Plaster Board Making Patents (Class 156/39)
  • Patent number: 10464851
    Abstract: The present invention relates to a method for producing a gypsum-containing foamed prefabricated building material and to a gypsum-containing foamed prefabricated building material.
    Type: Grant
    Filed: April 25, 2014
    Date of Patent: November 5, 2019
    Assignee: BASF Construction Solutions GmbH
    Inventors: Uwe Gehrig, Klaus Möller, Michael Schinabeck, Martin Pichler, Joachim Pakusch, Ekkehard Jahns
  • Patent number: 10456771
    Abstract: There is provided an oil absorbent pad for cleaning oil on a surface having an oil absorbent body having an upper surface and a lower surface, the body being formed from fiber recovered from recycled tires, and at least one of the upper surface and the lower surface is an outermost layer of the oil absorbent pad.
    Type: Grant
    Filed: September 12, 2014
    Date of Patent: October 29, 2019
    Inventor: Wayne Bennett
  • Patent number: 10457027
    Abstract: 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: Grant
    Filed: August 4, 2015
    Date of Patent: October 29, 2019
    Assignee: CertainTeed Gypsum, Inc.
    Inventors: Robert J. Hauber, Gerald D. Boydston
  • Patent number: 10399904
    Abstract: A gypsum board composition was disclosed which comprises stucco, adhesive, water and additive for improving bonding, wherein the additive for improving bonding is shown in chemical formula as MIMII(OH)2(An?).mH2O, wherein MI is a divalent metal ion, MII is a trivalent metal ion, and An? is an interlayer anion, and wherein MI and MII are different metals. Also, a gypsum board made with the composition of the above and a method for using a compound shown in the aforesaid chemical formula were disclosed.
    Type: Grant
    Filed: December 18, 2015
    Date of Patent: September 3, 2019
    Assignee: SAINT-GOBAIN PLACO
    Inventors: Kane Ironside, Hao Song
  • Patent number: 10265937
    Abstract: A method for manufacturing a sandwich component includes applying at least one matrix material to the upper side and/or the underside of at least one material blank, and arranging the material blanks above one another and/or next to one another. At least two of the material blanks differ in design or matrix material may be applied in different ways along the upper side and/or underside thereof, or matrix material is applied in different ways to at least one of the material blanks along the upper side and/or underside thereof. In that way, at least one horizontal and/or vertical zone of the sandwich component is created having different mechanical properties than other regions of the sandwich component. The material blanks are then pressed to form the sandwich component.
    Type: Grant
    Filed: December 21, 2015
    Date of Patent: April 23, 2019
    Assignee: MAGNA STEYR Fahrzeugtechnik AG & Co KG
    Inventor: Guenter Wolfsberger
  • Patent number: 10239230
    Abstract: A slurry distribution system can include a feed conduit and a distribution conduit in fluid communication therewith. The feed conduit can include a first feed inlet and a second feed inlet disposed in spaced relationship thereto. The distribution conduit can extend generally along a longitudinal axis and include an entry portion and a distribution outlet in fluid communication therewith. The entry portion is in fluid communication with the first and second feed inlets of the feed conduit. The distribution outlet extends a predetermined distance along a transverse axis, which is substantially perpendicular to the longitudinal axis. The slurry distribution system can be placed in fluid communication with a gypsum slurry mixer adapted to agitate water and calcined gypsum to form an aqueous calcined gypsum slurry.
    Type: Grant
    Filed: April 10, 2017
    Date of Patent: March 26, 2019
    Assignee: United States Gypsum Company
    Inventors: Alfred Li, Chris C. Lee, Cesar Chan, Ronald E. Schenck, Weixin David Song, Curtis B. Loring, James R. Wittbold, William J. Rago, Christopher Robert Nelson
  • Patent number: 10195765
    Abstract: As a lower forming plate 8, a forming plate having: a lower plate main body 10 constituted from an electrically conductive material; and a lower embedded electrode 12 embedded in the lower plate main body 10, the lower embedded electrode 12 being electrically insulated from the lower plate main body 10 by an insulator 14 and being embedded so as for a portion thereof to be exposed on the surface of the lower plate main body 10 making contact with a lower lining paper sheet 16 is used.
    Type: Grant
    Filed: March 24, 2014
    Date of Patent: February 5, 2019
    Assignee: YOSHINO GYPSUM CO., LTD.
    Inventors: Tsuyoshi Yoshida, Akira Himeno, Tomohiro Noguchi
  • Patent number: 10112318
    Abstract: A pressing assembly (10) and a method for forming a depression (105) within a moving, wet gypsum board (100) is disclosed. The assembly comprises a pressing head (16) comprising a pressing surface which is arranged to contact the board, and a support member (17), the pressing head (16) being arranged to compress a portion of the board between the pressing surface and the support member (17) to form a depression (105) within the board (10). The pressing surface comprises a first and second surface portion (24, 25) separated by a relief portion (27), which is arranged to press the board (100) toward the support head (17) with less compressive force than the first and second surface portion (24, 25).
    Type: Grant
    Filed: December 13, 2012
    Date of Patent: October 30, 2018
    Assignee: Saint-Gobain Placo SAS
    Inventors: Remi Jean, Jean-Louis Mongrolle, Dariusz Drag, Richard Morlat
  • Patent number: 9834929
    Abstract: This disclosure relates to using polyester films on building boards to enable improved surface coatings. The polyester film is preferably applied to a glass mat via an adhesive to form a laminate. This laminate is then bonded to the exterior surface of a gypsum board. The polyester film is advantageous because it allows for exterior surface coatings to be applied. In one embodiment, an exterior acrylic coating is applied to the polyester film. Boards constructed in accordance with this disclosure allow for exterior finishings to be achieved without the need for excessive finishing materials or steps.
    Type: Grant
    Filed: January 13, 2014
    Date of Patent: December 5, 2017
    Assignee: Saint-Gobain Placo SAS
    Inventors: Gerald D. Boydston, Bryan J. Wiltzius, Choung-Houng Lai, Michael J. Lemberger
  • Patent number: 9809930
    Abstract: The invention relates to a papermaking agent system in liquid form, which comprises (i) cationic starch solution, prepared by cooking a starch mixture comprising a starch component and a water component, and (ii) polymer composition, which has anionic and cationic groups and a cationic net charge of >0.1 meq/g. The polymer composition comprises or originates from at least one of constituents a), b) or c). Constituent a) contains an amphoteric polymer, which is a copolymer comprising structural units derived from acrylamide and/or methacrylamide monomers, and anionic and cationic groups attached to the copolymer. Constituent b) contains a first polymer, which is a copolymer comprising structural units derived from acrylamide and/or methacrylamide monomers, and anionic or cationic groups attached to the copolymer, as well as a second polymer, which comprises groups with opposite charge than the first polymer.
    Type: Grant
    Filed: November 13, 2013
    Date of Patent: November 7, 2017
    Assignee: Kemira OYJ
    Inventors: Asko Karppi, Matti Hietaniemi, Marco Polverari
  • Patent number: 9802866
    Abstract: This invention provides low density gypsum products. This invention also provides a method of making the low density gypsum products.
    Type: Grant
    Filed: November 2, 2006
    Date of Patent: October 31, 2017
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Weixin David Song
  • Patent number: 9732003
    Abstract: Wax emulsions for the manufacture of wallboard include water; a lignosulfonic acid or a salt thereof; and at least one wax selected from the group consisting of slack wax, paraffin wax and montan wax. The emulsions may have a pH of between about 6.5 and 7.9. Such emulsions can provide enhanced moisture resistance to the wallboard.
    Type: Grant
    Filed: October 17, 2016
    Date of Patent: August 15, 2017
    Assignee: Henry Company LLC
    Inventors: Amba Ayambem, Kate Sproul, Alex Gonzalez
  • Patent number: 9670097
    Abstract: Wax emulsions for the manufacture of wallboard include water; a lignosulfonic acid or a salt thereof; and at least one wax selected from the group consisting of slack wax, paraffin wax and montan wax. The emulsions may have a pH of between about 6.5 and 7.9. Such emulsions can provide enhanced moisture resistance to the wallboard.
    Type: Grant
    Filed: June 2, 2014
    Date of Patent: June 6, 2017
    Assignee: Henry Company LLC
    Inventors: Amba Ayambem, Alex Gonzalez, Kate Sproul
  • Patent number: 9670665
    Abstract: A building material configured to enhance sound attenuation and reduction in dB across a walled partition, the building material comprising a facing membrane, a core matrix disposed about the facing membrane, the core matrix comprising a plurality of microparticles and a binder solution configured to support the microparticles, the building material comprising at least a substantially exposed face, wherein a side of the core matrix is at least partially exposed to increase sound attenuation by reducing reflections from sound waves impinging on the building material as compared to a control building material lacking an exposed face. Two building materials may be used in conjunction with one another about a building structure, such as a stud wall, to create and define a sound trap that functions to reduce sound transmission across the partition formed by the stud wall and building materials.
    Type: Grant
    Filed: May 26, 2015
    Date of Patent: June 6, 2017
    Assignee: Ashtech Industries, LLC
    Inventors: Michael D. Kipp, Dilworth L. Pugh, Michael D. Ridges, William T. McCarvill
  • Patent number: 9593046
    Abstract: The use of an adhesion-promoting additive combination composed of one or more polyalkylenoxides out of the group comprising polypropylene oxides and ethylene oxide-propylene oxide copolymers, and of one or more starch ether derivatives out of the group comprising carboxyalkyl starch ethers and their alkali salts, and hydroxyalkyl starch ethers, in mortar compositions comprising mineral binders and water-redispersible polymer powders.
    Type: Grant
    Filed: April 5, 2012
    Date of Patent: March 14, 2017
    Assignee: Wacker Chemie AG
    Inventors: Thomas Bastelberger, Reinhard Härzschel, Xi Zhang
  • Patent number: 9523198
    Abstract: A coalescing additive is used in the manufacturing process for gypsum wallboard. Such an additive increases the surface area and density of the slurry at the paper to core interface by coalescing the foam cells away from the paper core interface. This permits a stronger paper to core bond to form and increases the compressive strength of the gypsum wallboard as compared to standard wallboards made from slurries with reduced water levels.
    Type: Grant
    Filed: August 11, 2011
    Date of Patent: December 20, 2016
    Assignee: National Gypsum Properties, LLC
    Inventors: William C. Martin, Eli Stav, Matthew J. Plante, Maryn L. Heermann
  • Patent number: 9283732
    Abstract: Gypsum plaster board, containing a gypsum matrix and 0.1 to 10% by weight carbon particles, wherein the particle size (d50) of the carbon particles ranges from 0.5 to 4 mm.
    Type: Grant
    Filed: February 8, 2011
    Date of Patent: March 15, 2016
    Assignee: Knauf Gips KG
    Inventors: Hans-Ulrich Hummel, Lothar Scheller, Dietmar Stich
  • Patent number: 9096036
    Abstract: 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: Grant
    Filed: June 28, 2011
    Date of Patent: August 4, 2015
    Assignee: CertainTeed Gypsum, Inc.
    Inventors: Robert Joseph Hauber, Gerald D. Boydston
  • Publication number: 20150125683
    Abstract: A gypsum composition, board, and method of producing a gypsum board with increased fire endurance are described. The set gypsum-containing composition can be used to prepare a gypsum board having fire endurance, based on the inclusion of silica gel.
    Type: Application
    Filed: November 5, 2013
    Publication date: May 7, 2015
    Applicant: United States Gypsum Company
    Inventors: Bangji CAO, Weixin D. SONG, Alfred LI
  • Patent number: 9017495
    Abstract: Methods and a reinforcement fabric are disclosed for making a reinforced smooth cementitious board having a cement skin adjacent to an outer face, by depositing a reinforcement fabric and a layer of hydraulic cementitious material, one on the other, wherein the reinforcement fabric comprises an open mesh united with a thin, porous nonwoven web.
    Type: Grant
    Filed: November 10, 2010
    Date of Patent: April 28, 2015
    Assignee: Saint-Gobain ADFORS Canada, Ltd.
    Inventor: John Frederick Porter
  • Publication number: 20150068657
    Abstract: The present invention provides composite materials comprising a population of cellulose fibers complexed with an activator, and an additive comprising synthetic fibers complexed with a tethering agent, wherein the tethering agent has an affinity for the activator, and wherein an interaction between the tethering agent and the activator attaches the synthetic fibers to the cellulose fibers to form the composite material. The present invention also provides methods of manufacture for such composite materials, and methods for their use, for example in forming gypsum board composites.
    Type: Application
    Filed: May 29, 2014
    Publication date: March 12, 2015
    Applicant: Soane Labs, LLC
    Inventors: Gangadhar Jogikalmath, David S. Soane
  • Publication number: 20150024228
    Abstract: A cementitious product with strengthened composite structure is provided. Energy-efficient methods for manufacturing such products are provided as well and include dewatering a partially-set cementitious product by applying vacuum, and also creating a concentration gradient across the product thickness. Systems for manufacturing such products are provided as well.
    Type: Application
    Filed: July 1, 2014
    Publication date: January 22, 2015
    Inventors: Alfred Li, Ronald E. Schenck, Chris C. Lee
  • Patent number: 8882943
    Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.
    Type: Grant
    Filed: September 14, 2011
    Date of Patent: November 11, 2014
    Assignee: CertainTeed Gypsum, Inc.
    Inventors: John W. College, Shane Libunao, Mark Harris
  • Publication number: 20140302280
    Abstract: A gypsum panel that incorporates a plant fiber other than paper is disclosed. The plant fiber material may be in the form of a facing material adhered to at least one side of the gypsum panel or in the form of loose fibers integrated with the gypsum panel as a matrix or both. Further, the plant fiber may be combined with conventional gypsum panel additives, is fully recyclable and environmentally sustainable. The present invention further relates to a method of making such a gypsum panel.
    Type: Application
    Filed: April 25, 2012
    Publication date: October 9, 2014
    Inventors: Keshav S. Gautam, Samuel C. Baer, Hubert C. Francis, Micheal S. Lerch
  • Patent number: 8834145
    Abstract: Disclosed is a gypsum board forming device which provides improved slurry spread. The device includes a forming table with an arcuate or angled profile that promotes a uniform slurry spread. An arcuate or angled hinge plate can also be included to further promote the uniform distribution of slurry prior to an extrusion plate.
    Type: Grant
    Filed: April 25, 2012
    Date of Patent: September 16, 2014
    Assignee: CertainTeed Gypsum, Inc.
    Inventor: Michael P Fahey
  • Patent number: 8821685
    Abstract: 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: Grant
    Filed: August 1, 2012
    Date of Patent: September 2, 2014
    Assignee: Georgia-Pacific Gypsum LLC
    Inventor: Chad A. Frank
  • Publication number: 20140138007
    Abstract: A cementitious board system which is reinforced on its opposed surfaces by an improved glass fiber mesh scrim with thicker yarn and larger mesh openings to provide a cementitious board with improved handling properties while retaining tensile strength and long term durability. The fabric is constructed as a mesh of high modulus strands of bundled glass fibers encapsulated by alkali and water resistant material, e.g. a thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The fabric provides a board system with long-lasting, high strength tensile reinforcement and improved handling properties regardless of their spatial orientation during handling. Included as part of the invention are methods for making the reinforced board.
    Type: Application
    Filed: January 7, 2014
    Publication date: May 22, 2014
    Applicant: United States Gypsum Company
    Inventors: Ashish DUBEY, Yanfei PENG
  • Publication number: 20140113128
    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: Application
    Filed: October 2, 2013
    Publication date: April 24, 2014
    Applicant: United States Gypsum Company
    Inventors: Yijun SANG, Chris C. LEE, Cesar CHAN, Weixin David SONG
  • Publication number: 20140113124
    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).
    Type: Application
    Filed: March 15, 2013
    Publication date: April 24, 2014
    Applicant: UNITED STATES GYPSUM COMPANY
    Inventors: Yijun SANG, Weixin D. SONG
  • Patent number: 8685188
    Abstract: The present invention provides an apparatus and a method for fractionating gypsum slurry which can surely control the density of the gypsum slurry fractionated from the mixer (fractionated slurry), which can restrict change of the flow rate of the fractionated slurry, and which can reduce the consumption of foam or foaming agent. The fractionation apparatus (30) fractionates the gypsum slurry from a mixer (4) for mixing calcined gypsum and water. The mixer has a hollow connector section (50), which allows the gypsum slurry to flow from a mixing area inside of the mixer into a chute section (5), and the chute section (5) discharging the inflow of gypsum slurry through its slurry discharge port onto a gypsum board liner paper. The fractionation apparatus has a slurry fractionation port (33) opening to the chute section or the hollow connector section, and causes a part of the gypsum slurry in the chute or hollow connector section to be delivered to a slurry delivery conduit (11,13,19).
    Type: Grant
    Filed: September 12, 2003
    Date of Patent: April 1, 2014
    Assignee: Yoshino Gypsum Co., Ltd.
    Inventors: Yukio Yamaji, Shinobu Kaneko
  • Patent number: 8591677
    Abstract: A composition, utility material, and method of making a utility material is disclosed. A composition having an improved setting time may include a plurality of microparticles mixed with a sodium silicate binder and an isocyanate setting agent, where the microparticle composition has a setting time of less than or equal to one hour. A utility material may be a wallboard that includes the composition.
    Type: Grant
    Filed: November 4, 2009
    Date of Patent: November 26, 2013
    Assignee: Ashtech Industries, LLC
    Inventors: Michael D. Kipp, Dilworth L. Pugh, Michael D. Ridges, William T. McCarvill
  • Patent number: 8580055
    Abstract: Provided herein are mixtures, emulsions and other additives for use in manufacturing gypsum wallboard. The mixtures and emulsions may be wax-based emulsions or wax-free mixtures or emulsions, with wax-based emulsions including water; at least one wax, a dispersant which may include sulfur or a sulfur-containing group, and a particular wetting agent or surfactant. Mixtures may also be prepared including water, a dispersant, and a particular wetting agent or surfactant. Gypsum slurries may be prepared using such emulsions and mixtures.
    Type: Grant
    Filed: January 22, 2010
    Date of Patent: November 12, 2013
    Assignee: Henry Company LLC
    Inventors: Jonathan Stuart, Dennis Michael Mahoney, Ariel Lender, Norman Davies
  • Patent number: 8568544
    Abstract: A fibrous mat-faced cementitious article comprising (a) a cementitious core, and (b) a first fibrous mat comprising polymer or mineral fibers and a hydrophobic finish on at least one surface thereof, wherein the hydrophobic finish is in contact with the cementitious core, and a method of preparing a fibrous mat-faced cementitious article, as well as a method of preparing a water-resistant cementitious article comprising (a) preparing an aqueous siloxane dispersion, wherein the dispersion comprises about 4 wt. % to about 8 wt. % siloxane, (b) combining the siloxane dispersion with a cementitious mixture to provide a cementitious slurry, (c) depositing the cementitious slurry onto a substrate, and (d) allowing the cementitious slurry to harden, thereby providing a cementitious article.
    Type: Grant
    Filed: October 28, 2011
    Date of Patent: October 29, 2013
    Assignee: United States Gypsum Company
    Inventors: Dick C. Engbrecht, Qingxia Liu, Michael P. Shake, Xuming Wang, David Paul Miller, Michael L. Bolind, Paul Reed, Donald L. Roelfs, Rafael Bury
  • Patent number: 8530064
    Abstract: Disclosed is a method for inhibiting the growth of mold on building materials by application onto and/or incorporation into the building material of a mold-inhibiting composition comprising dehydroacetic acid or a salt thereof and, optionally, an additional fungicidal agent such as a quaternary ammonium compound. A preferred application of the method is the inhibition of mold growth on plasterboard (drywall).
    Type: Grant
    Filed: October 7, 2009
    Date of Patent: September 10, 2013
    Assignee: Lonza, Inc.
    Inventors: Xiao Jiang, Leigh Walker
  • Publication number: 20130216796
    Abstract: The present invention relates to non-combustible composite panels, comprising two outer layers (24) and a core (10, 16). Moreover, the invention provides a method for manufacturing of non-combustible composite panels. The amount of organic ingredients within the core, is reduced insofar as to allow for a heat of combustion adequate to reach non-flammability, whilst providing sufficient flexibility for the composite panel. Magnesium hydroxide is implemented within the core to obtain extraordinary flame retardation. In order to manufacture the inventive composite panels a continuous press (34) is utilised replacing extruders (14) known by the state of the art.
    Type: Application
    Filed: August 19, 2011
    Publication date: August 22, 2013
    Inventors: Eberhard Correa, Bertrand Koenig
  • Publication number: 20130209782
    Abstract: A utility material can include microparticles, an organic binder and an inorganic binder. The microparticles can be present in an amount from about 25 wt % to about 60 wt %, based on wet formulation. The inorganic binder can optionally include sodium silicate. The organic binder can optionally include a vinyl acetate. The utility material can be formed into a variety of different products or building materials, such as wallboard, shear panels. In addition, the building material may be particularly used to attenuate sound.
    Type: Application
    Filed: January 7, 2013
    Publication date: August 15, 2013
    Applicant: AshTech Industries LLC
    Inventor: AshTech Industries LLC
  • Patent number: 8475762
    Abstract: A method and apparatus for providing an evenly mixed additive enhanced gypsum slurry to a web. Calcined gypsum and water are inserted into a mixer through at least one inlet of the mixer. The contents are agitated to form a slurry. The slurry is passed from an outlet of the mixer into a conduit. An additive is introduced into the slurry along a length of the conduit to achieve a flow stream of a slurry/additive mixture. A cross section of the flow stream is expanded in the conduit while not changing direction of the flow stream and a direction of the flow stream is changed while not expanding the cross section of the flow stream and conduit, all prior to the flow steam exiting from an outlet of the conduit.
    Type: Grant
    Filed: June 2, 2011
    Date of Patent: July 2, 2013
    Assignee: United States Gypsum Company
    Inventors: Alfred Li, Chris C. Lee, Chris Nelson, Cesar Chan, Weixin David Song
  • Patent number: 8470461
    Abstract: The invention generally provides gypsum-containing slurries including stucco, naphthalenesulfonate dispersant, and pregelatinized starch. The naphthalenesulfonate dispersant is present in an amount of about 0.1%-3.0% by weight based on the weight of dry stucco. The pregelatinized starch is present in an amount of at least about 0.5% by weight up to about 10% by weight of pregelatinized starch by weight based on the weight of dry stucco in the formulation. Other slurry additives can include trimetaphosphate salts, accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, gypsum wallboard, and a method of making gypsum wallboard.
    Type: Grant
    Filed: June 11, 2012
    Date of Patent: June 25, 2013
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Weixin D. Song, Michael R. Lynn
  • Patent number: 8444787
    Abstract: Provided are methods and systems for introducing a wet gypsum accelerator or other high viscosity production additive to an aqueous dispersion of calcined gypsum in a discharge apparatus downstream of a stucco mixer in which the dispersion was prepared. These methods and systems are useful in the production of various gypsum products such as board including wallboard and ceiling tiles.
    Type: Grant
    Filed: August 11, 2011
    Date of Patent: May 21, 2013
    Assignee: United States Gypsum Company
    Inventors: James R. Wittbold, W. David Song
  • Patent number: 8445101
    Abstract: A building material configured to enhance sound attenuation and reduction in dB across a walled partition, the building material comprising a facing membrane, a core matrix disposed about the facing membrane, the core matrix comprising a plurality of microparticles and a binder solution configured to support the microparticles, the building material comprising at least a substantially exposed face, wherein a side of the core matrix is at least partially exposed to increase sound attenuation by reducing reflections from sound waves impinging on the building material as compared to a control building material lacking an exposed face. Two building materials may be used in conjunction with one another about a building structure, such as a stud wall, to create and define a sound trap that functions to reduce sound transmission across the partition formed by the stud wall and building materials.
    Type: Grant
    Filed: September 25, 2008
    Date of Patent: May 21, 2013
    Assignee: Ashtech Industries, LLC
    Inventors: Michael D. Kipp, Dilworth L. Pugh, Michael D. Ridges, William T. McCarvill
  • Patent number: 8413333
    Abstract: The present invention is a method of making a backerboard having a fiberglass mesh on one side, and an impervious reinforcement membrane on the other side. The backerboard incorporates a low density, high compressive strength concrete core having an upper principal surface and a lower principal surface. The upper principal surface of the core is covered by a fiberglass mesh reinforcement layer, itself covered and bonded to the core by a thin layer of Portland cement. The lower principal surface of the backerboard is covered with a high tensile strength, impervious reinforcement membrane.
    Type: Grant
    Filed: February 22, 2010
    Date of Patent: April 9, 2013
    Inventor: Jeff Dinkel
  • Publication number: 20130074737
    Abstract: A wallboard, a method of preparing a wallboard, and a method of making a gypsum slurry to prepare a wallboard are provided. The wallboard includes a set gypsum dihydrate derived substantially from a non-fibrous form of calcium sulfate and selected from the group consisting of anhydrous gypsum and gypsum hemihydrate. The wallboard also includes an aerogel dispersed in the gypsum dihydrate.
    Type: Application
    Filed: September 20, 2012
    Publication date: March 28, 2013
    Applicant: Georgia-Pacific Gypsum LLC
    Inventor: Georgia-Pacific Gypsum LLC
  • Patent number: 8388926
    Abstract: The present invention relates to a system and associated method for the production of gypsum in manufacturing plant. More specifically, the invention relates to the production of alpha-type gypsum in a gypsum board manufacturing plant. The system yields increased efficiencies by capturing heat given off during processing steps and using that heat to reduce the energy needed for calcination. The invention finds particular application in the production alpha-type gypsum. The present invention is described in greater detail hereinafter in conjunction with the following specific embodiments.
    Type: Grant
    Filed: June 6, 2011
    Date of Patent: March 5, 2013
    Assignee: CertainTeed Gypsum, Inc.
    Inventor: John W. College
  • Patent number: 8382923
    Abstract: A gypsum board forming device (10) constitutes an apparatus of producing gypsum boards. A layered formation of a lower sheet (1), an upper sheet (2) and a gypsum slurry (6) passes through a forming gate (40). The forming device forms the formation into a plate-like configuration with use of upper and lower plates (20, 30). The upper plate (20) is constituted from a fixed substrate plate (21) and a movable plate (22), and the movable plate is in surface-to-surface contact with the upper sheet of the layered formation. A plurality of actuators (50) is supported by the substrate plate. Each of the actuators applies an upward or downward load (P) to the movable plate locally for a local deformation of the movable plate owing to a deflection thereof. A gate size (T) is locally changed by displacement of the movable plate relative to the substrate plate.
    Type: Grant
    Filed: April 29, 2008
    Date of Patent: February 26, 2013
    Assignee: Yoshino Gypsum Co., Ltd.
    Inventors: Shoichi Okazaki, Takumi Hatanaka, Ken Hayase
  • Patent number: 8377199
    Abstract: A gypsum stucco composition comprising the following components finely divided; calcium sulphate hemihydrate in calcined solid beta crystalline form; and in intimate mixture with said finely divided calcium sulphate hemihydrate and mixed therewith no later than calcination to form the hemihydrate, a sulphate salt comprising at least one of ammonium sulphate and aluminium sulphate, in an amount such that when the stucco composition is mixed with water and allowed to set, the resulting set plaster has increased compressive strength, flexural strength and/or E-modulus compared to a set plaster produced from said finely divided calcium sulphate hemihydrate containing no said sulphate salt.
    Type: Grant
    Filed: April 11, 2008
    Date of Patent: February 19, 2013
    Assignee: BPB Limited
    Inventors: Cedric Biguenet, Sam O'Keefe, Agnès Smith, Thierry Chotard
  • Patent number: 8337993
    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: Grant
    Filed: March 31, 2008
    Date of Patent: December 25, 2012
    Assignee: Serious Energy, Inc.
    Inventors: Kevin Surace, Meredith Ware, Denise Hoover, Jiaping Han, Tiandan Chen
  • Patent number: 8323429
    Abstract: The present invention relates to a method for producing three-dimensional plaster objects via thin layer deposition. The inventive method comprises steps of depositing a layer of a calcium sulfate hemihydrate slurry onto the surface of a support in a predetermined pattern and activating the slurry with an activating agent so as to accelerate the setting reaction of calcium sulfate hemihydrate and water to form set calcium sulfate dihydrate. The depositing and activating steps can be repeated as necessary until the desired three-dimensional plaster object is formed.
    Type: Grant
    Filed: July 31, 2009
    Date of Patent: December 4, 2012
    Assignee: United States Gypsum Company
    Inventors: Salvatore C. Immordino, Lee K. Yeung
  • Patent number: 8317914
    Abstract: A building material product comprising a cementitious binder, an aggregate and cellulose reinforcing fibers wherein the cellulose reinforcing fibers have been treated with cationic or nonionic oil. The resulting fiber when included in a fiber cement composite results in improved deflection of the composite at peak loading as well as improved impact strength while maintaining overall board strength.
    Type: Grant
    Filed: May 29, 2009
    Date of Patent: November 27, 2012
    Assignee: Weyerhaeuer NR Company
    Inventors: Robert T Hamilton, David J O'Callaghan, Hugh West
  • Patent number: 8303709
    Abstract: The invention provides a set gypsum-containing product having increased resistance to permanent deformation and a method for preparing it comprising forming a mixture of a calcium sulfate material, water, and an appropriate amount of one or more enhancing materials chosen from condensed phosphoric acids, each of which comprises 2 or more phosphoric acid units; and salts or ions of condensed phosphates, each of which comprises 2 or more phosphate units. The mixture is then maintained under conditions sufficient for the calcium sulfate material to form a set gypsum material.
    Type: Grant
    Filed: February 1, 2012
    Date of Patent: November 6, 2012
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Steven W. Sucech, Brent E. Groza, Raymond J. Mlinac, Frederick T. Jones, Paul J. Henkels
  • Patent number: 8298332
    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: Grant
    Filed: October 27, 2011
    Date of Patent: October 30, 2012
    Assignee: United States Gypsum Company
    Inventor: Ashish Dubey