Extruded gypsum-based materials

• US 9,890,083 B2
• Filed: 03/05/2014
• Issued: 02/13/2018
• Est. Priority Date: 03/05/2013
• Status: Active Grant

• Current Assignee: The Intellectual Gorilla GmbH
• Original Assignee: The Intellectual Gorilla GmbH
• Inventors: Daniels, Evan R., Andersen, Per Just
• Primary Examiner(s): Green, Anthony J
• Application Number:
  US14/781,832
• Publication Number:
  US 20160122247A1
• Time in Patent Office: 1,441 Days
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/10 of wood; of wood particle board
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2262/0223 Vinyl resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 16/0633 Polypropylene
• CPC Class Codes: C04B 16/0641 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 16/065 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 20/002 : Hollow or porous granular materials
• CPC Class Codes: C04B 2103/0079 : Rheology influencing agents
• CPC Class Codes: C04B 2103/20 : Retarders
• CPC Class Codes: C04B 2111/00129 : Extrudable mixtures
• CPC Class Codes: C04B 2111/00586 : Roofing materials
• CPC Class Codes: C04B 22/143 : Calcium-sulfate
• CPC Class Codes: C04B 24/06 : containing hydroxy groups
• CPC Class Codes: C04B 24/14 : Peptides; Proteins; Derivatives thereof
• CPC Class Codes: C04B 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 40/02 : Selection of the hardening environment
• CPC Class Codes: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/4543 : by spraying, e.g. by atomising
• CPC Class Codes: C04B 41/53 : involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete C04B41/0036 - C04B41/0054 take precedence
• CPC Class Codes: C04B 7/02 : Portland cement
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

An extrudable gypsum-based material is formed from a mixture that includes gypsum in the range of about 40 to 90% by dry weight percent, a secondary material in the range of about 0.1 to 50% by dry weight percent, a reinforcement fiber in the range of about 1 to 20% by dry weight percent, a rheology modifying agent in the range of about 0.5 to 10% by dry weight percent, a retarder in the range of about 0.1 to 8% by dry weight percent, a water in the range of 10 to 50% of a total wet material weight.

Claims

1. An extrudable gypsum-based material formed from a mixture comprising:

a calcium sulfate hemihydrate in the range of about 40 to 90% by dry weight percent;

a secondary material in the range of about 0.1 to 50% by dry weight percent selected from sand, cement, fly ash, slag, rock, expanded light weight aggregate, or a combination thereof;

a reinforcement fiber in the range of about 1 to 20% by dry weight percent;

a rheology modifying agent in the range of about 0.5 to 10% by dry weight percent selected from a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof;

a retarder in the range of about 0.1 to 8% by dry weight percent;

a water in the range of 16 to 25% of a total wet material weight; and

the mixture is extrudable.

2. The extrudable gypsum-based material as recited in claim 1, the reinforcement fiber comprising cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic or alkali-resistant fiber, or a combination thereof.

3. The extrudable gypsum-based material as recited in claim 1, the polysaccharide comprising a cellulose-based material, a cellulose-based material derivative, a starch-based material, a starch-based material derivative, or a combination thereof.

4. The extrudable gypsum-based material as recited in claim 3, the cellulose-based material is selected from the group consisting of methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC) and hydroxypropylmethylcellulose (HPMC).

5. The extrudable gypsum-based material as recited in claim 3, the starch-based material is selected from the group consisting of wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches, or dialdehyde starches.

6. The extrudable gypsum-based material as recited in claim 1, the retarder comprising sodium citrate, or a mixture of Plaster of Paris, sodium citrate and crystalline silica.

7. The extrudable gypsum-based material as recited in claim 1, wherein the extrudable gypsum-based material comprises a roofing tile or a wall panel.

8. A method for manufacturing an extrudable gypsum-based material comprising the steps of:

mixing a calcium sulfate hemihydrate in the range of about 40 to 90% by dry weight percent, a secondary material in the range of about 0.1 to 50% by dry weight percent selected from sand, cement, fly ash, slag, rock, expanded light weight aggregate, or a combination thereof, a reinforcement fiber in the range of about 1 to 20% by dry weight percent, a rheology modifying agent in the range of about 0.5 to 10% by dry weight percent selected from a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof, and a retarder in the range of about 0.1 to 8% by dry weight percent with water in the range of 16 to 25% of a total wet material weight;

extruding the mixture through a die using an extruder; and

allowing the extruded mixture to set.

9. The method as recited in claim 8, the reinforcement fiber comprising cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic or alkali-resistant fiber, or a combination thereof.

10. The method as recited in claim 8, the polysaccharide comprising a cellulose-based material, a cellulose-based material derivative, a starch-based material, a starch-based material derivative, or a combination thereof.

11. The method as recited in claim 10, the cellulose-based material is selected from the group consisting of methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC) and hydroxypropylmethylcellulose (HPMC).

12. The method as recited in claim 10, the starch-based material is selected from the group consisting of wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches, or dialdehyde starches.

13. The method as recited in claim 8, the retarder comprising sodium citrate, or a mixture of Plaster of Paris, sodium citrate and crystalline silica.

14. The method as recited in claim 8, wherein the extruded mixture is allowed to set for 2 to 3 hours.

15. The method as recited in claim 8, further comprising the step of curing the extruded mixture.

16. The method as recited in claim 8, further comprising the step of drying the extruded mixture.

17. The method as recited in claim 8, further comprising the step of molding, cutting, trimming, sanding or routing the extruded mixture into a specified shape.

18. The method as recited in claim 17, wherein the specified shape comprises a roofing tile or a wall panel.

19. The method as recited in claim 18, wherein:

the roofing tile has a thickness of between about 5 mm to 40 mm; and

the wall panel has a thickness of between about 5 mm to 250 mm.

20. The method as recited in claim 8, further comprising the step of spraying the extruded mixture with a water repellent.

21. The method as recited in claim 8, further comprising the step of decorating one or more surfaces of the extruded mixture by printing at least one image on the one or more surfaces or laminating a veneer on the one or more surfaces, or etching the at least one image on the one or more surfaces.