Patents Assigned to Georgia-Pacific Gypsum LLC
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Patent number: 10151104Abstract: Construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a core having a first surface and an opposed second surface, and an environmental sensor assembly associated with the panel and configured to detect an environmental condition of the panel and wirelessly communicate data on the environmental condition to a reader.Type: GrantFiled: September 13, 2017Date of Patent: December 11, 2018Assignee: Georgia-Pacific Gypsum LLCInventors: Charles R. Harrison, Lawrence Gollob, Clarence A. Shelton, Stuart Brandon Gilley, Timothy R. Fierbaugh
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Patent number: 10077552Abstract: 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 3, 2017Date of Patent: September 18, 2018Assignee: Georgia-Pacific Gypsum LLCInventors: Vincent B. Thomas, Rochelle Bradford, Christopher J. Sanders, Yi-Hsien Harry Teng
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Patent number: 10060058Abstract: Hybrid nonwoven mats are made by depositing a slurry of fibers and water onto a fibrous web and applying a binder onto the hybrid nonwoven mat formed therefrom. The fibers are sized and present in an amount such that the binder forms a substantially continuous film on the hybrid nonwoven mat. Gypsum panels may be faced with a hybrid nonwoven mat on one or both surfaces.Type: GrantFiled: November 16, 2015Date of Patent: August 28, 2018Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Christopher J. Sanders
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Patent number: 9963391Abstract: Gypsum based compositions, processes for making same, and articles made therefrom. In one example, the gypsum based composition can include about 1.5 wt % to about 3 wt % of a starch, about 11 wt % to about 14 wt % of a paper, about 0.7 wt % to about 2.3 wt % of vermiculite, about 1.3 wt % to about 3 wt % of a plurality of reinforcing fibers, about 7 wt % to about 10 wt % of a binding agent, about 2 wt % to about 4 wt % of perlite, and about 65 wt % to about 75 wt % of a calcium sulfate, where all weight percent values are based on a combined weight of the starch, paper, vermiculite, plurality of reinforcing fibers, binding agent, perlite, and calcium sulfate.Type: GrantFiled: March 15, 2017Date of Patent: May 8, 2018Assignee: Georgia-Pacific Gypsum LLCInventors: Scott J. Abolt, Luke R. Fitzwater, John F. Davis
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Patent number: 9938192Abstract: Gypsum panels, panel cores, and methods for the manufacture thereof are provided herein. A gypsum panel core includes gypsum and fiberglass, the fiberglass being present in the core in an amount of from about 1 lb/msf to about 6 lb/msf. The core has a thickness of about 1/2 inch, a weight of from about 1400 lb/msf to about 1750 lb/msf, and an ASTM E-119 wood stud fire test rating of at least 30 minutes.Type: GrantFiled: March 13, 2017Date of Patent: April 10, 2018Assignee: Georgia-Pacific Gypsum LLCInventors: Michael H. Moore, Christopher J. Sanders
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Patent number: 9932271Abstract: Gypsum composites containing cementitious materials and methods of making the same are provided. Gypsum composites include gypsum and a cementitious material. Methods of making gypsum composites include combining gypsum stucco, water, and a cementitious material to form a slurry, and setting and drying the slurry to form a gypsum composite.Type: GrantFiled: December 4, 2014Date of Patent: April 3, 2018Assignee: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Mark Alexander Leavitt, Jeffrey T. Fields, Vincent B. Thomas
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Publication number: 20180038101Abstract: Methods of making gypsum panels, fiberglass mats, and associated gypsum panels and building sheathing systems are provided. In one aspect, a method of making a gypsum panel includes depositing an aqueous liquid containing a wetting agent onto a fiberglass mat, such that the aqueous liquid penetrates an entire thickness of the fiberglass mat, and depositing a gypsum slurry onto the fiberglass mat onto which the aqueous liquid has been deposited, such that the gypsum slurry penetrates at least a portion of the fiberglass mat. In another aspect, a method of making a gypsum panel includes depositing an aqueous liquid containing a wetting agent onto a fiberglass mat, and depositing a gypsum slurry onto the fiberglass mat onto which the aqueous liquid has been deposited, prior to drying of the aqueous liquid, such that the gypsum slurry penetrates at least a portion of the fiberglass mat.Type: ApplicationFiled: August 2, 2017Publication date: February 8, 2018Applicant: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Rochelle F. Bradford
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Patent number: 9879426Abstract: Water-resistant gypsum boards and compositions and methods for their manufacture are provided. The methods include forming a mixture of water, hydroxide, and siliconate, adding siloxane to the mixture, adding calcium sulfate hemi-hydrate to the mixture to form an aqueous slurry, curing the aqueous slurry under heat, drying the aqueous slurry, and forming a water-resistant gypsum board.Type: GrantFiled: December 17, 2013Date of Patent: January 30, 2018Assignee: Georgia-Pacific Gypsum LLCInventor: Robert William Tilford
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Patent number: 9869089Abstract: 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: February 3, 2016Date of Patent: January 16, 2018Assignee: Georgia-Pacific Gypsum LLCInventors: Vincent B. Thomas, Rochelle Bradford, Christopher J. Sanders, Yi-Hsien Harry Teng
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Publication number: 20180002916Abstract: Construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a core having a first surface and an opposed second surface, and an environmental sensor assembly associated with the panel and configured to detect an environmental condition of the panel and wirelessly communicate data on the environmental condition to a reader.Type: ApplicationFiled: September 13, 2017Publication date: January 4, 2018Applicant: Georgia-Pacific Gypsum LLCInventors: Charles R. Harrison, Lawrence Gollob, Clarence A. Shelton, Stuart Brandon Gilley, Timothy R. Fierbaugh
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Publication number: 20170363134Abstract: 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: ApplicationFiled: June 16, 2017Publication date: December 21, 2017Applicant: Georgia-Pacific Gypsum LLCInventors: Vincent B. Thomas, Jason G. Peace, Seth C. Glenn
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Publication number: 20170328056Abstract: 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: ApplicationFiled: August 3, 2017Publication date: November 16, 2017Applicant: Georgia-Pacific Gypsum LLCInventors: Vincent B. Thomas, Rochelle Bradford, Christopher J. Sanders, Yi-Hsien Harry Teng
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Publication number: 20170267587Abstract: Gypsum based compositions, processes for making same, and articles made therefrom. In one example, the gypsum based composition can include about 1.5 wt % to about 3 wt % of a starch, about 11 wt % to about 14 wt % of a paper, about 0.7 wt % to about 2.3 wt % of vermiculite, about 1.3 wt % to about 3 wt % of a plurality of reinforcing fibers, about 7 wt % to about 10 wt % of a binding agent, about 2 wt % to about 4 wt % of perlite, and about 65 wt % to about 75 wt % of a calcium sulfate, where all weight percent values are based on a combined weight of the starch, paper, vermiculite, plurality of reinforcing fibers, binding agent, perlite, and calcium sulfate.Type: ApplicationFiled: March 15, 2017Publication date: September 21, 2017Applicant: Georgia-Pacific Gypsum LLCInventors: Scott J. Abolt, Luke R. Fitzwater, John F. Davis
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Publication number: 20170260738Abstract: 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: ApplicationFiled: March 10, 2017Publication date: September 14, 2017Applicant: Georgia-Pacific Gypsum LLCInventors: Charles R. Harrison, Lawrence Gollob, Clarence A. Shelton, Stuart Brandon Gilley
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Patent number: 9758965Abstract: Aspects of this disclosure relate to a method of manufacturing wallboard which includes providing a first layer of facing material, creasing the first layer facing material intermittently to create a series of creased portions, providing a gypsum slurry on the first layer of facing material and providing a second layer of facing material over the gypsum slurry. Further, creasing the first layer of facing material intermittently can include intermittently creasing the first layer of facing material in a substantially linear fashion extending in a first direction of the first layer of facing material so that the first layer of facing material exhibits a linear series of creased portions extending in the first direction of the first layer of facing material and a series of portions that are not creased extending in the first direction of the first layer of facing material.Type: GrantFiled: July 30, 2014Date of Patent: September 12, 2017Assignee: Georgia-Pacific Gypsum LLCInventor: Chad A. Frank
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Patent number: 9739059Abstract: 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: June 13, 2016Date of Patent: August 22, 2017Assignee: Georgia-Pacific Gypsum LLCInventors: Vincent B. Thomas, Rochelle Bradford, Christopher J. Sanders, Yi-Hsien Harry Teng
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Publication number: 20170197379Abstract: 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: ApplicationFiled: January 10, 2017Publication date: July 13, 2017Applicant: Georgia-Pacific Gypsum LLCInventors: Yi-Hsien Harry Teng, Andrew W. Tricker
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Publication number: 20170183262Abstract: Gypsum panels, panel cores, and methods for the manufacture thereof are provided herein. A gypsum panel core includes gypsum and fiberglass, the fiberglass being present in the core in an amount of from about 1 lb/msf to about 6 lb/msf. The core has a thickness of about 1/2 inch, a weight of from about 1400 lb/msf to about 1750 lb/msf, and an ASTM E-119 wood stud fire test rating of at least 30 minutes.Type: ApplicationFiled: March 13, 2017Publication date: June 29, 2017Applicant: Georgia-Pacific Gypsum LLCInventors: Michael H. Moore, Christopher J. Sanders
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Patent number: 9657440Abstract: Methods of making a multi-ply paperboard core include providing a number of paperboard furnishes and layering the furnishes to form a multi-ply paperboard web, wherein the two outermost plies are formed of furnish containing no size and the two plies adjacent the outermost plies are formed of furnish containing size. Apparatus for making a multi-ply paperboard core include two or more furnish sources configured to provide a number of paperboard furnishes, wherein at least one furnish source provides furnish containing no size and at least one furnish source provides furnish containing size, and a paperboard forming section wherein the furnishes are layered to form a multi-ply paperboard web in which the two outermost plies are formed of furnish containing no size and the two plies adjacent the two outermost plies are formed of furnish containing size.Type: GrantFiled: July 8, 2014Date of Patent: May 23, 2017Assignee: Georgia-Pacific Gypsum LLCInventors: Blake McCorriston, Gerry Finlayson, Vincent B. Thomas
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Patent number: 9593044Abstract: Gypsum panels, panel cores, and methods for the manufacture thereof are provided herein. A gypsum panel core includes gypsum and fiberglass, the fiberglass being present in the core in an amount of from about 1 lb/msf to about 6 lb/msf. The core has a thickness of about ½ inch, a weight of from about 1400 lb/msf to about 1750 lb/msf, and an ASTM E-119 wood stud fire test rating of at least 30 minutes.Type: GrantFiled: November 16, 2015Date of Patent: March 14, 2017Assignee: Georgia-Pacific Gypsum LLCInventors: Michael H. Moore, Christopher J. Sanders