Perlite Containing Patents (Class 106/698)
  • Patent number: 9458061
    Abstract: Cementitious mortar with improved characteristics for forming structures incorporating synthetic fibres, in particular in the form of webs, for reinforcing building structures. The mortar comprises a methylmethacrylate/n-butylacrylate copolymer resin and glass filaments dispersed in the mortar. The invention also relates to a reinforcement method for building structures, using said mortar.
    Type: Grant
    Filed: September 18, 2009
    Date of Patent: October 4, 2016
    Assignee: RUREDIL S.p.A.
    Inventor: Giovanni Mantegazza
  • Patent number: 9034097
    Abstract: A composition for the preparation of a fire protection mortar comprising 45 to 70% by weight of cement binder, 8 to 20% by weight calcite, 8 to 20% by weight mica, 0 to 5% by weight of xonotlite, 0.1 to 20% by weight of expanded perlite, 0.1 to 10% by weight of fibers, 0.01 to 2% by weight of air entrainer and foaming agent, 0.01 to 2% by weight of processing aids.
    Type: Grant
    Filed: February 4, 2014
    Date of Patent: May 19, 2015
    Assignee: Promat Research and Technology Centre NV
    Inventors: Xiao Wu, Ann Opsommer
  • Patent number: 9011708
    Abstract: The present invention relates to a thermal insulator using closed cell expanded perlite. The thermal insulator using closed cell expanded perlite of the present invention includes: expanded perlite 10 to 84 wt %ç, including dried and expanded perlite ore particles, having a surface with a closed cell shape, as an active ingredient; a liquid binder 15 to 85 wt %; and a reinforcing fiber 0.25 to 5 wt %. Accordingly, the present invention provides a thermal insulator, which enhances the rigidity of expanded perlite, minimizes porosity and gaps between the expanded perlite particles, by reducing compression ratio during compression molding, which results in lower density, improves constructability by lowering thermal conductivity, reduces material and energy costs and can reduce the area required for equipment installation by reducing the thickness of the thermal insulator.
    Type: Grant
    Filed: March 3, 2011
    Date of Patent: April 21, 2015
    Assignee: Kyungdong One Corporation
    Inventors: Bum-Gyu Baek, Sang-Yun Lee
  • Patent number: 8992679
    Abstract: Dry construction pellets that may be made by mixing predetermined portions of two or more components of cementitious materials without ingredients that would allow the mixture to cure, and separating the un-curable mixture of the two or more components into a plurality of pellets, each having substantially the predetermined portions of the two or more components. An extrusion system may include a transport line configured to transport the dry pellets in a gaseous transport stream.
    Type: Grant
    Filed: February 5, 2010
    Date of Patent: March 31, 2015
    Assignee: University of Southern California
    Inventor: Behrokh Khoshnevis
  • Patent number: 8968464
    Abstract: A plastic refractory material or a refractory mortar which harden when dried and which contain at least one light-weight filler, a binder, fibers and/or wollastonite as well as water is characterized in that blown closed-cell volcanic ash is used as the light-weight filler, the ash being provided with a superficial water-protection layer, in that an inorganic-organic hybrid binder is used as the binder, the binder containing silicic acid and an organic polymer, and in that the material or the mortar contains kaolin or kaolinite and silicon dioxide. It is suggested to publish the abstract without a drawing.
    Type: Grant
    Filed: February 23, 2011
    Date of Patent: March 3, 2015
    Assignee: TDH-GmbH Technischer Daemmstoffhandel
    Inventors: Rainer Angenendt, Peer Genth
  • Publication number: 20140318784
    Abstract: Methods and compositions are provided that utilize pumice and various additives. An embodiment provides a method of remedial cementing in a subterranean formation comprising: providing a lightweight settable composition comprising pumice, a calcium activator, and water, wherein the lightweight settable composition has a density of less than about 13.5 pounds per gallon and is free of Portland cement; and using the lightweight settable composition in a remedial cementing method to seal one or more voids in a well bore. Also provided are pumice-containing remedial compositions and systems for remedial cementing.
    Type: Application
    Filed: April 30, 2013
    Publication date: October 30, 2014
    Applicant: Halliburton Energy Services, Inc.
    Inventors: Jiten Chatterji, D. Chad Brenneis, James R. Benkley
  • Publication number: 20140318419
    Abstract: Methods and compositions are provided that utilize pumice and various additives. Embodiments provide pumice-containing remedial compositions. One of the pumice-containing remedial composition embodiments comprises pumice; a calcium activator; and water, wherein the pumice-containing remedial composition has a density of less than about 13.5 pounds per gallon, and wherein the pumice-containing remedial composition is free of Portland cement.
    Type: Application
    Filed: December 30, 2013
    Publication date: October 30, 2014
    Applicant: Halliburton Energy Services, Inc.
    Inventors: Jiten Chatterji, D. Chad Brenneis, James R. Benkley
  • Patent number: 8852336
    Abstract: A method is provided that solves the problem of the manner of obtainment of mass for production of shaped construction elements. The manner consists of the fact, that in the mechanical mixer a ceramic granulate is placed, preferably in the form of perlite and is soaked, preferably with water until complete soaking of the granulate and is mixed with the binding agent until obtainment of the situation, where each loose grain (1) of the granulate is coated with a layer of moist binding agent, creating a coating (2) around the grain. Priorly prepared moulds are filled with the obtained mass. The mass for production of shaped construction elements consists of 15-25% of bond weight, preferably in the form of perlite, 35-45% of binding agent weight, preferably in the form of plaster with improved resistance parameters and 35-45% of water weight.
    Type: Grant
    Filed: November 10, 2011
    Date of Patent: October 7, 2014
    Assignee: HCH Spólka z o.o.
    Inventors: Jerzy Haintze, Andrzej Haintze
  • Publication number: 20140130716
    Abstract: Methods and compositions are provided that relate to cementing operations, including a method of cementing that may comprise providing a settable composition that may comprise wollastonite, pumice, a calcium-ion source, and water, wherein the wollastonite may be present in an amount in a range of from about 25% to about 75% by combined weight of the wollastonite and pumice, and wherein the pumice may present in an amount in a range of from about 25% to about 75% by combined weight of the wollastonite and pumice. Embodiments of the method further may comprise allowing the settable composition to set.
    Type: Application
    Filed: March 22, 2013
    Publication date: May 15, 2014
    Applicant: Halliburton Energy Services, Inc.
    Inventors: Jiten Chatterji, D. Chad Brenneis, Crystal L. Keys
  • Publication number: 20140123879
    Abstract: Methods and compositions are disclosed that comprise interground perlite and hydraulic cement. An embodiment provides a composition comprising interground perlite and hydraulic cement. Another embodiment provides a composition comprising: interground unexpanded perlite and Portland cement, the interground having a mean particle size of about 0.5 microns to about 10 microns; and water.
    Type: Application
    Filed: December 30, 2013
    Publication date: May 8, 2014
    Applicant: HALLIBURTON ENERGY SERVICES, INC.
    Inventors: Jeffery Dwane Karcher, D. Chad Brenneis, Craig W. Roddy, James R. Benkley
  • Patent number: 8672028
    Abstract: Methods and compositions are disclosed that comprise interground perlite and hydraulic cement. An embodiment provides a method of cementing comprising: providing a settable composition comprising perlite, hydraulic cement, and water, wherein the perlite and hydraulic cement are interground prior to combination with the water to form the settable composition; and allowing the settable composition to set.
    Type: Grant
    Filed: July 11, 2011
    Date of Patent: March 18, 2014
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Jeffery D. Karcher, D. Chad Brenneis, Craig W. Roddy, James R. Benkley
  • Publication number: 20140047999
    Abstract: Process for production of acid and high temperature resistant cement composites, where the matrix is alkali activated F fly ash alone, F Fly ash combined with ground slag or ground slag alone. F-fly ash produces lower quality alkali activated cement systems. On the other hand the lack of calcium oxide results in very high resistance to medium and highly concentrated inorganic or organic acids. The high strength and low permeability of pure F-fly ash cement systems is achieved by using in the composition un-densified silica fume, the amorphous silicone dioxide obtained as by products in production of ferro-silicones. Precipitated nano-particle silica made from soluble silicates and nano-particle silica fume produced by burning silicon tetra chloride in the hydrogen stream.
    Type: Application
    Filed: November 14, 2011
    Publication date: February 20, 2014
    Inventor: Ivan Ràzl
  • Patent number: 8628713
    Abstract: An inorganic board contains, in a solid content ratio, 30 to 70 mass % of hydraulic material, 5 to 15 mass % of reinforcing fiber, and 1 to 30 mass % of wollastonite having a wet volume (after being allowed to stand for 30 minutes) of 15 to 45 ml. Also, a method includes: step of producing a slurry containing hydraulic material, reinforcing fiber, and wollastonite; step of producing a sheet by dehydrating the slurry; and step of pressing and curing the sheet; wherein, in the step of producing a slurry, a composition of the slurry is set so as to contain, in a solid content ratio, 30 to 70 mass % of hydraulic material, 5 to 15 mass % of reinforcing fiber, and 1 to 30 mass % of wollastonite having a wet volume (after being allowed to stand for 30 minutes) of 15 to 45 ml.
    Type: Grant
    Filed: March 5, 2013
    Date of Patent: January 14, 2014
    Assignee: Nichiha Corporation
    Inventors: Satoshi Ikeda, Yusuke Omori
  • Publication number: 20130326985
    Abstract: An aqueous gypsum plaster-cement composition comprises a hydraulic binder consisting of calcined gypsum and hydraulic cement in a weight ratio of from about 4:1 to about 2:1, an aggregate which comprises sand, a foam, a perlite, rice hulls or a mixture thereof, a superplasticizer comprising an air entraining agent, a retarder, and water in an amount of from about 0.4 to about 0.75 parts by weight per part of binder, with the proviso that the gypsum plaster-cement composition contains essentially neither a pozzolana nor lime. The use thereof, a method of constructing buildings using this composition and the buildings obtainable in this way are also described.
    Type: Application
    Filed: September 8, 2011
    Publication date: December 12, 2013
    Applicant: CRUPE INTERNATIONAL (IP) GMBH
    Inventors: Hubert Lichtinger, Bernd Bruno Winfried Eck
  • Publication number: 20130312641
    Abstract: Embodiments relate to cementing operations and, more particularly, in certain embodiments, to settable compositions that comprise kiln dust and wollastonite and methods of use in subterranean formations. An embodiment discloses a method of cementing comprising: providing a settable composition comprising kiln dust, wollastonite, and water; and allowing the settable composition to set.
    Type: Application
    Filed: July 31, 2013
    Publication date: November 28, 2013
    Applicant: Halliburton Energy Services, Inc.
    Inventors: Jiten Chatterji, Darrell Chad Brenneis, Baya Adams, Craig Wayne Roddy
  • Publication number: 20130228101
    Abstract: The invention solves the problem of the manner of obtainment of mass for production of shaped construction elements. The manner consists of the fact, that in the mechanical mixer a ceramic granulate is placed, preferably in the form of pearlite and is soaked, preferably with water until complete soaking of the granulate and is mixed with the binding agent until obtainment of the situation, where each loose grain (1) of the granulate is coated with a layer of moist binding agent, creating a coating (2) around the grain. Priorly prepared moulds are filled with the obtained mass. The mass for production of shaped construction elements consists of 15-25% of bond weight, preferably in the form of pearlite, 35-45% of binding agent weight, preferably in the form of plaster with improved resistance parameters and 35-45% of water weight.
    Type: Application
    Filed: November 10, 2011
    Publication date: September 5, 2013
    Applicant: HCH SPOLKA Z O.O.
    Inventors: Jerzy Haintze, Andrzej Haintze
  • Patent number: 8486868
    Abstract: An embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising unexpanded perlite, cement kiln dust, and water; and allowing the settable composition to set. Another embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising ground unexpanded perlite, Portland cement interground with pumicite, and water; and allowing the settable composition to set. Yet another embodiment of the present invention comprises a settable composition comprising: ground unexpanded perlite; cement kiln dust; and water.
    Type: Grant
    Filed: November 5, 2012
    Date of Patent: July 16, 2013
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Chad Brenneis, Jeffery Karcher, Craig W. Roddy
  • Publication number: 20130139728
    Abstract: A method of making a rapid setting lightweight cementitious composition with improved compressive strength for products such as boards is disclosed. The method mixes fly ash, alkali metal salt of citric acid and lightweight aggregate with water. Compositions which include fly ash, alkali metal salts of citric acid and lightweight aggregate are also disclosed.
    Type: Application
    Filed: January 31, 2013
    Publication date: June 6, 2013
    Applicant: UNITED STATES GYPSUM COMPANY
    Inventor: United States Gypsum Company
  • Patent number: 8450391
    Abstract: Methods and compositions are provided that relate to weighted elastomers. The weighted elastomers may comprise an elastomer and a weighting agent attached to an outer surface of the elastomer. An embodiment includes a method of cementing that comprises providing a cement composition containing cement, water, and a weighted elastomer. In addition, the cement composition may be introduced into a subterranean formation and allowed to set therein.
    Type: Grant
    Filed: June 23, 2010
    Date of Patent: May 28, 2013
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Craig W. Roddy, Jeffery D. Karcher, Rickey L. Morgan, D. Chad Brenneis
  • Patent number: 8440596
    Abstract: An embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising unexpanded perlite, cement kiln dust, and water; and allowing the settable composition to set. Another embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising ground unexpanded perlite, Portland cement interground with pumicite, and water; and allowing the settable composition to set. Yet another embodiment of the present invention comprises a settable composition comprising: ground unexpanded perlite; cement kiln dust; and water.
    Type: Grant
    Filed: September 7, 2012
    Date of Patent: May 14, 2013
    Assignee: Halliburton, Energy Services, Inc.
    Inventors: Chad Brenneis, Jeffery Karcher, Craig W. Roddy
  • Patent number: 8434553
    Abstract: An embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising unexpanded perlite, cement kiln dust, and water; and allowing the settable composition to set. Another embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising ground unexpanded perlite, Portland cement interground with pumicite, and water; and allowing the settable composition to set. Yet another embodiment of the present invention comprises a settable composition comprising: ground unexpanded perlite; cement kiln dust; and water.
    Type: Grant
    Filed: September 7, 2012
    Date of Patent: May 7, 2013
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Chad Brenneis, Jeffery Karcher, Craig W. Roddy
  • Patent number: 8403045
    Abstract: An embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising unexpanded perlite, cement kiln dust, and water; and allowing the settable composition to set. Another embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising ground unexpanded perlite, Portland cement interground with pumicite, and water; and allowing the settable composition to set. Yet another embodiment of the present invention comprises a settable composition comprising: ground unexpanded perlite; cement kiln dust; and water.
    Type: Grant
    Filed: December 21, 2010
    Date of Patent: March 26, 2013
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Chad Brenneis, Jeffery Karcher, Craig W. Roddy
  • Publication number: 20130025505
    Abstract: The present invention relates to an aircraft-arresting paving material which is installed in locations such as aircraft runway safety zones or landing strips and is adapted to ensure that an aircraft do not leave the runway, by itself breaking if an aircraft which has landed overruns or departs and as a result proceeds upwards, and the present invention relates to a production method for the same, and also to a low-strength waterproof perlite concrete produced so as to include perlite aggregate having a waterproof coating so as to be suitable as the overrun prevention paving material.
    Type: Application
    Filed: April 19, 2011
    Publication date: January 31, 2013
    Applicant: THE KOREA TRANSPORT INSTITUTE
    Inventor: Jae-Hyun Han
  • Publication number: 20130008351
    Abstract: Embodiments disclose method and compositions that comprise cement kiln dust and rice husk ash. An embodiment comprises a method of cementing comprising: placing a settable composition into a subterranean formation, the settable composition comprising cement kiln dust, rice husk ash, and water; and allowing the settable composition to set. Another embodiment discloses a settable composition comprising cement kiln dust, rice husk ash, and water.
    Type: Application
    Filed: September 14, 2012
    Publication date: January 10, 2013
    Applicant: Halliburton Energy Services, Inc.
    Inventors: Craig W. Roddy, Jiten Chatterji, D. Chad Brenneis, Callie R. Jarratt
  • Publication number: 20120325477
    Abstract: An embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising unexpanded perlite, cement kiln dust, and water; and allowing the settable composition to set. Another embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising ground unexpanded perlite, Portland cement interground with pumicite, and water; and allowing the settable composition to set. Yet another embodiment of the present invention comprises a settable composition comprising: ground unexpanded perlite; cement kiln dust; and water.
    Type: Application
    Filed: September 7, 2012
    Publication date: December 27, 2012
    Applicant: HALLIBURTON ENERGY SERVICES, INC.
    Inventors: Chad Brenneis, Jeffery Karcher, Craig W. Roddy
  • Publication number: 20120325119
    Abstract: An embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising unexpanded perlite, cement kiln dust, and water; and allowing the settable composition to set. Another embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising ground unexpanded perlite, Portland cement interground with pumicite, and water; and allowing the settable composition to set. Yet another embodiment of the present invention comprises a settable composition comprising: ground unexpanded perlite; cement kiln dust; and water.
    Type: Application
    Filed: September 7, 2012
    Publication date: December 27, 2012
    Applicant: HALLIBURTON ENERGY SERVICES, INC.
    Inventors: Chad Brenneis, Jeffery Karcher, Craig W. Roddy
  • Patent number: 8329785
    Abstract: A wall repair compound useful for filling and repairing cracks, holes, and other imperfections in a wall surface includes a conventional filler material, a conventional binder material, and a dust reducing additive which reduces the quantity of airborne dust particles generated when sanding the hardened joint compound. Airborne dust reducing additives include oils, surfactants, solvents, waxes, and other petroleum derivatives. The additive can be added to conventional ready-mixed joint compounds and to setting type joint compounds. A method of reducing the quantity of airborne dust generated when sanding a fully hardened joint compound includes mixing a sufficient quantity of the dust reducing additive with the joint compound prior to when the joint compound has been applied to the wall.
    Type: Grant
    Filed: May 21, 2008
    Date of Patent: December 11, 2012
    Assignee: 3M Innovative Properties Company
    Inventor: Nathaniel P. Langford
  • Publication number: 20120167803
    Abstract: Methods of making particulates for use in a subterranean application comprising: providing particulates of a settable composition comprising a cementitious material, a filler material, and an activator of the cementitious material; and pre-curing the particulates until the particulates reach a crush strength of about 50 psi or greater; and curing the pre-cured particulates at a temperature in the range of about 230° F. to about 600° F., so that at least a portion of the particulates comprise a newly formed crystalline phase.
    Type: Application
    Filed: March 12, 2012
    Publication date: July 5, 2012
    Applicant: HALLIBURTON ENERGY SERVICES, INC.
    Inventors: Hongyu Luo, Lewis R. Norman, Ronald J. Powell, Rajesh K. Saini, Ashok K. Santra, Craig W. Roddy
  • Publication number: 20120152539
    Abstract: Methods and compositions are disclosed that comprise interground perlite and hydraulic cement. An embodiment provides a method of cementing comprising: providing a settable composition comprising perlite, hydraulic cement, and water, wherein the perlite and hydraulic cement are interground prior to combination with the water to form the settable composition; and allowing the settable composition to set.
    Type: Application
    Filed: July 11, 2011
    Publication date: June 21, 2012
    Applicant: HALLIBURTON ENERGY SERVICES, INC.
    Inventors: Jeffrey Karcher, Chad Brenneis, Craig W. Roddy, James R. Benkley
  • Publication number: 20120012029
    Abstract: Various embodiments of a high-performance environmentally friendly building panel and related manufacturing methods are disclosed. Certain example embodiments described herein relate to various high-performance building panel configurations that utilize at least one engineered mixture produced with a desired thickness, shape and dimension, and manufactured through several preferential manufacturing methods. To selectively enhance some of the high-performance building panel characteristics such as its ability to withstand significant loads, mitigate possible contamination by bacteria growth, as well as its ability to be fire-retardant or fire-suppressant, and other credible operating scenarios the characteristics of different engineered mixtures may be combined during the panel forming process.
    Type: Application
    Filed: September 26, 2011
    Publication date: January 19, 2012
    Applicant: Southern Cross Building Products, LLC
    Inventor: Rodrigo Vera
  • Patent number: 8057915
    Abstract: The acoustical product of the present invention comprises an acoustical product including a matrix of calcium sulfate dihydrate crystals and expanded perlite distributed throughout the matrix. The expanded perlite has a particle size distribution with at least 10% of the perlite having a particle diameter of 700 microns or more, and the amount of expanded perlite to calcium sulfate dihydrate is about 35% to about 75% by weight, based upon the dry weight of the calcium sulfate dihydrate. A dispersing agent and glass fibers having a particle length of about ¼ inch to about 1 inch are dispersed throughout the gypsum matrix.
    Type: Grant
    Filed: May 31, 2007
    Date of Patent: November 15, 2011
    Assignee: United States Gypsum Company
    Inventors: W. David Song, Mark H. Englert, Qiang Yu, Martin W. Brown, Richard B. Stevens
  • Patent number: 8038790
    Abstract: Structural cement panel for resisting transverse and shear loads equal to transverse and shear loads provided by plywood and oriented strain board, when fastened to framing for use in shear walls, flooring and roofing systems. The panels provide reduced thermal transmission compared to other structural cement panels. The panels employ one or more layers of a continuous phase resulting from curing an aqueous mixture of calcium sulfate alpha hemihydrate, hydraulic cement, coated expanded perlite particles filler, optional additional fillers, active pozzolan and lime. The coated perlite has a particle size of 1-500 microns, a median diameter of 20-150 microns, and an effective particle density (specific gravity) of less than 0.50 g/cc. The panels are reinforced with fibers, for example alkali-resistant glass fibers. The preferred panel contains no intentionally added entrained air. A method of improving fire resistance in a building is also disclosed.
    Type: Grant
    Filed: December 23, 2010
    Date of Patent: October 18, 2011
    Assignee: United States Gypsum Company
    Inventors: Ashish Dubey, Cesar Chan
  • Publication number: 20110139036
    Abstract: Light structural mortar compositions containing light loads, type II synthetic anhydrite and additives and methods for the production and use thereof are disclosed and described. Such compositions may be useful for application in ferro-cement constructive systems in order to provide thermal, acoustic and anti-seismic characteristics desirable for coating on interior and exterior walls and ceilings/roofs, as a substitution of cement-based mortar.
    Type: Application
    Filed: February 20, 2009
    Publication date: June 16, 2011
    Inventors: Rodrigo Lobo Morales, Patricio Miguel OFarrill González
  • Publication number: 20110100626
    Abstract: An embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising unexpanded perlite, cement kiln dust, and water; and allowing the settable composition to set. Another embodiment of the present invention comprises a method of cementing comprising: placing a settable composition into a well bore, the settable composition comprising ground unexpanded perlite, Portland cement interground with pumicite, and water; and allowing the settable composition to set. Yet another embodiment of the present invention comprises a settable composition comprising: ground unexpanded perlite; cement kiln dust; and water.
    Type: Application
    Filed: December 21, 2010
    Publication date: May 5, 2011
    Applicant: HALLIBURTON ENERGY SERVICES, INC.
    Inventors: Chad Brenneis, Jeffery Karcher, Craig W. Roddy
  • Publication number: 20100212549
    Abstract: The present invention concerns a method for preparing materials containing binder systems derived from amorphous silica and bases as well as the materials prepared by the method. Relative to known methods, the present invention allows for a continuous production of material as the two components of the binder are brought onto into contact where the binder system is to be applied. The product achieved by the invention has a broad range of applications, such as for construction materials, insulating materials, fire proof materials, reinforcement materials etc. The present invention also relates to a method for preparing materials containing binder systems derived from amorphous inorganic material and bases as well as the materials prepared by the method.
    Type: Application
    Filed: January 22, 2010
    Publication date: August 26, 2010
    Inventors: Kjeld HOLBEK, Erik Gydesen Sogaard
  • Publication number: 20100175590
    Abstract: A joint compound system includes a set-inhibited, pre-wetted, setting-type, ready-mix joint compound and a set initiator. The set-inhibited, pre-wetted, setting-type joint compound includes a ready-mixed, setting-type joint compound base with a calcium-free phosphate set preventing agent that impedes chemical hydration of a gypsum component of the setting-type joint compound. The joint compound base is free of calcium carbonate. The set initiator includes alum to reinitiate the chemical hydration reactions.
    Type: Application
    Filed: November 19, 2009
    Publication date: July 15, 2010
    Inventors: Richard B. Stevens, Charles J. Miller
  • Patent number: 7731792
    Abstract: Disclosed herein is a method for producing a recycled hardened material using waste gypsum. The method comprises treating acidic wastewater generated in the production of copper, zinc or titanium or the production of sodium hydroxide (caustic soda) and chlorine using saline water, with calcium hydroxide (slaked lime), so as to precipitate sludge, and mixing the precipitated sludge with pulp sludge ashes having pozzolanic properties.
    Type: Grant
    Filed: July 7, 2005
    Date of Patent: June 8, 2010
    Inventor: Jong-Won Park
  • Publication number: 20090130452
    Abstract: Wallboards, as well as other building materials, are produced by methods which use significantly reduced embodied energy, generating far less greenhouse gases when compared with the energy used to fabricate gypsum wallboard. A novel cementitious core, consisting in one embodiment of post-industrial waste such as slag and combined with pH modifiers, provides a controlled exothermic reaction to create a gypsum-wallboard-like core which can be wrapped in a selected material such as recycled paper and manufactured on a conveyor system to appear, weigh and handle similar to gypsum wallboard, but without the large amounts of energy required to make gypsum wallboard. The manufacturing process results in lower greenhouse gas emissions than the processes used to make gypsum wallboard.
    Type: Application
    Filed: March 31, 2008
    Publication date: May 21, 2009
    Inventors: Kevin Surace, Meredith Ware, Denise Hoover, Jiaping Han, Tiandan Chen
  • Publication number: 20090011207
    Abstract: Cementitious compositions and methods for making same, in which the cementitious compositions include 35-60 wt. % cementitious reactive powder (also termed Portland cement-based binder), 2-10 wt. % expanded and chemically coated perlite filler, 20-40 wt. % water, entrained air, and optional additives such as water reducing agents, chemical set-accelerators, and chemical set-retarders. In addition, the lightweight cementitious compositions may contain 0-25 wt. % on a wet basis secondary fillers such as expanded clay, shale aggregate, and pumice.
    Type: Application
    Filed: July 5, 2007
    Publication date: January 8, 2009
    Applicant: United States Gypsum Company
    Inventor: Ashish DUBEY
  • Publication number: 20080314295
    Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.
    Type: Application
    Filed: August 13, 2008
    Publication date: December 25, 2008
    Applicant: NOVA CHEMICALS INC.
    Inventors: Tricia Guevara, Michael T. Williams, David A. Cowan, John K. Madish, Kolapo Adelwale, Roger Moore, Mary Margaret Moore, Tobias Blain Hileman
  • Publication number: 20080299413
    Abstract: The acoustical product of the present invention comprises an acoustical product including a matrix of calcium sulfate dihydrate crystals and expanded perlite distributed throughout the matrix. The expanded perlite has a particle size distribution with at least 10% of the perlite having a particle diameter of 700 microns or more, and the amount of expanded perlite to calcium sulfate dihydrate is about 35% to about 75% by weight, based upon the dry weight of the calcium sulfate dihydrate. A dispersing agent and glass fibers having a particle length of about ¼ inch to about 1 inch are dispersed throughout the gypsum matrix.
    Type: Application
    Filed: May 31, 2007
    Publication date: December 4, 2008
    Inventors: W. David Song, Mark H. Englert, Qiang Yu, Martin W. Brown, Richard B. Stevens
  • Patent number: 7407996
    Abstract: A wall repair compound useful for filling and repairing cracks, holes, and other imperfections in a wall surface includes a conventional filler material, a conventional binder material, and a dust reducing additive which reduces the quantity of airborne dust particles generated when sanding the hardened joint compound. Airborne dust reducing additives include oils, surfactants, solvents, waxes, and other petroleum derivatives. The additive can be added to conventional ready-mixed joint compounds and to setting type joint compounds. A method of reducing the quantity of airborne dust generated when sanding a fully hardened joint compound includes mixing a sufficient quantity of the dust reducing additive with the joint compound prior to when the joint compound has been applied to the wall.
    Type: Grant
    Filed: February 17, 2006
    Date of Patent: August 5, 2008
    Assignee: 3M Innovative Properties Company
    Inventor: Nathaniel P. Langford
  • Patent number: 6936099
    Abstract: Low density joint compounds, and methods for their use are disclosed. Joint compounds comprising water, calcium carbonate, a foaming agent, and a rheology modification agent contain a plurality of stable air bubbles. Joint compounds can have densities of about 4 pounds per gallon to about 8 pounds per gallon. A presently prepared composition has a density of about 4.8 pounds per gallon. A presently preferred foaming agent is a polyether siloxane copolymer. A presently preferred rheology modification agent is poly(ethylene oxide). The joint compounds can comprise additional components such as perlite, mica, talc, preservatives, and latex.
    Type: Grant
    Filed: March 19, 2003
    Date of Patent: August 30, 2005
    Assignee: National Gypsum Properties, LLC
    Inventor: Amba Ayambem
  • Patent number: 6902614
    Abstract: A composition and method for treating a surface is described. In one embodiment, the composition comprises about 10% to 90% by weight of cement, about 10% to 90% by weight of plaster, about 0.01% to about 20% by weight of lime, and about 0% to about 30% by weight of perlite. In another embodiment, the composition comprises plaster, cement, perlite, lime, joint compound and water, wherein the plaster, cement, perlite, and lime are in a ratio of about 10-90: 10-90: 0-30: 0.01-20 by weight. In another embodiment, the composition is prepared by a method comprising: (a) providing a first mixture comprising plaster, cement, perlite, and lime; (b) converting the first mixture to a second mixture by a method selected from the group consisting of stirring the first mixture, passing the first mixture through a strainer, and milling the first mixture; and (c) mixing the second mixture with joint compound and water to obtain the composition.
    Type: Grant
    Filed: March 21, 2003
    Date of Patent: June 7, 2005
    Inventors: Slawomir Ratomski, Valerie Rodriguez, Vezen Wu
  • Patent number: 6881257
    Abstract: A machinable light weight sisal-based concrete structural building material and a method of making the same are disclosed. The material includes short sisal fibers in a range from about 22% (v/v) to about 33% (v/v); a cement in a range from about 12% (v/v) to about 22% (v/v); and perlite in a range from about 51% (v/v) to about 59% (v/v). The method includes the steps of mixing an amount of cement with an amount of perlite to form a solid mixture; adding water and mixing water with the solid mixture to form a sludge; adding an amount of sisal fibers and mixing the sisal fibers into the sludge to form an uniform final composition; and pouring the final composition into a mold and setting the final composition to a solid form structural building material. The produced structural building material can be machined, screwed, cut, and nailed.
    Type: Grant
    Filed: July 10, 2003
    Date of Patent: April 19, 2005
    Inventor: Seymour Beauboeuf
  • Patent number: 6846358
    Abstract: The present invention describes an improved building material composition, useful for example as a fire door core and to improved methods of making this composition. The building material of the present invention is prepared from an aqueous mixture of expanded perlite and a fast setting, cementitious composition consisting essentially of a hydraulic cement having (1) a Portland cement and (2) a calcium aluminate cement, which composition can be molded and shaped into a fire door core.
    Type: Grant
    Filed: April 25, 2003
    Date of Patent: January 25, 2005
    Assignee: Georgia-Pacific Gypsum, Inc.
    Inventor: Hubert C. Francis
  • Publication number: 20040182287
    Abstract: Low density joint compounds, and methods for their use are disclosed. Joint compounds comprising water, calcium carbonate, a foaming agent, and a rheology modification agent contain a plurality of stable air bubbles. Joint compounds can have densities of about 4 pounds per gallon to about 8 pounds per gallon. A presently prepared composition has a density of about 4.8 pounds per gallon. A presently preferred foaming agent is a polyether siloxane copolymer. A presently preferred rheology modification agent is poly(ethylene oxide). The joint compounds can comprise additional components such as perlite, mica, talc, preservatives, and latex.
    Type: Application
    Filed: March 19, 2003
    Publication date: September 23, 2004
    Applicant: NATIONAL GYPSUM PROPERTIES, LLC
    Inventor: Amba AYAMBEM
  • Publication number: 20030136306
    Abstract: The invention provides a poultice or sacrificial render comprising fibrous material and diatomaceous earth. Preferably, the ratio of fibre to diatomaceous earth is in the range 1:6 to 6:1 and the fibrous material contains relatively long fibres, such as would be obtained from the manufacturing or pulping of quality paper, for example fibres in the range 1 mm to 4 mm. The invention also provides a poultice mixture comprising fibre, diatomaceous earth and water and optional additives such as a binder or thickening agent and a biocide. The invention also provides a method of removing salt from a salt permeable object comprising the step of applying the poultice mixture to the salt permeable object.
    Type: Application
    Filed: January 30, 2003
    Publication date: July 24, 2003
    Inventor: Barrie David Cooper
  • Patent number: 6475275
    Abstract: A cement composition contains 35-85% by weight of a cement, 3-15% by weight of a clay, 1-50% by weight of an aggregate and/or a fibrous material, and 0.2-5% by weight of a high efficiency retarder. A benefit of the present invention is that equipment used to apply cement compositions need not be cleaned every night when used on a construction site.
    Type: Grant
    Filed: October 21, 1999
    Date of Patent: November 5, 2002
    Assignee: Isolatek International
    Inventors: Edward Nebesnak, Robert Ostertog
  • Patent number: RE42511
    Abstract: Bonded aggregate compositions such as concrete, concrete repair products, high temperature refractories, high temperature insulation and fire resistant insulation are made from an aqueous solution of phosphoric acid and a separate, storable dry mixture of suitable aggregate, monocalcium phosphate, and calcium in the form of calcium aluminate cement or calcium oxide. The proportion of wet to dry constituents is variable so as to select the working time and strength of the aggregate composition, typically on the order of ten to fifteen minutes. The mixture of the preferred dry constituents, and the binder to be mixed with the aggregate to yield the preferred dry mixture, are also disclosed.
    Type: Grant
    Filed: September 10, 2004
    Date of Patent: July 5, 2011
    Assignee: Stellar Materials Incorporated
    Inventors: Jean Tremblay, David Mintz, Neil Mintz