Abstract: A free form ceiling panel for suspended ceiling systems that creates the appearance of moguls. The free form ceiling panels fit into a suspended ceiling grid. The free form ceiling is a grid system made up of curving tee members and preformed curved panels. The grid members curve in predefined radii into which formed panels are placed. The frame is formed from individual curved grid members that meet at their respective ends to form intersections. The grid members are rigid preformed members that are curved so that when interconnected a curve is formed.

Abstract: A composition and method for treating a set gypsum-containing material are disclosed. The composition is formed from at least water at least one trimetaphosphate salt, at least one monobasic phosphate salt, and at least one acyclic polyphosphate salt having at least three phosphate units. The method comprises applying to a set gypsum material at least two of the following inorganic phosphates: at least one monobasic phosphate salt, at least one trimetaphosphate salt, and at least one acyclic polyphosphate salt having at least three phosphate units. The method can be for inhibiting re-calcination of a set gypsum containing material, and/or for enhancing the strength, surface hardness, paintability, abrasion resistance, and/or water erosion resistance of a set gypsum-containing material. Also disclosed is a method of making a set gypsum-containing material.

Abstract: A composition including, but not limited to, a mixture of a calcium sulfate material, water, and a tetrametaphosphate compound is disclosed. Desirably, the inclusion of the tetrametaphosphate compound (e.g., salt or ion) in a pre-set treatment of a calcium sulfate material enhances the resistance to permanent deformation (e.g., sag), dimensional stability, and/or compressive strength of the composition while also preferably avoiding any significant retardive effect on the rate of hydration of calcined gypsum to calcium sulfate dihydrate. A set gypsum-containing product and a method for producing a set gypsum-containing product having increased resistance to permanent deformation are also disclosed.

Abstract: A ready-mixed composition, which sets when mixed with an activator for the reaction of calcined gypsum with water to form set gypsum, is disclosed. The composition comprises water and calcined gypsum in a weight ratio of water to calcined gypsum of from about 0.15 to about 0.5, as well as a set preventer comprising a polyacrylic acid and/or a salt thereof. The composition has a viscosity of from about 5,000 centipoise to about 48,000 centipoise. Also disclosed is a kit that comprises separately packaged components. One of the components is a composition comprising calcined gypsum and a polyacrylic acid and/or a salt thereof, and, optionally, water. Another component of the kit comprises an activator which, when mixed with the composition, permits the composition to set.

Abstract: The invention provides a set gypsum-containing product having increased resistance to permanent deformation and a method for preparing it comprising forming a mixture of a calcium sulfate material, water, and an appropriate amount of one or more enhancing materials chosen from condensed phosphoric acids, each of which comprises 2 or more phosphoric acid units; and salts or ions of condensed phosphates, each of which comprises 2 or more phosphate units. The mixture is then maintained under conditions sufficient for the calcium sulfate material to form a set gypsum material.

Abstract: A suspended ceiling island is constructed of sheet metal panels that since they are assembled without a supporting gridwork can be configured to create substantially any desired free form island shape. Typically, the panels have a pair of generally opposed straight sides and a pair of generally opposed free form sides. The straight sides, ideally, include upstanding flanges that are used to stiffen, interconnect and suspend the panels. Additionally, the flanges can be shaped into hollow sections similar to standard grid tee shapes to enable the use of standard hardware to attach trim strips to the perimeter of the island.

Abstract: The present invention relates to a scalable suspension system for domed shaped ceilings that includes a framework of suspension members interconnected to a central hub. The framework of suspension members are used to support a domed shaped ceiling fabricated from plaster or gypsum wallboard. The suspension members include primary spoke members, secondary spoke members, intercostal members and cross tees. The primary spoke members are attached to the central hub component. The intercostal members are spanned between the primary spoke members. The secondary spoke members are connected to the intercostal members, and extend between the primary spoke members. The primary and secondary spoke members are interconnected by the cross tees to create a unified structure. The hub includes radially indexed integral tabs that facilitate the attachment of the hanger wires and allows for the rigid attachment of the primary spoke members in a precise radial pattern.

Abstract: A rough-surfaced substrate, such as a fiberboard, is provided with a smoother surface by applying a coating comprising calcium sulfate hemihydrate which has been prevented from hydrating to gypsum by set preventer, and which sets when brought into contact with a set initiator, e.g. aluminum sulfate, preferably present on the surface of the substrate.

Abstract: An improved method and apparatus for imparting a smooth surface to a gypsum fiber panels. The method involves imparting energy to the surface of the slurry as the slurry is dewatered just prior to rehydration. The apparatus used to impart the energy is an air lance including an air source such as a blower, a distribution manifold and a plurality of nozzles to direct the flow of air at the surface of the slurry. In operation, the air lance directs a flow of air against the surface of the slurry. The flow disrupts the slurry to a fraction of its total depth, thus dispersing clumps or flocs of crystals in the depth that would give the surface of the finished panel a rough surface if they were allowed to remain.

Abstract: A connector for a main tee of a suspended ceiling grid that has improved self-aligning and connection force properties. The connector has an end tab with a forward portion bent at a lead angle and a receiving pocket with an outwardly flared entrance that, with an opposed identical connector, cooperate to provide smooth horizontal alignment. The end portion, additionally, includes an edge profile that vertically aligns itself with the receiving pocket of the opposed connector. The receiving pocket includes a spring-like resilient wall that limits the assembly force to overcome interference with projecting lock lances even when the connectors are nearly out of dimensional tolerance. The spring-like pocket wall, shape of the lock lance, and reinforcing beads contribute to an improved audible click signaling that a connection has been completed. The lock lance works with a relief groove to augment self-alignment of the connectors.

Abstract: Disclosed is a ready-to-use self-gauging coating compound containing about 65%-75% solids that provides a flat finely textured finish with improved abuse (abrasion) resistance properties. The coating composition comprises a resin binder in which there is dispersed an aggregate consisting of particles in a selected size range in a quantity sufficient to form a layer of particles one particle deep on the substrate when the coating is applied to the substrate.

Abstract: An improved method and apparatus for imparting a smooth surface to gypsum fiber panels. The method involves imparting energy to the surface of a slurry as the slurry is dewatered just prior to rehydration. The apparatus used to impart the energy is a water spray including a source of pressurized water such as a pump, a distribution manifold and a plurality of nozzles to direct the water spray at the surface of the slurry. In operation, the water spray is directed against the surface of the slurry. The flow disrupts the slurry to a fraction of its total depth, thus dispersing clumps or flocs of commingled crystals and fibers in the depth that would give the surface of the finished panel a rough surface if they were allowed to remain.

Abstract: The present invention provides a low dusting joint compound comprising a filler, a binder, a thickener and one or more synthetic polymeric waxes that are at least slightly soluble in water and are solid at room temperature. Preferably the wax includes a high molecular weight polyethylene glycol or methoxy polyethylene glycol having an average melting point of from about 80° F. (27° F.) to about 150° F. (80° C.). These additives impart low dusting properties without a sticky or oily feel. High molecular weight synthetic waxes also act as an internal binder to hold the joint compound together and improves paint gloss retention. The invention results in a joint compound with improved properties for drywall finishing.

Abstract: A coating for gypsum board includes a binder, a soy protein, and two or more pigments. Two of the pigments include calcium carbonate and magnesium carbonate and the magnesium carbonate makes up at least 20% by weight of the coating on a dry basis.

Abstract: A rapid setting cementitious composition useful for making cement boards employs an insoluble form of anhydrous calcium sulfate (anhydrite) to accelerate setting and to permit reducing the amount of high alumina cement usage.

Abstract: The invention provides a set gypsum-containing product having increased resistance to permanent deformation and a method for preparing it comprising forming a mixture of a calcium sulfate material, water, and an appropriate amount of one or more enhancing materials chosen from condensed phosphoric acids, each of which comprises 2 or more phosphoric acid units; and salts or ions of condensed phosphates, each of which comprises 2 or more phosphate units. The mixture is then maintained under conditions sufficient for the calcium sulfate material to form a set gypsum material.

Abstract: A reinforced, lightweight, dimensionally stable panel capable of resisting shear loads when fastened to framing equal to or exceeding shear loads provided by plywood or oriented strand board panels. The panels employ a core of a continuous phase resulting from the curing of an aqueous mixture of calcium sulfate alpha hemihydrate, hydraulic cement, an active pozzolan and lime, the continuous phase being reinforced with alkali-resistant glass fibers and containing ceramic microspheres, or a blend of ceramic and polymer microspheres, or being formed from an aqueous mixture having a weight ratio of water-to-reactive powder of 0.6/1 to 0.7/1 or a combination thereof. At least one outer surface of the panels may include a cured continuous phase reinforced with glass fibers and containing sufficient polymer spheres to improve nailability or made with a water-to-reactive powders ratio to provide an effect similar to polymer spheres, or a combination thereof.

Abstract: The joint compound of the present invention utilizes hollow resin microspheres with a mean particle size less than 75 microns and exhibiting no more than 1.5% increase in density under high shear stress testing.

Abstract: A process for making an improved gypsum/wood fiber board is described. Products resulting from the process are also described. The process comprises adding a diisocyanate, specifically methylenediphenyldiisocyanate (MDI) to an aqueous slurry of calcium sulfate material and cellulosic fibers, where the MDI is added as an emulsion stable in the conditions in which the slurry is maintained. The process further includes passing the MDI containing slurry onto a flat porous forming surface to form a filter cake; removing a substantial portion of the water from the filter cake through the porous surface; pressing the filter cake to form a board and remove additional water; and drying the board to remove the remaining free water.

Abstract: A gypsum/fiber board having improved impact resistance is produced by mixing predetermined amounts of fibers, calcined gypsum and water to form a mixture of wetted, loose fibers; laying out a reinforcing mesh over the upper surface of a forming belt; depositing said mixture on said mesh to form a layer of said mixture, said; and compressing said mesh together with said layer of mixture to embed said mesh in the lower surface of said layer to form a board composed of bonded fibers and gypsum with said mesh embedded in the surface thereof.