Modified landplaster as a wallboard filler

Abstract

A gypsum slurry includes calcium sulfate hemihydrate, water and calcium sulfate dihydrate is coated with a hydrophilic, dispersible coating. The coating is less soluble than the calcium sulfate hemihydrate to delay exposure of the landplaster to the remainder of the slurry, preventing premature crystallization and the early stiffening that accompanies it. Another embodiment is a gypsum slurry that includes calcium sulfate hemihydrate, a polycarboxylate dispersant, water and coated calcium sulfate dihydrate. In this case, the hydrophilic, dispersible coating is selected to serve as a modifier to enhance the ability of the dispersant to fluidize the gypsum slurry.

1 . A gypsum slurry comprising: 
 calcium sulfate hemihydrate;    water; and    calcium sulfate dihydrate coated with a hydrophilic, dispersible coating, wherein said coating is less soluble than calcium sulfate hemihydrate.    
     
     
         2 . The slurry of  claim 1  wherein the temperature of said water is greater than 100° F.  
     
     
         3 . The slurry of  claim 1  wherein said coating is at least one of the group consisting of a phosphate, a phosphonate, a hydroxide and a carbonate coating.  
     
     
         4 . The slurry of  claim 1  wherein said calcium sulfate dihydrate has been treated with at least one of the group consisting of soda ash and hydrated lime.  
     
     
         5 . The slurry of  claim 1  wherein said coating is applied at a rate of up to 0.2% based on the total dry weight of calcium sulfate.  
     
     
         6 . The slurry of  claim 1  wherein said coated calcium sulfate dihydrate is present in amounts of up to about 10% by weight based on the combined weight of said calcium sulfate hemihydrate and said calcium sulfate dihydrate.  
     
     
         7 . The slurry of  claim 1  further comprising a polycarboxylate dispersant.  
     
     
         8 . The slurry of  claim 7  wherein said coating comprises a modifier that enhances the efficacy of the dispersant.  
     
     
         9 . The slurry of  claim 7  wherein said modifier comprises at least one of the group consisting of soda ash, trisodium phosphate, lime, calcium carbonate and tetrasodium pyrophosphate.  
     
     
         10 . A method of making a gypsum slurry, comprising: 
 selecting a hydrophilic, dispersible coating that is less soluble than calcium sulfate dihydrate;    coating calcium sulfate dihydrate with said coating;    combining the coated calcium sulfate dihydrate with calcium sulfate hemihydrate and water to form the slurry.    
     
     
         11 . The method of  claim 10  wherein said combining step comprises mixing.  
     
     
         12 . The method of  claim 10  wherein said coating step comprises precipitating, spraying or dipping.  
     
     
         13 . The method of  claim 10  further comprising adding a polycarboxylate dispersant to the slurry.  
     
     
         14 . The method of  claim 13 , wherein said coating comprises a modifier for enhancing performance of said dispersant.  
     
     
         15 . A method of making a wallboard panel comprising: 
 selecting a hydrophilic, dispersible coating material that is both less soluble than calcium sulfate dihydrate and enhances the efficacy of a polycarboxylate dispersant;    coating calcium sulfate dihydrate with said coating material;    combining the coated calcium sulfate dihydrate with calcium sulfate hemihydrate, the polycarboxylate dispersant and water to form a slurry;    depositing the slurry on a facing material;    forming the panel; and    allowing the slurry to set.    
     
     
         16 . The wallboard panel of  claim 15 , wherein said coating material comprises at least one selected from the group consisting of carbonates, hydroxides, phosphates and phosphonates.  
     
     
         17 . The wallboard panel of  claim 15 , wherein said coating material is applied in amounts of up to 0.2% based on the combined dry weight of the calcium sulfate hemihydrate and calcium sulfate dihydrate.  
     
     
         18 . The wallboard panel of  claim 15 , wherein the calcium sulfate dihydrate comprises from about 3% to about 10% of the combined weight of the calcium sulfate dihydrate and the calcium sulfate hemihydrate.