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.

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.

Abstract: Disclosed is an apparatus and method for capturing the hot humid gases from a gypsum board dryer and utilizing those gases in the production of a synthetic gas (referred to as “syngas”). The syngas produced can then be utilized within a gypsum board plant to reduce the amount of natural gas needed. The method utilizes the heated water vapor (H2O) and carbon dioxide (CO2) found within the flue gas of a board dryer. The H2O and CO2 are used in a gasification process to yield the syngas.

Abstract: Photocatalytic roofing granules include a binder and inert mineral particles, with photocatalytic particles dispersed in the binder.

Abstract: A ceiling panel according to the present invention has opposed translucent membranes secured in a tensioned state across a perimeter frame. The frame includes frame members that are designed to oppose inward bowing of the perimeter frame caused by the tensioned membranes. The frame members have a side profile shaped to conceal a grid support network with the lower translucent member extending across and about a lower edge of the perimeter frame. The invention also includes a modified structure for supporting of translucent panels below a grid network.

Abstract: The present invention relates generally to photovoltaic devices, and more particularly to photovoltaic roofing products in which photovoltaic elements are affixed to roofing substrates. In one embodiment of the invention, a photovoltaic roofing panel comprising a roofing panel substrate having a top surface; and at least six discrete photovoltaic elements affixed to the roofing panel substrate with their photovoltaically-active areas exposed at the top surface of the roofing panel. Another embodiment of the invention is a photovoltaic roofing assembly comprising: a plurality of discrete photovoltaic roofing elements, each comprising one or more photovoltaic elements affixed to a roofing substrate; and a joining member, wherein the plurality of photovoltaic roofing elements are disposed on and affixed to the joining member and are electrically interconnected.

Abstract: The present invention relates generally to the photovoltaic generation of electrical energy. The present invention relates more particularly to photovoltaic arrays for use in photovoltaically generating electrical energy. Aspects of the present invention provide a variety of photovoltaic roofing elements and systems that include, for example, interlocking geometries to provide for water handling and integration with conventional roofing materials; and wire management features that can protect wiring and associated electrical components from physical and/or environmental damage.

Abstract: A shingle, a method of making it, and a roof embodying the shingle is provided, in which an exterior surface of the shingle is provided with an attached reinforcement layer through which fasteners may be applied when the shingle is applied to a roof.

Abstract: Disclosed are various methods for reducing levels of elemental sulfur within gypsum products such as wall board. Gypsum sometimes includes increased levels of elemental sulfur. Such sulfur can be corrosive and otherwise harmful at elevated levels. The disclosure contemplates reacting the elemental sulfur with copper to copper sulfide. This reaction has the benefit of reducing the levels of elemental sulfur present within the final gypsum product. The copper can be added at any of a variety of locations in the manufacturing process. This is a very efficient method for reducing elemental sulfur in the production of gypsum products.

Abstract: A method of shortening cycle time required to compression mold shingle or tile is provided, wherein carrier plates are comprised of a surface material and a base, and receive a thermoplastic material, thereon. The roofing material is applied to the carrier plate and the carrier plate is subjected to induction heating, by which its surface material has its temperature raised, without substantially raising the temperature of the carrier plate base, such that the thermoplastic material applied thereto is kept heated in the compression mold. Cooling of the thermoplastic material is by heat transfer from the carrier plate surface material to the carrier plate base, and with both materials having good heat conduction capability. The carrier plate surface material has a high receptivity to being heated by induction heating relative the carrier plate base. The carrier plates are serially delivered through the process, to the compression mold.

Abstract: A coating composition including an inorganic sol material and an organic colorant is applied to mineral particles and cured at a temperature less than 200 degrees Celsius.

Abstract: A fire resistant roofing material includes a core sheet and a sheet of conductive material having a thermal conductivity greater than about 25 W/m-K. The sheet of conductive material is coextensively bonded with the core sheet, and coated with a polymer-modified bituminous material having fire-resistant properties.

Abstract: A composition and process for the manufacture thereof for use in a hybrid building material comprising at least in part Syngenite (K2Ca(SO4)2.H2O) and Struvite-K (KMgPO4.6H2O). Specified constituents, including magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate) are mixed in predetermined ratios and the reaction proceeds through multiple phases reactions which at times are proceeding simultaneously and in parallel and reaction may even compete with each other for reagents if the Struvite-K reaction is not buffered to slow down the reaction rate). A number of variable factors, such as water temperature, pH mixing times and rates, have been found to affect resultant reaction products. Preferred ratios of chemical constituents and manufacturing parameters, including predetermined and specified ratios of Struvite-K and Syngenite may be provided for specified purposes, optimized in respect of stoichiometry to reduce the combined heat of formation to non-destructive levels.

Abstract: A multilayer roofing sheet includes a laminate formed from an upper sheet having a textured lower surface and a lower sheet having a fusible upper surface mechanically interlocked together.

Abstract: Roofing granules are prepared by coating granule cores with a coating material including composite nanoparticles and curing the coating layer to dissolve the aggregate binder and disperse the nanoparticles in the coating.

Abstract: A lighting system for ceiling grid systems advantageously uses a grid member designed to cooperate with a strip light to secure the strip light generally aligned beneath the grid system. The grid system can be initially installed with the cooperating grid members at specified locations. The strip lights can then be installed to the grid system. This arrangement simplifies installation particularly installations in commercial type spaces and larger scale architectural projects.

Abstract: The purpose of the invention is a process for obtaining a material comprising a substrate at least part of whose surface and at least one of whose faces is based on organic compounds, the said process being implemented at atmospheric pressure comprises moreover the following stages: In the immediate vicinity of the said substrate a zone containing active species of a non-thermal plasma is created; into the said zone is injected at least one precursor of a chemical element so as to deposit upon at least one face of the said substrate (at least part of whose surface comprises an organic compound base), a first thin layer capable of protecting the said substrate against oxidation reactions, specifically those due to radicals. A further purpose of the invention is the material obtainable according to this process.

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.

Abstract: Disclosed is a system and method for constructing fibrous mats. In accordance with the disclosure, continuous lengths of filament are pre-coated with a liquefied thermoplastic. The pre-coated filaments are then laid down upon a belt to form a fibrous mat. The filaments can be laid down in continuous lengths or they can be chopped into discontinuous lengths. The filaments are heated after they have been laid down in order to re-liquefy the thermoplastic and facilitate bonding between intersecting fibers. The disclosure further relates to a system and method for incorporating constructed fibrous mats into a composite building board.