Abstract: The present invention comprises apparatus for the manufacture improved structural panel with synthetic ingredients, such as vermiculite and fibers. The improved structural panel achieves enhanced lateral and surface integrity by the use of fibers within the core of the structural panel and adhesives and smooth materials (such as foil) as a surface coating. The apparatus is particularly suited for manufacture of the structural panel at low cost and high efficiency.

Abstract: A building board comprises a core of gypsum which has penetrated a glass fiber sheet embedded in one face and a coating of gypsum integral with the core material which has passed through the sheet. An apparatus for making such a board includes; a lower forming surface and an upper forming surface defining a forming zone between them in which the plasterboard is formed. A supply of a first slurry is provided to the lower forming surface. A supply of a second slurry is provided to a glass fiber sheet to coat the upper surface of the sheet with the second slurry. A device is provided for passing the coated sheet into the forming space, whereby the lower surface of the sheet contacts the upper surface of the first slurry. A vibrator roller is provided for vibrating the upper forming surface so that the first slurry passes through the sheet into the second slurry. A method of making the board is also disclosed.

Abstract: A composite fabric for use in reinforcement, particularly tensile reinforcement, of cementitious boards and similar prefabricated building wall panels. The fabric is constructed as a mesh of continuously coated, high modulus of elasticity strands. The high modulus strands are preferably bundled glass fibers encapsulated by alkali and water resistant 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 long-lasting, high strength tensile reinforcement of the panels or boards regardless of their spatial orientation during handling. The reinforcement also enhances the impact resistance of the boards after installation. Included as part of the invention are methods for making the reinforcement, cementitious boards and panels including the reinforcement, and methods for manufacturing such boards and panels.

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.

Abstract: A composite fabric for use in reinforcement, particularly tensile reinforcement, of cementitious boards and similar prefabricated building wall panels. The fabric is constructed as a mesh of continuously coated, high modulus of elasticity strands. The high modulus strands are preferably bundled glass fibers encapsulated by alkali and water resistant 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 long-lasting, high strength tensile reinforcement of the panels or boards regardless of their spatial orientation during handling. The reinforcement also enhances the impact resistance of the boards after installation. Included as part of the invention are methods for making the reinforcement, cementitious boards and panels including the reinforcement, and methods for manufacturing such boards and panels.

Abstract: A novel construction board composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a construction board composition comprising primarily gypsum, and in a construction board composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum construction board formulations, thus reducing the weight while maintaining the strength of the construction board structure. In a preferred embodiment, the lightweight, strengthened gypsum construction board of the present invention also comprises an optional covering veneer that is applied to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength.

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 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: The present invention provides an architectural material obtained by forming a decorative layer containing calcium carbonate as a binder component on the surface of a base material, and laminating a ventilating protective sheet having a peeling strength of 200 to 4000 mN on the surface of the decorative layer without interposing an adhesive layer separately, and a process for producing the architectural material. The architectural material has excellent soiling resistance or abrasion resistance, and is highly practical.

Abstract: The invention provides a glass fiber facing sheet for engineered surfaces such as cement boards which reduces the pitting associated with open mesh glass scrims. The glass fiber facing sheet comprises an open mesh glass scrim having a plurality of intersecting continuous multifilament yarns which are bonded at their crossover points to provide dimensional stability to the scrim. A melt blown polymer web is preferably joined to one face of the glass scrim and covers the mesh openings in the scrim. The opposed face of the scrim defines an exposed grid profile surface which is available for mechanical interaction between the scrim and the cementitious slurry used in cement boards. In cement boards, the glass fiber facing sheet of the present invention is preferably mechanically integrated into a surface portion of the cement core along the exposed grid profile of the scrim.

Abstract: An inorganic board consisting of an inorganic base layer formed by a paper making method and an inorganic surface layer formed by the dry method on said inorganic base layer is provided in the present invention. A synthetic resin emulsion and/or a rubber latex is coated on and permeates said inorganic base layer so as to supply the water to said inorganic surface layer and improve the delamination strength between said inorganic base layer and said inorganic surface layer.

Abstract: A lightweight gypsum board is provided, including, by dry weight, gypsum as the largest single ingredient, perlite as the second largest single ingredient, and starch as a minor ingredient, in the board. The starch may be pre-cooked prior to mixing, and is dispersed in the core of the board to act as a binder for binding the gypsum to the perlite. Gypsum board made according to the invention is lighter in weight, yet has a comparable nail pull value to conventional wallboard.

Abstract: The object of the present invention is to prevent delamination of an inorganic board. To attain this object, a method of manufacturing an inorganic board comprising forming a single mat by the paper making method by using slurry of raw material mixture substantially consisting of cement material, fiber material and inorganic filler inside of which is empty wherein said empty inorganic filler is effected on an alkali treatment; laminating the plural number of said single mats to form a laminated mat; and molding, incubating and curing said laminated mat.

Abstract: In a gypsum board faced with a fibrous mat, for example, a mat of glass filaments adhesively bound together, improvements are realized by the use of a reinforcing binder in the mat.

Abstract: A process for making a thin, sealant-coated, fire and indentation resistant gypsum panel. A layer of a mixture of cellulosic fibers moistened with water and an additive to restrict the adhesion of cellulosic fibers to one another, is deposited on at least two separate conveyors to form a fibrous matt on each conveyor. A layer of dry calcined gypsum containing set accelerator is deposited on the fibrous matt on each conveyor which contains, by weight on a dry weight basis, about 70-90% gypsum, about 10%-19% cellulosic fiber and about 1%-9% of combined additive and set accelerator. Each layer on each conveyor is directed to a mixing station to form a homogeneous layer, and the formed homogeneous layers on separate conveyors are placed atop one another on a single conveyor to form a combined homogeneous layer. Water is added to the layer or layers to rehydrate calcined gypsum. The combined homogeneous layer is subjected to pressure to form a pressed, homogeneous fiber-reinforced gypsum panel, and dried.

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: This invention relates to a panel of material comprising a film comprising a layer of a solid polyolefin and a layer of copolyester wherein said copolyester comprises:(1) a dicarboxylic acid component comprising repeat units from at least 90 mole percent terephthalic acid; and(2) a diol component comprising repeat units from 20 to 40 mole percent diethylene glycol and 80 to 60 mole percent ethylene glycol, based on 100 mole percent dicarboxylic acid and 100 mole percent diol,said layer of a copolyester being intimately bonded to a wooden substrate and said polyolefin layer being exposed on the outer surface of said film.

Abstract: Composite panels with high fire-proofing capacity have two outer layers and a core that features a core mixture containing aluminum hydroxide in compacted form, lightweight fillers, in some cases fine grained or splintery aluminum hydroxide, as desired magnesium hydroxide and polymer-based binding agents. The composite panels are suitable e.g. as facade panels for building constructions.

Abstract: A method of, and compositions for, the making of a fire-resistant door core assembly. Doors produced from the door core assemblies. In the making of a door core assembly, an aqueous slurry containing gypsum cement and diatomaceous earth is prepared. The slurry may also include expanded mineral ore material and Portland cement. The slurry preliminarily hardens during a green cure stage.

Abstract: A method and apparatus for producing light-weight construction panels having a cementitious core layer surfaced with a layer of reinforcing fabric bonded to the two faces of the core includes the use of slurry applicator having a supporting member and a doctor in addition to a moving carrier for the slurry coated fabric. The edges of the panel also are covered with the fabric and may be open mesh edges. Cementitious slurry, for example, portland cement slurry, is applied to the fabric by means of a supporting member over which the fabric is drawn and a doctor means adjustably mounted above the supporting member. The supporting member is of a non-base-reactive material such as polypropylene or stainless steel; the use of such a supporting member permits better application of the slurry to the fabric before placement of the slurry coated fabric on the moving carrier.

Abstract: A method and apparatus for producing gypsum board. The method includes the steps of mixing a predetermined amount of fibers, absorbent, and water to form a mixture of wetted, loose fibers, mixing the wetted fibers with predetermined amount of dry calcined gypsum, forming the mixture into a matt having a substantially uniform consistency and compressing the matt to form a board composed of bonded fibers and gypsum. The resulting board has a smooth exterior and can be a homogeneous or a multilayer board.

Abstract: An improved composite material is produced by mixing gypsum and host particles of a stronger substance, such as wood fibers, in a dilute slurry; heating the slurry, under pressure, to convert the gypsum to calcium sulfate alpha hemihydrate; and substantially dewatering the hot slurry before rehydrating the hemihydrate back to gypsum. The resulting material is a homogoneous mass comprising gypsum crystals physically interlocked with the discrete host particles.According to a further aspect of the invention, an improved wallboard, having fire resistance, dimensional stability and excellent strength properties, is produced by compressing the composite mass before hydrating it to a final set.

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: A method for reducing the consistency of a water and gypsum stucco slurry comprising admixing water, stucco, and an additive, the additive in an amount effective to reduce the consistency of the admixed slurry as compared to a slurry containing only water and stucco, and the additive selected from the group consisting of one or more polyalkylene polyamines having a molecular weight below 1,000.

Abstract: Glass mat-faced gypsum boards having a set core containing gypsum dihydrate and at least a minimum amount of chopped fibers, as well as other optional fire-resistant additives, are provided. The resulting boards obtain superior fire resistance properties over conventional paper-faced boards of like thickness which include a similar amount of chopped glass fibers.

Abstract: A glass fibre reinforced composition of a settable mix of plaster, a water-based phenol formaldehyde resin, an acid hardener and a reinforcement of glass fibres. A product of this composition can be produced by spraying the fluid mix and fibre component separately but simultaneously onto a surface.

Abstract: Decorative interior molding is molded from a slurry of gypsum, water, perlite, and a foaming agent. The slurry is surrounded by paper, cured, and dried.

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: The present invention is directed to a process for the manufacture of plasterboard optionally strengthened with reinforcing materials by mixing gypsum capable of rehydration with water and optionally reinforcing materials and subsequently pressing the resulting mixture, characterized in that polyisocyanates are added to the mixture used for producing the plasterboard and/or are applied to the surface of the finished plasterboard. The invention is also directed to the optionally reinforced plasterboard.

Abstract: A method is described for the continuous production of glass fiber mesh reinforced concrete panels consisting of a layer of light weight concrete core mix bonded to a web of glass fiber mesh on each face. An uncured ribbon of reinforced concrete is first formed, suitable for cutting into individual panels. A new method of depositing the cement slurry or core mix on the web of fiber glass has been developed; this is accomplished by conveying the web over a reversely-turning pumping roller which transfers a controlled amount of slurry or core mix to the web.

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: An apparatus is described for the continuous production of glass fiber mesh reinforced concrete panels consisting of a layer of light weight concrete core mix bonded to a web of glass fiber mesh on each face. An uncured ribbon of reinforced concrete is first formed, suitable for cutting into individual panels. A new method of depositing the cement slurry or core mix on the web of fiber glass has been developed; this is accomplished by conveying the web over a reversely-turning pumping roller which transfers a controlled amount of slurry or core mix to the web.

Abstract: Device for the continuous manufacture of manufactured articles reinforced with mixtures of hydraulic binders and consisting of:a conveyor belt;a plurality `A` of process stations for the formation of superimposed thin and uniform layers of a net of a hydraulic binder mix, each station consisting of:a feeder of the reinforced net 4;a wetting and degassing device 5 of the net 4;a means 2 for metering the binders mix;a section 7 for feeding and laying the net 4 on the conveyor belt 1;compacting elements 16;a means 6 for the extraction of water during the compacting state; anda second metering device 2' for the hydraulic binders mix;a levelling and sizing station 23;a final water-extracting station 26;a pressing station 27;a longitudinal and cross-cutting station 35, and a gathering station 36 for the produced plates.

Abstract: A decorative tile having a front face with a design thereon varies in density so that the front face of the tile presents a solid appearance, but the overall weight of the tile is less than for a comparable conventional plaster tile. The tile of the invention can be made from a mixture including a binder, fiber strands, and a bulk enhancing agent. The decorative tile of this invention is particularly useful for ceiling decoration.

Abstract: A gypsum plaster and chopped glass fiber tile having increased insulation values, reduced weight and reduced density due to the presence of vermiculite and perlite.

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: The prefabricated element comprises a plurality of parallel layers which adhere to each other. A first layer (2) of low-density mortar contains a sheet (5) of woven mineral fibers extending parallel to and close to the internal surface. An intermediate layer (3) has exactly the same composition as the first layer but is filled with particles (7) of low-density heat-insulating material and also contains a sheet (6) of woven mineral fibers. A last layer (4) has exactly the same composition as the first layer but does not contain a sheet of woven mineral fibers.

Abstract: Blown mineral wool fibers are introduced into slurries (such as gypsum board core formulations and steel column fireproofing plaster formulations) by first blending and coating the blown mineral wool with a powdered calcium sulfate to produce a light, open nodulated effect. When mixed into aqueous calcined gypsum slurries, the nodules open up, thoroughly dispersing the mineral wool--calcium sulfate blend in the aqueous slurry and contributing fire resistant properties to the set gypsum product.

Abstract: Described is a novel gypsum board and a manufacturing method therefor by first forming a particulate layer securely adhered to the base paper for the gypsum board and by utilizing an adhesion layer which has been formed by the reaction of the particulate layer for pasting the gypsum core material on the base paper for board, so that adhesion between the core material and the base paper is enhanced as well as the strength of the gypsum board itself is improved.

Abstract: A process for the production of a moldable fibre-containing cementitious composition in which at least one mat of a water-insoluble fibrous material is contacted with at least one surface of a shaped article of a moldable cementitious composition, the cementitious composition comprising a homogeneous mixture of at least one hydraulic cement, water in a proportion of not more than 25% by weight of the hydraulic cement in the composition, and at least one water-soluble or water-dispersible polymeric material in a proportion of at least 1% by weight of the hydraulic cement in the composition.The moldable cementitious composition may be in the form of a sheet and in the process two or more sheets may be used with a fibrous mat being sandwiched between adjacent pairs of sheets of cementitious composition.Also a moldable fibre-containing cementitious composition and fibre-reinforced cement product produced by curing of the composition.

Abstract: A cement board of homogeneous composition from face to face and having a substantially uniform thickness is made continuously by distributing a sole cementitious composition on a moving carrier sheet and smoothing the surface by rotating a cylindrical roller in a direction counter to the movement of the carrier sheet. An upper reinforcing network is submerged under the surface by feeding it under the counter rotating roller.

Abstract: A network of reinforcing fibers is pressed against the surface of an underlying carrier sheet by the weight of a concrete mix. A vertical gap between the sheet and the network is created so that the concrete mix may penetrate the voids of the network and spread out on the underlying sheet to embed the fibers.

Abstract: The present invention discloses a reinforcement product for use in cement boards and a method of manufacturing said product and of manufacturing cement boards using this product.The reinforcement product of the present invention comprises cross-layered webs of plastic fibres with a preponderance of fibres laid in the trans-axial direction, and continuous filaments or fibrillated tapes located between the layers to impart a high degree of strength in the axial direction. The cross-layered web and the filaments or tapes are compacted to form a reinforcement product which can be rolled up and handled for further processing on cement board forming machines. The webs of plastic fibre are formed by monoaxially orientating on extruded sheet of plastics material in axial direction, then fibrillating the sheet to form a cohesive fibre mass which is cut into lengths and carded to break up the film into a coarse fibrous mass which when stripped from the carding machine forms said plastic fibre web.

Abstract: A concrete plate assembly, e.g. as load carrying members or for building facades, comprises an inner concrete slab, an outer concrete slab spaced from the inner slab, and at least one main or stress-absorbing anchor embedded and interconnecting the slabs which are reinforced. The intervening space can be filled with an insulation and/or can constitute an insulating air space. According to the invention, at least one of the concrete slabs in the region of the connecting anchor, is provided with a closed reinforcing ring which lies in the plane of the slab, preferably midway of the cross section thereof, the anchor being embedded in the concrete within the reinforcing ring and preferably centrally thereof.

Abstract: A building board comprises a core 31 of set cementitious material, such as gypsum, faced on at least one side by a fabric or web 33 of mineral fibres embedded in the face of the core and a continuous film 32 of the cementitious material having a higher density and lower porosity than the core extending over the outer face of the fabric. The film may have a smooth surface or a desired textured or figured surface. The preferred fabric or web 33 is a non-woven glass fibre tissue and it is preferred that a continuous film 32 of gypsum at the surface should not exceed 2 mm in thickness. The board is made by bringing the fabric or web into contact with the respective face of a layer of an aqueous slurry of gypsum plaster or other cementitious material, and vibrating the layer of slurry in contact with the fabric or web until slurry penetrates the web and the latter is completely embedded.

Abstract: An improved process for the manufacture of reinforced shaped articles from water-hardening materials. A plurality of continuous networks of synthetic organic polymer material having at least two meshes per square centimeter are incorporated in said water-hardening materials as reinforcement. The networks are prepared by forming meshes in an unfibrillated film of the synthetic organic polymer material.

Abstract: An improved process for the manufacture of reinforced shaped articles from water-hardening materials. A plurality of continuous networks of synthetic organic polymer material having at least two meshes per square centimeter are incorporated in said water-hardening materials as reinforcement. The networks are prepared by forming meshes in an unfibrillated film of the synthetic organic polymer material.

Abstract: The present invention relates to a continuous process for manufacturing articles comprised of fiber-reinforced hydraulically bound material. A layer of the fiber-reinforcing and hydraulically bindable materials are placed on a first endless carrier while a second similar layer is formed on a second endless carrier. The layer formed on the second carrier is deposited on the layer formed on the first carrier by reversing the second carrier and the composite layer formed as a result is thereafter given the desired shape and is hardened.A number of fibrous network structures are used with the hydraulically bindable material and the two are formed into a layer with the networks distributed in it. Water is removed from that layer by suction, while on the second carrier a number of fibrous networks are likewise supplied to be formed into a layer comprised of the hydraulically bindable material with the networks distributed in it and water is also removed by suction from this layer.

Abstract: Blocks or panels 10, more especially of porous or cellular structure, are faced with a fabric or web inorganic fibres, preferably in the form of glass fibre tissue, bonded to the block or panel by a composition 14 of thermosetting condensation polymer and gypsum, preferably in a ratio between 1:1.6 and 1:4.0. The amount of the composition is preferably such as to provide a film of minimal thickness over the surface of the fabric or web, corresponding to a glass: resin plus gypsum proportion of 8 to 25%. Such coatings when applied to foamed plastics, chip-board or glass fibre panels provide boards suitable for ceilings or partitions and having ample strength and flame resistance. The blocks or panels may be made continuously by applying fibrous tissues, impregnated with a fluid mixture of plaster and resin by roller spreaders, to the face of panel elements supported between release sheets, for example of polypropylene. Pressure may be applied and maintained, if desired, until the fluid mixture has set.