Abstract: To provide a manufacturing method and a manufacturing device for a peeling member capable of manufacturing the peeling member having less variation in quality and excellent durability for long-time use at a low cost with excellent productivity by a simple structure. The manufacturing method for the peeling member includes sticking a non-adhesive resin film. In sticking the non-adhesive resin film, a distal end edge 2b of a distal end portion 2a of a base material 2 is arranged at a side of an adhesive layer of a non-adhesive resin film 4 such that an end portion of the non-adhesive resin film 4 is protruded from the distal end edge 2b, and then the non-adhesive resin film 4 is stuck on both surfaces of the distal end portion 2a of a base material 2 to wrap the distal end edge 2b of the base material 2 by pressing a plurality rollers 21 to 25 sequentially onto the non-adhesive resin film 4 from an one side end portion toward an another side end portion in a longitudinal direction of the base material 2.

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.

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.

Abstract: A method for producing insulation tape. A strip of fabric is provided and a layer of insulation powder material is deposited onto the fabric. The fabric is folded over the insulation powder to form insulation tape that may be wrapped around pipes. The method of folding the fabric includes first bending the fabric into a trough shape that has a bottom portion and lateral upstanding flaps that terminate in lateral edges. The insulation powder may be deposited onto the bottom portion of the trough. The insulation powder is packed onto the bottom portion. Tape with adhesive on both sides is placed on one of the flaps so that when the flaps are folded in overlapping contact over the insulation powder the powder is enclosed and the flaps remain secured to each other. Stitching may be added to further secure the adhered flaps to each other and to the bottom portion.

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.

Abstract: A gypsum board corner assembly is formed with an integrated reinforcement strip. The strip may be a folded sheet-metal strip or a thin rod. First, a gypsum board is formed with a groove that extends substantially through the entire gypsum core, but leaves the laminate paper of one side. Then a reinforcement insert is placed in the groove. Here, the insert is formed of or includes ferromagnetic material. The insert is subjected to a magnetic field to pull the insert into the groove, by action of the magnet. After an amount of adhesive is applied in the groove, the gypsum board is folded along the groove while the insert is being pulled into the groove by the magnet. The resulting gypsum board corner assembly has a very accurately placed insert that defines a straight corner edge thereof.

Abstract: A gypsum board corner assembly is formed with an integrated reinforcement strip. The strip may be a folded sheet-metal strip or a thin rod. First, a gypsum board is formed with a groove that extends substantially through the entire gypsum core, but leaves the laminate paper of one side. Then a reinforcement insert is placed in the groove. Here, the insert is formed of or includes ferromagnetic material. The insert is subjected to a magnetic field to pull the insert into the groove, by action of the magnet. After an amount of adhesive is applied in the groove, the gypsum board is folded along the groove while the insert is being pulled into the groove by the magnet. The resulting gypsum board corner assembly has a very accurately placed insert that defines a straight corner edge thereof.

Abstract: A masonry flashing is disclosed having a polymeric membrane and a pressure-activated adhesive in a peel-and-stick product. The flashing is used in cavity walls, typically a wall with an inner wythe of masonry block and an outer wythe of brick. The adhesive layer is a hot melt with various additives, which additives provide reinforcement to the flashing structure. The reinforcement can be fiber glass or filamentous fragments of polypropylene that are admixed into the adhesive. The flashing has a release sheet and, after removal thereof, the adhesive is pressed against the rough surface of the masonry block creating a durable bond with the inner wythe. Incorporated into the masonry flashing are various high-strength, polymeric webs including a spun-bonded polyolefin, an ethylene propylene diene terpolymer, and a polyvinylchloride with an ethylene interpolymer.

Abstract: A system and method of making a plaster panel to use in the construction of a wall of a building in a relatively faster, easier, more efficient, and more precise manner for either interior or exterior walls is disclosed. The created plaster panels may include a slab of cementitious composition including a mixture of sizes of cut expanded polystyrene, a quantity of monofilament fiber, and a binding agent. At least one layer of a mesh may surround the slab, wherein the resulting panel is light in weight, flexible and strong. Such panels may be fixed in place to a building frame by suitable fasteners such as nails or screws, while causing little or no fracturing of the panel.

Abstract: A gypsum board comprises a set gypsum layer having a first face and a second face. A fibrous mat is affixed to at least one of the faces. The mat comprises a non-woven web bonded together with a resinous binder. The web comprises a blend of a major portion composed of chopped continuous glass fibers having an average fiber diameter ranging from about 8 to 17 ?m and a minor portion composed of fine staple fibers having an average fiber diameter of less than about 5.5 ?m, the minor portion comprising about 1-30 percent of the dry weight of the web. The board is exceedingly durable. It has a smooth surface that is readily finished in an aesthetically pleasing way, using paint or other wall covering systems.

Abstract: A method of continuously forming a multilayer panel includes making a gypsum slurry, then dividing the gypsum slurry into at least a primary gypsum slurry and a secondary gypsum slurry. An additive slurry having water and an intumescent material is created, then added to the secondary gypsum slurry to make an expandable layer slurry that is spread over at least a portion of a facing material. The primary gypsum slurry is distributed over the secondary gypsum slurry over the facing material and the expanding layer slurry to form a core. Optionally, another layer, an edge coating, is applied to the expanding layer for additional fire protection. The edge coating includes a second intumescent material. During a fire, the expanding layer expands to increase the thickness of the fire exposed gypsum panel and the edge coating expands to seal the gap between adjoining gypsum panels.

Abstract: A weatherproofing backer for installing windows and doors is described as having a foam layer and an adhesive layer. The adhesive is pressure-activated and is self-sealing about attaching hardware. The foam is self-setting and, in use, molds to the flange of the window unit. When installed, the foam layer is compressed between the inner window frame and rough opening and between the window flange and the wall surface adjacent the rough opening. The weatherproofing backer is designed to extend beyond the flange of the window unit and thereby receive the weatherproofing membrane thereover. The weatherproofing backer, then acts as a sealed bridge between the membrane and the window unit precluding entry of air and water. Both the foam and the adhesive have fire retardants in the formulation thereof. A tape form with a self-skinned foam layer and a sheet form, with polymeric covering web are provided.

Abstract: Methods and systems are provided for preparing a heat resistance accelerator (HRA) slurry. Also provided are methods and systems for introducing a HRA slurry 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.

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.

Abstract: There is provided a lightweight plaster board having a cellular porous plaster core, excellent in adhesion to a covering base paper for a plaster board, free from dry-out in side edge parts of the plaster board, and with no disadvantage in workability for driving a nail into the plaster board. The plaster board includes a plaster core having a front surface, a back surface, and four side surfaces, and at least one covering base paper that covers the front surface, the back surface, and the at least two opposite side surfaces of the plaster core.

Abstract: A production line for producing sheets based on hydraulic binder, the production line including in an upstream zone of the production line, marking device for marking a facing material of the preform with a mark; in a downstream zone of the production line, detecting device for detecting the mark made by the marking device; a cutting device; and an actuating device for actuating said cutting device after receiving a detection signal from the detection device.

Abstract: The method of forming pleated filter media includes providing a generally planar web of filter material, folding the web to form a pleated web having a plurality of fold lines, arranging the plurality of pleats in a first spaced configuration defined by a first distance between adjacent pleat tips, applying a continuous strand of adhesive to the web, and adjusting the arrangement of the plurality of pleats into a second spaced configuration defined by a second distance between adjacent pleat tips. The web has a front face and a rear face. Each fold line is intermediate oppositely sloping first and second wall surfaces. The plurality of fold lines form a plurality of pleats having a first plurality of pleat tips and a second plurality of pleat valleys. The second distance is different from the first distance.

Abstract: An apparatus and method for applying reference or grid markings to wallboard during the manufacturing process is disclosed. Reference or grid markings are applied to one sheet of cover paper at a location between the originating cover paper rolls and the cover paper creaser or creasers. This is accomplished by locating and aligning multiple print heads across the width of the continuously passing cover paper, such that markings are ejected onto the cover paper in a specific and coordinated fashion. In addition to using any suitable commercially-available computer equipment to coordinate printer head activity, this function is accomplished by attaching each print head to a common horizontal support element and provide individual adjustments that are perpendicular to, and with the directional flow of the passing cover paper.

Abstract: Gypsum board having inorganic fiber, preferably glass fiber, preferably glass fiber, includes providing face sheets which have been completely impregnated with a gypsum slurry so as to penetrate through said random interstices between the inorganic fibers and to thereby cover the board surfaces with gypsum slurry. The gypsum board product is formed by passing the wet gypsum board through a board forming station having double forming plates, an upper forming plate having at least a portion thereof being set at a predetermined angle relative to a lower forming plate and having a separation between the forming plates defining a predetermined dimension substantially equal to the desired thickness of the manufactured gypsum board product. The method provides a multilayer gypsum board having a polymeric compound added to unset gypsum so as to provide a gypsum board ready for finishing.

Abstract: An apparatus and method for applying reference or grid markings to wallboard during the manufacturing process is disclosed. Reference or grid markings are applied to one sheet of cover paper at a location between the originating cover paper rolls and the cover paper creaser or creasers. This is accomplished by locating and aligning multiple print heads across the width of the continuously passing cover paper, such that markings are ejected onto the cover paper in a specific and coordinated fashion. In addition to using any suitable commercially-available computer equipment to coordinate printer head activity, this function is accomplished by attaching each print head to a common horizontal support element and provide individual adjustments that are perpendicular to, and with the directional flow of the passing cover paper.

Abstract: A method is provided for continuous production of gypsum boards which comprises forming a laminate of gypsum slurry between a facing paper and a backing paper and continuously forming a longitudinal recess along the side edges of the laminate surface, and a lateral recess at spaced intervals on the laminate surface thereby producing a four-tapered edge gypsum board which is uniquely suitable as a material of construction in the building industry.

Abstract: An applicator 16 is used to apply a label 10 to a shaped CD ROM (not shown). The applicator 16 comprises a central projection 18 and peripheral locator pins 20a and 20b, as well as a well 22 in which to receive a shaped CD ROM. A label is secured to a CD ROM held in the well 22 by placing locator tabs of the label over the locator pins 20a and 20b to ensure correct relative location of the CD ROM and the label.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

Abstract: A reinforced plasterboard has a first layer of paper, a core of a cementitious material, a mesh reinforcement and adjacent to that mesh reinforcement a further layer of paper. The mesh may be in contact with the paper layer.

Abstract: A cementitious panel comprising a cementitious core which is fabric-reinforced at the surface thereof and whose longitudinal edges are reinforced by a network of fibers. A panel may be obtained wherein the surface edge reinforcement layers are relatively strong and hard such that a nail or screw may be driven through the edge of panel without pre-drilling and without breaking, even when nailed or screwed almost at the very limit of the edge of the panel. Such a panel may provide a long lasting substrate for humid or wet areas such as shower rooms and bath rooms.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

Abstract: There is disclosed a hybrid laminate comprising: a substrate layer containing a compact of first powder; and a functional material layer being in contact with the substrate layer and containing a compact of second powder; wherein the compact of the first powder comprises a glass material; the compact of the second powder comprises a ceramic material having at least one specific electric property selected from dielectricity, magnetism, resistivity and insulation; at least a part of the first powder is in a sintered state; and the second powder is in an unsintered state and is bonded together by diffusion or a flow of a part of the material of the substrate layer into the functional material layer.

Abstract: A wood veneer laminated gypsum board comprises a gypsum core and lamination f a paper or a paper-like outer layer on both sides, an aluminum backed wood veneer bonded to the paper outer layer, and debossed designs on the wood veneer which penetrates beyond the surface of the gypsum board. The wood veneer laminated gypsum board is formed by spraying or applying a mixture of adhesive diluted with liquid softening agent, which may include water or water mixed with other materials, on the aluminum side of the aluminum-backed wood veneer. The paper or paper-like outer covering is lightly sprayed or coated with the softening agent. The coated aluminum backed wood veneer is placed on the lightly coated the gypsum board. The wood veneer is moistened with water. The wood veneer and the gypsum board is pressed with application of heat for a predetermined period.

Abstract: A flame resistant to nonflammable composite panel is produced from a nonextrudable core mixture with a pourable, nonflammable filling material and a binder, and on both sides cover strips flexibly bonded to the core. For a continuous production of the composite panel in one operation, the core mixture is poured onto an inrunning lower cover strip, in contact with a lower adhesive film facing the core mixture, and a pile is formed there, extending over the entire width of the adhesive film, both continuously and uniformly drawn through a V gap and compacted there for the first time and calibrated to thickness, an upper adhesive film, upwardly limiting the precompacted core mixture, is fed in and brought into contact with a continuously fed cover strip and the sandwich is pressed with further compaction, heated, cooled and cut to the final length of the composite panel.

Abstract: A cement board having bare surfaces and a woven mesh of reinforcing fibers underlying the top, bottom, and longitudinal edge surfaces is made continuously on an improved apparatus which comprises a pair of edger rails which slidably rest on a conveyor belt and define the path of the cement board being made on the conveyor belt and a means for folding and pressing outer margins of the bottom mesh into the edge surfaces and the top surface.

Abstract: An elongate sheet of flexible, fluid impervious material is folded into longitudinally extending pleats and coiled into a roll for use with masking apparatus of either the stationary or the hand held type. The sheet is coiled in a direction for continuous application of tape to overlap an edge of the outer surface of the roll as the folded sheet and the tape are dispensed. The first pleat is provided with a laterally projecting terminal portion to receive the tape and prevent contact between the underlying sheet material and the tape. After a length of the material is dispensed, severed from the roll and adhesively affixed to the surface to be masked, the sheet is extended laterally to unfold the pleats.

Abstract: A method and apparatus for forming shaped articles from glass fiber reinforced gypsum. An aqueous slurry of gypsum hemi-hydrate, water and glass fibers contains between 22 and 45 parts by weight water, 100 parts by weight gypsum hemi-hydrate and 3 to 10 parts by weight glass fiber. The slurry is deposited as a continuous ribbon on a moving, water-impermeable formable sheet which is pre-shaped and thereafter the slurry ribbon is pressed into a desired profile. The formable sheet and slurry ribbon are maintained in the desired profile until the slurry sets. Thereafter the product ribbon is cut transversely into lengths as desired. The formable sheet may be removed before cutting, or may be retained in engagement with the product ribbon during and after cutting to serve as a protective cover for the surface of the article. The process and apparatus are especially adapted to produce liner sheets for building construction panels.

Abstract: Plastic sheet material, laminated to the front face and side edges of wallboard, having excess sheet width at each side edge, is uniformly and rapidly trimmed to a neat skived edge which becomes firmly adhered to the wallboard edge, by abrading through the sheet material with a rotary abrader such as a nylon brush.

Abstract: A predecorated printed paper on the gypsum wallboard with a clear washable coating over the printed paper, and having a thin coating of polyethylene emulsion on the back paper which overcomes the tendency of the coated predecorated paper to stick to the back paper of an adjacent board when the boards are piled in stacks for storage and shipment.

Abstract: The invention relates to the manufacture of cementitious board, such as gypsum board, faced with paper or other sheets and having an improved accuracy of edge profile. A sheet to be folded at the lateral edges of the board is scored, and quick-setting adhesive, preferably a hot melt adhesive, is applied along the lines of folding. The sheet is then folded to the desired configuration and held until the adhesive has set thus establishing an accurate profile that withstands the action of the aqueous slurry of cementitious material and the application of the other sheet. The invention can be applied to various profiles, including square edge, tapered edge, rebated and tongue-and-groove.