 2 mils to less than 7 mils. [00161 Preferred cover sheets may be made of paper as in conventional gypsum wallboard, although other useful cover sheet materials known in the art (e.g. fibrous glass mates) may be used. However, particular heavy paper cover sheets preferably will be used as top (face) cover sheets in the embodiments of the present invention. Useful cover sheet paper include Manila 7-ply and News-Line 5-ply, available from United States Gypsum Corporation, Chicago, Illinois; and Grey-Back 3-ply and Manila Ivory 3-ply, available from Caraustar, Newport, Indiana. A preferred bottom cover sheet paper is 5-ply News-Line (e.g. 42 - 46 lb/MSF). A preferred top cover sheet paper is Manila 7-ply. A particularly preferred top cover sheet paper is heavy Manila paper (60 lb/MSF, thickness 18 mils), available from Caraustar, Newport, Indiana. Other heavy, thick paper will also be preferred, ranging in thickness from about 15 - 20 mils. 6 WO 2008/042060 PCT/US2007/018978 [0017] Fibrous mats may also be used as one or both of the cover sheets. Preferably the fibrous mats will be nonwoven glass fiber mats in which filaments of glass fiber are bonded together by an adhesive. Most preferably, the nonwoven glass fiber mats will have a heavy resin coating. For example, Duraglass nonwoven glass fiber mats, available from Johns-Manville, having a weight of about 1.5 lb/100 ftz, with about 40-50% of the mat weight coming from the resin coating, could be used. [00181 It is noted here that in manufacturing of conventional gypsum wallboard, the top or face paper is laid down and moves along the production line first, and so constitutes what is known in the art as the "bottom" of the process, despite contacting and forming the top or face of the wallboard product. Conversely, the bottom or back paper is applied last in the manufacturing process in what is known as the "top" of the process. These same conventions will apply in the formation and preparation of the composite gypsum boards of the present invention. Reference is made to Example 7B below. [00191 It is preferred that a naphthalenesulfonate dispersant be used in gypsum containing slurries prepared in accordance with the present invention. The naphthalenesulfonate dispersants used in the present invention include polynaphthalenesulfonic acid and its salts (polynaphthalenesulfonates) and derivatives, which are condensation products of naphthalenesulfonic acids and formaldehyde. Particularly desirable polynaphthalenesulfonates include sodium and calcium naphthalenesulfonate. The average molecular weight of the naphthalenesulfonates can range from about 3,000 to 27,000, although it is preferred that the molecular weight be about 8,000 to 22,000, and more preferred that the molecular weight be about 12,000 to 17,000. As a commercial product, a higher molecular weight dispersant has higher viscosity, and lower solids content, than a lower molecular weight dispersant. Useful naphthalenesulfonates include DILOFLO, available from GEO Specialty Chemicals, Cleveland, Ohio; DAXAD, available from Hampshire Chemical Corp., Lexington, Massachusetts; and LOMAR D, available from GEO Specialty Chemicals, Lafayette, Indiana. The naphthalenesulfonates are preferably used as aqueous solutions in the range 35 55% by weight solids content, for example. It is most preferred to use the naphthalenesulfonates in the form of an aqueous solution, for example, in the 7 WO 2008/042060 PCT/US2007/018978 range of about 40-45% by weight solids content. Alternatively, where appropriate, the naphthalenesulfonates can be used in dry solid or powder form, such as LOMAR D, for example. [00201 - The polynaphthalenesulfonates useful in the present invention have the general structure (I):

CH

2 n (I) wherein n is >2, and wherein M is sodium, potassium, calcium, and the like. 10021] The naphthalenesulfonate dispersant, preferably as an about 45% by weight solution in water, may be used in a range of from about 0.5% to about 3.0% by weight based on the weight of dry stucco used in the gypsum composite formulation. A more preferred range of naphthalenesulfonate dispersant is from about 0.5% to about 2.0% by weight based on the weight of dry stucco, and a most preferred range from about 0.7% to about 2.0% by weight based on the weight of dry stucco. In contrast, known gypsum wallboard contains this dispersant at levels of about 0.4% by weight, or less, based on the weight of dry stucco. 100221 Stated in an another way, the naphthalenesulfonate dispersant, on a dry weight basis, may be used in a range from about 0.1% to about 1.5% by weight based of the weight of dry stucco used in the gypsum composite formulation. A more preferred range of naphthalenesulfonate dispersant, on a dry solids basis, is from about 0.25% to about 0.7% by weight based on the weight of dry stucco, and 8 WO 2008/042060 PCT/US2007/018978 a most preferred range (on a dry solids basis) from about 0.3% to about 0.7% by weight based on the weight of dry stucco. [0023] The gypsum-containing slurry can optionally contain a trimetaphosphate salt, for example, sodium trimetaphosphate. Any suitable water-soluble metaphosphate or polyphosphate can be used in accordance with the present invention. It is preferred that a trimetaphosphate salt be used, including double salts, that is trimetaphosphate salts having two cations. Particularly useful trimetaphosphate salts include sodium trimetaphosphate, potassium trimetaphosphate, calcium trimetaphosphate, sodium calcium trimetaphosphate, lithium trimetaphosphate, ammonium trimetaphosphate, and the like, or combinations thereof. A preferred trimetaphosphate salt is sodium trimetaphosphate. It is preferred to use the trimetaphosphate salt as an aqueous solution, for example, in the range of about 10-15% by weight solids content. Other cyclic or acyclic polyphosphates can also be used, as described in U.S. Patent No. 6,409,825 to Yu et al., herein incorporated by reference. [00241 Sodium trimetaphosphate is a known additive in gypsum-containing compositions, although it is generally used in a range of from about 0.05% to about 0.08% by weight based on the weight of dry stucco used in the gypsum slurry. In the embodiments of the present invention, sodium trimetaphosphate (or other water-soluble metaphosphate or polyphosphate) can be present in the range of from about 0.12% to about 0.4% by weight based on the weight of dry stucco used in the gypsum composite formulation. A preferred range of sodium trimetaphosphate (or other water-soluble metaphosphate or polyphosphate) is from about 0.12% to about 0.3% by weight based on the weight of dry stucco used in the gypsum composite formulation. [00251 There are two forms of stucco, alpha and beta. These two types of stucco are produced by different means of calcination. In the present inventions either the beta or the alpha form of stucco may be used. [0026] Starches, including pregelatinized starch in particular, must be used in gypsum-containing slurries prepared in accordance with the present invention. A 9 WO 2008/042060 PCT/US2007/018978 preferred pregelatinized starch is pregelatinized corn starch, for example pregelatinized corn flour available from Bunge Milling, St. Louis, Missouri, having the following typical analysis: moisture 7.5%, protein 8.0%, oil 0.5%. crude fiber 0.5%, ash 0.3%; having a green strength of 0.48 psi; and having a loose bulk density of 35.0 lb/ft 3 . Pregelatinized com starch should be used in an amount of at least about 0.5% by weight up to about 10% by weight, based on the weight of dry stucco used in the gypsum-containing slurry. [0027] The present inventors have further discovered that an unexpected increase in dry strength (particularly in wallboard) can be obtained by using at least about 0.5% by weight up to about 10% by weight pregelatinized starch (preferably pregelatinized corn starch) in the presence of about 0.1% by weight to 3.0% by weight naphthalenesulfonate dispersant (starch and naphthalenesulfonate levels based on the weight of dry stucco present in the formulation). This unexpected result can be obtained whether or not water-soluble metaphosphate or polyphosphate is present. [0028] In addition, it has unexpectedly been found that pregelatinized starch can be used at levels of at least about 10 lb/MSF, or more, in the dried gypsum wallboard made in accordance with the present invention, yet high strength and low weight can be achieved. Levels as high as 35-45 lb/MSF pregelatinized starch in the gypsum wallboard have been shown to be effective. As an example, Formulation B, as shown in Tables 1 and 2 below, includes 45 lb/MSF, yet produced a board weight of 1042 lb/MSF having excellent strength. In this example (Formulation B), a naphthalenesulfonate dispersant as a 45% by weight solution in water, was used at a level of 1.28% by weight. [0029] A further unexpected result may be achieved with the present invention when the naphthalenesulfonate dispersant trimetaphosphate salt combination is combined with pregelatinized corn starch, and optionally, paper fiber or glass fiber. Gypsum wallboard made from formulations containing these three ingredients have increased strength and reduced weight, and are more economically desirable due to the reduced water requirements in their manufacture. 10 WO 2008/042060 PCT/US2007/018978 [0030] Accelerators can be used in the gypsum-containing compositions of the present invention, as described in U.S. Patent No. 6,409,825 to Yu et al., herein incorporated by reference. One desirable heat resistant accelerator (HRA) can be made from the dry grinding of landplaster (calcium sulfate dihydrate). Small amounts of additives (normally about 5% by weight) such as sugar, dextrose, boric acid, and starch can be used to make this HRA. Sugar, or dextrose, is currently preferred. Another useful accelerator is "climate stabilized accelerator" or "climate stable accelerator," (CSA) as described in U.S. Patent No. 3,573,947, herein incorporated by reference. [00311 Water/stucco (w/s) ratio is an important parameter, since excess water must eventually be driven off by heating. In the embodiments of the present invention, a generally preferred w/s ratio is from about 0.7 to about 1.3. A more preferred w/s ratio in the main gypsum slurry formulations should be in the range from 0.8 -1.2. [0032] Other gypsum slurry additives can include accelerators, binders, waterproofing agents, paper or glass fibers and other known constituents. [00331 The following examples further illustrate the invention. They should not be construed as in any way limiting the scope of the invention. EXAMPLE 1 [00341 Sample Gypsum Slurry Formulations [0035] Gypsum slurry formulations are shown in Table 1 below. All values in Table 1 are expressed as weight percent based on the weight of dry stucco. Values in parentheses are dry weight in pounds (lb/MSF). 11 WO 2008/042060 PCT/US2007/018978 TABLE 1 Component Formulation A Formulation B Stucco (Ib/MSF) (732) (704) sodium trimetaphosphate 0.20 (1.50) 0.30 (2.14) Dispersant (naphthalenesulfonate) 0.18 (1.35) 0.58 1 (4.05) Pregelatinized starch (dry powder) 2.7 (20) 6.4 (45) Board starch 0.41 (3-0) 0 Heat resistant accelerator (HRA) (15) (15) Glass fiber 0.27 (2.0) 0.28 (2.0) Paper fiber 0 0.99 (7.0) Soap* 0.03 (0.192) 0.03 (0.192) Total Water (lb.) 805 852 Water / Stucco ratio 1.10 1.21 *Used to pregenerate foam. 1.28% by weight as a 45% aqueous solution. EXAMPLE 2 [0036J Preparation of Wallboards [0037] Sample gypsum wallboards were prepared in accordance with U.S. Patent Nos. 6,342,284 to Yu et al. and 6,632,550 to Yu et al., herein incorporated by reference. This includes the separate generation of foam and introduction of the foam into the slurry of all of the other ingredients as described in Example 5 of these patents. [0038] Test results for gypsum wallboards made using the Formulations A and B of Example 1, and a normal control board are shown in Table 2 below. As in this example and other examples below, nail pull resistance, core hardness, and flexural strength tests were performed according to ASTM C-473. Additionally, it is noted that typical gypsum wallboard is approximately % inch thick and has a weight of between about 1600 to 1800 pounds per 1,000 square feet of material, or 12 WO 2008/042060 PCT/US2007/018978 lb/MSF. ("MSF" is a standard abbreviation in the art for a thousand square feet; it is an area measurement for boxes, corrugated media and wallboard.) TABLE 2 Lab test result Control Board Formulation A Formulation B Board Board Board weight 1587 1066 1042 (lb/MSF) Nail pull resistance 81.7 50.2 72.8 (lb) Core hardness (lb) 16.3 5.2 11.6 Humidified bond load 17.3 20.3 15.1 (Ib) Humidified bond 0.6 5 11.1 failure (%) Flexural strength, 47 47.2 52.6 face-up (MD) (lb) _ Flexural strength, 51.5 66.7 78.8 face-down (MD) (Ib) Flexural strength, 150 135.9 173.1 face-up (XMD) (lb) Flexural strength, 144.4 125.5 165.4 face-down (XMD) (Ib) MD: machine direction XMD: across machine direction [0039] As illustrated in Table 2, gypsum wallboards prepared using the Formulation A and B slurries have significant reductions in weight compared to the control board. With reference again to Table 1, the comparisons of the Formulation A board to the Formulation B board are most striking. The water/stucco (w/s) ratios are similar in Formulation A and Formulation B. A significantly higher level of naphthalenesulfonate dispersant is also used in Formulation B. Also, in Formulation B substantially more pregelatinized starch was used, about 6% by weight, a greater than 100% increase over Formulation A accompanied by marked strength increases. Even so, the water demand to produce the required flowability remained low in the Formulation B slurry, the difference being about 10% in 13 WO 2008/042060 PCT/US2007/018978 comparison to Formulation A. The low water demand in both Formulations is attributed to the synergistic effect of the combination of naphthalenesulfonate dispersant and sodium trimetaphosphate in the gypsum slurry, which increases the fluidity of the gypsum slurry, even in the presence of a substantially higher level of pregelatinized starch. 100401 As illustrated in Table 2, the wallboard prepared using the Formulation B slurry has substantially increased strength compared with the wallboard prepared using the Formulation A slurry. By incorporating increased amounts of pregelatinized starch in combination with increased amounts of naphthalenesulfonate dispersant and sodium trimetaphosphate, nail pull resistance in the Formulation B board improved by 45% over the Formulation A board. Substantial increases in flexural strength were also observed in the Formulation B board as compared to the Formulation A board. EXAMPLE 3 [0041] 1/2 Inch Gypsum Wallboard Weight Reduction Trials 10042] Further gypsum wallboard examples (Boards C, D and E), including slurry formulations and test results are shown in Table 3 below. The slurry formulations of Table 3 include the major components of the slurries. Values in parentheses are expressed as weight percent based on the weight of dry stucco. 14 WO 2008/042060 PCT/US2007/018978 TABLE 3 Trial formulation Control Formulation Formulation Formulation component/parameter Board C Board D Board E Board Dry stucco (Ib/MSF) 1300 1281 1196 1070 Accelerator (lb/MSF) 9.2 9.2 9.2 9.2 DILOFLO '(b/MSF) 4.1 (0.32%) 8.1 (0.63%) 8.1 (0.68%) 8.1 (0.76%) Regular starch 5.6 (0.43%) 0 0 0 (Ib/MSF) Pregelatinized corn 0 10 (0.78%) 10 (0.84%) 10 (0.93%) starch (Ib/MSF) Sodium 0.7 (0.05%) 1.6 (0.12%) 1.6(0.13%) 1.6 (0.15%) trimetaphosphate (Ib/MSF) Total water / stucco 0.82 0.82 0.82 0.84 ratio (w/s) Trial formulation test results Dry board weight 1611 1570 1451 1320 (IbIMSF) Nail pull resistance (Ib) 77.3t 85.5 77.2 65.2 tASTM standard: 77 lb DILOFLO is a 45% Naphthalensulfonate solution in water [00431 As illustrated in Table 3, Boards C. D, and E were made from a slurry having substantially increased amounts of starch, DILOFLO dispersant, and sodium trimetaphosphate in comparison with the control board (about a two-fold increase 15 WO 2008/042060 PCT/US2007/018978 on a percentage basis for the starch and dispersant, and a two- to three-fold increase for the trimetaphosphate), while maintaining the w/s ratio constant. Nevertheless, board weight was significantly reduced and strength as measured by nail pull resistance was not dramatically affected. Therefore, in this example of an embodiment of the invention, the new formulation (such as, for example, Board D) can provide increased starch formulated in a usable, flowable slurry, while maintaining the same w/s ratio and adequate strength. EXAMPLE 4 [00441 Wet Gypsum Cube Strength Test [00451 The wet cube strength tests were carried out by using Southard CKS board stucco, available from United States Gypsum Corp., Chicago, Illinois and tap water in the laboratory to determine their wet compressive strength. The following lab test procedure was used. [0046] Stucco (1000 g), CSA (2 g), and tap water (1200 cc) at about 70'F were used for each wet gypsum cube cast. Pregelatinized corn starch (20 g, 2.0% based on stucco wt.) and CSA (2 g, 0.2% based on stucco wt.) were thoroughly dry mixed first in a plastic bag with the stucco prior to mixing with a tap water solution containing both naphthalenesulfonate dispersant and sodium trimetaphosphate. The dispersant used was DILOFLO dispersant (1.0 - 2.0%, as indicated in Table 4). Varying amounts of sodium trimetaphosphate were used also as indicated in Table 4. [00471 The dry ingredients and aqueous solution were initially combined in a laboratory Warning blender, the mixture produced allowed to soak for 10 sec, and then the mixture was mixed at low speed for 10 sec in order to make the slurry. The slurries thus formed were cast into three 2'X2"X2" cube molds. The cast cubes were then removed from the molds, weighed, and sealed inside plastic bags to prevent moisture loss before the compressive strength test was performed. The compressive strength of the wet cubes was measured using an ATS machine and recorded as an average in pounds per square inch (psi). The results obtained were as follows: 16 WO 2008/042060 PCT/US2007/018978 TABLE 4 Sodium DILOFLO1 trimetaphosphate, (wt% based Wet cube Wet cube Test grams (wt%. based on dry weight compressive Sample on dry stucco) stucco) (2"X2"X2"), strength, psi No. g 1 0 1.5 183.57 321 2 0.5 (0.05) 1.5 183.11 357 3 1(0.1) 1.5 183.19 360 4 2 (0.2) 1.5 183.51 361 5 4(0.4) 1.5 183.65 381 6 10(1.0) 1.5 183.47 369 7 0 1.0 184.02 345 8 0.5(0.05) 1.0 183.66 349 9 1 (0.1) 1.0 183.93 356 10 2(0.2) 1.0 182.67 366 11 4(0.4) 1.0 183.53 365 12 10(1.0) 1.0 183.48 341 13 0 2.0 183.33 345 14 0.5 (0.05) 2.0 184.06 356 15 1(0.1) 2.0 184.3 363 17 WO 2008/042060 PCT/US2007/018978 Sodium DILOFLO1 trimetaphosphate, (wt% based Wet cube Wet cube Test grams (wt/s based on dry weight compressive Sample on dry stucco) stucco) (2"X2"X2"), strength, psi No. g 16 2(0.2) 2.0 184.02 363 17 4 (0.4) 2.0 183.5 368 18 10(1.0) 2.0 182.68 339 DILOFLO is a 45% Naphthalensulfonate solution in water [00481 As illustrated in Table 4. Samples 4-5, 10-11. and 17, having levels of sodium trimetaphosphate in the about 0.12 - 0.4 % range of the present invention generally provided superior wet cube compressive strength as compared to samples with sodium trimetaphosphate outside this range. EXAMPLE 5 [0049] 1/2 Inch Light Weight Gypsum Wallboard Plant Production Trials [00501 Further trials were performed (Trial Boards 1 and 2), including slurry formulations and test results are shown in Table 5 below. The slurry formulations of Table 5 include the major components of the slurries. Values in parentheses are expressed as weight percent based on the weight of dry stucco. 18 WO 2008/042060 PCT/US2007/018978 TABLE 5 Trial formulation Control Plant Control Plant component/parameter Board I Formulation Board 2 Formulation Trial Board I Trial Board 2 Dry stucco (b/MSF) 1308 1160 1212 1120 DILOFLO' (Ib/MSF) 5.98 7.98 (0.688%) 7.18 8.99 (0.803%) (0.457%) (0.592%) Regular starch (lb/MSF) 5.0 0 4.6 0 (0.38%) (0.38%) Pregelatinized com 2.0 10 (0.86%) 2.5 9.0 (0.80%) starch (Ib/MSF) (0.15%) (0.21%) Sodium 0.7 2.0 (0.17%) 0.6 1.6 (0.14%) trimetaphosphate (0.05%) (0.05%) (Ib/MSF) Total water / stucco ratio 0.79 0.77 0.86 0.84 (w/s) Trial formulation test results Dry board weight 1619 1456 1553 1443 (ib/MSF) Nail pull resistance (Ib) 815 82.4 80.7 80.4 Flexural strength, 41.7 43.7 44.8 46.9 average (MD) (lb) Flexural strength, 134.1 135.5 146 137.2 average (XMD) (lb) Humidified bond ' load, 19.2 17.7 20.9 19.1 average (lb) I I Humidified bond Z 1.6 0.1 0.5 0 failure (%) _ t ASTM standard: 77 lb MD: machine direction XMD: across machine direction 1 DILOFLO is a 45% Naphthalensulfonate solution in water 2 90"F/ 90% Relative Humidity 3 It is well understood that under these test conditions, percentage failure rates < 50% are acceptable. [0051] As illustrated in Table 5, Trial Boards 1 and 2 were made from a slurry having substantially increased amounts of starch, DILOFLO dispersant, and sodium trimetaphosphate, while slightly decreasing the w/s ratio, in comparison with the control boards. Nevertheless, strength as measured by nail pull resistance and 19 WO 2008/042060 PCT/US2007/018978 flexural testing was maintained or improved, and board weight was significantly reduced. Therefore, in this example of an embodiment of the invention, the new formulation (such as, for example, Trial Boards 1 and 2) can provide increased trimetaphosphate and starch formulated in a usable, flowable slurry, while maintaining substantially the same w/s ratio and adequate strength. EXAMPLE 6 [0052] 1/2 Inch Ultra-Light Weight Gypsum Wallboard Plant Production Trials (0053] Further trials were performed (Trial Boards 3 and 4) using Formulation B (Example 1) as in Example 2, except that the pregelatinized com starch was prepared with water at 10% concentration (wet starch preparation) and a blend of HYONIC 25 AS and PFM 33 soaps (available from GEO Specialty Chemicals, Lafayette, Indiana) was used. For example, Trial Board 3 was prepared with a blend of HYONIC 25 AS and PFM 33 ranging from 65-70% by weight of 25AS, and the balance PFM 33. For example, Trial Board 4 was prepared with a 70/30 wtiwt. blend of HYONIC 25AS /HYONIC PFM 33. The trial results are shown in Table 6 below. 20 WO 2008/042060 PCT/US2007/018978 TABLE 6 Trial Board 3 Trial Board 4 (Formulation B plus (Formulation B plus HYONIC soap HYONIC soap blend Lab test result blend 65135) 70130) (n = 12) (n = 34)* Board weight (Ib/MSF) 1106 1013 Nail pull resistance (Ib) 85.5 80.3 Core hardnessb (Ib) >15 12.4 Flexural strength, average 55.6 60.3 1 (MD) (Ib) Flexural strength, averaged 140.1 142.3 (XMD) (Ib) * Except as marked. n = 4 MD: machine direction XMD: across machine direction a ASTM standard: 77 lb b ASTM standard: 11 lb 'ASTM standard: 36 lb d ASTM standard: 107 lb [00541 As illustrated in Table 6. strength characteristics as measured by nail pull and core hardness were above the ASTM standard. Flexural strength was also measured to be above the ASTM standard. Again, in this example of an embodiment of the invention, the new formulation (such as, for example, Trial Boards 3 and 4) can provide increased trimetaphosphate and starch formulated in a usable, flowable slurry, while maintaining adequate strength. EXAMPLE 7 [0055] 1/2 Inch Ultra-Light Weight Composite Gypsum Board. A. Slurry formulation [0056] A representative gypsum slurry formulation for producing gypsum composite board is shown in Table 7 below. All values in Table 7 are expressed as 21 WO 2008/042060 PCT/US2007/018978 weight percent based on the weight of dry stucco. Values in parentheses are dry weight in pounds (Ib/MSF). TABLE 7 Component Formulation C Stucco (lb/MSF) (714) sodium trimetaphosphate 0.315 (2.25) Dispersant (naphthalenesulfonate) 0.630 '(4.50) Pregelatinized starch ' 6.30 (45.0) Heat resistant accelerator (HRA) (15) Glass fiber 0.560 (4.00) Paper fiber 1.12 (8.00) Soap* 0.03 (0.192) Total Water (lb.) 931 Water / Stucco ratio t 1.30 *Used to pregenerate foam. Note: 10-14% by weight of slurry was not treated with soap foam. 11.40% by weight as a 45% aqueous solution. 2 Pregel starch can be added as a dry powder, or alternatively, as 10% pre dispersed starch in water (wet starch preparation). B. Preparation of Composite Boards with Dry Pregelatinized Starch [0057j The composite boards were prepared as in Example 2, using Formulation C above, with the following exceptions. Dry powder pregelatinized corn starch was used to prepare the slurry. Heavy Manila paper (60 lb/MSF, caliper 0.018 in.) was used as the top (face) cover sheet, to which was applied 6-8% by weight of the non-foamed high density gypsum slurry having a wet density of 80 pcf, across the entire surface of the paper. After application of the main foamed slurry, the bottom (back) cover sheet was applied, (News-Line paper - 42 lb/MSF, caliper 0.0125 in.) which included on its gypsum core-facing surface 4-6% by weight of the non foamed high density gypsum slurry having a wet density of 80-85 pcf, across the entire surface of the paper. 22 WO 2008/042060 PCT/US2007/018978 C. Preparation of Composite Boards with Wet Pregelatinized Starch [0058] Composite boards were prepared as set forth above, except that the pregelatinized corn starch was prepared in solution with water at 10% concentration (wet starch preparation). EXAMPLE 8 [0059] Testing of 1/2 Inch Ultra-Light Weight Composite Gypsum Board [0060] Test results for composite gypsum boards prepared in Examples 7B and 7C are shown in Table 8 below. As in this example and other examples, nail pull resistance, core hardness, and flexural strength tests were performed according to ASTM C-473. 2 ft. X 4ft. trial board samples were tested after conditioning at 70'F/50%R.H. TABLE 8 Lab test result Ex. 7B. Composite Ex. 7C. Composite Board (Wet Board (Dry Starch) Starch) (n = 8) (n = 8) Board weight 1041 1070 (lb/MSF) Nail pull resistance 69.6 83.1 (Ib) Core hardness (Ib) 9.4 10.9 Paper-to-core Bond Good/ok Good/ok (face/ back) 10061] As illustrated in Table 8, the Example 7C. composite board exceeds the ASTM standard for nail pull resistance, and essentially meets the core hardness standard (see Table 6). This demonstrates that the use of strong, heavy face paper and regular back paper, both adhered to a low density core using a non-foamed high density bonding layer, can provide a board having light weight, and increased strength. 23 WO 2008/042060 PCT/US2007/018978 [00621 The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g.. "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. [0063] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the invention. 24

Claims (5)

1. A composite gypsum board comprising: a set gypsum core having a dry density; the set gypsum core adjacent to a bonding layer having a dry density, the set gypsum core dry density being less than the bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board having a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the set gypsum core has an average core hardness of at least about 11 pounds (about 5 kg) as determined in accordance with ASTM C473.

2. A composite gypsum board comprising: a set gypsum core having a dry density; the set gypsum core adjacent to a bonding layer having a dry density, the set gypsum core dry density being less than the bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board having a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the board has a ratio of dry density (pcf) to average core hardness (lb) of less than about

3.2, wherein the core hardness is determined in accordance with ASTM C473. 3. A composite gypsum board comprising: a set gypsum core having a dry density; the set gypsum core adjacent to a bonding layer having a dry density, the set gypsum core dry density being less than the bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board having a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the board, when at a thickness of about 1/2 inch (about 1.3 cm), has a nail pull resistance to average core hardness ratio from about 4 to about 8, each as determined in accordance with ASTM C473. 25

4. A method of making a composite gypsum board, the method comprising: (a) mixing at least water and stucco, and optionally foam, to form a first slurry; (b) depositing a portion of the first slurry of (a) on a cover sheet to form a bonding layer; (c) adding foam to at least a portion of the first slurry of (a) and mixing to form a second slurry, wherein the second slurry comprises a greater amount of foam than the first slurry and has a lower wet density than the first slurry; (d) depositing the second slurry of (c) onto the bonding layer to form a panel; (e) cutting the panel into a board of predetermined dimensions; and (f) drying the board; wherein a set gypsum core is formed from the second slurry of (c) and has a dry density less than the first bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board has a dry density of about 35 pcf (about 560 kg/m 3 ) or less; and the board has a ratio of dry density (pcf) to average core hardness (lb) of less than about 3.2, wherein the core hardness is determined in accordance with ASTM C473.

5. A method of making a composite gypsum board, the method comprising: (a) mixing at least water and stucco, and optionally foam, to form a first slurry; (b) depositing a portion of the first slurry of (a) on a cover sheet to form a bonding layer; (c) adding foam to at least a portion of the first slurry of (a) and mixing to form a second slurry, wherein the second slurry comprises a greater amount of foam than the first slurry and has a lower wet density than the first slurry; (d) depositing the second slurry of (c) onto the bonding layer to form a panel; (e) cutting the panel into a board of predetermined dimensions; and (f) drying the board; wherein a set gypsum core is formed from the second slurry of (c) and has a dry density less than the first bonding layer dry density by a differential of at least about 10 pcf (about 160 kg/m 3 ); the board has a dry density of about 35 pcf (about 560 kg/i 3 ) or less; and 26 the board, when at a thickness of about % inch (about 1.3 cm), has a nail pull resistance to average core hardness ratio from about 4 to about 8, each as determined in accordance with ASTM C473. 27