Abstract: A method of manufacturing a decorative surface includes the steps of a) impregnating a paper substrate with a thermosetting resin; b) jetting a colour pattern with one or more aqueous inkjet inks including a polymer latex binder on the thermosetting resin impregnated paper; c) drying the one or more aqueous inkjet inks; and d) heat pressing the thermosetting paper carrying the colour pattern into a decorative surface.

Abstract: A method and kit for renovating and reconstructing wet rooms, wherein panel modules are attached to a wall, floor, and/or ceiling of the wet room, by providing panel modules having a water-impermeable coating or core; determining an installation position of a panel module; attaching a water-resistant sealing strip section to form an outer contour of the panel module; applying a water resistant sealing adhesive to the sealing strip section such that the sealing adhesive continuously underlays edge regions of two adjacent panel modules; and pressing a first panel module onto a first subregion of the sealing adhesive and a second panel module adjoining the first panel module whereby the two adjacent side regions of the panel modules are completely underlaid with sealing adhesive to produce a seal point between the panel modules to prevent moisture from entering the wall, floor, or ceiling through a joint formed between the panel modules.

Abstract: Formulations and methods for papermaking use one or more volatile debonders, where the volatile debonder forms a solution or an emulsion with water in a paper precursor, and where the volatile debonder is evaporable from the paper precursor before the paper precursor is completely dried to form a paper sheet during papermaking. Two volatile debonders having different boiling points can be used, where they are miscible in water and in each other, and where one volatile debonder has a higher molecular weight and the other volatile debonder has a lower boiling point.

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.

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.

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.

Abstract: A method of manufacturing a water-resistant gypsum article, comprising sonicating a water-resistance additive in water to form a emulsion; combining the emulsion, calcined gypsum, and gauging water to form a slurry; and forming and setting the slurry to form the water-resistant gypsum article.

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.

Abstract: Emulsions are provided which are useful in imparting water-resistance to gypsum wood fiber products. In one embodiment, the emulsions comprise a wax or a combination of waxes, an alkyl phenol, at least one surfactant, Polynaphthalenesulfonic acid, and an alkali metal hydroxide. In another embodiment, the emulsions comprise a wax or a combination of waxes, an alkyl phenol, at least one surfactant, polynaphthalenesulfonic acid, an alkali metal hydroxide, and a complexed starch.

Abstract: This invention relates to a gypsum board coating comprising cardboard with a water-repellent treatment, containing a treatment agent which prevents the growth of micro-organisms. This invention also relates to a gypsum board comprising such a coating and a method for producing the cardboard-coated gypsum board.

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: Polymerization of siloxane is improved using a gypsum-based slurry that includes stucco, Class C fly ash, magnesium oxide and an emulsion of siloxane and water. This slurry is used in a method of making water-resistant gypsum articles that includes making an emulsion of siloxane and water, then combining the slurry with a dry mixture of stucco, magnesium oxide and Class C fly ash. The slurry is then shaped as desired and the stucco is allowed to set and the siloxane polymerizes. The resulting product is useful for making a water-resistant gypsum panel having a core that includes interwoven matrices of calcium sulfate dihydrate crystals and a silicone resin, where the interwoven matrices have dispersed throughout them a catalyst comprising magnesium oxide and components from a Class C fly ash.

Abstract: This invention relates to a composition suitable for use in making moisture resistant gypsum products. In particular, this invention relates to resin dispersions and their use in combination with gypsum to form moisture resistant gypsum compositions which are settable by hydration. Further, the invention relates to moisture resistant products formed from such settable gypsum compositions, e.g. panels and boards, and a method for the manufacture of such moisture resistant gypsum products.

Abstract: A method of manufacture of multilayer gypsum board, and a gypsum additive delivery system, including wet gypsum board passing through a board forming station in which additives are delivered to one or more layers of a multi layered gypsum board panels, such as engineered polymers, providing a better and more water resistance surface. Preferably, the gypsum board has a first layer of a mixture of set gypsum having an outer surface and a polymeric compound or wax emulsion additive entrained therein and impregnated in a thin sheet of randomly aligned inorganic fibers to essentially encase the core gypsum within two facing layers.

Abstract: Articles, including fiberboard, are made from a pumpable, flowable slurry including alpha-calcined calcium sulfate hemihydrate anchored in pores of host particles, alpha-calcined calcium sulfate hemihydrate, a silicone compound, magnesium oxide, and water. The magnesium oxide catalyzes the reaction of the silicone compound into a silicone resin. In a preferred method of making a water resistant fiberboard calcium sulfate dihydrate is combined with the host particles and water to form a slurry which is heated under pressure to calcine the calcium sulfate dihydrate to form alpha-calcined calcium sulfate hemihydrate. After relieving the pressure, a silicone compound and magnesium oxide are added to the slurry. The slurry is dewatered to form a filter cake, which is then formed into a desired shape and allowed to set.

Abstract: A gypsum wallboard core, and methods and apparatus for making the same are disclosed. Methods of making a gypsum wallboard core include extruding a gypsum slurry containing water, gypsum, slip agents, water-reducing agents, surfactants and, optional additives, through a die and onto a substantially flat, smooth, moving surface. The die has provisions at its outer sides for the introduction of slip agents into the slurry, and provisions at its lateral outer edges for the introduction of a strength-enhancing agent. Once extruded onto the conveyor belt, the slurry is chemically-activated to set and form a hardened board core which then may be easily removed from the conveyor belt and dried.

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: A water-resistant prefabricated structural element comprising a substrate based on cured plaster, said substrate being able to be obtained by at least the following steps: (a) homogeneously mixing a dry material, comprising mostly at least one hydratable calcium sulfate, a water-repellent agent comprising at least one silicone compound, and water and preforming said substrate in the wet state; (b) drying the preformed substrate in order to obtain said substrate formed in the solid and dry state; wherein the homogeneous mix, prior to the preforming of the substrate in the wet state, also includes a mineral additive comprising at least one mineral component having a synergistic water-repellency affinity with said silicone compound.

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 method of manufacturing a composite product comprising providing a substrate layer and a slurry formulation including a hydraulic binder and dewatering agent. The slurry is then applied to the substrate layer to form a functional layer and the functional layer dewatered through the substrate layer. The application of the slurry to form the functional layer and dewatering steps can be repeated to build up a laminated composite product. Functional additives may be included in each layer to provide desired properties to that layer and indeed to the subsequent composite product.

Abstract: A system for making wallboard or backerboard sheets may include a mixer for mixing materials for making aerated concrete, at least one face layer supply, and a former downstream from the mixer. The former is for forming core material having opposing first and second major surfaces and comprising aerated concrete, and for securing at least one face layer from the at least one face layer supply onto at least one of the first and second major surfaces of the core material. The system may also include a cutter downstream from the former for 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.

Abstract: A gypsum/fiber board having improved impact resistance is produced by mixing predetermined amounts of fibers, calcined gypsum and water to form a mixture of wetted, loose fibers; laying out a reinforcing mesh over the upper surface of a forming belt; depositing said mixture on said mesh to form a layer of said mixture, said; and compressing said mesh together with said layer of mixture to embed said mesh in the lower surface of said layer to form a board composed of bonded fibers and gypsum with said mesh embedded in the surface thereof.

Abstract: The present invention relates to water-resistant gypsum compositions, methods of making such composition, as well as manufacturing methods and products comprising such compositions.

Abstract: A water repellent composition for gypsum containing masonry materials is disclosed. The composition contains as organohydrogensiloxane and polyvinyl alcohol, the combination of which provides unexpectedly high water repellency.

Abstract: A disposable diaper comprises a liquid-impervious outer sheet (2), defining a narrower crotch region (27) between two wider end or belt regions (28, 29), an absorbent pad (22), fastening members (24) for closing the diapers, and elastic members (4) attached under tension to the impervious sheet (2) on both sides of the absorbent pad (22), substantially over the whole length of the impervious sheet, with a higher tension in the crotch region (27) than in the end regions (28, 29), having, in the two end regions (28, 29), sections (4c) converging in the direction of the transverse edges of the impervious sheet, so that the elastic members (4) form an elastic barrier which practically surrounds the absorbent pad (22) and provide the impervious sheet both with a lengthwise elasticity in the crotch region and a transverse elasticity in the end regions.

Abstract: A composition suitable for use in making water-resistant gypsum products is provided. The composition is an aqueous emulsion comprising water, a paraffinic hydrocarbon wax, a Montan wax, an alkali metal or ammonium hydroxide in an amount sufficient to at least partially saponify the Montan wax, an emulsifier and a dispersant.

Abstract: The present invention provides a novel method of rendering a wallboard water-repellent comprising applying to the wallboard a water-repellent composition comprising a hydrogen siloxane component and a high molecular weight silicone.

Abstract: Process and apparatus for the continuous production of gypsum fiber plates in which the fiber component is dewatered and rediluted with water recovered from the gypsum-fiber suspension after it has been spread on a belt, passed over at least two suction boxes and densified on the last suction box by a densifying device engaging the filter cake layer from the top.

Abstract: The water resistance of gypsum compositions, such as those used in gypsum wallboard, is improved by incorporating in the compositions an aqueous emulsion containing a paraffinic hydrocarbon having a melting point of 40.degree. to 80.degree. C., montan wax and polyvinyl alcohol.

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 lightweight wallboard having a density in the range of 10 pcf to 30 pcf and comprised of a faced layer of expanded siliceous inorganic particles, such as expanded perlite, bonded together by inorganic binder, such as sodium silicate. The board is made by depositing a mixture of particles, binder and water onto a moving web of facing material, contacting the mixture with an upper moving web of facing material, compacting the mixture to the desired shape and density and drying the resulting board. Fire resistant and water repellent versions of the formula are also disclosed.

Abstract: A method for incorporating siloxane into a water-resistant, gypsum-based article is disclosed, comprising, (A) adding said siloxane to water; (B) mixing said siloxane/water mixture with calcined gypsum to form an aqueous slurry; and (C) allowing said slurry to set to form a set gypsum-based, water-resistant article.

Abstract: A backer board for use as a base to which ceramic tile is bonded for a bathtub or shower area, in which the board is made by forming a gypsum core board with fiber glass laminated composite facings, which include an inner fiber glass scrim, an outer fiber glass nonwoven matte and an acrylic film, which film is formed of an acrylic latex of a class commonly employed as an ingredient in Portland cement mortar for applying ceramic tile.

Abstract: An exterior finishing system for a building. including particularly an exterior insulation system, which includes a fibrous mat-faced gypsum board, preferably a board in which the set gypsum core thereof is water resistant, and preferably one in which the set gypsum core is sandwiched between two sheets of porous glass mat, with the outer surface of at least one of said mats being substantially free of set gypsum, and means for preparing the board, including control of the viscosity of the aqueous gypsum slurry from which the set gypsum core of the board is formed. Also, the use of fibrous mat-faced gypsum board as the shaft liner panel in a shaft wall assembly.

Abstract: A water-repellent plaster molding is produced by forming a foam of water, surfactant and polyalkyl-hydrogen-siloxane adding this foam to a paste of plaster powder in water, and letting the mixture set.

Abstract: An improved sizing is feasible by adding into a papermaking pulp slurry an aqueous dispersion prepared by mixing an aqueous solution of an ampholytic acrylamide polymer having both cationic and anionic groups with a liquid substituted succinic anhydride or with an anhydrous liquid mixture of a liquid substituted succinic anhydride and an oil-in-water type surfactant. Such a paper sizing process is very useful for making plasterboard base paper of multilayered structure composed of at least one surface layer having a high hot water resistance and at least one back layer having a good adhesiveness to plaster slush.

Abstract: A method for producing a lightweight set cementitious product, and more specifically, gypsum wallboard, having excellent strength and paper-to-core bond, which method comprises producing a foam comprising polyvinyl alcohol and water, introducing the foam thus formed into an aqueous cementitious slurry, depositing the slurry between paper cover sheets, and permitting the cementitious slurry to set. In a further embodiment an emulsion formed of asphalt and wax is added to the cementitious slurry to impart water resistance, the polyvinyl alcohol of the foaming agent cooperating with the asphalt and wax emulsion to improve the water resistant properties of the set gypsum wallboard.

Abstract: A composite paper particularly adapted for use as cover sheets in the production of gypsum wallboard, the paper being sufficiently porous to permit better drainage and more rapid drying in the production of the paper, and when applied to the surfaces of a gypsum slurry for forming wallboard, permits less heat to be utilized in the wallboard conversion, thereby saving energy in the board production required for drying the board. The paper comprises in weight percent:(A) cellulosic fibers in an amount of from about 65% to about 90% and preferably having a fiber freeness of from about 300 ml to about 550 ml Canadian Standard Freeness,(B) calcium sulfate as a filler in an amount of from about 10% to about 35%,(C) a binder in an amount from about 1% to about 31/2%,(D) a flocculant in an amount of from about 0.1% to about 0.2%,(E) a buffering agent in an amount from about 0.

Abstract: Use of an organopolysiloxane having the formula ##STR1## in which R.sup.1 is an alkyl or aryl radical, at least 80% of the R.sup.1 radicals being alkyl radicals,R.sup.2 is an alkyl radical or the R.sup.4 Z radical, at least 2/3 of the R.sup.2 radicals being R.sup.4 Z radicals, in whichR.sup.4 is a difunctional hydrocarbon radical,Z is --NH.sub.2, --NH(CH.sub.2).sub.c --NH.sub.2, --NH(CH.sub.2).sub.c NH(CH.sub.2).sub.c NH.sub.2, in which c is 2, 3, --NHCONH.sub.2 radical, --SH, --S.sub.4 --R.sup.4 --Si(OR.sup.3).sub.3, --P(C.sub.6 H.sub.5).sub.2 or ##STR2## R.sup.3 is an alkyl radical with 1 to 4 carbon atoms, or a hydrogen radical,a is not less than 4,b/a is not less than 0.001, but not greater than 0.5, andx is not less than 0.1, but not greater than 2,as a material for decreasing the water absorption of paper which is intended to be used for coating plaster paste in the manufacture of paper-laminated plaster boards. The organosilicon compounds cure without the use of special catalysts.

Abstract: A method of surface treatment for plaster articles to improve wear and water resistance is disclosed. The method includes the step of forming the article, allowing the article to set, drying to remove excess water, applying a coat of substantially molten Candelilla wax onto an exterior surface of said article, maintaining said wax at a temperature of no less than 155.degree. F. (68.degree. C.) for sufficient period of time to allow said wax to substantially fill exterior pores and irregularities, and cooling said article to solidify the wax. Also disclosed is a wear resistant and water repellent plaster article comprising a formed plaster article having an exterior surface portion thereof coated with a thin layer of Candelilla wax, said coated surface portion providing a substantially water impregnable barrier and providing enhanced wear resistance.

Abstract: An organopolysiloxane suitable for use in treating paper to be used in plaster boards. The organopolysiloxane is obtained by reacting a polysiloxanol of the formula ##STR1## in which R.sup.1 is a methyl or a phenyl radical, at least 90% of the R.sup.1 radicals however being methyl radicals, andn=20 to 250,with a silane having the formulaH.sub.2 N--R.sup.3 --Si(OR.sup.2).sub.3in whichR.sup.2 is a lower alkyl radical with 1 to 4 carbon atoms,R.sup.3 is a bivalent alkyl radical with 1 to 6 carbon atoms or the --(CH.sub.2).sub.x R.sup.4 (CH.sub.2).sub.y --NH.sub.2 radical, in whichR.sup.4 is oxygen, sulfur or the --NH-- or --NH--CH.sub.2 CH.sub.2 --NH-- radical andx.ltoreq.3, andy.ltoreq.2,in such amounts that 1 SiOH group of the polysiloxanol corresponds to more than 1 and up to 3 OR.sup.2 groups of the silane. Method for preparation of paper and cardboard for use in plaster boards as well as plaster boards made by using the present invention are disclosed.

Abstract: A wooden board for use for example as a table top has a moisture-proof coating on its upper surface and an edging of synthetic material which is sprayed under pressure on to the cut edge surface of the board. The edging overlaps the adjacent edge of the upper surface of the board and penetrates a profiled cut-out in the edge surface. In order to give a good moisture seal, the cut-out profile has an inwards directed back cut immediately under the upper board surface and a lower outwardly directed projection.