Patents by Inventor Robert J. Hauber
Robert J. Hauber has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11161783Abstract: A composition and process for manufacture thereof used in hybrid inventive building materials comprising Syngenite (K2Ca(SO4)2.H2O) and Struvite-K (KMgPO4.6H2O). Starting constituents include magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate), mixed in predetermined ratios, cause reactions to proceed through multiple phases, which reactions variously are proceeding simultaneously and in parallel. Variables, e.g., 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 weight percent and specified ratios of Struvite-K and Syngenite are provided for building products used for specified purposes. Reactions are optimized in stoichiometry and additives to reduce the combined heat of formation to non-destructive levels. Various additives help control and guide reactions.Type: GrantFiled: November 18, 2019Date of Patent: November 2, 2021Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston, Nathan Frailey, Severine Lamberet, Gaurav V. Pattarkine, Isaac K. Cherian, Sergio Centurione, Anirban Ghosh
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Patent number: 10767368Abstract: 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: GrantFiled: December 29, 2017Date of Patent: September 8, 2020Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston
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Patent number: 10589443Abstract: A method for producing building boards includes unwinding a facing sheet from a supply roll of facing sheet over top of a forming table that includes a series of nozzles. A volume of cementitious material is deposited from a slurry mixing device to the unwound facing sheet. Pressurized air is supplied from an air source to the series of nozzles, whereby a cushion of air is created between the unwound facing sheet and the forming table.Type: GrantFiled: November 30, 2017Date of Patent: March 17, 2020Assignee: SAINT-GOBAIN PLACO SASInventors: Robert J. Hauber, Gerald D. Boydston, Nathan Gregory Frailey, Michael P. Fahey, Bryan J. Wiltzius, John M. Bridenstine
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Publication number: 20200079691Abstract: A composition and process for manufacture thereof used in hybrid inventive building materials comprising Syngenite (K2Ca(SO4)2.H2O) and Struvite-K (KMgPO4.6H2O). Starting constituents include magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate), mixed in predetermined ratios, cause reactions to proceed through multiple phases, which reactions variously are proceeding simultaneously and in parallel. Variables, e.g., 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 weight percent and specified ratios of Struvite-K and Syngenite are provided for building products used for specified purposes. Reactions are optimized in stoichiometry and additives to reduce the combined heat of formation to non-destructive levels. Various additives help control and guide reactions.Type: ApplicationFiled: November 18, 2019Publication date: March 12, 2020Inventors: Robert J. Hauber, Gerald D. Boydston, Nathan Frailey, Severine Lamberet, Gaurav V. Pattarkine, Isaac K. Cherian, Sergio Centurione, Anirban Ghosh
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Patent number: 10479728Abstract: A composition and process for manufacture thereof used in hybrid inventive building materials comprising Syngenite (K2Ca(SO4)2.H2O) and Struvite-K (KMgPO4.6H2O). Starting constituents include magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate), mixed in predetermined ratios, cause reactions to proceed through multiple phases, which reactions variously are proceeding simultaneously and in parallel. Variables, e.g., 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 weight percent and specified ratios of Struvite-K and Syngenite are provided for building products used for specified purposes. Reactions are optimized in stoichiometry and additives to reduce the combined heat of formation to non-destructive levels. Various additives help control and guide reactions.Type: GrantFiled: October 14, 2014Date of Patent: November 19, 2019Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston, Nathan Frailey, Severine Lamberet, Gaurav V. Pattarkine, Isaac K. Cherian, Sergio Centurione, Anirban Ghosh
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Patent number: 10472284Abstract: 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 (KMgPO4ยท6H2O). 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.Type: GrantFiled: August 17, 2016Date of Patent: November 12, 2019Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston, Nathan Frailey, Severine Lamberet, Gaurav V. Pattarkine, Isaac K. Cherian, Sergio Centurione, Anirban Ghosh
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Patent number: 10457027Abstract: 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 undissolved 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: GrantFiled: August 4, 2015Date of Patent: October 29, 2019Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston
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Publication number: 20180187416Abstract: 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: ApplicationFiled: December 29, 2017Publication date: July 5, 2018Inventors: Robert J. Hauber, Gerald D. Boydston
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Publication number: 20180079106Abstract: Discloses is an apparatus and method for utilizing air along a building board forming line for the purpose of reducing friction between the board and the underlying forming tables. The device employs a series of air nozzles that are formed within the face of the forming tables. An air source delivers pressurized air to the nozzles. As completed or partially completed boards travel along the forming tables, an air cushion is created to reduce the friction between the board and the underlying table. The pressurized air can also be used to transport the boards and promote the even distribution of slurry during formation. The various components of the present invention, and the manner in which they interrelate, are described in greater detail hereinafter.Type: ApplicationFiled: November 30, 2017Publication date: March 22, 2018Inventors: Robert J. Hauber, Gerald D. Boydston, Nathan Gregory Frailey, Michael P. Fahey, Bryan J. Wiltzius, John M. Bridenstine
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Patent number: 9885179Abstract: 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: GrantFiled: February 16, 2016Date of Patent: February 6, 2018Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston
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Publication number: 20170008804Abstract: 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.Type: ApplicationFiled: August 17, 2016Publication date: January 12, 2017Applicant: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston, Nathan Frailey, Severine Lamberet, Gaurav V. Pattarkine, Isaac K. Cherian, Sergio Centurione, Anirban Ghosh
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Patent number: 9486980Abstract: 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: GrantFiled: April 1, 2013Date of Patent: November 8, 2016Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston
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Patent number: 9475730Abstract: 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.Type: GrantFiled: June 8, 2012Date of Patent: October 25, 2016Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston
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Publication number: 20160273220Abstract: 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: ApplicationFiled: February 16, 2016Publication date: September 22, 2016Inventors: Robert J. Hauber, Gerald D. Boydston
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Patent number: 9422193Abstract: 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.Type: GrantFiled: August 12, 2014Date of Patent: August 23, 2016Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston, Nathan Frailey, Severine Lamberet, Gaurav V. Pattarkine, Isaac K. Cherian, Sergio Centurione, Anirban Ghosh
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Publication number: 20160236979Abstract: A composition and process for manufacture thereof used in hybrid inventive building materials comprising Syngenite (K2Ca(SO4)2.H2O) and Struvite-K (KMgPO4.6H2O). Starting constituents include magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate), mixed in predetermined ratios, cause reactions to proceed through multiple phases, which reactions variously are proceeding simultaneously and in parallel. Variables, e.g., 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 weight percent and specified ratios of Struvite-K and Syngenite are provided for building products used for specified purposes. Reactions are optimized in stoichiometry and additives to reduce the combined heat of formation to non-destructive levels. Various additives help control and guide reactions.Type: ApplicationFiled: October 14, 2014Publication date: August 18, 2016Applicant: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston, Nathan Frailey, Severine Lamberet, Gaurav V. Pattarkine, Isaac K. Cherian, Sergio Centurione, Anirban Ghosh
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Publication number: 20160052248Abstract: 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 undissolved 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: ApplicationFiled: August 4, 2015Publication date: February 25, 2016Inventors: Robert J. Hauber, Gerald D. Boydston
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Patent number: 9259888Abstract: 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: GrantFiled: July 15, 2013Date of Patent: February 16, 2016Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston
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Patent number: 9186869Abstract: 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: GrantFiled: June 8, 2012Date of Patent: November 17, 2015Assignee: CertainTeed Gypsum, Inc.Inventors: Robert J. Hauber, Gerald D. Boydston
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Publication number: 20150197941Abstract: The present disclosure relates to performance enhancing surface coatings for building boards. More particularly, the disclosure relates to the using of building boards employing surface adhesives to eliminate the need for fasteners in holding building boards in place after installation.Type: ApplicationFiled: January 12, 2015Publication date: July 16, 2015Inventors: Michael S. Urso, Robert J. Hauber, Gerald D. Boydston