Water-settable Material (e.g., Gypsum, Etc.) Patents (Class 428/703)
  • Patent number: 10495129
    Abstract: Self-sealing fasteners and associated building panels, systems, and methods are provided. In one aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a coating material disposed on at least a portion the external surface. In another aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a polymer annulus surrounding at least a portion of the external surface of the of the elongated fastener body at or adjacent the head of the fastener.
    Type: Grant
    Filed: June 16, 2017
    Date of Patent: December 3, 2019
    Assignee: Georgia-Pacific Gypsum LLC
    Inventors: Vincent B. Thomas, Jason G. Peace, Seth C. Glenn
  • Patent number: 10352127
    Abstract: A polymetaphosphate composition and method for temporarily sealing a perforation in a wellbore to facilitate a treatment therein and a well tool which can include a flow path, and a flow blocking device which selectively prevents flow through the flow path. The well tool can include a polymetaphosphate composition. A method of constructing a downhole well tool can include forming a structure of a solid mass comprising a polymetaphosphate composition, and incorporating the structure into the well tool.
    Type: Grant
    Filed: October 21, 2015
    Date of Patent: July 16, 2019
    Assignee: A. Schulman, Inc.
    Inventors: Bradley L. Todd, Stanley J. Heath
  • Patent number: 10233641
    Abstract: This disclosure relates to using polyester films on building boards to enable improved surface coatings. The polyester film is preferably applied to a glass mat via an adhesive to form a laminate. This laminate is then bonded to the exterior surface of a gypsum board. The polyester film is advantageous because it allows for exterior surface coatings to be applied. In one embodiment, an exterior acrylic coating is applied to the polyester film. Boards constructed in accordance with this disclosure allow for exterior finishings to be achieved without the need for excessive finishing materials or steps.
    Type: Grant
    Filed: September 22, 2017
    Date of Patent: March 19, 2019
    Assignee: Saint-Gobain Placo SAS
    Inventors: Gerald D. Boydston, Bryan J. Wiltzius, Choung-Houng Lai, Michael J. Lemberger
  • Patent number: 9249053
    Abstract: The present invention provides a composite wall panel with good thermal insulation and sufficient strength for structural use which is designed for the fabrication of energy efficient building. The composite wall panel of the present invention comprises a foamed concrete core with sufficient compressive strength and low thermal conductivity which is sandwiched between two lightweight ductile fiber reinforced cementitious composite (FRCC) protective layers with low thermal conductivity, good barrier resistance to moisture/chloride ion/gas, multiple cracking as well as certain amount of steel reinforcements. These composite wall panels are useful in a variety of buildings in both cold and hot regions.
    Type: Grant
    Filed: February 18, 2013
    Date of Patent: February 2, 2016
    Assignee: NANO AND ADVANCED MATERIALS INSTITUTE LIMITED
    Inventors: Christopher Kin Ying Leung, Kwok Fai Cheung, Honggang Zhu, Sze Wai Lin
  • Patent number: 9102076
    Abstract: Composites such as self-supporting rigid composites that include aerogel have low thermal conductivity and attractive mechanical properties. Methods for preparing such composites include, for example, combining an aerogel-containing material with a binder to form a slurry and allowing the slurry to harden. At least part of the hardening process in conducted under compression.
    Type: Grant
    Filed: November 22, 2010
    Date of Patent: August 11, 2015
    Assignee: Cabot Corporation
    Inventors: Dhaval Arun Doshi, Thomas Michael Miller, Joshua Harby Chase, Catherine Meryl Norwood
  • Publication number: 20150147579
    Abstract: A composition comprising at least one first divalent unit represented by formula: and at least one of a second divalent unit comprising a pendant Z group or a monovalent unit comprising a thioether linkage and a terminal Z group, wherein each Z group is independently selected from the group consisting of —P(O)(OY)2 and —O—P(O)(OY)2. R? and R?? are each independently selected from the group consisting of hydrogen and alkyl having from 1 to 4 carbon atoms. Y is selected from the group consisting of hydrogen, alkyl, trialkylsilyl, and a counter cation. Methods of treating a surface using these compositions and articles with a surface in contact with these compositions are provided. Methods of making these compositions are also provided.
    Type: Application
    Filed: January 30, 2015
    Publication date: May 28, 2015
    Inventors: Chetan P. Jariwala, Gregory D. Clark, Jason T. Petrin, Rudolf J. Dams, Steven J. Martin, Mark J. Pellerite
  • Patent number: 9034097
    Abstract: A composition for the preparation of a fire protection mortar comprising 45 to 70% by weight of cement binder, 8 to 20% by weight calcite, 8 to 20% by weight mica, 0 to 5% by weight of xonotlite, 0.1 to 20% by weight of expanded perlite, 0.1 to 10% by weight of fibers, 0.01 to 2% by weight of air entrainer and foaming agent, 0.01 to 2% by weight of processing aids.
    Type: Grant
    Filed: February 4, 2014
    Date of Patent: May 19, 2015
    Assignee: Promat Research and Technology Centre NV
    Inventors: Xiao Wu, Ann Opsommer
  • Publication number: 20150104629
    Abstract: A gypsum composition, board, and method of producing a gypsum board with increased fire endurance are described. The set gypsum-containing composition can be used to prepare a gypsum board having fire endurance, based on particular water-to-stucco ratios.
    Type: Application
    Filed: October 15, 2013
    Publication date: April 16, 2015
    Applicant: United States Gypsum Company
    Inventors: Bangji CAO, Weixin D. SONG, Cesar CHAN
  • Patent number: 8974925
    Abstract: Described herein is a composite board and a method of producing a composite board, the board having increased fire endurance. The board comprises a sheet having a thickness greater than about 0.014 inches, and a thermal conductivity of about 0.1 w/(m.k.) or less. The composite board can be part of a wall assembly comprising two boards defining an interior cavity, the sheet facing the interior cavity.
    Type: Grant
    Filed: October 15, 2013
    Date of Patent: March 10, 2015
    Assignee: United States Gypsum Company
    Inventors: Bangji Cao, Weixin D. Song, Cesar Chan, Scott Leckie
  • Patent number: 8974597
    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.
    Type: Grant
    Filed: July 2, 2013
    Date of Patent: March 10, 2015
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Steven W. Sucech, Brent E. Groza, Raymond J. Mlinac, Frederick T. Jones, Paul J. Henkels
  • Publication number: 20150064433
    Abstract: Membrane-ready fibrous faced gypsum panels, methods, and apparatus are provided. The panels include a first fibrous mat having a first surface and a second surface, a second fibrous mat having a first surface and a second surface, a gypsum core in contact with the second surfaces of the first and second fibrous mats, and a material coating that covers the first surface of the first fibrous mat and forms a substantially smooth outer surface.
    Type: Application
    Filed: August 26, 2014
    Publication date: March 5, 2015
    Inventors: Michael D. Foster, Brian W. Bland, Ali Fadhel, James E. Bailey, Shaobing Wu
  • Patent number: 8968621
    Abstract: Gypsum plasterboard is produced by combining calcium sulphate hemihydrate (stucco) with water to form an aqueous slurry. Uncalcined gypsum having a specific surface area below 0.3 m2/g is added to the slurry and the slurry is discharged onto a support so as to form a sheet of gypsum plasterboard.
    Type: Grant
    Filed: June 23, 2004
    Date of Patent: March 3, 2015
    Assignee: BPB Limited
    Inventors: Winfried Johannes Josef Spikermann, Kane Ian Ironside
  • Publication number: 20150056404
    Abstract: In one aspect, composite construction materials are described herein. In some embodiments, a composite construction panel comprises a substrate layer, a cover layer separated from the substrate layer by one or more spacers, and at least one mat disposed between the substrate layer and the cover layer, wherein the mat comprises at least one phase change material disposed in at least one phase change region.
    Type: Application
    Filed: September 14, 2012
    Publication date: February 26, 2015
    Applicant: Phase Change Energy Solutions, inc.
    Inventors: Reyad I Sawafta, Ken Farrish, Byron Owens, Peter F. Horwath, James D. Thornsberry
  • Patent number: 8940091
    Abstract: Surfactant-coated hemihydrate gypsum which is coated with 0.01 to 1 part by weight of a surfactant based on 100 parts by weight of hemihydrate gypsum, wherein the residual rate of the surfactant when the surfactant-coated hemihydrate gypsum is heated up to 300° C. is not less than 40 wt % of the amount of the surfactant before heating.
    Type: Grant
    Filed: August 21, 2012
    Date of Patent: January 27, 2015
    Assignee: Tokuyama Corporation
    Inventors: Shingo Hiranaka, Hiroyoshi Kato
  • Patent number: 8916277
    Abstract: Wallboards, as well as other building materials, are produced by methods which use significantly reduced embodied energy, generating far less greenhouse gases when compared with the energy used to fabricate gypsum wallboard. A novel cementitious core, consisting in one embodiment of post-industrial waste such as slag and combined with pH modifiers, provides a controlled exothermic reaction to create a gypsum-wallboard-like core which can be wrapped in a selected material such as recycled paper and manufactured on a conveyor system to appear, weigh and handle similar to gypsum wallboard, but without the large amounts of energy required to make gypsum wallboard. The manufacturing process results in lower greenhouse gas emissions than the processes used to make gypsum wallboard.
    Type: Grant
    Filed: November 14, 2012
    Date of Patent: December 23, 2014
    Assignee: Serious Energy, Inc.
    Inventors: Kevin Surace, Meredith Ware, Denise Hoover, Jiaping Han, Tiandan Chen
  • Patent number: 8917018
    Abstract: A system and process for controlling electronic interactions between two or more interactable materials.
    Type: Grant
    Filed: January 19, 2011
    Date of Patent: December 23, 2014
    Assignee: Ramot at Tel-Aviv University Ltd.
    Inventors: Bogdan Belgorodsky, Eyal Drug, Ludmila Fadeev, Netta Hendler, Elad Mentovich, Shachar Richter, Michael Gozin
  • Patent number: 8852338
    Abstract: A composite panel is made from wood and cementitious binders, with flat surfaces and several possible colors. The panel comprises 35 to 85% of grey or white Portland cement; 10 to 30% of debarked resinous wood particles; 5 to 20% of semi-hydrated calcium sulphate; 0 to 10% of a surface accelerator; 0 to 10% of aluminum sulphate solution; 0 to 30% of calcium carbonate; and 0 to 15% of pigments. The process of preparation for the existing VIROC panel is adjusted to the new material. This panel, in addition to being very resistant and showing high performances in terms of resistance to impact, humidity, temperature variation, noise and fungi, as well as other microorganisms, also complies with all the requirements of the associated product standard.
    Type: Grant
    Filed: October 25, 2013
    Date of Patent: October 7, 2014
    Assignee: Secil-Companhia Geral de Cal e Cimento, S.A.
    Inventor: Angela Maria Jesus De Sequeira Serra Nunes
  • Patent number: 8841484
    Abstract: Disclosed are certain partially fluorinated amide compounds and composite materials containing the compounds. Also disclosed are methods for making the composite materials.
    Type: Grant
    Filed: September 20, 2011
    Date of Patent: September 23, 2014
    Assignee: E I du Pont de Nemours and Company
    Inventors: Keith W. Hutchenson, Anilkumar Raghavanpillai, Stefan Reinartz
  • Patent number: 8801852
    Abstract: A gypsum slurry is provided that includes calcium sulfate hemihydrate; water; a dispersant component comprising at least one of the following a comb-branched polymer with polyether side chains, naphthalene sulfonate-formaldehyde condensate or melamine sulfonate-formaldehyde condensate; a foaming agent; and a polycondensation component with three polycondensation repeating units. Also provided is a method for making a gypsum slurry with a foaming agent in which the ratio between the dispersant component and the polycondensation component is adjusted to control for the size of foam bubbles in the gypsum slurry. Gypsum products made from the gypsum slurry are provided and methods for making the products are provided as well.
    Type: Grant
    Filed: November 8, 2013
    Date of Patent: August 12, 2014
    Assignee: United States Gypsum Company
    Inventors: Chris C. Lee, Alfred C. Li, Richard J. Haszel, David R. Blackburn, James R. Wittbold, Brent Groza
  • Publication number: 20140205861
    Abstract: Reinforced boards and/or walls, and methods of producing thereof. In some non-limiting examples, there is provided a reinforced gypsum board and a process for the production thereof. In one example, the reinforced board may include one or more reinforcing elements, e.g., to enhance the rigidity of the board and/or to provide support for the board.
    Type: Application
    Filed: November 27, 2013
    Publication date: July 24, 2014
    Inventor: Dany Amar
  • Publication number: 20140147615
    Abstract: A multilayer thermal insulation composite for fire protection applications. The composite includes a fibrous insulation layer, at least one inorganic heat absorbing layer disposed on one side of the fibrous insulation layer, and at least one superinsulation layer disposed on at least one side of the composite adjacent the heat absorbing layer or the fibrous insulation layer. The composite may further include a scrim layer comprising a high temperature resistant, flexible, woven or non-woven scrim or scrim and high temperature resistant material disposed around the multilayer thermal insulation composite partially or substantially totally encapsulating the composite. The composite is lightweight and flexible, exhibits reduced heat transfer to the cold-face, with improved thermal insulation capability.
    Type: Application
    Filed: January 30, 2014
    Publication date: May 29, 2014
    Applicant: UNIFRAX I LLC
    Inventors: Joseph A. FERNANDO, Kennth B. MILLER
  • Patent number: 8715409
    Abstract: A calcium sulfoaluminate-based concrete with a permeability of less than 1000 Coulombs. Rapid-setting low chloride-ion permeability calcium sulfoaluminate (CSA) cements and concretes include CSA and a suitable polymer such as a sol-gel derived, organic-inorganic, silica based hybrid coating solutions of polystyrene-butylacrylate polymers containing active silanol groups protected by hydroxyl groups containing polyalcohol, or other polymers. Such polymers may be added as powders or as liquid in the finish mill. Other rapid-setting low chloride-ion permeability (CSA) cements and concretes include CSA with selected particle size distributions, and do not require use of any polymer. These CSA cements and concretes have low chloride-ion permeability, high early strength, fast setting times, low-shrinkage, and high freeze-thaw resistance.
    Type: Grant
    Filed: May 6, 2011
    Date of Patent: May 6, 2014
    Assignee: PKL Corporation
    Inventors: Edward K. Rice, Grant M. Kao, Eric P. Bescher
  • Publication number: 20140106159
    Abstract: A barrier suitable for use in building construction materials. The barrier is formed from a plurality of members. Each member has a heat-resistant core or shell, a heat-reactive intumescent or flame retardant layer formed on an outer surface of the heat-resistant core, an antistatic and oil-phobic layer formed on an outer surface of the heat-reactive intumescent layer.
    Type: Application
    Filed: December 17, 2013
    Publication date: April 17, 2014
    Inventor: Joseph Riordan
  • Patent number: 8691007
    Abstract: A wallboard, a method of preparing a wallboard, and a method of making a gypsum slurry to prepare a wallboard are provided. The wallboard includes a set gypsum dihydrate derived substantially from a non-fibrous form of calcium sulfate and selected from the group consisting of anhydrous gypsum and gypsum hemihydrate. The wallboard also includes an aerogel dispersed in the gypsum dihydrate.
    Type: Grant
    Filed: September 20, 2012
    Date of Patent: April 8, 2014
    Assignee: Georgia-Pacific Gypsum LLC
    Inventors: Susnata Samanta, Hubert Francis
  • Publication number: 20140093679
    Abstract: A building exterior material is made of a curable composition which has excellent water vapor permeability. The building exterior material comprises a building exterior substrate coated with a curable composition comprising an organic polymer (A) containing a silicon-containing group capable of being cross-linked by forming a siloxane bond, wherein the organic polymer (A) is a polyoxyalkylene polymer (A1) containing an oxyethylene repeating unit in a backbone skeleton, a weight of the oxyethylene repeating unit in the component (A1) being 1 to 80% by weight of the total weight of the component (A1), and/or a (meth)acrylate polymer (A2) containing an oxyethylene repeating unit at a side chain, a weight of the oxyethylene repeating unit in the component (A2) being 1 to 50% by weight of the total weight of the component (A2), and the curable composition is cured into a cured product having a thickness of 0.1 to 3.0 mm.
    Type: Application
    Filed: April 13, 2012
    Publication date: April 3, 2014
    Applicant: KANEKA CORPORATION
    Inventor: Toshihiko Okamoto
  • Patent number: 8657950
    Abstract: An inorganic material board, which is a cured mat formed by dehydrating a slurry including 30 to 53 wt % of blast furnace slag, 2 to 5 wt % of gypsum having an average particle size of 200 to 2000 ?m, 5 to 11 wt % of alkaline material, 5 to 15 wt % of reinforcing fibers, and 31 to 50 wt % of inorganic admixture with respect to a total solid content, and in which a weight ratio of the blast furnace slag to the gypsum to the alkaline material is 1:0.05 to 0.15:0.15 to 0.35. It is desirable that the blast furnace slag has a specific surface area of 3000 to 5000.
    Type: Grant
    Filed: March 11, 2013
    Date of Patent: February 25, 2014
    Assignee: Nichiha Corporation
    Inventors: Kenta Terai, Hiromi Fujiwara
  • Patent number: 8656675
    Abstract: The invention is directed to a composite foam material that is alkaline and heat resistance. The composite foam material comprises a foam layer that having a film layer attached thereto and in which at least one of the film or foam layers includes a carbon free radical scavenger agent that is dispersed therein. The carbon free radical scavengers neutralize free radicals that are generated in the polymeric material (e.g., film or foam layer) and help prevent the degradation of the foam composite material. In particular, foam composite materials in accordance with the present invention can be used in underlayment applications in which exposure to heat can degrade the underlayment. As a result, the durability and useful life of the composite sheet material can be extended. In some embodiments of the present invention provides a floor underlayment material that overcomes many of the problems discussed above.
    Type: Grant
    Filed: May 31, 2013
    Date of Patent: February 25, 2014
    Assignee: Sealed Air Corporation (US)
    Inventors: Shau-Tarng Lee, Claes Hermansson, Brent Sholl
  • Patent number: 8632631
    Abstract: High SRI cementitious systems comprising integral concrete coloring admixtures, toppings, dry-shake hardeners, and other cementitious systems are provided. The high-SRI cementitious systems comprise one or more IR reflective pigments and other components to make-up the cementitious system, depending on the application. The high-SRI cementitious systems of the invention may be in the form of mixtures which increase the total solar reflectivity (TSR or albedo) and the Solar Reflectance Index (SRI) of concrete. The high-SRI cementitious systems may be toppings mixed with water for application to existing concrete surfaces, dry-shake hardeners for application to freshly-placed plastic concrete, or the IR reflective pigments may be mixed into integrally colored concrete in various forms, such as conventional cast-in-place concrete, lightweight concrete, pervious concrete and concrete building panels, pavers or masonry units.
    Type: Grant
    Filed: August 7, 2012
    Date of Patent: January 21, 2014
    Assignee: L. M. Scofield Company
    Inventors: Stanley G. Stratton, Phillip J. Arnold, James K. Crawford, Pritam S. Dhaliwal, Martin Ellis Wild
  • Patent number: 8628865
    Abstract: The invention relates to a method for producing a sheet from renewable raw materials. In the method, after mixing a composition to produce a sheet from renewable raw materials, this composition is applied to a conveyor belt. Protruding materials or unevennesses are eliminated with the aid of a device, preferably a simple doctor blade. Without supplying heat, the composition is then subjected to a first drying process on the conveyor belt, before the endless sheet created in this way is cut into sections. The sections are then passed on to final drying in a storage device. After complete drying, regions at the extremities of the sections that have been adversely affected by cutting up the endless sheet are removed from these sections and chopped up into chips. These chips are returned to the further production process in a final method step by feeding them into the composition for producing a sheet from renewable raw materials.
    Type: Grant
    Filed: July 6, 2009
    Date of Patent: January 14, 2014
    Assignee: Strohlos Produktentwicklung KG
    Inventor: Christian Losehand
  • Patent number: 8603239
    Abstract: This invention relates to a formulation with the addition of low density additives of volcanic ash, hollow ceramic microspheres or a combination of microspheres and volcanic ash or other low density additives into cementitious cellulose fiber reinforced building materials. This formulation is advantageously lightweight or low density compared as compared to current fiber cement products without the increased moisture expansion and freeze-thaw degradation usually associated with the addition of lightweight inorganic materials to fiber cement mixes. The low density additives also give the material improved thermal dimensional stability.
    Type: Grant
    Filed: April 25, 2012
    Date of Patent: December 10, 2013
    Assignee: James Hardie Technology Limited
    Inventors: James A. Gleeson, Kalynne H. Paradis, Brian P. Sloane, David L. Melmeth, Dean M. Seligman
  • Patent number: 8597426
    Abstract: A panel is provided that includes stucco, water and a dispersant component having dispersing properties and comprising a comb-branched polymer with polyether side chains, naphthalene sulfonate-formaldehyde condensate or melamine sulfonate-formaldehyde condensate. A polycondensation component is also included in the slurry that includes three repeating units. A method of making the gypsum panel includes combining stucco, water and a first dosage of a first dispersant to form a slurry, the first. A second dosage of a second dispersant is added to the slurry. Properties of the gypsum slurry are tested and it is formed into a product. The product sets and properties of the product are identified. The first dosage or the second dosage is changed based on the properties of the slurry or product.
    Type: Grant
    Filed: August 27, 2010
    Date of Patent: December 3, 2013
    Assignee: United States Gypsum Company
    Inventors: Chris C. Lee, Alfred C. Li, Richard J. Haszel, David R. Blackburn, James R. Wittbold, Brent Groza
  • Patent number: 8597779
    Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each insulation board includes a foam material that includes polyisucyanurate, the foam material having a first density. Each cover board includes a material including polyisocyanurate, the material having a second density greater than the first. The roofing system may further include a waterproofing membrane adapted for overlying the cover boards. The insulation boards and cover boards may include facers on top or bottom surfaces.
    Type: Grant
    Filed: February 4, 2013
    Date of Patent: December 3, 2013
    Assignee: Johns Manville
    Inventors: Duane Paradis, Christopher J Griffin, Raymond C Swann, Joel Evan Hazy, Brad C Burdic
  • Patent number: 8592040
    Abstract: Polymer emulsion formulations suitable for use as binders or in coating systems generally are provided. The formulations comprise a copolymer derived from one or more vinyl ester monomers of the formula I, one or more copolymerizable surfactants of formula II, and optionally one or more additional co-monomers. Gypsum boards, methods of making gypsum boards, and methods of making the copolymer are also disclosed.
    Type: Grant
    Filed: September 5, 2008
    Date of Patent: November 26, 2013
    Assignee: BASF SE
    Inventors: Peter C. Hayes, Ronald Horwitz
  • Publication number: 20130251986
    Abstract: A building material includes a paneled article having a first side and a second side. A layer of encapsulated latent heat storage material is disposed on the first side of the panel and a coating is disposed over the layer of encapsulated latent heat storage material.
    Type: Application
    Filed: March 15, 2011
    Publication date: September 26, 2013
    Applicant: GEORGIA-PACIFIC GYPSUM LLC
    Inventors: Joel T. Charlton, Keshav S. Gautam
  • Publication number: 20130251938
    Abstract: The present invention provides flexible binder compositions comprising one or more polycarboxy emulsion copolymer has a measured Tg of 40° C. or less, such as from ?45° C. to 25° C., and a polyol crosslinker. In one embodiment, the binder compositions comprising the polycarboxy emulsion copolymer can be used in making pultruded composites, such as sheets, for example, flexible gypsum board facing sheets, and flexible non-woven articles such as, for example, carpet backing.
    Type: Application
    Filed: May 17, 2013
    Publication date: September 26, 2013
    Inventors: James T. CONNAUGHTON, I, William C. FINCH, Michael D. KELLY, Hal C. MORRIS, Xun TANG
  • Patent number: 8535790
    Abstract: Mold- and moisture-resistant gypsum boards and methods for making them are disclosed, the method comprising applying a slurry that forms a gypsum core to an upper or a lower facing sheet impregnated with a thermoset resin (e.g., a phenol-formaldehyde resin) in an amount effective to (i) allow water vapor passage through the facing sheet when the thermoset resin is in its uncured state and (ii) provide mold and moisture resistance to the facing sheet when the thermoset resin is in its cured state and heating sufficiently to cure said resin and dry said gypsum core, thereby yielding said gypsum board.
    Type: Grant
    Filed: September 8, 2011
    Date of Patent: September 17, 2013
    Assignee: Georgia-Pacific Chemicals LLC
    Inventors: Frederick C. Dupre, Jr., Kathleen Dalburg
  • Patent number: 8530064
    Abstract: Disclosed is a method for inhibiting the growth of mold on building materials by application onto and/or incorporation into the building material of a mold-inhibiting composition comprising dehydroacetic acid or a salt thereof and, optionally, an additional fungicidal agent such as a quaternary ammonium compound. A preferred application of the method is the inhibition of mold growth on plasterboard (drywall).
    Type: Grant
    Filed: October 7, 2009
    Date of Patent: September 10, 2013
    Assignee: Lonza, Inc.
    Inventors: Xiao Jiang, Leigh Walker
  • Patent number: 8484922
    Abstract: The invention is directed to a composite foam material that is alkaline and heat resistance. The composite foam material comprises a foam layer that having a film layer attached thereto and in which at least one of the film or foam layers includes a carbon free radical scavenger agent that is dispersed therein. The carbon free radical scavengers neutralize free radicals that are generated in the polymeric material (e.g., film or foam layer) and help prevent the degradation of the foam composite material. In particular, foam composite materials in accordance with the present invention can be used in underlayment applications in which exposure to heat can degrade the underlayment. As a result, the durability and useful life of the composite sheet material can be extended. In some embodiments of the present invention provides a floor underlayment material that overcomes many of the problems discussed above.
    Type: Grant
    Filed: February 17, 2010
    Date of Patent: July 16, 2013
    Assignee: Sealed Air Corporation (US)
    Inventors: Shau-Tarng Lee, Claes Hermansson, Brent Sholl
  • Patent number: 8481168
    Abstract: The present disclosure describes various building materials used in the building and construction industry, and to buildings or objects constructed therefrom, and to methods of making these building materials. The building materials comprise a polymeric material, such as sodium alginate and/or calcium alginate which confers significant flame-, fire- and heat-resistance or imperviousness to the materials. Other substances can be added to the materials to improve cross-linking and/or to produce resistance to fungal degradation. The building materials which can be produced, processed, or treated using the alginate polymers of the invention include, but are not limited to, wood products; masonry products; wall, roofing, flooring and siding products; and paint products. Further, sodium alginate in the form of a gel may be used as a firebreak to effectively stop the advance of grass fires, wildfires, and forest fires.
    Type: Grant
    Filed: July 19, 2012
    Date of Patent: July 9, 2013
    Assignee: Tamarisk Technologies, L.L.C.
    Inventor: Daniel R. DeBrouse
  • Publication number: 20130171900
    Abstract: The invention relates to an insulating construction element made of at least one board comprising fibres, aerogel particles and at least one binder. To achieve an insulating construction element which is especially easy to handle, easy to produce and which has high insulation properties the board comprises 20 to 40 percent by weight mineral wool fibres, 45 to 70 percent by weight aerogel particles and 8 to 12 percent by weight binder which components are pressed and cured to the board having a density of 130 kg/m3 to 200 kg/m3.
    Type: Application
    Filed: May 18, 2011
    Publication date: July 4, 2013
    Applicant: ROCKWOOL INTERNATIONAL A/S
    Inventors: Ulrich Bauer, Kristian Skovgaard Joergensen, Cor, J. M. Ghijzen
  • Patent number: 8470461
    Abstract: The invention generally provides gypsum-containing slurries including stucco, naphthalenesulfonate dispersant, and pregelatinized starch. The naphthalenesulfonate dispersant is present in an amount of about 0.1%-3.0% by weight based on the weight of dry stucco. The pregelatinized starch is present in an amount of at least about 0.5% by weight up to about 10% by weight of pregelatinized starch by weight based on the weight of dry stucco in the formulation. Other slurry additives can include trimetaphosphate salts, accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, gypsum wallboard, and a method of making gypsum wallboard.
    Type: Grant
    Filed: June 11, 2012
    Date of Patent: June 25, 2013
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Weixin D. Song, Michael R. Lynn
  • Patent number: 8470436
    Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each insulation board includes a polymer foam material having a first density. Each cover board includes a material including polyisocyanurate, the material having a second density greater than the first. The foam material of the insulation boards may include, for example, polystyrene, polyurethane, or a phenolic material. The insulation boards and cover boards may include facers on top or bottom surfaces.
    Type: Grant
    Filed: February 4, 2013
    Date of Patent: June 25, 2013
    Assignee: Johns Mansville
    Inventors: Duane Paradis, Christopher J Griffin, Raymond C Swann, Joel Evan Hazy, Brad C Burdic
  • Publication number: 20130143036
    Abstract: A new roofing tile with enhanced surface durability and processes for manufacturing the same. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.
    Type: Application
    Filed: June 1, 2012
    Publication date: June 6, 2013
    Inventors: Andreas DRECHSLER, Jürgen KLEIN, Florence YZIQUEL, Jeffrey CHEN, Emmanuel FOURDRIN
  • Publication number: 20130101838
    Abstract: An about ? inch to ¾ inch thick low weight, low density gypsum panel with fire resistance capabilities sufficient to provide a Thermal Insulation Index of at least 17.0 minutes which when subjected to U419 test procedures will not fail for at least 30 minutes and, in selected embodiments, also has outstanding water resistance properties.
    Type: Application
    Filed: December 12, 2012
    Publication date: April 25, 2013
    Applicant: UNITED STATES GYPSUM COMPANY
    Inventor: UNITED STATES GYPSUM COMPANY
  • Patent number: 8426017
    Abstract: A cover board composite for overlying insulation of a roofing system includes a high-density core layer that is at least predominantly of a polymer material, a facer overlying and bonded to a bottom major surface of the core layer, and a reinforcement interposed between the facer and the bottom major surface of the core layer to coincide with a fastener pattern for securing the cover board composite to a roof deck and increase a per-fastener wind-uplift pull through rating for the cover board composite.
    Type: Grant
    Filed: June 3, 2010
    Date of Patent: April 23, 2013
    Assignee: Johns Manville
    Inventors: Duane Paradis, Christopher J. Griffin, Raymond C. Swann, Joel Evan Hazy, Brad C. Burdic
  • Patent number: 8409711
    Abstract: An article of manufacture including reinforcement material embedded in a phosphate cement composition is provided. The phosphate cement composition includes about 10 to 40 percent by weight calcium or magnesium oxide, about 10 to 40 percent by weight acid phosphate, and about 10 to 50 percent by weight vermiculite or perlite or mixture thereof.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: April 2, 2013
    Assignee: Grancrete, Inc.
    Inventors: Jeffrey L. Selph, James W. Paul, Jr.
  • Patent number: 8404365
    Abstract: Paper useful in the manufacture of gypsum wallboard is surfaced treated with an additive to improve the bonding affinity of the paper for wet plaster thereby permitting the manufacture of gypsum wallboard with little or no added starch and reduced amounts of water. A surface treating adhesive, a method of converting the paper and wallboards containing the paper are also described.
    Type: Grant
    Filed: March 22, 2007
    Date of Patent: March 26, 2013
    Assignee: Hercules Incorporated
    Inventor: Charles L. Burdick
  • Patent number: 8399089
    Abstract: A nanomaterial based admixture improves the fire retardancy of foam-based GFRC material to a minimum of 3 hours, creating Nano GFRC. A dispersion of nanoclay in water is prepared by heating water to 80-90 ° C., adding the desired amount of nanoclay and stirring with a magnetic stirrer for 30-45 minutes, producing a stable and uniform dispersion. Concrete is made by mixing sand, acryl, water, nanoclay solution, and cement in a bucket, adding enough water reducer to thin the mixture enough to stir, adding fibers, and mixing the composite using a rotor for about 10 minutes. Polystyrene foam is sandwiched with the prepared mixture on all sides to make the concrete. This resulting concrete is lightweight and strong, reduces CO and CO2 emissions by a factor of three compared to standard GFRC, and shows dramatic improvement in fire retardant properties.
    Type: Grant
    Filed: December 1, 2008
    Date of Patent: March 19, 2013
    Assignee: Oceanit Laboratories, Inc
    Inventors: Vinod P. Veedu, Ian Kitajima
  • Patent number: 8389109
    Abstract: A building element selected from a roofing tile or siding element may be formed from a first cementitious mixture and a second cementitious mixture containing a photocatalytic cementitious mixture. The first cementitious mixture and the photocatalytic cementitious mixture may be co-formed into a shaped uncured two layer monolith having a base layer of the first cementitious mixture and a top layer of the photocatalytic cementitious mixture. The shaped uncured two layer monolith is then cured. The resulting building element may be algae-resistant.
    Type: Grant
    Filed: March 2, 2011
    Date of Patent: March 5, 2013
    Assignee: 3M Innovative Properties Company
    Inventors: Mark T. Anderson, Rachael A. T. Gould, Jeffry L. Jacobs
  • Patent number: RE44070
    Abstract: The invention provides a light weight composite gypsum board including a foamed low density set gypsum core, a top non-foamed (or reduced-foamed) bonding high density layer and a bottom non-foamed (or reduced-foamed) bonding high density layer, a top cover sheet bonded to the foamed low density set gypsum core by the top non-foamed (or reduced-foamed) bonding high density layer, and a bottom cover sheet bonded to the foamed low density set gypsum core by the bottom non-foamed (or reduced-foamed) bonding high density layer. The foamed low density set gypsum core is prepared having a density of less than about 30 pcf using soap foam in the gypsum-containing slurry. The combination of components provide a composite gypsum board having light weight and high strength.
    Type: Grant
    Filed: June 15, 2012
    Date of Patent: March 12, 2013
    Assignee: United States Gypsum Company
    Inventors: Qiang Yu, Weixin D. Song