Plaster Board Making Patents (Class 156/39)
-
Patent number: 12152385Abstract: Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel.Type: GrantFiled: July 21, 2023Date of Patent: November 26, 2024Assignee: Gold Bond Building Products, LLCInventors: Eli Stav, Joseph J. Bailey, Bradley G. Busche, Brian G. Randall
-
Patent number: 12071376Abstract: Gypsum board having improved performance is obtained by controlling the distribution of starch in the gypsum core of the board and the gelling temperature of the starch. Starch migration in the board is controlled by the degree of acid-modification, to adjust the starch viscosity profile. The starch gelling temperature is controlled by chemical modification of the starch —OH groups.Type: GrantFiled: May 22, 2023Date of Patent: August 27, 2024Assignee: Gold Bond Building Products, LLCInventors: Eli Stav, Ma-Ikay Miatudila
-
Patent number: 12012361Abstract: A geopolymer cement and a method of producing the same are provided. A geopolymer cement binder may be provided including a geopolymer precursor and magnesium oxide as an alkali activator. The geopolymer cement binder may be mixed with water using high shear mixing.Type: GrantFiled: October 5, 2020Date of Patent: June 18, 2024Assignee: PREMIER MAGNESIA, LLCInventors: Jerry Elliot Rademan, Mark A. Shand, John Kirin Gehret, Peyton Pool, Sr.
-
Patent number: 11891336Abstract: Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains at least one set gypsum layer sandwiched between two cover sheets. The set gypsum layer is formed from at least stucco and water. The stucco material generally includes a high salt impurity content, for example, when the stucco is calcined from certain sources of low-quality synthetic gypsum. For example, in some embodiments, the salts are chloride salts, e.g., sodium chloride (NaCl), potassium chloride (KCl), magnesium chloride (MgCl2), and/or calcium chloride (CaCl2)). At least one of the cover sheets is composed of high absorption paper, which enhances the bond between the set gypsum layer and the cover sheet.Type: GrantFiled: June 18, 2020Date of Patent: February 6, 2024Assignee: United States Gypsum CompanyInventors: Qinghua Li, Mark K. Hemphill
-
Patent number: 11834375Abstract: Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains a set gypsum core sandwiched between two cover sheets. The core is formed from a slurry containing stucco, water, and optional ingredients such as foaming agent, accelerator, retarder, polyphosphate, starch, and dispersant, and core intumescent material. The board also contains at least one skim coat and/or hard edges. A face skim coat layer can be included on one side of the core, facing a face cover sheet. A back skim coat layer can be included on the other side of the core, facing a back cover sheet. Hard edges are known in the art and can be formed, e.g., continuously from a stucco slurry for forming the face and/or back skim coats. Preferably, the back skim coat layer and/or the hard edges are formed from a slurry containing stucco, water, skim coat or edge intumescent material (which have the same desired characteristics), and other optional additives as desired.Type: GrantFiled: January 22, 2021Date of Patent: December 5, 2023Assignee: United States Gypsum CompanyInventors: Qinghua Li, Mark K. Hemphill, Naveen Punati
-
Patent number: 11787739Abstract: Disclosed is an acid-modified flour and a method of making the acid-modified flour. The acid-modified flour is desirably prepared using a dry milling process. A starting flour is combined with a strong acid to form a mixture. The mixture is heated. A neutralizer is added to increase the pH of the mixture. If desired, the mixture can be dried and any agglomerates can be removed. The acid-modified flour can be used as a binder in a slurry for preparing one or more gypsum layers in a gypsum board.Type: GrantFiled: September 18, 2020Date of Patent: October 17, 2023Assignee: United States Gypsum CompanyInventors: Yijun Sang, Mark Hemphill
-
Patent number: 11772372Abstract: The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board, and a method of making such gypsum board. For instance, the method comprises: providing a first encasing layer and a first sound damping layer on the first encasing layer wherein the sound damping layer includes at least 50 wt. % of a first sound damping polymer; depositing a gypsum slurry comprising stucco and water on the sound damping layer to form a gypsum core; providing a second encasing layer on the gypsum slurry; and allowing the stucco to convert to calcium sulfate dihydrate.Type: GrantFiled: June 4, 2021Date of Patent: October 3, 2023Assignee: Gold Bond Building Products, LLCInventors: Joseph J. Bailey, Richard Weir, R. G. Iyer, Eli Stav, Bradley J. Busche
-
Patent number: 11559968Abstract: The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board. The gypsum board comprises a gypsum core including gypsum and a sound damping polymer. The gypsum core includes a first gypsum layer surface and a second gypsum layer surface opposing the first gypsum layer surface. In addition, a first encasing layer is disposed on the first gypsum layer surface and a second encasing layer is disposed on the second gypsum layer surface.Type: GrantFiled: December 6, 2019Date of Patent: January 24, 2023Assignee: Gold Bond Building Products, LLCInventors: Joseph J. Bailey, Eli Stav, Richard Weir, R. G. Iyer
-
Patent number: 11220783Abstract: The object of the invention is the use of an aqueous dispersion of a vinylacetate-ethylene-copolymer and of at least one polyethylene imine as a binder in a carpet coating composition for the production of carpets.Type: GrantFiled: November 9, 2016Date of Patent: January 11, 2022Assignee: Wacker Chemie AGInventors: Timo Melchin, Gerhard Kögler, Holger Künstle
-
Patent number: 11186067Abstract: Gypsum boards formed from synthetic gypsum and other gypsum sources having high chloride salt concentrations. Gypsum boards may include a board core including set gypsum. A total concentration of the chloride anion in the board core ranges from about 500 ppm to about 3000 ppm, typically about 1000 ppm to about 3000 ppm, based on weight of the calcium sulfate hemihydrate. An inner surface of a front paper cover sheet contacts a first face of the board core. An inner surface of a back paper cover sheet contacts a second face of the board core. A starch layer coats the inner surface of at least one of the front and back cover sheet. Methods of making the gypsum board, and a wall system for employing the gypsum boards, are also provided.Type: GrantFiled: May 2, 2019Date of Patent: November 30, 2021Assignee: UNITED STATES GYPSUM COMPANYInventors: Qinghua Li, Runhai Lu, Charles W. Cochran, Mark Hemphill
-
Patent number: 11136757Abstract: Gypsum panels and methods of making the same are provided. A gypsum panel includes a gypsum core containing set gypsum and unexpanded perlite ore, wherein the unexpanded perlite ore is present in the gypsum core in an amount greater than any other component, other than the gypsum.Type: GrantFiled: August 30, 2019Date of Patent: October 5, 2021Assignee: Georgia-Pacific Gypsum LLCInventors: Yongan Yuan, Stuart Brandon Gilley, Bryan Wiltzius
-
Patent number: 10464851Abstract: 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: GrantFiled: April 25, 2014Date of Patent: November 5, 2019Assignee: BASF Construction Solutions GmbHInventors: Uwe Gehrig, Klaus Möller, Michael Schinabeck, Martin Pichler, Joachim Pakusch, Ekkehard Jahns
-
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
-
Patent number: 10456771Abstract: 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: GrantFiled: September 12, 2014Date of Patent: October 29, 2019Inventor: Wayne Bennett
-
Patent number: 10399904Abstract: 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: GrantFiled: December 18, 2015Date of Patent: September 3, 2019Assignee: SAINT-GOBAIN PLACOInventors: Kane Ironside, Hao Song
-
Patent number: 10265937Abstract: 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: GrantFiled: December 21, 2015Date of Patent: April 23, 2019Assignee: MAGNA STEYR Fahrzeugtechnik AG & Co KGInventor: Guenter Wolfsberger
-
Patent number: 10239230Abstract: 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: GrantFiled: April 10, 2017Date of Patent: March 26, 2019Assignee: United States Gypsum CompanyInventors: 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: 10195765Abstract: 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: GrantFiled: March 24, 2014Date of Patent: February 5, 2019Assignee: YOSHINO GYPSUM CO., LTD.Inventors: Tsuyoshi Yoshida, Akira Himeno, Tomohiro Noguchi
-
Patent number: 10112318Abstract: 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: GrantFiled: December 13, 2012Date of Patent: October 30, 2018Assignee: Saint-Gobain Placo SASInventors: Remi Jean, Jean-Louis Mongrolle, Dariusz Drag, Richard Morlat
-
Patent number: 9834929Abstract: 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: GrantFiled: January 13, 2014Date of Patent: December 5, 2017Assignee: Saint-Gobain Placo SASInventors: Gerald D. Boydston, Bryan J. Wiltzius, Choung-Houng Lai, Michael J. Lemberger
-
Patent number: 9809930Abstract: 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: GrantFiled: November 13, 2013Date of Patent: November 7, 2017Assignee: Kemira OYJInventors: Asko Karppi, Matti Hietaniemi, Marco Polverari
-
Patent number: 9802866Abstract: This invention provides low density gypsum products. This invention also provides a method of making the low density gypsum products.Type: GrantFiled: November 2, 2006Date of Patent: October 31, 2017Assignee: United States Gypsum CompanyInventors: Qiang Yu, Weixin David Song
-
Patent number: 9732003Abstract: 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: GrantFiled: October 17, 2016Date of Patent: August 15, 2017Assignee: Henry Company LLCInventors: Amba Ayambem, Kate Sproul, Alex Gonzalez
-
Patent number: 9670665Abstract: 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: GrantFiled: May 26, 2015Date of Patent: June 6, 2017Assignee: Ashtech Industries, LLCInventors: Michael D. Kipp, Dilworth L. Pugh, Michael D. Ridges, William T. McCarvill
-
Patent number: 9670097Abstract: 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: GrantFiled: June 2, 2014Date of Patent: June 6, 2017Assignee: Henry Company LLCInventors: Amba Ayambem, Alex Gonzalez, Kate Sproul
-
Patent number: 9593046Abstract: 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: GrantFiled: April 5, 2012Date of Patent: March 14, 2017Assignee: Wacker Chemie AGInventors: Thomas Bastelberger, Reinhard Härzschel, Xi Zhang
-
Patent number: 9523198Abstract: 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: GrantFiled: August 11, 2011Date of Patent: December 20, 2016Assignee: National Gypsum Properties, LLCInventors: William C. Martin, Eli Stav, Matthew J. Plante, Maryn L. Heermann
-
Patent number: 9283732Abstract: 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: GrantFiled: February 8, 2011Date of Patent: March 15, 2016Assignee: Knauf Gips KGInventors: Hans-Ulrich Hummel, Lothar Scheller, Dietmar Stich
-
Patent number: 9096036Abstract: 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: June 28, 2011Date of Patent: August 4, 2015Assignee: CertainTeed Gypsum, Inc.Inventors: Robert Joseph Hauber, Gerald D. Boydston
-
Publication number: 20150125683Abstract: 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: ApplicationFiled: November 5, 2013Publication date: May 7, 2015Applicant: United States Gypsum CompanyInventors: Bangji CAO, Weixin D. SONG, Alfred LI
-
Patent number: 9017495Abstract: 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: GrantFiled: November 10, 2010Date of Patent: April 28, 2015Assignee: Saint-Gobain ADFORS Canada, Ltd.Inventor: John Frederick Porter
-
Publication number: 20150068657Abstract: 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: ApplicationFiled: May 29, 2014Publication date: March 12, 2015Applicant: Soane Labs, LLCInventors: Gangadhar Jogikalmath, David S. Soane
-
Publication number: 20150024228Abstract: 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: ApplicationFiled: July 1, 2014Publication date: January 22, 2015Inventors: Alfred Li, Ronald E. Schenck, Chris C. Lee
-
Patent number: 8882943Abstract: 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: GrantFiled: September 14, 2011Date of Patent: November 11, 2014Assignee: CertainTeed Gypsum, Inc.Inventors: John W. College, Shane Libunao, Mark Harris
-
Publication number: 20140302280Abstract: 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: ApplicationFiled: April 25, 2012Publication date: October 9, 2014Inventors: Keshav S. Gautam, Samuel C. Baer, Hubert C. Francis, Micheal S. Lerch
-
Patent number: 8834145Abstract: 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: GrantFiled: April 25, 2012Date of Patent: September 16, 2014Assignee: CertainTeed Gypsum, Inc.Inventor: Michael P Fahey
-
Patent number: 8821685Abstract: 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: GrantFiled: August 1, 2012Date of Patent: September 2, 2014Assignee: Georgia-Pacific Gypsum LLCInventor: Chad A. Frank
-
Publication number: 20140138007Abstract: 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: ApplicationFiled: January 7, 2014Publication date: May 22, 2014Applicant: United States Gypsum CompanyInventors: Ashish DUBEY, Yanfei PENG
-
Publication number: 20140113128Abstract: 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: ApplicationFiled: October 2, 2013Publication date: April 24, 2014Applicant: United States Gypsum CompanyInventors: Yijun SANG, Chris C. LEE, Cesar CHAN, Weixin David SONG
-
Publication number: 20140113124Abstract: 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: ApplicationFiled: March 15, 2013Publication date: April 24, 2014Applicant: UNITED STATES GYPSUM COMPANYInventors: Yijun SANG, Weixin D. SONG
-
Patent number: 8685188Abstract: 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: GrantFiled: September 12, 2003Date of Patent: April 1, 2014Assignee: Yoshino Gypsum Co., Ltd.Inventors: Yukio Yamaji, Shinobu Kaneko
-
Patent number: 8591677Abstract: 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: GrantFiled: November 4, 2009Date of Patent: November 26, 2013Assignee: Ashtech Industries, LLCInventors: Michael D. Kipp, Dilworth L. Pugh, Michael D. Ridges, William T. McCarvill
-
Patent number: 8580055Abstract: 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: GrantFiled: January 22, 2010Date of Patent: November 12, 2013Assignee: Henry Company LLCInventors: Jonathan Stuart, Dennis Michael Mahoney, Ariel Lender, Norman Davies
-
Patent number: 8568544Abstract: 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: GrantFiled: October 28, 2011Date of Patent: October 29, 2013Assignee: United States Gypsum CompanyInventors: 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: 8530064Abstract: 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: GrantFiled: October 7, 2009Date of Patent: September 10, 2013Assignee: Lonza, Inc.Inventors: Xiao Jiang, Leigh Walker
-
Publication number: 20130216796Abstract: 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: ApplicationFiled: August 19, 2011Publication date: August 22, 2013Inventors: Eberhard Correa, Bertrand Koenig
-
Publication number: 20130209782Abstract: 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: ApplicationFiled: January 7, 2013Publication date: August 15, 2013Applicant: AshTech Industries LLCInventor: AshTech Industries LLC
-
Patent number: 8475762Abstract: 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: GrantFiled: June 2, 2011Date of Patent: July 2, 2013Assignee: United States Gypsum CompanyInventors: Alfred Li, Chris C. Lee, Chris Nelson, Cesar Chan, Weixin David Song
-
Patent number: 8470461Abstract: 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: GrantFiled: June 11, 2012Date of Patent: June 25, 2013Assignee: United States Gypsum CompanyInventors: Qiang Yu, Weixin D. Song, Michael R. Lynn
-
Patent number: 8444787Abstract: 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: GrantFiled: August 11, 2011Date of Patent: May 21, 2013Assignee: United States Gypsum CompanyInventors: James R. Wittbold, W. David Song