Encased Layer Derived From Inorganic Settable Ingredient Patents (Class 428/70)
  • Patent number: 10683235
    Abstract: A method for continuously forming gypsum-based panels of high fixing strength comprises the steps of: • forming a mixture comprising stucco, non-pregelatinized migratory starch, glass fibre, fluidizer and water; • casting the mixture in a continuous band; • maintaining the band under conditions sufficient for the stucco to form an interlocking matrix of set gypsum; • cutting the band to form one or more wet panel precursors; and • drying the wet panel precursor to form one or more gypsum-based panels. • The weight ratio of water to stucco in the mixture is less than 0.7; • the stucco is present in the mixture in an amount of over 60 wt % relative to the total solids content of the mixture; • the starch is present in the mixture in an amount of over 3 wt % relative to the the stucco; • the glass fibre is present in the mixture in an amount of over 1 wt % relative to the stucco; • the fluidizer is is present in the mixture in an amount of at least 0.
    Type: Grant
    Filed: December 14, 2016
    Date of Patent: June 16, 2020
    Assignee: Saint-Gobain Placo SAS
    Inventors: Richard Morlat, James Fletcher, Radomir Kamler
  • Patent number: 10562206
    Abstract: The present disclosure embraces cementitious panels, and systems and methods of manufacturing cementitious panels. An exemplary cementitious panel includes a cementitious core material, a plurality of sheets of facing material surrounding the cementitious core material, and a radiation-cured adhesive. An exemplary method of manufacturing a cementitious panel includes conveying a slurry of cementitious core material and a plurality of sheets of facing material, applying a radiation-curable adhesive to at least one of the sheets of facing material, forming a continuous length of cementitious panel material, at least partly curing the radiation-curable adhesive with one or more beams of radiation emitting from one or more radiation-emitting devices, and cutting the continuous length of cementitious panel material laterally to a desired length, providing a cementitious panel.
    Type: Grant
    Filed: June 1, 2018
    Date of Patent: February 18, 2020
    Assignee: National Gypsum Properties, LLC
    Inventors: Brian Bland, Brian G. Randall
  • Patent number: 10538456
    Abstract: A building product in the form of an internal lining board (10) made up of a mixture of hemp shiv (14) and a binder which may be clay based or lime based. The mixture is located between two layers (12) of lining paper (10).
    Type: Grant
    Filed: July 18, 2016
    Date of Patent: January 21, 2020
    Assignee: ADAPTAVATE LTD.
    Inventor: Thomas James Christopher Robinson
  • Patent number: 10407345
    Abstract: This invention provides low dust low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set gypsum core formed between two substantially parallel cover sheets, the set gypsum core preferably having a total void volume from about 80% to about 92%, and made from a slurry including stucco, pregelatinized starch, and a naphthalenesulfonate dispersant. The combination of the pregelatinized starch and the naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small air bubble voids (and water voids) provides dust control during cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products.
    Type: Grant
    Filed: September 14, 2017
    Date of Patent: September 10, 2019
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Weixin David Song
  • Patent number: 10406779
    Abstract: This invention provides gypsum wallboards with a unique microstructure where the walls between voids are enhanced in thickness and strength to substantially improve the strength and handling properties of the wallboards. A method of making lightweight gypsum wallboards is also provided.
    Type: Grant
    Filed: November 2, 2017
    Date of Patent: September 10, 2019
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Weixin David Song
  • Patent number: 10377108
    Abstract: Disclosed herein are gypsum products with at least one high efficiency heat sink additive. The gypsum products, e.g., gypsum panels, are less susceptible to the damaging effects of extreme heat as the temperature rises due to the presence of the at least one additive.
    Type: Grant
    Filed: February 13, 2013
    Date of Patent: August 13, 2019
    Inventors: Cesar Chan, Weixin D. Song, Bangji Cao, Guy Rosenthal, Qiang Yu, Srinivas Veeramasuneni
  • Patent number: 9499980
    Abstract: A lightweight cementitious panel formed from a core mix is disclosed. The lightweight cementitious panel comprises one or more lightweight aggregate filler in the amount of 0.5 to 5 weight percent of the core mix, one or more binders in the amount of 35 to 75 weight percent of the core mix, rheological admixture in the amount of about 0.5 to 5 weight percent of the core mix, surfactant in the amount of 0 to 0.1 weight percent of the core mix, one or more normal weight aggregate filler in the amount of 5 to 50 weight percent of the core mix, and water in the amount of 5 to 20 weight percent of the core mix.
    Type: Grant
    Filed: September 16, 2013
    Date of Patent: November 22, 2016
    Assignee: National Gypsum Properties, LLC
    Inventor: Marie-Andrée Mathieu
  • Patent number: 9023449
    Abstract: Composite reinforcement “Astrofleks” is used in building structures for reinforcement of insulation wall panels, solid concrete and prefabricated buildings. The composite reinforcement comprises the outer layer (1), inside of which the inner layer (2) is placed, on the outer surface of outer layer (1) there are relief elements (3) to improve adhesion of nanocomposite reinforcement with concrete. According to embodiment number 1, layer (1) is made of nanocomposite carbon in which the polymer matrix is modified by carbon nanostructures. Layer (2) is made of lightweight highly mobile concrete, containing in its composition components in the following ratio (% wt.): Cement—20-50; filler—70-30; plasticizer—0.02-2.5; water—the rest. According to embodiment number 2, layer (1) is made of nanocomposite carbon in which the polymer matrix is modified by polyhedral multi-layered carbon nanostructures of fulleroid type at a ratio of 0.01-10% by weight of the polymer matrix.
    Type: Grant
    Filed: May 31, 2010
    Date of Patent: May 5, 2015
    Assignee: Virtum i Sverige AB
    Inventors: Andrey Nikolaevich Ponomarev, Aleksandr Pavlovich Beloglazov
  • Publication number: 20150113912
    Abstract: A self-confining structural article includes a ceramic matrix with a reinforcement member disposed within the ceramic matrix. The reinforcement member is continuous, and has a mesh with holes not exceeding 4 mm in size.
    Type: Application
    Filed: May 31, 2013
    Publication date: April 30, 2015
    Inventor: Hwai-Chung Wu
  • Patent number: 9017787
    Abstract: The ceiling tile, in one embodiment of the invention, is a laminate of a rigid core layer, such as gypsum, having one surface covered by a display layer of plastic sheet material. An opposite surface of the core layer is covered by a layer of light reflective material. The design layer has a design surface that is viewable when the tile is installed in a ceiling, and the light reflective layer has an exposed light reflective surface. Both the design layer and the light reflective layer form leak tight seals on the opposite surfaces of the rigid core layer. The entire peripheral edge of the tile laminate and marginal portions of the design surface and light reflective surface are covered by a plastic leak tight tape that forms a gas tight seal at the peripheral edge of the tile laminate.
    Type: Grant
    Filed: June 19, 2012
    Date of Patent: April 28, 2015
    Assignee: Tower IPCO Company Limited
    Inventor: Norman Stone
  • Publication number: 20150089889
    Abstract: A composite product includes gypsum in an amount of 60 to 90% by weight, fibers in an amount of 1.5 to 26% by weight substantially homogeneously distributed through the composite, and a rheology-modifying agent in an amount of 0.5 to 6% by weight. The composite is caused or allowed to cure to form a cured composite. The cured composite is a fire resistant component used in a fire-rated door core, a fire-rated door or a fire-rated building panel. The fire resistant component may include a building panel, a door panel, a door core, a door rail, a door stile, a door lock block, a door border, or a door insert.
    Type: Application
    Filed: November 17, 2014
    Publication date: April 2, 2015
    Inventors: Evan R. Daniels, Jonathan Newton
  • Publication number: 20150075103
    Abstract: A modular construction system for quick and convenient construction of buildings, comprising construction panels generally in the order of 600 m wide. The modular construction system includes construction panels, framed construction panels, lintel panels, and framed lintel panels, that together allow a wide variety of building configurations to be assembled. The construction panel includes a cast cement wall member and partially embedded channel shaped sheet steel support members, with the wall member defining an extended portion that extends from the support member to the edge of a major face of the wall member. The framed construction panels is 600 mm wide and includes shaped sheet steel support members extending from a major face at least partially around its periphery.
    Type: Application
    Filed: December 22, 2010
    Publication date: March 19, 2015
    Applicant: RCP Holdings Limited
    Inventor: Reginald Arthur Richards
  • Publication number: 20150017378
    Abstract: The ceiling tile, in one embodiment of the invention, is a laminate of a rigid core layer, such as gypsum, having one surface covered by a display layer of plastic sheet material. An opposite surface of the core layer is covered by a layer of light reflective material. The design layer has a design surface that is viewable when the tile is installed in a ceiling, and the light reflective layer has an exposed light reflective surface. Both the design layer and the light reflective layer form leak tight seals on the opposite surfaces of the rigid core layer. The entire peripheral edge of the tile laminate and marginal portions of the design surface and light reflective surface are covered by a plastic leak tight tape that forms a gas tight seal at the peripheral edge of the tile laminate.
    Type: Application
    Filed: June 19, 2012
    Publication date: January 15, 2015
    Inventor: Norman Stone
  • Publication number: 20140290172
    Abstract: A presence detection system for detecting presence of a living being (2) within an area (4), the system comprising a first light source (6a) providing light of a first spectrum, a first sensing means (8a; 10a) which is arranged to filter the light of the first spectrum. The first sensing means produces a first presence detection signal (12a) based on the light of the first spectrum originated from the first light source and reflected from the living being (2). The presence detection system comprises a processor device (14) for concluding the living being's presence within the area (4) based on the first presence detection signal (12a). The processor device provides a position (22a) of the living being (2) within the area based on the intensity of the first presence detection signal (12a) and based on the known position of the first light source (6a) within the area (4). The invention further relates to a lighting system comprising the above described presence detection system.
    Type: Application
    Filed: December 22, 2010
    Publication date: October 2, 2014
    Applicant: RCP Holdings Limited
    Inventor: Reginald Arthur Richards
  • Patent number: 8828894
    Abstract: A reinforcement mesh, an architectural moulding reinforced by the mesh, and methods of making the architectural moulding and the mesh. The mesh is adhered by an adhesive to the architectural moulding. In the mesh, weft yarns bend relative to warp yarns to conform to and against a curved profile of the architectural moulding, and the warp yarns are unbent and adhered against the moulding.
    Type: Grant
    Filed: June 7, 2007
    Date of Patent: September 9, 2014
    Assignee: Saint-Gobain ADFORS Canada, Ltd.
    Inventor: Mark Joseph Newton
  • Patent number: 8703266
    Abstract: A knitted spacer fabric has a tightly knitted bottom layer, a more loosely knitted upper layer and linking fibers extending across the space between the lower and upper faces. Settable material, e.g. cement, is introduced into the space between the upper and lower faces and can be caused to set by the addition of a liquid, e.g. water. Until set, the fabric is flexible and can be shaped but after the material in space has set, the fabric is rigid and can be used as a structural element in a wide range of situations. The bottom layer has an extension that extends beyond the upper face and is connected to the upper face by elastic connecting fibers that draw the extension towards the other face, thereby at least partly closing the space at the edge of the cloth and preventing the settable material from spilling out.
    Type: Grant
    Filed: December 7, 2012
    Date of Patent: April 22, 2014
    Assignee: Concrete Canvas Technology Ltd.
    Inventors: William Campbell Crawford, Peter Eric Brewin
  • Publication number: 20140057066
    Abstract: Building boards and method for manufacturing the same are provided. The building board comprises a cement layer (102) and a magnesium oxide layer (104). The method for manufacturing the building board comprises the steps of providing a cement board and a magnesium oxide board, dehydrating and binding the cement board and the magnesium oxide board. The performance of moisture proofing, fungus proofing, erode proofing, fireproof and others can be improved by utilizing the building boards.
    Type: Application
    Filed: April 12, 2012
    Publication date: February 27, 2014
    Applicant: NEWSPIRIT CHINA LTD.
    Inventor: Hongliang Cai
  • Publication number: 20130216762
    Abstract: Disclosed herein are gypsum products with at least one high efficiency heat sink additive. The gypsum products, e.g., gypsum panels, are less susceptible to the damaging effects of extreme heat as the temperature rises due to the presence of the at least one additive.
    Type: Application
    Filed: February 13, 2013
    Publication date: August 22, 2013
    Applicant: UNITED STATES GYPSUM COMPANY
    Inventor: United States Gypsum Company
  • Publication number: 20130129946
    Abstract: A knitted spacer fabric has a tightly knitted bottom layer, a more loosely knitted upper layer and linking fibres extending across the space between the lower and upper faces. Settable material, e.g. cement, is introduced into the space between the upper and lower faces and can be caused to set by the addition of a liquid, e.g. water. Until set, the fabric is flexible and can be shaped but after the material in space has set, the fabric is rigid and can be used as a structural element in a wide range of situations. The bottom layer has an extension that extends beyond the upper face and is connected to the upper face by elastic connecting fibres that draw the extension towards the other face, thereby at least partly closing the space at the edge of the cloth and preventing the settable material from spilling out.
    Type: Application
    Filed: December 7, 2012
    Publication date: May 23, 2013
    Applicant: Concrete Canvas Technology Ltd.
    Inventor: Concrete Canvas Technology Ltd.
  • Patent number: 8343609
    Abstract: A knitted spacer fabric having a tightly knitted bottom layer, a more loosely knitted upper layer and linking fibres extending across the space between the lower and upper faces. Settable material, e.g. cement, is introduced into the space between the upper and lower faces and can be caused to set by the addition of a liquid, e.g. water. Until set, the fabric is flexible and can be shaped but after the material in space has set, the fabric is rigid and can be used as a structural element in a wide range of situations. The bottom layer has an extension that extends beyond the upper face and is connected to the upper face by elastic connecting fibres that draw the extension towards the other face, thereby at least partly closing the space at the edge of the cloth and preventing the settable material from spilling out.
    Type: Grant
    Filed: January 29, 2010
    Date of Patent: January 1, 2013
    Assignee: Concrete Canvas Technology Ltd.
    Inventors: William Campbell Crawford, Peter Eric Brewin
  • Patent number: 8227068
    Abstract: The ceiling tile, in one embodiment of the invention, is a laminate of a rigid core layer, such as gypsum, having one surface covered by a display layer of plastic sheet material. An opposite surface of the core layer is covered by a layer of light reflective material. The design layer has a design surface that is viewable when the tile is installed in a ceiling, and the light reflective layer has an exposed light reflective surface. Both the design layer and the light reflective layer form leak tight seals on the opposite surfaces of the rigid core layer. The entire peripheral edge of the tile laminate and marginal portions of the design surface and light reflective surface are covered by a plastic leak tight tape that forms a gas tight seal at the peripheral edge of the tile laminate.
    Type: Grant
    Filed: February 10, 2012
    Date of Patent: July 24, 2012
    Assignee: Tower IPCO Company Limited
    Inventor: Norman Stone
  • Patent number: 8215083
    Abstract: A previously formed unitary building exterior envelope product is provided, comprising: a mineral fiber insulation board including a binder having a hydrophobic agent and is resistant to liquid water-penetration and has first and second major surfaces, an exterior facing material, which resists air infiltration and liquid water penetration, laminated to the first major surface, the exterior facing material being permeable to water vapor, and a continuous interior facing laminated to the second major surface, so that the second major surface is resistant to liquid water-penetration and is permeable to water vapor. The section of product is mounted to an exterior side of a plurality of framing members of an exterior wall of a building, so that the interior facing faces the framing members. An exterior layer is mounted to the framing members using a connection device that passes through the section of product, with the facing material facing the exterior layer.
    Type: Grant
    Filed: July 6, 2009
    Date of Patent: July 10, 2012
    Assignee: Certainteed Corporation
    Inventors: Murray S. Toas, Stephen O. Barefoot, Michael J. Lembo
  • Publication number: 20120076969
    Abstract: Composite reinforcement “Astrofleks” is used in building structures for reinforcement of insulation wall panels, solid concrete and prefabricated buildings. The composite reinforcement comprises the outer layer (1), inside of which the inner layer (2) is placed, on the outer surface of outer layer (1) there are relief elements (3) to improve adhesion of nanocomposite reinforcement with concrete. According to embodiment number 1, layer (1) is made of nanocomposite carbon in which the polymer matrix is modified by carbon nanostructures. Layer (2) is made of lightweight highly mobile concrete, containing in its composition components in the following ratio (% wt.): Cement—20-50; filler—70-30; plasticizer—0.02-2.5; water—the rest. According to embodiment number 2, layer (1) is made of nanocomposite carbon in which the polymer matrix is modified by polyhedral multi-layered carbon nanostructures of fulleroid type at a ratio of 0.01-10% by weight of the polymer matrix.
    Type: Application
    Filed: May 31, 2010
    Publication date: March 29, 2012
    Inventors: Andrey Nikolaevich Ponomarev, Aleksandr Pavlovich Beloglazov
  • Patent number: 8062985
    Abstract: A flexible composite multiple layer fire-resistant insulation structure has a primary facing surface and a secondary facing surface. There is at least one dimensionally stable membrane having a primary membrane surface and a secondary membrane surface. At least a portion of the secondary facing surface is attached to the primary membrane surface. There is also at least one lofted insulative layer having a primary insulative surface and a secondary insulative surface. The at least one woven fabric facing layer may be formed of various materials, including amorphous silica glass and S-glass fiberglass. Different weaving patterns may be used to weave the facing layer. The facing layer may include a fire resistive treatment, which may in turn include a phosphate containing compound, and more particularly, may include dicalcium phosphate. In certain embodiments, multiple layers of the above are provided, and the structure may be enclosed in an abrasion resisting sheath.
    Type: Grant
    Filed: October 29, 2007
    Date of Patent: November 22, 2011
    Assignee: Owens Corning Intellectual Capital, LLC
    Inventors: Robert P Collier, Brian P O'Riordan, Thomas P. McGuire
  • Patent number: 7998547
    Abstract: A construction board is formed from a composition comprising one or more of the following ingredients: magnesium oxide, magnesium chloride, a binding agent (e.g., perlite), wood shavings, recycled board scraps, and water. The construction board further includes fiberglass and polyester paper sheets on opposite sides of the construction board. A method of fabricating the construction board is also disclosed to include mixing magnesium chloride with water to form a solution, mixing the solution with magnesium oxide, perlite and a binding agent to form a paste, and pouring the paste onto a mold to form a construction board. The paste is poured onto a mold which is then passed through a series of rollers to spread out the paste evenly across the mold and to form the paste into the desired thickness. The resulting construction board is fire and water resistant and much more durable than conventional sheetrock.
    Type: Grant
    Filed: July 3, 2007
    Date of Patent: August 16, 2011
    Assignee: Jet Products, LLC
    Inventors: Michael E. Feigin, Tak Sing Choi
  • Patent number: 7927420
    Abstract: The present invention describes a fire resistant building material composition, useful for example as a fire door core and to a method of making this composition where the building material of the present invention is prepared from an aqueous slurry of calcined gypsum, paper fibers, a water insoluble organic binder, fiber reinforcement and a set retarder.
    Type: Grant
    Filed: December 13, 2007
    Date of Patent: April 19, 2011
    Assignee: Georgia-Pacific Gypsum LLC
    Inventor: Hubert C. Francis
  • Publication number: 20110076438
    Abstract: A method for creating a three-dimensional solid freeform fabrication object includes spreading a reactive powder on a substrate, selectively dispensing a core binder in the reactive powder to form a core material, and selectively dispensing a shell binder in the reactive powder to form a shell on the core material.
    Type: Application
    Filed: September 27, 2010
    Publication date: March 31, 2011
    Inventors: Isaac Farr, Terry M. Lambright
  • Patent number: 7914914
    Abstract: Sheathing panels are produced by methods which do not require natural resources such as wood and use significantly reduced embodied energy when compared with the energy used to fabricate gypsum sheathing panels. A novel binder, consisting in one embodiment of monopotassium phosphate and magnesium oxide, and combined with various fillers, is incorporated with hollow tubes or water soluble fibers to create a gypsum board-like core which can be formed into a suitable sheathing panel handled and installed in a typical manner. The panel is manufactured to have a desirable shear resistance and water vapor permeability, important performance elements in building envelope design. The manufacturing process results in a panel that does not require mature trees as source material, does not off gas, and involves much lower greenhouse gas emissions than the processes used to make traditional wood or gypsum-based sheathing panels.
    Type: Grant
    Filed: June 30, 2007
    Date of Patent: March 29, 2011
    Assignee: Serious Materials, Inc.
    Inventor: Brandon D. Tinianov
  • Publication number: 20110020585
    Abstract: A PZT (lead zirconate titanate) element including one or more outside surfaces including a layer of encapsulation and metallization material and the method of making the same including at least the steps of providing a wafer of ceramic material including a base and one or more walls defining one or more recesses in the wafer which are filled with an encapsulation material. The encapsulation material is then cured and a layer of metallization is applied to one or more of the outside surfaces of the wafer and encapsulation material. Cuts are then made through the layer of metallization and cured encapsulation material to divide the wafer into a plurality of individual and separate ceramic elements with one or more surfaces including a layer of metallization and encapsulation.
    Type: Application
    Filed: July 21, 2010
    Publication date: January 27, 2011
    Inventors: Jeffrey A. Steinfeldt, Carl Jojola, Bruce Johnson
  • Patent number: 7867597
    Abstract: A construction board is formed from a composition comprising one or more of the following ingredients: magnesium oxide, magnesium chloride, a binding agent (e.g., perlite), wood shavings, recycled board scraps, and water. The construction board further includes fiberglass and polyester paper sheets on opposite sides of the construction board. A method of fabricating the construction board is also disclosed to include mixing magnesium chloride with water to form a solution, mixing the solution with magnesium oxide, perlite and a binding agent to form a paste, and pouring the paste onto a mold to form a construction board. The paste is poured onto a mold which is then passed through a series of rollers to spread out the paste evenly across the mold and to form the paste into the desired thickness. The resulting construction board is fire and water resistant and much more durable than conventional Sheetrock® brand plaster wallboard.
    Type: Grant
    Filed: August 13, 2007
    Date of Patent: January 11, 2011
    Assignee: Jet Products, LLC
    Inventors: Michael E. Feigin, John Wayne Wisenbaker, Jr., James Allen Wambaugh
  • Patent number: 7776170
    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.
    Type: Grant
    Filed: October 12, 2006
    Date of Patent: August 17, 2010
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Frederick T. Jones, Qingxia Liu
  • Publication number: 20100077698
    Abstract: Sheathing panels are produced by methods which do not require natural resources such as wood and use significantly reduced embodied energy when compared with the energy used to fabricate gypsum sheathing panels. A novel binder, consisting in one embodiment of monopotassium phosphate and magnesium oxide, and combined with various fillers, is incorporated with hollow tubes or water soluble fibers to create a gypsum board-like core which can be formed into a suitable sheathing panel handled and installed in a typical manner. The panel is manufactured to have a desirable shear resistance and water vapor permeability, important performance elements in building envelope design. The manufacturing process results in a panel that does not require mature trees as source material, does not off gas, and involves much lower greenhouse gas emissions than the processes used to make traditional wood or gypsum-based sheathing panels.
    Type: Application
    Filed: June 30, 2007
    Publication date: April 1, 2010
    Inventor: BRANDON D. TINIANOV
  • Publication number: 20090304980
    Abstract: A lightweight masonry compound (027) including the wrapping or protector cover (024, 025), said compound in a band form with particular dimensions in thickness, width and length; ready to use on site without the need of any equipment or tools; preferably having bonding strength and compressive strength equivalent or better than standard conventional mortar or dry premix or wet premix; capable of bonding masonry products.
    Type: Application
    Filed: February 20, 2006
    Publication date: December 10, 2009
    Inventor: Chan Wiryakusuma
  • Patent number: 7255907
    Abstract: A construction board is formed from a composition comprising one or more of the following ingredients: magnesium oxide, magnesium chloride, a binding agent (e.g., perlite), wood shavings, recycled board scraps, and water. The construction board further includes fiberglass and polyester paper sheets on opposite sides of the construction board. A method of fabricating the construction board is also disclosed to include mixing magnesium chloride with water to form a solution, mixing the solution with magnesium oxide, perlite and a binding agent to form a paste, and pouring the paste onto a mold to form a construction board. The paste is poured onto a mold which is then passed through a series of rollers to spread out the paste evenly across the mold and to form the paste into the desired thickness. The resulting construction board is fire and water resistant and much more durable than conventional sheetrock.
    Type: Grant
    Filed: January 31, 2005
    Date of Patent: August 14, 2007
    Inventors: Michael E. Feigin, Tak Sing Choi
  • Patent number: 7238402
    Abstract: A gypsum board having roughened surface glass fiber reinforcement. The roughened surface of glass fiber is created by incorporating nano or micro particles of colloidal silica or clay or other inorganic particles in a silane based sizing composition. The sizing coating is partially or completely cured and incorporated in gypsum wet mix either as additions of chopped fibers or as placement of roughened surface glass fiber mats at selected locations within a cast gypsum sheet. The roughened surface of glass fiber with nano or micro particles compliantly bonded with silane polymer transfers load from gypsum to glass fibers providing improved strength and flexure resistance of gypsum boards.
    Type: Grant
    Filed: March 10, 2004
    Date of Patent: July 3, 2007
    Assignee: Johns Manville
    Inventors: Timothy G. Swales, Philippe M. Scheerlinck, Thomas G. Grassl
  • Patent number: 7141292
    Abstract: A laminar mat comprises a rigid planar tile of moulded plastics material having on respective faces a planar layer integrated therewith during moulding of the tile, the planar layers each being of similar material. Non-adhesive integration of the planar layers during moulding eliminates the need for adhesive. The mat may be moulded so as to include one or more projections, recesses and living hinges.
    Type: Grant
    Filed: July 7, 2000
    Date of Patent: November 28, 2006
    Assignee: Innavisions, Limited
    Inventor: John Kenneth Kirby
  • Patent number: 6964801
    Abstract: A heat shield suitable for motor vehicles and a method for manufacturing the heat shield is provided. The heat shield is intended to protect temperature-sensitive assemblies, components and connection lines from the direct impact of heat radiation and, possibly, acts as insulation. Moreover, the heat shield may also provide advantageous soundproofing properties. The heat shield is comprised of first and second plates that are at least partially deformable and an insulating material positioned between said plates. Preferably, at least a portion of said insulating material is in the form of compacted powder or flakes.
    Type: Grant
    Filed: January 7, 1998
    Date of Patent: November 15, 2005
    Assignee: Dana Corporation
    Inventors: Bernd Bretschneider, Kai-Uwe Lemke, Dieter Grafl
  • Patent number: 6936326
    Abstract: The microporous heat insulation body consists of a compressed heat insulation material containing from 30 to 90% by weight of a finely divided metal oxide, from 0 to 30% by weight of an opacifier, from 0 to 10% by weight of an inorganic fibrous material, and from 0 to 15% by weight of an inorganic binder, and additionally from 2 to 45% by weight, preferably from 5 to 15% by weight of xonotlite.
    Type: Grant
    Filed: December 16, 1999
    Date of Patent: August 30, 2005
    Assignee: Promat International N.V.
    Inventors: Octavian Anton, Ann Opsommer
  • Patent number: 6927183
    Abstract: The present invention provides a reinforced article with an injected inner reinforcing mixture layer deposited between a covering material and a core material.
    Type: Grant
    Filed: September 4, 2002
    Date of Patent: August 9, 2005
    Assignee: Diversitech Corporation
    Inventor: Dennis Christen
  • Patent number: 6893752
    Abstract: A mold-resistant gypsum panel includes a core of an interlocking matrix of calcium sulfate dihydrate crystals, a facing material on at least one side of the panel and a salt of pyrithione dispersed through both the core and the facing materials. A method of making a mold-resistant gypsum product is also provided. A slurry of calcined gypsum, water and a water-soluble pyrithione salt is formed, then deposited on a sheet of facing material. The slurry on the facing material is shaped into a panel and maintained under conditions sufficient for the calcined gypsum to react with the water to form a core comprising an interlocking matrix of set gypsum crystals. Heating of the panel causes evaporation of the water that did not react with the calcined gypsum.
    Type: Grant
    Filed: June 28, 2002
    Date of Patent: May 17, 2005
    Assignee: United States Gypsum Company
    Inventors: Srinivas Veeramasuneni, Rodney Phillip Musselman
  • Patent number: 6818273
    Abstract: The microporus heat insulation body consists of a core of a compressed heat insulation material containing from 30 to 90% by weight of a finely divided metal oxide and further additives, wherein one or both surfaces thereof have a cover of a heat-resistant material and where the covers are the same or different and at least one side consists of prefabricated mica sheets.
    Type: Grant
    Filed: June 19, 2001
    Date of Patent: November 16, 2004
    Assignee: Promat International N.V.
    Inventors: Octavian Anton, Ann Opsommer
  • Patent number: 6815049
    Abstract: A composition including, but not limited to, a mixture of a calcium sulfate material, water, and a tetrametaphosphate compound is disclosed. Desirably, the inclusion of the tetrametaphosphate compound (e.g., salt or ion) in a pre-set treatment of a calcium sulfate material enhances the resistance to permanent deformation (e.g., sag), dimensional stability, and/or compressive strength of the composition while also preferably avoiding any significant retardive effect on the rate of hydration of calcined gypsum to calcium sulfate dihydrate. A set gypsum-containing product and a method for producing a set gypsum-containing product having increased resistance to permanent deformation are also disclosed.
    Type: Grant
    Filed: December 11, 2001
    Date of Patent: November 9, 2004
    Assignee: United States Gypsum Company
    Inventors: Srinivas Veeramasuneni, Qiang Yu, William A. Frank
  • Publication number: 20040182272
    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.
    Type: Application
    Filed: March 20, 2003
    Publication date: September 23, 2004
    Inventors: William Ralph Fox, Melissa Susan Merfeld
  • Patent number: 6773822
    Abstract: A novel gypsum board having antifungal properties is disclosed. The board comprises a gypsum core, front and back paper facings and an antifungal agent effective at inhibiting fungal growth. A preferred antifungal agent is cetyl pyridinium chloride. The antifungal agent can be present in the gypsum core and/or on one or both of the paper facings. In addition, the antifungal agent may be encapsulated in a material that releases the antifungal agent over time and/or upon exposure to moisture. Also disclosed are methods for preparing the aforementioned antifungal gypsum board.
    Type: Grant
    Filed: August 1, 2002
    Date of Patent: August 10, 2004
    Assignee: Temple-Inland Forest Products Corporation
    Inventor: Charles Capps
  • Patent number: 6767647
    Abstract: A gypsum wallboard that exhibits antimicrobial characteristics is disclosed. A method for making the wallboard is also disclosed. Suitable antimicrobial agents that may be applied to the wallboard or any components thereof include propiconazole, sodium pyrithione, tolyl diiodomethyl sulfone; tebuconazole; thiabendazole; 3-iodo-2-propynyl butylcarbamate; and mixtures thereof.
    Type: Grant
    Filed: June 6, 2003
    Date of Patent: July 27, 2004
    Assignee: Microban Products Company
    Inventors: Howard Wayne Swofford, Stephen A. Payne, Kevin Dean Drake
  • Patent number: 6746759
    Abstract: A resin mixture for forming a stable closed cell foam contains a phenolic resole, a chain extending agent, and as curing agents, a base, and an ester and/or an aliphatic carbonate. The chain extending agent is especially an epoxy resin and/or a phenolic novalak resin.
    Type: Grant
    Filed: April 12, 2002
    Date of Patent: June 8, 2004
    Assignee: Kingspan Industrial Insulation Limited
    Inventors: Mark Stanley Harris, Vincent Coppock, Norman Ryder, Graham Morgan Edgerley
  • Publication number: 20040089393
    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.
    Type: Application
    Filed: November 4, 2003
    Publication date: May 13, 2004
    Inventor: Edward W. Watras
  • Publication number: 20040043180
    Abstract: A method of producing an iridescent reflecting surface on an object is presented. Flakes of dry non metallic reflecting material such as cholesteric liquid crystal (CLC) material are applied to the surface so that the flakes are parallel with the surface and bound with a binder to the surface.
    Type: Application
    Filed: February 3, 2003
    Publication date: March 4, 2004
    Inventors: Yingqiu Jiang, Le Li, Sadeg Faris
  • Patent number: 6680127
    Abstract: A novel gypsum board having antifungal properties is disclosed. The board comprises a gypsum core, front and back paper facings and an antifungal agent effective at inhibiting fungal growth. A preferred antifungal agent is cetylpyridinium chloride. The antifungal agent can be present in the gypsum core and/or on one or both of the paper facings. In addition, the antifungal agent may be encapsulated in a material that releases the antifungal agent over time and/or upon exposure to moisture. Also disclosed are methods for preparing the aforementioned antifungal gypsum board.
    Type: Grant
    Filed: September 17, 2002
    Date of Patent: January 20, 2004
    Assignee: Temple-Inland Forest Products, Corporation
    Inventor: Charles L. Capps
  • Patent number: 6515717
    Abstract: A computer-based system for producing a multi-color multilayer image on a substrate using multi-colored cholesteric liquid crystal (CLC) pigment materials made from CLC flakes tuned to predetermined bands of color. A computer-controlled image generator automatically generates an image specifying a pattern over which binder material is to be applied to a substrate by a binder material applicator. A plurality of CLC pigment applicators automatically apply patterns of different-color CLC pigment material to a pattern of binder material applied to the substrate, binding thereto as the binder material dries. An output device is used to automatically return the substrate to a different one of CLC pigment applicators after each application of a pattern of different-color CLC pigment material to the pattern of binder material.
    Type: Grant
    Filed: August 28, 1998
    Date of Patent: February 4, 2003
    Assignee: Reveo, Inc.
    Inventors: Yingqiu Jiang, Le Li, Sadeg Faris