U.S. patent application number 13/704559 was filed with the patent office on 2013-09-26 for building material containing latent heat storage material and methods of making the same.
This patent application is currently assigned to GEORGIA-PACIFIC GYPSUM LLC. The applicant listed for this patent is Joel T. Charlton, Keshav S. Gautam. Invention is credited to Joel T. Charlton, Keshav S. Gautam.
Application Number | 20130251986 13/704559 |
Document ID | / |
Family ID | 45348500 |
Filed Date | 2013-09-26 |
United States Patent
Application |
20130251986 |
Kind Code |
A1 |
Charlton; Joel T. ; et
al. |
September 26, 2013 |
Building Material Containing Latent Heat Storage Material and
Methods of Making the Same
Abstract
A building material includes a paneled article having a first
side and a second side. A layer of encapsulated latent heat storage
material is disposed on the first side of the panel and a coating
is disposed over the layer of encapsulated latent heat storage
material.
Inventors: |
Charlton; Joel T.; (Roswell,
GA) ; Gautam; Keshav S.; (Duluth, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Charlton; Joel T.
Gautam; Keshav S. |
Roswell
Duluth |
GA
GA |
US
US |
|
|
Assignee: |
GEORGIA-PACIFIC GYPSUM LLC
Atlanta
GA
|
Family ID: |
45348500 |
Appl. No.: |
13/704559 |
Filed: |
March 15, 2011 |
PCT Filed: |
March 15, 2011 |
PCT NO: |
PCT/US11/28425 |
371 Date: |
March 4, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61356201 |
Jun 18, 2010 |
|
|
|
Current U.S.
Class: |
428/341 ;
427/372.2; 428/432; 428/703 |
Current CPC
Class: |
B32B 13/14 20130101;
B32B 2262/101 20130101; E04C 2/043 20130101; B32B 2255/12 20130101;
E04B 1/7608 20130101; B32B 2255/02 20130101; B32B 5/022 20130101;
Y10T 428/273 20150115; B32B 13/08 20130101; B32B 2419/00
20130101 |
Class at
Publication: |
428/341 ;
428/703; 428/432; 427/372.2 |
International
Class: |
E04B 1/76 20060101
E04B001/76 |
Claims
1. A gypsum board comprising: a gypsum core; and a facing material
comprising a first side and second side opposite the first side,
the second side is bonded to the gypsum core, wherein in an area
proximate to the bond a latent heat storage material is disposed
with a remainder of the gypsum core being substantially free of
latent heat storage material.
2. The gypsum board of claim 1, wherein the latent heat storage
material is in the form of capsules containing phase change
material.
3. The gypsum board of claim 2, wherein the capsules are
microcapsules.
4. The gypsum board of claim 2, wherein the capsules are
macrocapsules.
5. The gypsum board of claim 1, wherein the facing material is a
glass mat.
6. A gypsum board comprising: a gypsum core having a main portion
and a second portion, the second portion being more dense than the
main portion, wherein the second portion comprises a latent heat
storage material; and a facing material comprising a first side and
second side opposite the first side, the second side is bonded to
the second portion of the gypsum core.
7. The gypsum board of claim 6, wherein the latent heat storage
material is in the form of capsules containing phase change
material.
8. The gypsum board of claim 7, wherein the capsules are
microcapsules.
9. The gypsum board of claim 7, wherein the capsules are
macrocapsules.
10. A gypsum board comprising: a gypsum core; a facing material
comprising a first side and second side opposite the first side,
the second side is bonded to the gypsum core; a layer of
encapsulated latent storage material disposed on the first side;
and a coating layer disposed over the layer of encapsulated latent
storage material such that substantially no encapsulated latent
heat storage material is exposed to an outer surface of the coating
layer.
11. The gypsum board of claim 10, wherein the latent heat storage
material is in the form of capsules containing phase change
material.
12. The gypsum board of claim 11, wherein the capsules are
microcapsules.
13. The gypsum board of claim 11, wherein the capsules are
macrocapsules.
14. A gypsum board comprising: a gypsum core; a facing material
comprising a first side and second side opposite the first side,
the second side is bonded to the second portion of the gypsum core;
and a coating layer disposed on the second side, wherein the
coating comprises capsules of latent heat storage material.
15. The gypsum board of claim 14, wherein the latent heat storage
material is in the form of capsules containing phase change
material.
16. The gypsum board of claim 15, wherein the capsules are
microcapsules.
17. The gypsum board of claim 15, wherein the capsules are
macrocapsules.
18. A gypsum board comprising: a gypsum core; a facing material
comprising a first side and second side opposite the first side,
the second side is bonded to the second portion of the gypsum core;
and a coating layer disposed on the second side, wherein the
coating comprises capsules of latent heat storage material.
19. The gypsum board of claim 18, wherein the latent heat storage
material is in the form of capsules containing phase change
material.
20. The gypsum board of claim 19, wherein the capsules are
microcapsules.
21. The gypsum board of claim 19, wherein the capsules are
macrocapsules.
22. A gypsum board comprising: a gypsum core; a first fiber mat
comprising a first side and second side opposite the first side,
the second side is bonded to the second portion of the gypsum core;
a first coating penetrating the first fiber mat from the first side
into the fiber mat; a second fiber mat comprising a first side and
second side opposite the first side, the second side is bonded to
the gypsum core; a second coating penetrating the second fiber mat
from the first side into the fiber mat; wherein both the first
fiber mat and the second fiber mat each comprise glass fibers
nominally about 10 to 16 microns in diameter and about one-quarter
(1/4) to about one (1) inch in length, the first fiber mat in the
absence of coating has a basis weight of 1 to 3 pounds per 100
square feet; and wherein at least one of the first coating and the
second coating each comprise a capsules of latent heat storage
material and an organic binder.
23. The gypsum board of claim 1, wherein the latent heat storage
material is in the form of capsules containing a phase change
material.
24. The gypsum board of claim 23, wherein the capsules are
microcapsules.
25. The gypsum board of claim 23, wherein the capsules are
macrocapsules.
26. A method of making a gypsum board comprising: depositing a
gypsum slurry for forming a set gypsum core onto a non-coated side
of a pre-coated fiber mat, the fiber mat having a coating on a side
opposite the non-coated side, the coating comprising an organic
binder and a latent heat storage material; and drying the gypsum
slurry to form a set gypsum core.
27. A method of making a gypsum board comprising: depositing a
gypsum slurry for forming a set gypsum core onto a facing material;
drying the gypsum slurry to form a set gypsum core; applying a
latent heat storage material on the facing material on a side
opposite in contact with set gypsum core; and applying a coating
over the latent heat storage material.
28. A building material comprising: a paneled article having a
first side and a second side; a layer of encapsulated latent heat
storage material disposed on the first side; and a coating disposed
over the layer of encapsulated latent heat storage material.
Description
BACKGROUND
[0001] The present disclosure generally relates to building
material products comprising latent heat storage materials, and
more particularly, to gypsum boards comprising phase change
materials and methods of making the same.
[0002] There is a general desire in all technical fields to be
energy efficient. In the building industry, for example, there is a
permanent need to decrease the energy costs related to heating and
cooling indoor rooms. A reduction in energy consumption can also
have the added benefit of reducing carbon dioxide emissions.
Recently, governmental bodies world-wide are considering setting
caps on the amount of carbon dioxide emissions, which is creating a
demand for more energy efficient buildings and building
materials.
[0003] Accordingly, a continual need exists for improved building
materials that aid in providing energy efficiency to buildings.
BRIEF SUMMARY
[0004] Disclosed herein are building materials, namely gypsum
boards containing a latent heat storage material, and methods of
making the same.
[0005] In one embodiment, a gypsum board comprises a gypsum core;
and a facing material comprising a first side and second side
opposite the first side, the second side is bonded to the gypsum
core, wherein in an area proximate to the bond a latent heat
storage material is disposed with a remainder of the gypsum core
being substantially free of latent heat storage material.
[0006] In a second embodiment, a gypsum board comprises a gypsum
core having a main portion and a second portion, the second portion
being more dense than the main portion, wherein the second portion
comprises a latent heat storage material; and a facing material
comprising a first side and second side opposite the first side,
the second side is bonded to the second portion of the gypsum
core.
[0007] In a third embodiment, a gypsum board comprises a gypsum
core; a facing material comprising a first side and second side
opposite the first side, the second side is bonded to the gypsum
core; a layer of encapsulated latent storage material disposed on
the first side; and a coating layer disposed over the layer of
encapsulated latent storage material such that substantially no
encapsulated latent heat storage material is exposed to an outer
surface of the coating layer.
[0008] In a fourth embodiment, a gypsum board comprises a gypsum
core; a facing material comprising a first side and second side
opposite the first side, the second side is bonded to the second
portion of the gypsum core; and a coating layer disposed on the
second side, wherein the coating comprises capsules of latent heat
storage material.
[0009] In a fifth embodiment, a gypsum board comprises a gypsum
core; a facing material comprising a first side and second side
opposite the first side, the second side is bonded to the second
portion of the gypsum core; and a coating layer disposed on the
second side, wherein the coating comprises capsules of latent heat
storage material.
[0010] In a sixth embodiment, a gypsum board comprises a gypsum
core; a first fiber mat comprising a first side and second side
opposite the first side, the second side is bonded to the second
portion of the gypsum core; a first coating penetrating the first
fiber mat from the first side into the fiber mat; a second fiber
mat comprising a first side and second side opposite the first
side, the second side is bonded to the gypsum core; a second
coating penetrating the second fiber mat from the first side into
the fiber mat; wherein both the first fiber mat and the second
fiber mat each comprise glass fibers nominally about 10 to 16
microns in diameter and about one-quarter (1/4) to about one (1)
inch in length, the first fiber mat in the absence of coating has a
basis weight of 1 to 3 pounds per 100 square feet; and wherein at
least one of the first coating and the second coating each comprise
a capsules of latent heat storage material and an organic
binder.
[0011] In one embodiment, a method of making a gypsum board
comprises: depositing a gypsum slurry for forming a set gypsum core
onto a non-coated side of a pre-coated fiber mat, the fiber mat
having a coating on a side opposite the non-coated side, the
coating comprising an organic binder and a latent heat storage
material; and drying the gypsum slurry to form a set gypsum
core.
[0012] In a second embodiment, a method of making a gypsum board
comprises: depositing a gypsum slurry for forming a set gypsum core
onto a facing material; drying the gypsum slurry to form a set
gypsum core; applying a latent heat storage material on the facing
material on a side opposite in contact with set gypsum core; and
applying a coating over the latent heat storage material.
[0013] In one embodiment, a building material comprises a paneled
article having a first side and a second side; a layer of
encapsulated latent heat storage material disposed on the first
side; and a coating disposed over the layer of encapsulated latent
heat storage material.
[0014] The above described and other features are exemplified by
the following Figures and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Referring to the exemplary drawings wherein like elements
are numbered alike in the several Figures:
[0016] FIG. 1 is a cross-sectional view of an exemplary gypsum
board comprising a phase change material in coating;
[0017] FIG. 2 is a cross-sectional view of an exemplary gypsum
board comprising a phase change material disposed in a layer of the
core of gypsum board;
[0018] FIG. 3 is a cross-sectional view of an exemplary gypsum
board comprising a phase change material disposed on facing
material with a coating disposed over the phase change material;
and
[0019] FIG. 4 is shows a highly schematic view of an apparatus for
making gypsum board.
DETAILED DESCRIPTION
[0020] Disclosed herein is building materials containing latent
heat storage materials and methods of making the same. Examples of
building materials include, but are not limited to, gypsum board,
wafer board, particle board, oriented strand board (OSB), plywood,
fiberboard, medium density fiberboard (MDF), oriented strand lumber
(OSL) parallel strand lumber (PSL), laminated veneer lumber (LVL),
laminated strand lumber (LSL), cement board, wood, wood veneer,
wood-plastic composites, plastic, plastic-cement composites, and
combinations comprising at least one of the foregoing.
[0021] In one embodiment, the building material comprises a paneled
article having a first side and a second side; a layer of
encapsulated latent heat storage material disposed on the first
side; and a coating disposed over the layer of encapsulated latent
heat storage material. For ease in discussion, reference is
hereinafter made to a gypsum board as an example of a building
material for ease in discussion with the understanding that this
disclosure can be adopted by a person of skill in the art to other
building materials.
[0022] The term "latent heat storage" material is defined herein as
a substance that has a phase transition temperature within a
temperature range within which heat-transfer is intended. These
materials are sometimes also referred to as phase change materials
(PCMs). The PCMs disclosed herein have a solid/liquid phase
transition in the temperature range from -20.degree. C. (degrees
Celsius) to 120.degree. C.
[0023] Without wanting be bound by theory, it is believed that the
location of the PCM in gypsum board can improve efficiency of heat
transfer, thereby allowing less PCM material to be employed
compared to, for example, homogenously distributing PCM in a gypsum
core. More particularly, it is believed that the closer the PCM is
to the surface of the gypsum board the more efficient the heat
transfer will be. Embodiments are hereinafter described that have a
stratified structure having a layer comprising a PCM.
[0024] Referring now to FIG. 1, an exemplary embodiment of a gypsum
board 10 is shown. The gypsum board 10 comprises a board core 12
faced with a first facing material 14 and a second facing material
16. The facing material 14 and 16 may be the same or different. For
example, both facing material 14 and 16 may comprise glass fibers,
both may comprise paper, or one may comprise paper and the other
glass fibers. Other materials are envisioned for the facing
materials 14 and 16 and are not a critical aspect of the invention.
In one embodiment, both facing materials 14 and 16 comprise glass
fibers nominally about 10 to 16 microns in diameter and about
one-quarter (1/4) to about one (1) inch in length, the first fiber
mat in the absence of coating has a basis weight of 1 to 3 pounds
per 100 square feet.
[0025] The board core 12 is basically of the type used in gypsum
structural products commonly known as gypsum wallboard, dry wall,
gypsum board, gypsum lath and gypsum sheathing. The core of such a
product is formed by mixing water with powdered anhydrous calcium
sulfate or calcium sulfate hemi-hydrate (CaSO.sub.4.1/2H.sub.2O),
also known as calcined gypsum, to form an aqueous gypsum slurry,
and thereafter allowing the slurry mixture to hydrate or set into
calcium sulfate dihydrate (CaSO.sub.4.2H.sub.2O), a relatively hard
material. The invention is not limited to any particular content of
gypsum in the core.
[0026] A coating layer 18 is disposed on the first facing material
14. An optional coating layer 22 can be disposed on facing material
16. The coating material employed in coating layer 18 and 20 can be
the same or different. In one embodiment, the coating layer 18
comprises a plurality of capsules 20 containing PCM. The capsules
containing PCM are disposed within the coating such that
substantially no capsules containing PCM is exposed to an outer
surface of the coating layer 18. The term "substantially" free or
substantially none is being used throughout this disclosure to mean
less than 10% by weight, based on a total weight (as defined by
context, e.g., weight of coating), specifically less than 5% by
weight.
[0027] The coating material used in coating layer 18 is selected to
be compatible with the encapsulation material of PCM capsules 20
and the desired application. For example, if the coating layer 18
is disposed on the facing material 14 to form a pre-coated facing
material, the porosity of the coating is controlled to allow water
to evaporate thru the coating layer 18. In "post" coating
operations, porosity of the coating is less important. The term
"post coating" is being used herein to refer to a coating operation
after the gypsum board has been formed and dried in a drier. One
potential advantage of post coating is less energy can be consumed
compared to drying a gypsum board containing PCM, since the PCM
absorbs heat energy.
[0028] Embodiments are envisioned where the coating layer comprises
an organic binder, an inorganic binder or combinations of organic
and inorganic binders. The choice of binder will vary depending on
application and method employed in making the gypsum board 10.
[0029] In one embodiment, the coating material used in the coating
layer 18 comprises an organic binder. Examples of organic binders
include, but are not limited to, styrene-butadiene-rubber (SBR),
styrene-butadiene-styrene (SBS), ethylene-vinyl-chloride (EVCl),
poly-vinylidene-chloride (PVdC), modified poly-vinyl-chloride
(PVC), poly-vinyl-alcohol (PVOH), ethylene-vinyl-acetate (EVA), and
poly-vinyl-acetate (PVA). Asphalt is not generally used as a binder
in making a coated mat useful in this invention.
[0030] The coating layer 18 can optionally comprise a filler
material. Examples of filler materials include, but are not limited
to, ground limestone (calcium carbonate), sand, mica, talc, gypsum
(calcium sulfate dihydrate), aluminum trihydrate (ATH), antimony
oxide, or a combination of any two or more of these substances.
[0031] The PCM capsules 20 can be microcapsules, microcapsules, or
a combination of the foregoing. The capsules comprise a capsule
core of latent heat storage material and capsule wall of polymeric
material, wherein about 90% or greater of the total weight of the
capsule is the latent heat storage material. The term
"microcapsule" is being used throughout this disclosure refers to
capsules having a mean diameter of 1 to 100 .mu.m (micrometers).
The term "macrocapsule" is being used throughout this disclosure
referred to any capsules having a mean diameter greater than 100
.mu.m. The choice of capsule size will be variable dependent on
desired application (e.g. fire rating).
[0032] Example of PCM materials and methods of making are discussed
in U.S. Pat. No. 7,166,355 and include, but are not limited to: 1)
aliphatic hydrocarbon compounds such as saturated or unsaturated
C.sub.10-C.sub.40-hydrocarbons which are branched or specifically
linear, e.g. n-tetradecane, n-pentadecane, n-hexadecane,
n-heptadecane, n-octadecane, n-nonadecane, n-eicosane,
n-heneicosane, n-docosane, n-tricosane, n-tetracosane,
n-pentacosane, n-hexacosane, n-heptacosane, n-octacosane, and
cyclic hydrocarbons, e.g. cyclohexane, cyclooctane, cyclodecane; 2)
aromatic hydrocarbon compounds such as benzene, naphthalene,
biphenyl, o- or n-terphenyl, C.sub.1-C.sub.40-alkyl-substituted
aromatic hydrocarbons such as dodecylbenzene, tetradecylbenzene,
hexadecylbenzene, hexylnaphthalene or decylnaphthalene; 3)
saturated or unsaturated C.sub.6-C.sub.30-fatty acids such as
lauric, stearic, oleic or behenic acid, specifically eutectic
mixtures of decanoic acid with, for example, myristic, palmitic or
lauric acid; 4) fatty alcohols such as lauryl, stearyl, oleyl,
myristyl and cetyl alcohols, mixtures such as coconut fatty alcohol
and the oxo alcohols obtained by hydroformylation of
.alpha.-olefins and further reactions; C.sub.6-C.sub.30-fatty
amines such as decylamine, dodecylamine, tetradecylamine or
hexadecylamine; 5) esters such as C.sub.1-C.sub.10-alkyl esters of
fatty acids, e.g. propyl palmitate, methyl stearate or methyl
palmitate, and specifically their eutectic mixtures or methyl
cinnamate; 6) natural and synthetic waxes such as montanic acid
waxes, montanic ester waxes, carnauba wax, polyethylene wax,
oxidized waxes, polyvinyl ether wax, ethylene-vinyl acetate wax or
hard waxes from Fischer-Tropsch processes; 7) halogenated
hydrocarbons such as chloroparaffin, bromooctadecane,
bromopentadecane, bromononadecane, bromoeicosane, bromodocosane. An
example of a commercially available microcapsule PCM is
Micronal.TM. from BASF.
[0033] Referring now to FIG. 2, an exemplary embodiment of a gypsum
board 100 is shown. This embodiment illustrates another potential
location option to allow the PCM to be proximate to a surface of
the gypsum board. The gypsum board 100 comprises a board core 112
faced with a first facing material 114 and a second facing material
116. A coating layer 118 is disposed on the first facing material
114. An optional coating layer 122 can be disposed on facing
material 116. In this example, a plurality of capsules 120
containing PCM are located in a layer within the board core 112
itself. It is to be understood by a person of skill in the art that
the choice of materials used in this embodiment can be the same as
those mentioned above in relation to the embodiment shown in FIG.
1.
[0034] Referring now to FIG. 4, one convenient way to dispose the
capsules in a layer within the board core is to meter them from a
holding tank 401 into a separate stream of gypsum slurry at
throughoutlet 417 to provide a relatively thin layer of aqueous
calcined gypsum slurry 418 on the non-coated surface of sheet 416.
The thin layer of gypsum slurry 418 is somewhat more dense than the
aqueous slurry of gypsum that is used to form the main portion of
the core of the gypsum board (main core slurry discharged through
outlet 419 from mixer 420 to form gypsum slurry layer 423). The
slurry used to form the thin layer 18 is about 18-20% more dense
than the density of the slurry 23 used to form the main portion of
the core. A portion of this denser slurry also is often used to
form hard edges of the gypsum board as well. The continuous
sandwich of slurry and applied facing materials (414 and 416) is
carried down conveyors 422.
[0035] Other embodiments are envisioned where the PCM is applied
downstream or upstream of the mixer such that the PCM is in
proximity of the facing material. The challenge in these approaches
is to provide a sufficient amount of gypsum slurry contact with the
facing material. Vibrating tables may also be employed as a means
of having the PCMs settle near the surface of the gypsum board.
Additionally, the relatively more heavy macrocapsules compared to
microcapsules can advantageously settle near the surface of gypsum
board.
[0036] Referring now to FIG. 3, an exemplary embodiment of a gypsum
board 200 is shown. This embodiment illustrates yet another
potential location option to allow the PCM to be proximate to a
surface of the gypsum board. The gypsum board 200 comprises a board
core 212 faced with a first facing material 214 and a second facing
material 216. A coating layer 218 is disposed on the first facing
material 214. However, in comparison to the embodiment illustrated
in FIG. 1, the plurality of capsules 220 containing PCM is present
in a greater concentration near the surface of the facing material
214. The challenge in this approach is to provide a sufficient
amount of coating contact with the facing material to create a
bond.
[0037] While FIGS. 1-3 are discussed as separate embodiments for
the purposes of illustration, it is to be understood that various
combinations of these embodiments is envisioned. Embodiments are
also envisioned where the facing material is eliminated. Further
these boards can be laminated to other structures to provide
multiple functions (e.g., sound abatement).
[0038] Advantageously, embodiments illustrated herein are helpful
in creating a building material that when used in place of a
similar building product without PCM provides greater energy
efficiency in a build, which thereby can reduce carbon dioxide foot
print of a building.
[0039] Ranges disclosed herein are inclusive and combinable (e.g.,
ranges of "up to about 25 wt %, or, more specifically, about 5 wt %
to about 20 wt %", is inclusive of the endpoints and all
intermediate values of the ranges of "about 5 wt % to about 25 wt
%," etc.). "Combination" is inclusive of blends, mixtures, alloys,
reaction products, and the like. Furthermore, the terms "first,"
"second," and the like, herein do not denote any order, quantity,
or importance, but rather are used to distinguish one element from
another, and the terms "a" and "an" herein do not denote a
limitation of quantity, but rather denote the presence of at least
one of the referenced item. The modifier "about" used in connection
with a quantity is inclusive of the stated value and has the
meaning dictated by context, (e.g., includes the degree of error
associated with measurement of the particular quantity). The suffix
"(s)" as used herein is intended to include both the singular and
the plural of the term that it modifies, thereby including one or
more of that term. Reference throughout the specification to "one
embodiment", "another embodiment", "an embodiment", and so forth,
means that a particular element (e.g., feature, structure, and/or
characteristic) described in connection with the embodiment is
included in at least one embodiment described herein, and may or
may not be present in other embodiments. In addition, it is to be
understood that the described elements may be combined in any
suitable manner in the various embodiments.
[0040] While the invention has been described with reference to
exemplary embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalent elements
may be substituted for elements thereof without departing from the
scope of the invention. In addition, many modifications may be made
to adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiments disclosed for carrying this invention, but
that the invention will include all embodiments falling within the
scope of the appended claims.
* * * * *