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US-20260125318-A1 - FIRE RESISTANT GYPSUM PANELS, AND METHODS

US20260125318A1US 20260125318 A1US20260125318 A1US 20260125318A1US-20260125318-A1

Abstract

Fire resistant gypsum panels are provided herein, with assemblies including the same, and methods for making the same. A gypsum panel includes a set gypsum core and a mat facing material. The set gypsum core includes a fire resistant additive. The fire resistant additive consists essentially of clay, or a non-intumescent fire resistant additive. The panel displays an acceptable fire rating without requiring the use of vermiculite or intumescent materials.

Inventors

  • Fabio Enrique ESGUERRA
  • Allison N. GOINS
  • Anne H. Ksionzyk
  • Christopher J. Sanders
  • Bryan J. Wiltzius

Assignees

  • GEORGIA-PACIFIC GYPSUM LLC

Dates

Publication Date
20260507
Application Date
20251217

Claims (14)

  1. 1 . A gypsum panel, comprising: a set gypsum core comprising a fire resistant additive, the fire resistant additive consisting essentially of clay, wherein the clay is present in the set gypsum core in an amount of from about 0.5 to about 15 weight percent; and a mat facing material associated with a surface of the set gypsum core, wherein the panel displays a fire rating of not less than one hour when constructed as according to ASTM C1396 and tested in accordance with ASTM Test Method E119: Standard Test Methods for Fire Tests of Building Construction and Materials.
  2. 2 . The gypsum panel of claim 1 , wherein the clay is present in the set gypsum core in an amount of from about 1 to about 10 weight percent.
  3. 3 . The gypsum panel of claim 1 , wherein the clay is uncalcined kaolin, calcined kaolin, fire clay, ball clay, or any combination thereof.
  4. 4 . The gypsum panel of claim 1 , wherein the clay is present in the set gypsum core in an amount of from about 30 to about 110 lb/msf.
  5. 5 . The gypsum panel of claim 1 , wherein the gypsum panel displays an average volume shrinkage of 5% or less or an average thickness thermal shrinkage of 20% or less at temperatures up to 927° C.
  6. 6 . The gypsum panel of claim 1 , wherein the set gypsum core further comprises a structural reinforcing material.
  7. 7 . A building assembly comprising a plurality of the gypsum panels of claim 1 , wherein the assembly passes one or more of the following standards: 2005 National Building Code of Canada and 2006 British Columbia Section 9.27.2.2, Item 1b; ASTM E 2273-03 Standard Test Method for determining the Draining Efficiency of Exterior Insulating and Finish Systems (EIFS) Clad Wall Assemblies; ASTM E 2925-17, Standard Specification for Manufactured Polymeric Drainage and Ventilation Materials; and ASTM C1715-10, Standard Test Method for Evaluation of Water Leakage Performance of Masonry Wall Drainage Systems.
  8. 8 . A method of making a gypsum panel of claim 1 , comprising: forming a first gypsum slurry by combining stucco, water, and a fire resistant additive, the fire resistant additive consisting essentially of clay; setting the first gypsum slurry to form at least part of a core of the gypsum panel; and associating a mat facing material with a surface of the set gypsum core, wherein the clay is present in the set gypsum core in an amount of from about 0.5 to about 15 weight percent, wherein the panel displays a fire rating not less than one hour when constructed as according to ASTM C1396 and tested in accordance with ASTM Test Method E119: Standard Test Methods for Fire Tests of Building Construction and Materials.
  9. 9 . A gypsum panel, comprising: a set gypsum core comprising clay in the absence of any non-clay fire resistant additives present in an amount effective to alter the fire resistance performance of the panel, a mat facing material associated with a surface of the set gypsum core, wherein the panel displays a fire rating not less than one hour when constructed as according to ASTM C1396 and tested in accordance with ASTM Test Method E119: Standard Test Methods for Fire Tests of Building Construction and Materials.
  10. 10 . The gypsum panel of claim 9 , wherein the clay is present in the gypsum core in an amount of from about 0.5 to about 15 weight percent.
  11. 11 . The gypsum panel of claim 10 , wherein the clay is uncalcined kaolin, calcined kaolin, fire clay, ball clay, or any combination thereof.
  12. 12 . The gypsum panel of claim 9 , wherein the gypsum panel displays an average volume shrinkage of 5% or less or an average thickness thermal shrinkage of 20% or less at temperatures up to 927° C.
  13. 13 . The gypsum panel of claim 9 , wherein the set gypsum core further comprises a structural reinforcing material.
  14. 14 . A building assembly comprising a plurality of the gypsum panels of claim 13 , wherein the assembly passes one or more of the following standards: 2005 National Building Code of Canada and 2006 British Columbia Section 9.27.2.2, Item 1b; ASTM E 2273-03 Standard Test Method for determining the Draining Efficiency of Exterior Insulating and Finish Systems (EIFS) Clad Wall Assemblies; ASTM E 2925-17, Standard Specification for Manufactured Polymeric Drainage and Ventilation Materials; and ASTM C1715-10, Standard Test Method for Evaluation of Water Leakage Performance of Masonry Wall Drainage Systems.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is a Divisional of U.S. patent application Ser. No. 18/016,873, filed Jan. 19, 2023, which application is a National Phase of PCT/IB2021/056994, filed on Jul. 30, 2021, which claims priority to U.S. Provisional Application No. 63/062,534, filed on Aug. 7, 2020, which are incorporated herein by reference in their entireties. BACKGROUND The present invention relates generally to the field of panels for use in building construction, and more particularly to gypsum panels and methods of making gypsum panels. Typical building panels, such as interior building panels, building sheathing, or roof panels, include a core material, such as gypsum, and a mat facer, such as a paper facer or fiberglass mat facer. During manufacturing, the gypsum core material is traditionally applied as a slurry to a surface of the mat facer and allowed to set, such that the mat facer and gypsum core are adhered at the interface. Conventionally, such panels are heavy—with weights above 2000 lbs/msf—and lighter panels may suffer from performance issues and/or require costly ingredients to achieve certain properties (e.g., physical properties and fire resistance). WO2014/187703 discloses fire resistant calcium sulfate-based products comprising gypsum and a clay additive at a dosage above 22 weight percent. However, it would be desirable to provide relatively lightweight panels while maintaining necessary physical properties and fire resistance. SUMMARY In one aspect, a gypsum panel is provided, including a set gypsum core and a mat facing material. The set gypsum core includes a fire resistant additive. The fire resistant additive consists essentially of clay. The clay is present in the set gypsum core in an amount of from about 0.5 to about 15 weight percent. The mat facing material is associated with a surface of the set gypsum core. The panel displays a fire rating of not less than one hour when constructed as according to ASTM C1396 and tested in accordance with ASTM Test Method E119: Standard Test Methods for Fire Tests of Building Construction and Materials. In another aspect, a gypsum panel is provided, including a set gypsum core and a mat facing material. The set gypsum core includes clay in the absence of any non-clay fire resistant additives present in an amount effective to alter the fire resistance performance of the panel. The mat facing material is associated with a surface of the set gypsum core. The panel displays a fire rating not less than one hour when constructed as according to ASTM C1396 and tested in accordance with ASTM Test Method E119: Standard Test Methods for Fire Tests of Building Construction and Materials. In yet another aspect, a gypsum panel is provided, including a set gypsum core and a mat facing material. The set gypsum core includes a non-intumescent fire resistant additive. The non-intumescent fire resistant additive includes silica in an amount of at least 40% by weight of the non-intumescent fire resistant additive. The non-intumescent fire resistant additive includes ceramic flux agent in a total amount of more than 0% by weight and less than or equal to 5% by weight of the non-intumescent fire resistant additive. The mat facing material is associated with a surface of the set gypsum core. Methods for making gypsum panels, and building assemblies including gypsum panels are also provided. BRIEF DESCRIPTION OF THE DRAWINGS The detailed description is set forth with reference to the accompanying drawings illustrating examples of the disclosure, in which use of the same reference numerals indicates similar or identical items. Certain embodiments of the present disclosure may include elements, components, and/or configurations other than those illustrated in the drawings, and some of the elements, components, and/or configurations illustrated in the drawings may not be present in certain embodiments. FIG. 1 is a cross-sectional view of a gypsum panel. FIG. 2 is a cross-sectional view of a gypsum panel FIG. 3 is a cross-sectional view of a gypsum panel. FIG. 4 is a graph showing the % volume expansion of various experimental samples subjected to a high temperature volume expansion test, according to the Examples. FIG. 5 is a graph showing the dilatometer volume shrinkage of various experimental samples subjected to high temperature, according to the Examples. FIG. 6 is a graph showing the % shrinkage of various experimental samples subjected to a high temperature thermal shrinkage (diameter) test, according to the Examples. FIG. 7 is a graph showing the % shrinkage of various experimental samples subjected to a high temperature thermal shrinkage (thickness) test, according to the Examples. FIG. 8 is a graph showing the time of thermal transmission of various experimental samples subjected to a thermal transmission test, according to the Examples. FIG. 9 is a graph showing the % volume expansion of various experimental samples subjected to a high