Patents Assigned to Georgia-Pacific Gypsum LLC
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Patent number: 11873261Abstract: Gypsum panels and methods of making gypsum panels are provided. Methods of making gypsum panels include: depositing a first gypsum slurry onto a first surface of a first fiberglass mat; allowing the first gypsum slurry to set to form at least a portion of a gypsum core; and applying a substantially continuous barrier coating comprising a polymer binder to a second surface, opposite the first surface, of the first fiberglass mat, in an amount of from about 1 lb/MSF to about 40 lb/MSF, such that the substantially continuous barrier coating has an average thickness of from about 1 micron to about 100 microns, wherein the substantially continuous barrier coating eliminates at least 99 percent of pin holes present in the exposed second surface of the first fiberglass mat.Type: GrantFiled: February 9, 2023Date of Patent: January 16, 2024Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Xian-yong Wang, Stuart Brandon Gilley
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Patent number: 11808294Abstract: Self-sealing fasteners and associated building panels, systems, and methods are provided. In one aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a coating material disposed on at least a portion the external surface. In another aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a polymer annulus surrounding at least a portion of the external surface of the of the elongated fastener body at or adjacent the head of the fastener.Type: GrantFiled: October 29, 2019Date of Patent: November 7, 2023Assignee: Georgia-Pacific Gypsum LLCInventors: Vincent B. Thomas, Jason G. Peace, Seth C. Glenn
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Publication number: 20230242458Abstract: Gypsum panels and methods of making gypsum panels are provided. Methods of making gypsum panels include: depositing a first gypsum slurry onto a first surface of a first fiberglass mat; allowing the first gypsum slurry to set to form at least a portion of a gypsum core; and applying a substantially continuous barrier coating comprising a polymer binder to a second surface, opposite the first surface, of the first fiberglass mat, in an amount of from about 1 lb/MSF to about 40 lb/MSF, such that the substantially continuous barrier coating has an average thickness of from about 1 micron to about 100 microns, wherein the substantially continuous barrier coating eliminates at least 99 percent of pin holes present in the exposed second surface of the first fiberglass mat.Type: ApplicationFiled: February 9, 2023Publication date: August 3, 2023Applicant: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Xian-yong Wang, Stuart Brandon Gilley
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Publication number: 20230212854Abstract: Disclosed is a structural sheathing panel with an integrated drainage mechanism, comprising: a structural panel core; a plurality of rows, each row of the plurality of rows comprising raised elements deposited on an external surface of the panel and spaced from one another, each of the raised elements having an elongated, linear profile which has a longitudinal axis, wherein the longitudinal axis of at least one of the raised elements of each row is not parallel to any edge of the panel.Type: ApplicationFiled: April 28, 2021Publication date: July 6, 2023Applicant: Georgia-Pacific Gypsum LLCInventors: John CHAMBERLIN, Vincent B. THOMAS
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Patent number: 11680404Abstract: Building panels, assemblies of building panels, and associated methods are provided. A building panel includes a structural core, such as a set gypsum core, at least one filamentous scrim associated with the core, and a nonwoven mat facer.Type: GrantFiled: June 5, 2020Date of Patent: June 20, 2023Assignee: Georgia-Pacific Gypsum LLCInventors: Stuart Brandon Gilley, Charles Richard Harrison, Hamed Mustafa Kayello, Xianyong Wang
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Patent number: 11660777Abstract: Gypsum panels and methods of making the same are provided. A method of making a gypsum panel includes forming a first gypsum slurry by combining stucco, water, a siliconate, and a phosphate salt or polymer, and setting the first gypsum slurry to form at least part of a core of the gypsum panel, wherein the gypsum panel displays a 2-hour water absorption test weight increase of at least 10 weight percent less than an otherwise identical comparative panel containing no phosphate salt or polymer in its core.Type: GrantFiled: August 9, 2019Date of Patent: May 30, 2023Assignee: Georgia-Pacific Gypsum LLCInventors: Xian-Yong Wang, Stuart Brandon Gilley
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Patent number: 11643817Abstract: Building panels, assemblies of building panels, and associated methods are provided. A building panel includes a structural core, such as a set gypsum core, at least one filamentous scrim associated with the core, and a nonwoven mat facer.Type: GrantFiled: June 5, 2020Date of Patent: May 9, 2023Assignee: Georgia-Pacific Gypsum LLCInventors: Stuart Brandon Gilley, Charles Richard Harrison, Hamed Mustafa Kayello, Xianyong Wang
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Patent number: 11608637Abstract: Gypsum panels and methods for their manufacture are provided herein. The gypsum panels include a gypsum core having a first surface and a second opposed surface and a first fiberglass mat associated with the first surface of the gypsum core, such that gypsum from the gypsum core penetrates at least a portion of the first fiberglass mat.Type: GrantFiled: April 17, 2020Date of Patent: March 21, 2023Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Andrew W. Tricker, Vincent B. Thomas, Rochelle Bradford, Christopher J. Sanders
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Patent number: 11608302Abstract: Gypsum panels and methods of making gypsum panels are provided. Methods of making gypsum panels include: depositing a first gypsum slurry onto a first surface of a first fiberglass mat; allowing the first gypsum slurry to set to form at least a portion of a gypsum core; and applying a substantially continuous barrier coating comprising a polymer binder to a second surface, opposite the first surface, of the first fiberglass mat, in an amount of from about 1 lb/MSF to about 40 lb/MSF, such that the substantially continuous barrier coating has an average thickness of from about 1 micron to about 100 microns, wherein the substantially continuous barrier coating eliminates at least 99 percent of pin holes present in the exposed second surface of the first fiberglass mat.Type: GrantFiled: December 7, 2018Date of Patent: March 21, 2023Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Xian-Yong Wang, Stuart Brandon Gilley
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Patent number: 11535558Abstract: Gypsum panels and methods for their manufacture are provided herein. The gypsum panels include a gypsum core having a first surface and a second opposed surface and a first fiberglass mat associated with the first surface of the gypsum core, such that gypsum from the gypsum core penetrates at least a portion of the first fiberglass mat.Type: GrantFiled: May 14, 2020Date of Patent: December 27, 2022Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Andrew W. Tricker, Vincent B. Thomas, Rochelle Bradford, Christopher J. Sanders
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Publication number: 20220212996Abstract: Disclosed is a gypsum panel comprising a gypsum core comprising set gypsum and a colloidal material comprising colloidal silica, colloidal alumina, or both.Type: ApplicationFiled: May 6, 2020Publication date: July 7, 2022Applicant: Georgia-Pacific Gypsum LLCInventors: Yongan Yuan, Stuart Brandon Gilley
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Patent number: 11339820Abstract: Self-sealing fasteners and associated building panels, systems, and methods are provided. In one aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a coating material disposed on at least a portion the external surface. In another aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a polymer annulus surrounding at least a portion of the external surface of the of the elongated fastener body at or adjacent the head of the fastener.Type: GrantFiled: April 30, 2020Date of Patent: May 24, 2022Assignee: GEORGIA-PACIFIC GYPSUM LLCInventors: Vincent B. Thomas, Jason G. Peace, Seth C. Glenn
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Patent number: 11253889Abstract: In one aspect, a gypsum panel includes a gypsum core, a fiberglass mat, and a wetting agent deposited across an entire thickness of the fiberglass mat. The wetting agent is deposited onto the first fiberglass mat in an uncoated state of the fiberglass mat such that the wetting agent penetrates the entire thickness of the fiberglass mat.Type: GrantFiled: September 18, 2019Date of Patent: February 22, 2022Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Rochelle F. Bradford
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Patent number: 11248375Abstract: Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels.Type: GrantFiled: August 26, 2019Date of Patent: February 15, 2022Assignee: Georgia-Pacific Gypsum LLCInventors: Vincent B. Thomas, Rochelle Bradford, Christopher J. Sanders, Yi-Hsien Harry Teng
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Patent number: 11136757Abstract: Gypsum panels and methods of making the same are provided. A gypsum panel includes a gypsum core containing set gypsum and unexpanded perlite ore, wherein the unexpanded perlite ore is present in the gypsum core in an amount greater than any other component, other than the gypsum.Type: GrantFiled: August 30, 2019Date of Patent: October 5, 2021Assignee: Georgia-Pacific Gypsum LLCInventors: Yongan Yuan, Stuart Brandon Gilley, Bryan Wiltzius
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Patent number: 11136267Abstract: Gypsum panels and methods of making gypsum panels are provided. A method of making a gypsum panel includes combining gypsum stucco and a halide salt sequestration agent with water to form a gypsum slurry and setting the gypsum slurry to form at least a portion of a gypsum core, wherein the halide salt sequestration agent is present in an amount effective to sequester at least a portion of halide salt present in the gypsum stucco. A gypsum panel includes a gypsum core that comprises set gypsum and a halide salt sequestration agent, wherein the halide sequestration agent sequesters at least a portion of halide salt present in the gypsum core.Type: GrantFiled: September 30, 2019Date of Patent: October 5, 2021Assignee: Georgia-Pacific Gypsum LLCInventors: Charles R. Harrison, Stuart Brandon Gilley
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Publication number: 20210171398Abstract: Methods of making gypsum panels, and the panels and systems of panels prepared by such methods are provide. The methods include forming a first gypsum slurry by combining stucco, water, and a siliconate and setting the first gypsum slurry to form at least part of a core of the gypsum panel.Type: ApplicationFiled: May 8, 2019Publication date: June 10, 2021Applicant: GEORGIA-PACIFIC GYPSUM LLCInventors: Xian-Yong WANG, Stuart Brandon GILLEY
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Patent number: 10960643Abstract: Gypsum panels, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a gypsum core having a first surface and an opposed second surface, a first facer material associated with the first surface of the gypsum core, and an environmental sensor assembly associated with the gypsum panel and configured to detect an environmental condition of the gypsum panel and wirelessly communicate data on the environmental condition to a reader.Type: GrantFiled: September 18, 2019Date of Patent: March 30, 2021Assignee: Georgia-Pacific Gypsum LLCInventors: Charles R. Harrison, Lawrence Gollob, Clarence A. Shelton, Stuart Brandon Gilley
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Patent number: 10737460Abstract: Coated nonwoven fibrous mats, building panels, and methods for making the same are provided. A coated nonwoven fiber mat includes a nonwoven fibrous mat having a continuous barrier coating on a surface thereof. The continuous barrier coating includes a set composition of gypsum and a binder. A building panel includes a panel core associated with a coated nonwoven fiber mat. A method of making a coated nonwoven fibrous mat includes depositing a composition of water, gypsum stucco, and a binder onto a surface of a nonwoven fibrous mat and setting the composition to form a continuous barrier coating.Type: GrantFiled: January 10, 2017Date of Patent: August 11, 2020Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Andrew W. Tricker
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Patent number: 10697177Abstract: Gypsum panels and methods for their manufacture are provided herein. The gypsum panels include a gypsum core having a first surface and a second opposed surface and a first fiberglass mat associated with the first surface of the gypsum core, such that gypsum from the gypsum core penetrates at least a portion of the first fiberglass mat.Type: GrantFiled: February 3, 2016Date of Patent: June 30, 2020Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Andrew W. Tricker, Vincent B. Thomas, Rochelle Bradford, Christopher J. Sanders