Patents Assigned to Certainteed Gypsum, Inc.
  • Patent number: 8409391
    Abstract: Disclosed are building board manufacturing techniques that minimize the build-up of slurry on associated forming equipment and also produce panels with enhanced physical properties. The methods involve applying a dissolvable film laminate to one or more fiber mats at the outset of the forming process. In the un-dissolved state, the film acts as a containment envelope for the gypsum slurry and any free floating glass fibers. During subsequent curing, the film is dissolved by vaporized water. In its dissolved state, the film is liquefied and coats the fibers of the underlying mat. This results in a building board with improved physical properties.
    Type: Grant
    Filed: June 7, 2010
    Date of Patent: April 2, 2013
    Assignee: CertainTeed Gypsum, Inc.
    Inventors: Robert Joseph Hauber, Gerald D. Boydston
  • Publication number: 20130061777
    Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.
    Type: Application
    Filed: September 14, 2011
    Publication date: March 14, 2013
    Applicant: CERTAINTEED GYPSUM, INC.
    Inventors: John W. College, Shane Libunao, Mark Harris
  • Patent number: 8388926
    Abstract: The present invention relates to a system and associated method for the production of gypsum in manufacturing plant. More specifically, the invention relates to the production of alpha-type gypsum in a gypsum board manufacturing plant. The system yields increased efficiencies by capturing heat given off during processing steps and using that heat to reduce the energy needed for calcination. The invention finds particular application in the production alpha-type gypsum. The present invention is described in greater detail hereinafter in conjunction with the following specific embodiments.
    Type: Grant
    Filed: June 6, 2011
    Date of Patent: March 5, 2013
    Assignee: CertainTeed Gypsum, Inc.
    Inventor: John W. College
  • Patent number: 8371038
    Abstract: The present invention relates to an improved method for using heat energy in a gypsum board plant. More specifically, the method contemplates taking heat from a gasifier, or other alternative heat source, and using it to dry gypsum boards. In order to control humidity levels, this heat is delivered to one or more board dryers via a heat exchanger.
    Type: Grant
    Filed: November 25, 2008
    Date of Patent: February 12, 2013
    Assignee: CertainTeed Gypsum, Inc.
    Inventors: John College, Felipe J. Yanes, David Corbin
  • Patent number: 8353401
    Abstract: Disclosed is a fastening system that is adapted for securing a sheathing board to an associated framing member. The system includes a feedband for retaining a series of fasteners and a powered drill for sequentially driving the fasteners. The feedband is made from a membrane of a polymeric compound. As the fastener is driven into the sheathing board, a portion of the membrane tears away from the surrounding feedband and becomes seated beneath the fastener. This acts to seal the penetration point and prevent water intrusion and otherwise prevents deterioration of the sheathing board.
    Type: Grant
    Filed: September 28, 2009
    Date of Patent: January 15, 2013
    Assignee: CertainTeed Gypsum, Inc.
    Inventors: Robert J. Hauber, Mark E. Hennis, Michael P. Fahey
  • Publication number: 20120308795
    Abstract: Disclosed is a flooring system consisting of a slab (or base) floor, a floor covering, and a composite underlayment extending between the slab floor and floor covering. The composite underlayment may include, for example, one or more set gypsum layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to an underlying set gypsum layer. The plastic coating chemically bonds and cross-links with polymer additives within the set gypsum core. The result is an underlayment that is a fully integrated polymer matrix with greatly improved durability and surface strength with only minimal increases in cost or weight.
    Type: Application
    Filed: June 8, 2012
    Publication date: December 6, 2012
    Applicant: CERTAINTEED GYPSUM, INC.
    Inventors: Robert J. Hauber, Gerald D. Boydston
  • Publication number: 20120205047
    Abstract: Disclosed is a gypsum board forming device which provides improved slurry spread. The device includes a forming table with an arcuate or angled profile that promotes a uniform slurry spread. An arcuate or angled hinge plate can also be included to further promote the uniform distribution of slurry prior to an extrusion plate. As a result of the improved slurry spread, gypsum board with increased strength and durability can be created.
    Type: Application
    Filed: April 25, 2012
    Publication date: August 16, 2012
    Applicant: CERTAINTEED GYPSUM, INC.
    Inventor: Michael P. Fahey
  • Publication number: 20110297310
    Abstract: Disclosed are building board manufacturing techniques that minimize the build-up of slurry on associated forming equipment and also produce panels with enhanced physical properties. The methods involve applying a dissolvable film laminate to one or more fiber mats at the outset of the forming process. In the un-dissolved state, the film acts as a containment envelope for the gypsum slurry and any free floating glass fibers. During subsequent curing, the film is dissolved by vaporized water. In its dissolved state, the film is liquefied and coats the fibers of the underlying mat. This results in a building board with improved physical properties.
    Type: Application
    Filed: June 7, 2010
    Publication date: December 8, 2011
    Applicant: CertainTeed Gypsum, Inc.
    Inventors: Robert Joseph Hauber, Gerald D. Boydston
  • Publication number: 20110300032
    Abstract: The present invention relates to a system and associated method for the production of gypsum in manufacturing plant. More specifically, the invention relates to the production of alpha-type gypsum in a gypsum board manufacturing plant. The system yields increased efficiencies by capturing heat given off during processing steps and using that heat to reduce the energy needed for calcination. The invention finds particular application in the production alpha-type gypsum. The present invention is described in greater detail hereinafter in conjunction with the following specific embodiments.
    Type: Application
    Filed: June 6, 2011
    Publication date: December 8, 2011
    Applicant: CERTAINTEED GYPSUM, INC.
    Inventor: John W. College
  • Publication number: 20110297291
    Abstract: Disclosed are building board manufacturing techniques that minimize the build-up of slurry on associated forming equipment and also produce panels with enhanced physical properties. The methods involve applying a dissolvable film laminate to one or more fiber mats at the outset of the forming process. In the un-dissolved state, the film acts as a containment envelope for the gypsum slurry and any free floating glass fibers. During subsequent curing, the film is dissolved by vaporized water. In its dissolved state, the film is liquefied and coats the fibers of the underlying mat. This results in a building board with improved physical properties.
    Type: Application
    Filed: June 28, 2011
    Publication date: December 8, 2011
    Applicant: CERTAINTEED GYPSUM, INC.
    Inventors: Robert Joseph Hauber, Gerald D. Boydston
  • Publication number: 20110256372
    Abstract: Disclosed is a composite building board construction. The board includes a set gypsum core and a fibrous mat that is pre-coated with a cementitious layer. A thermoplastic coating is then applied over the cementitious layer. Additives can be added to one or more of the layers to provide enhanced performance characteristics. Also discloses are various manufacturing techniques for applying a hot melt thermoplastic coating to cementitious layer.
    Type: Application
    Filed: January 14, 2011
    Publication date: October 20, 2011
    Applicant: CERTAINTEED GYPSUM, INC.
    Inventors: Robert Joseph Hauber, Gerald D. Boydston
  • Patent number: 7955587
    Abstract: The present invention relates to a system and associated method for the production of gypsum in manufacturing plant. More specifically, the invention relates to the production of alpha-type gypsum in a gypsum board manufacturing plant. The system yields increased efficiencies by capturing heat given off during processing steps and using that heat to reduce the energy needed for calcination. The invention finds particular application in the production alpha-type gypsum. The present invention is described in greater detail hereinafter in conjunction with the following specific embodiments.
    Type: Grant
    Filed: March 2, 2009
    Date of Patent: June 7, 2011
    Assignee: CertainTeed Gypsum, Inc.
    Inventor: John College
  • Patent number: 7726040
    Abstract: Disclosed is an apparatus and method for the uniform drying of boards, such as gypsum wallboards. The apparatus includes a dryer through which a series of boards are conveyed in a side-by-side relationship. While in the dryer, heated air is delivered over the boards via a series of separate air channels. A bypass duct delivers a portion of or a totality of unreheated air to the outermost channels where the cooler air displaces a volume of the warmer air. As a result, the air in the outermost channels is cooler than the air in the interior channels. Air from the outermost channels is then directed over the exposed longitudinal edges of the boards.
    Type: Grant
    Filed: October 13, 2006
    Date of Patent: June 1, 2010
    Assignee: CertainTeed Gypsum, Inc.
    Inventor: Felipe J. Yanes
  • Publication number: 20100055431
    Abstract: Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength.
    Type: Application
    Filed: June 8, 2009
    Publication date: March 4, 2010
    Applicant: CertainTeed Gypsum, Inc.
    Inventor: John College
  • Patent number: 7498014
    Abstract: The present invention relates to a system and associated method for the production of gypsum in manufacturing plant. More specifically, the invention relates to the production of alpha-type gypsum in a gypsum board manufacturing plant. The system yields increased efficiencies by capturing heat given off during processing steps and using that heat to reduce the energy needed for calcination. The invention finds particular application in the production alpha-type gypsum. The present invention is described in greater detail hereinafter in conjunction with the following specific embodiments.
    Type: Grant
    Filed: January 12, 2007
    Date of Patent: March 3, 2009
    Assignee: Certainteed Gypsum, Inc.
    Inventor: John College