Patents Assigned to United States Gypsum Company
  • Patent number: 11466453
    Abstract: A punch assembly for creating clean holes in a wallboard sheet having at least one surface with a face paper layer. The punch assembly includes a frame having a lower assembly configured to support the wallboard sheet, a plate on an upper frame assembly being reciprocable relative to the at least one surface of the wallboard sheet, at least one stripper bushing connected to the plate, where the at least one stripper bushing including a hole and a piercing edge, and at least one punch configured to move through the hole in the at least one stripper bushing. In operation, the plate is moved against the at least one surface of the wallboard sheet so that the piercing edge of the at least one stripper bushing contacts the face paper layer and at least partially cuts the face paper layer prior to the at least one punch moving through the wallboard sheet to form at least one clean hole in the wallboard sheet.
    Type: Grant
    Filed: January 23, 2015
    Date of Patent: October 11, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: James J. Lehane, Peder John Gulbrandsen
  • Patent number: 11453613
    Abstract: A ready-mixed setting type joint compound in which formation of gypsum seeds has been inhibited. A method for controlling a setting reaction by mixing a ready-mixed setting type joint compound with one or more metal ion control agents comprising aminopolycarboxylic acid and/or a salt thereof, and further mixing the setting type joint compound with one or more non-calcium phosphate compounds. The method may further comprise mixing the setting type joint compound with a set activator obtained by blending together a first set activator including a cadmium compound, lead compound and/or zinc compound and a second set activator including a ferrous compound, aluminum compound and/or manganese compound.
    Type: Grant
    Filed: September 24, 2018
    Date of Patent: September 27, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Guy L. Rosenthal, Charles J. Miller, Tyler Kincaid, Joseph Schlude
  • Patent number: 11414352
    Abstract: Method of making foamed gypsum slurry having 15 to 90 volume percent gas bubbles including: passing first slurry including water and on dry basis 50 to 98 wt. % calcium sulfate hemihydrate, 1 to 50 wt. % calcium carbonate, and 0.1 to 10 wt. % cellulose thickener via a first hose to a Wye connector conduit first inlet opening at Rate C and passing alum solution via a second hose to a second inlet opening of the conduit at Rate D to create combined mixed stream passing from the conduit to a static mixer for mixing for Time 3 to activate at least a portion of the calcium carbonate and alum to generate CO2 and create the foamed gypsum slurry; transferring the slurry from the mixer to a cavity between two wall boards via a third hose. Allowing the slurry in the cavity to expand, harden and dry.
    Type: Grant
    Filed: March 5, 2019
    Date of Patent: August 16, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: David D. Pelot, Samar Emami, Robert H. Negri, Juan Carlos Ruiz Castaneda, Christopher R. Nelson, John J. Roxburgh, Edgar R. De La Rosa Cruz, Jorge A. Garcia Torres, Miguel Gama Goicochea, Antonio Contreras, Juan Huitzil
  • Patent number: 11407145
    Abstract: A gypsum slurry mixer output canister is provided, including a canister housing having an upper end, an opposite lower end and defining a canister interior, a cover secured to the upper end, a slurry inlet in operational relationship to the upper end, a spiral block associated with the upper end, and having a helical flow surface depending into the interior. A flow distributor is secured to the lower end and is in fluid communication with the interior, and a slurry outlet is defined by the lower canister housing end.
    Type: Grant
    Filed: September 18, 2020
    Date of Patent: August 9, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Jason Lash, Michael Krell, Leslie Eversole, Domingo Rosario
  • Publication number: 20220242092
    Abstract: This invention provides gypsum wallboards with a unique microstructure where the walls between voids are enhanced in thickness and strength to substantially improve the strength and handling properties of the wallboards. A method of making lightweight gypsum wallboards is also provided.
    Type: Application
    Filed: April 19, 2022
    Publication date: August 4, 2022
    Applicant: United States Gypsum Company
    Inventors: Qiang YU, Weixin D. SONG
  • Patent number: 11384524
    Abstract: A modular assembly is provided and includes a modular frame to be installed at least partially below grade and at least two panels attached to the modular frame, where the at least two panels are made of a material that withstands lateral, vertical and shear forces generated by surrounding below grade materials. The modular frame and the at least two panels are joined together as a unit prior to installation.
    Type: Grant
    Filed: September 16, 2019
    Date of Patent: July 12, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Frank Pospisil, Breton Betz
  • Patent number: 11338548
    Abstract: This invention provides gypsum wallboards with a unique microstructure where the walls between voids are enhanced in thickness and strength to substantially improve the strength and handling properties of the wallboards. A method of making lightweight gypsum wallboards is also provided.
    Type: Grant
    Filed: July 22, 2019
    Date of Patent: May 24, 2022
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Weixin D. Song
  • Patent number: 11306028
    Abstract: This invention provides low dust low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set gypsum core formed between two substantially parallel cover sheets, the set gypsum core preferably having a total void volume from about 80% to about 92%, and made from a slurry including stucco, pregelatinized starch, and a naphthalenesulfonate dispersant. The combination of the pregelatinized starch and the naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small air bubble voids (and water voids) provides dust control during cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products.
    Type: Grant
    Filed: July 24, 2019
    Date of Patent: April 19, 2022
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Weixin D. Song
  • Patent number: 11267759
    Abstract: Disclosed is a method and system for blending a foam modifier with foaming agent on-line, e.g., as may be particularly useful for gypsum or cement slurries. The foam modifier comprises a fatty alcohol that is added to a gypsum or cement slurry that includes foaming agent, such as an alkyl sulfate surfactant. The fatty alcohol can be a C6-C16 fatty alcohol in some embodiments. The use of such a foam modifier can be used, for example, to stabilize the foam, reduce waste of foaming agent, improve void size control in the final product, and improve the gypsum board manufacturing process.
    Type: Grant
    Filed: April 13, 2020
    Date of Patent: March 8, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Annamaria Vilinska, Alfred C. Li, Weixin D. Song
  • Patent number: 11267227
    Abstract: An exterior sheathing cementitious panel which prevents water penetration and air leakage is provided. Methods for manufacturing exterior sheathing cementitious panels with a highly efficient integrated air/water barrier membrane are provided as well.
    Type: Grant
    Filed: January 10, 2020
    Date of Patent: March 8, 2022
    Assignees: UNITED STATES GYPSUM COMPANY, TREMCO INCORPORATED
    Inventors: Michael P. Shake, Robert H. Negri, Paula McKnight, Paul Shipp, James M. Ullett, Timothy G. Kenny, Brett R. Link, Pamela Hernandez, Kristin Schulte, Dante Marimpietri, Casey Sovey, Muneer Mohammad, Dominic Cremona, Ellen Zerucha, Scottie Lee Stinson
  • Patent number: 11236234
    Abstract: A building construction product comprising an ionochromic dye, wherein the building construction product has a first color when the product comprises water, wherein the first color is dependent on the presence of metal ions in solution in the product; and wherein the product has a second color when the product has solidified. Methods of monitoring setting and drying reactions of building construction products, including setting-type and drying-type joint compounds and plasters.
    Type: Grant
    Filed: January 3, 2018
    Date of Patent: February 1, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Alexander Donovan, Joseph Schlude
  • Patent number: 11224990
    Abstract: Continuous method including mixing water and cementitous powder to form slurry; mixing the slurry and reinforcement fibers in a single pass horizontal continuous mixer to form fiber-slurry mixture, the mixer including an elongated mixing chamber having a reinforcement fiber inlet port, and upstream of the fiber inlet port is an inlet port to introduce water and cementitous powder together as one stream or at least two inlet ports to introduce water and dry cementitous powder separately as separate streams into the chamber, a rotating horizontal shaft/s within the chamber, part of the chamber for mixing the fibers and slurry and moving the fiber-slurry mixture to a mixture outlet; discharging the fiber-slurry mixture from the mixer outlet; forming and setting the fiber-slurry mixture on a moving surface; cutting the set mixture into fiber reinforced concrete panels and removing the panels from the moving surface.
    Type: Grant
    Filed: July 28, 2017
    Date of Patent: January 18, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Ashish Dubey, Peter B. Groza, Christopher R. Nelson
  • Patent number: 11225046
    Abstract: Embodiments of a system and a method for manufacturing a gypsum board can be used to produce a gypsum board having at least one perforated cover sheet via a cover sheet perforator system. The cover sheet perforator system can include a perforator roller is disposed downstream of a forming station along a machine direction, a roller support frame for rotatably supporting the perforator roller such that its rotational axis extends along the cross-machine direction, and a motor arranged with the perforator roller to rotate the perforator roller about the rotational axis. The drive motor can be adapted to rotate the perforator roller with a tangential speed substantially equal to the line speed to produce a series of perforation holes in an upwardly-facing cover sheet as the gypsum board moves past the perforator roller.
    Type: Grant
    Filed: March 29, 2017
    Date of Patent: January 18, 2022
    Assignee: United States Gypsum Company
    Inventors: Dale M. Shubert, Ronald E. Schenck, Thomas Gregory Rowland, John Matthew Willi
  • Patent number: 11225793
    Abstract: Mat-faced cementitious board including: (a) a cementitious core; (b) a fibrous mat having an inner first surface facing at least one face of the cementitious core, and an outer second surface, wherein the inner first surface and the outer second surface are opposed; (c) a hydrophobic, non-setting coating resulting from applying to the outer second surface of the fibrous mat a layer of hydrophobic finish composition including: (i) about 50 to about 80 weight % non-setting, inorganic filler having a mean particle diameter of about 12 microns to about 35 microns, (ii) about 20% to about 50 weight % an aqueous dispersion of a film-forming polymer, (iii) 0% to about 30 weight % additional water; (iv) an absence of fly ash, (v) an absence of pozzolanic material, (vi) an absence of hydraulic cement, (vii) an absence of calcium sulfate hemihydrate, and (viii) an absence of calcium sulfate anhydrite.
    Type: Grant
    Filed: April 1, 2019
    Date of Patent: January 18, 2022
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Yanfei Peng, Rafael Bury, Jeffrey W. Donelan
  • Patent number: 11186067
    Abstract: Gypsum boards formed from synthetic gypsum and other gypsum sources having high chloride salt concentrations. Gypsum boards may include a board core including set gypsum. A total concentration of the chloride anion in the board core ranges from about 500 ppm to about 3000 ppm, typically about 1000 ppm to about 3000 ppm, based on weight of the calcium sulfate hemihydrate. An inner surface of a front paper cover sheet contacts a first face of the board core. An inner surface of a back paper cover sheet contacts a second face of the board core. A starch layer coats the inner surface of at least one of the front and back cover sheet. Methods of making the gypsum board, and a wall system for employing the gypsum boards, are also provided.
    Type: Grant
    Filed: May 2, 2019
    Date of Patent: November 30, 2021
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Qinghua Li, Runhai Lu, Charles W. Cochran, Mark Hemphill
  • Patent number: 11186066
    Abstract: Gypsum boards formed from synthetic gypsum and other gypsum sources having high chloride salt concentrations. The gypsum boards may include a set gypsum board core layer between a front and back paper cover sheets. The back paper cover sheet has a plurality of perforations extending therethrough. Methods of making the gypsum boards, and a wall system for employing the gypsum boards, are also provided. The concentration of the chloride anion in aqueous gypsum slurry used to make the set gypsum board core layer and to perform the methods of the invention may range from about 500 ppm to about 3000 ppm, typically from about 500 ppm to about 2000 ppm per 1,000,000 parts by weight calcium sulfate hemihydrate, more typically from about 500 ppm to about 1500 ppm per 1,000,000 parts by weight calcium sulfate hemihydrate.
    Type: Grant
    Filed: May 2, 2019
    Date of Patent: November 30, 2021
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Mark Hemphill, Qinghua Li, Charles W. Cochran
  • Patent number: 11186398
    Abstract: A device is provided for closing, sealing and conveying corrugated cartons having a top flap and a next adjacent flap, and includes a frame, a moving conveyor belt associated with the frame and defining a track with an inlet end and an outlet end, and a fixed bracket secured to the frame and having a first plurality of linearly aligned rollers defining a first side of the track. A movable bracket is associated with the frame, having a second plurality of linearly aligned rollers defining a second side of the track and being transversely movable relative to the track under operator control.
    Type: Grant
    Filed: August 6, 2019
    Date of Patent: November 30, 2021
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: David Burchett, Doug Wilson, Christopher Hovanec
  • Patent number: 11180412
    Abstract: Aqueous cementitious slurries including predominantly Type I Portland cement containing an aluminate additive. The aluminate additive is an aluminate salt other than calcium aluminate or calcium sulfoaluminate, preferably sodium aluminate. Cementitious reactive powders of the slurry include the Type I Portland cement and 0.1-10 wt. % of the aluminate additive as an accelerator. The slurries may have a set time of about 10 minutes or less. Due to the short set time, the cementitious reactive powders may facilitate cement board fabrication by continuous manufacturing processes. Methods for making cement boards may include disposing the aqueous cementitious slurry including the cementitious reactive powders in a continuous layer, preferably upon a porous support, and setting the aqueous cementitious slurry with a set time of about 10 minutes or less.
    Type: Grant
    Filed: February 25, 2020
    Date of Patent: November 23, 2021
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Qinghua Li, Yanfei Peng
  • Patent number: 11173629
    Abstract: A method in which a stream of dry cementitious powder passes through a first conduit and aqueous medium stream passes through a second conduit to feed a slurry mixer to make cementitious slurry. The cementitious slurry passes through a third conduit and a reinforcement fiber stream passes through a fourth conduit to feed a fiber-slurry mixer which mixes the slurry and discrete fibers to make a stream of fiber-slurry mixture. An apparatus for performing the method is also disclosed.
    Type: Grant
    Filed: July 28, 2017
    Date of Patent: November 16, 2021
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Ashish Dubey, Peter B. Groza, Christopher R. Nelson
  • Patent number: 11168030
    Abstract: Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise), and an extruded pregelatinized starch.
    Type: Grant
    Filed: August 2, 2018
    Date of Patent: November 9, 2021
    Assignee: UNITED STATES GYPSUM COMPANY
    Inventors: Yijun Sang, Chris C. Lee, Cesar Chan, Weixin David Song