Abstract: The present invention is directed to a gypsum panel with enhanced fire resistance properties and a method of making such gypsum panel. In one embodiment, the gypsum panel comprises a gypsum core, a fire resistance composition, a first facing material, and a second facing material. The fire resistance composition may include phosphorus, nitrogen, boron, or a combination thereof. The weight ratio of phosphorus to nitrogen may be 40-95:0-50. The weight ratio of phosphorus to boron may be 40-95:0-10. The methods of the present invention are directed to making the aforementioned gypsum panels.

Abstract: The present invention is directed to gypsum panels with controlled intumescence and a method of making such gypsum panels. In one embodiment, the gypsum panel comprises a gypsum core, a first facing material, and a second facing material. The gypsum panel comprises a fire resistance composition. The fire resistance composition and/or any components thereof may be milled. The methods of the present invention are directed to making the aforementioned gypsum panels.

Abstract: The present disclosure is directed to a gypsum panel and a method of making a gypsum panel. For instance, the gypsum panel comprises: a first facing material having an outer surface and an inner surface opposing the outer surface; a thermal barrier layer adjacent the inner surface of the first paper material, the thermal barrier layer comprising a thermal additive; a gypsum core having an outer surface facing the thermal barrier layer and an inner surface opposing the outer surface, the gypsum core comprising a first filler comprising silica, alumina, or a mixture thereof; and a second facing material adjacent the inner surface of the gypsum core.

Abstract: The present disclosure is directed to a method of manufacturing gypsum board as well as the resulting gypsum board. The method comprises providing a gypsum slurry with a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. As a result, the gypsum board includes gypsum and a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. The gypsum board exhibits an area shrinkage of less than 20%.

Abstract: The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, in one embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and one or more components of a reclaim gypsum panel, such as reclaimed gypsum and reclaimed facing material. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and one or more components of a reclaim gypsum panel, such as reclaimed gypsum and reclaimed facing material, onto the first facing material, and providing a second facing material on the gypsum slurry.

Abstract: The present disclosure is directed to a method of manufacturing gypsum board as well as the resulting gypsum board. The method comprises providing a gypsum slurry with a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. As a result, the gypsum board includes gypsum and a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. The gypsum board exhibits an area shrinkage of less than 10%.

Abstract: The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, in one embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and one or more fire resistance additives. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and one or more fire resistance additives onto the first facing material, and providing a second facing material on the gypsum slurry.

Abstract: The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core. The gypsum core includes gypsum, a thermal insulation additive, and a shrinkage reduction additive. The gypsum core includes 3 wt. % or less of vermiculite based on the weight of the gypsum in the gypsum core. The gypsum panel passes ASTM E119-20.

Abstract: The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, in one embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and one or more components of a reclaim gypsum panel, such as reclaimed gypsum and reclaimed facing material. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and one or more components of a reclaim gypsum panel, such as reclaimed gypsum and reclaimed facing material, onto the first facing material, and providing a second facing material on the gypsum slurry.

Abstract: The present disclosure is directed to a method of manufacturing gypsum board as well as the resulting gypsum board. The method comprises providing a gypsum slurry with a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. As a result, the gypsum board includes gypsum and a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. The gypsum board exhibits an area shrinkage of less than 10%.

Abstract: The present disclosure is directed to a method of manufacturing gypsum board as well as the resulting gypsum board. The method comprises providing a gypsum slurry with a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. As a result, the gypsum board includes gypsum and a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. The gypsum board exhibits an area shrinkage of less than 10%.