Abstract: Disclosed is a foam modifier, e.g., 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.

Abstract: Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

Abstract: Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the hoard core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

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.

Abstract: A noncombustible exterior structural wall of a building, where the noncombustible wall includes a steel frame with a plurality of vertically oriented support studs, a plurality of noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels with an absence of an air/weather membrane.

Abstract: A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.

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.

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.

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.

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.

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).

Abstract: Disclosed is a composite gypsum board comprising a board core and a concentrated layer of substantial thickness (e.g., at least about 0.02 inches). The concentrated layer includes a higher weight percentage of an enhancing additive than the board core. The board core has a thickness greater than the thickness of the concentrated layer and forms the bulk of the board volume. The concentrated layer has a higher density (e.g., at least about 1.1 times greater) than the density of the board core. Also disclosed is a method of preparing a composite gypsum board.

Abstract: A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.

Abstract: Disclosed are methods relating to an extruded pregelatinized, partially hydrolyzed starch prepared by mixing at least water, non-pregelatinized starch, and acid to form a starch precursor. The acid can be a weak acid that substantially avoids chelating calcium ions or a strong acid in a small amount. In the method, pregelatinization and acid-modification of the starch precursor occurs in one step in an extruder. Also disclosed are methods of preparing board using the starch prepared according to the methods, as well as starches and boards prepared by various methods of the invention.

Abstract: A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.

Abstract: A modified gypsum set accelerator and a method of preparing the same is provided, which includes dry loose finely ground particles of a mixture of ground dry calcium sulfate dihydrate and a grinding aid selected from one or more of beta-naphthalene sulfonate formaldehyde condensate, trimetaphosphate phosphate salt, tripolyphosphate salt, tetra-pyrophosphate salt, and pregelatinized starch.

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.

Abstract: Disclosed is a method and system for blending a foam modifier with foaming agent online, 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.

Abstract: Disclosed are a gypsum board, and related slurries and methods. The gypsum board comprises a gypsum layer disposed between two cover sheets. The gypsum layer comprises a crystalline matrix of set gypsum and expandable graphite. The expandable graphite exhibits volume expansion at high temperatures. Optionally, unexpanded vermiculite can also be included in the gypsum layer to provide an expansion component at even higher temperatures. Because of synergy between the expandable graphite and unexpanded vermiculite in accordance with some embodiments, less vermiculite can be included in the board than in conventional board that contained vermiculite. The board desirably can pass one or more fire-related tests, and is a fire-rated board in some embodiments.

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).