ВЫКЛЮЧАТЕЛЬ И СПОСОБ ЕГО ИЗГОТОВЛЕНИЯ

Выключатель для управления работой устройства содержит панель (16) и акустический датчик (26). Панель образует перегородку в строительной конструкции, а акустический датчик выполнен с возможностью обнаружения акустических волн, проходящих через панель. При приложении пользователем давления к панели датчик обнаруживает сформированные акустические волны и выдает сигналы для управления работой устройства, такого как дверной звонок, источник света, телевизионная система, звуковая система, вентиляционная система, оконная штора, или жалюзи, радио или устройство оповещения. 6 н. и 22 з.п. ф-лы, 8 ил.

ГИПСОВАЯ ПАНЕЛЬ, ПРИМЕНИМАЯ В СЫРЫХ ИЛИ ВЛАЖНЫХ ОБЛАСТЯХ

Изобретение относится к строительным материалам и касается гипсовой панели, применимой в сырых или влажных областях. Панель содержит центральный слой, который имеет по меньшей мере одну сторону, покрытую нетканым материалом. Нетканый материал имеет две стороны: внутреннюю сторону, находящуюся в контакте с гипсовым центральным слоем, и внешнюю сторону, находящуюся на противоположной стороне гипсового центрального слоя. Внутренняя сторона нетканого материала имеет неровность поверхности Ra от 25 до 60 мкм, предпочтительно от 25 до 50 мкм, предпочтительно от 25 до 40 мкм. Внешняя сторона нетканого материала имеет неровность поверхности Ra меньше 25 мкм. Изобретение обеспечивает усовершенствование соединения между плитой и гипсом. 2 н. и 16 з.п. ф-лы, 7 табл., 10 ил.

СТРОИТЕЛЬНАЯ ПАНЕЛЬ, ОБЛАДАЮЩАЯ УЛУЧШЕННОЙ ПРОЧНОСТЬЮ КРЕПЛЕНИЯ

Настоящее изобретение относится к гипсовой панели, содержащей первую полимерную добавку и вторую полимерную добавку, распределенные в ней, где первая полимерная добавка представляет собой поливинилацетат, а вторая полимерная добавка представляет собой крахмал, где гипсовая панель содержит погруженные в нее стеклянные волокна в количестве 2-10 мас. % по отношению к гипсу; где общее количество первой и второй полимерных добавок составляет более 4 мас. % и менее 15 мас.% по отношению к гипсу. В гипсовой панели количество первой полимерной добавки может быть равно или превышать количество второй полимерной добавки. Причем крахмал может быть этилированным. Технический результат - повышение прочности панели. Повышение текучести штукатурных суспензий и повышение устойчивости к гигроскопическому расширению. 3 табл., 3 з.п. ф-лы.

ГИПСОВАЯ ПАНЕЛЬ, ОБЛИЦОВАННАЯ МАТОМ НЕТКАНОГО СТЕКЛОВОЛОКНИСТОГО МАТЕРИАЛА

Гипсовая панель включает слой схватившегося гипса, имеющий первую лицевую поверхность и вторую лицевую поверхность. По меньшей мере, к одной из лицевых поверхностей прикрепляют волокнистый мат. Мат включает полотно нетканого стекловолокна, связанное вместе смолообразным связующим. Полотно образовано из рубленого стекловолокна, имеющего средний диаметр волокна в диапазоне от приблизительно 9,5 до 12,5 мкм и длину 6-18 мм. Охарактеризованы: второй вариант гипсовой панели, способ изготовления изделия, волокнистый мат и гидравлически схватывающаяся панель. Технический результат: повышение долговечности панели, имеющей гладкую поверхность, легко подвергающуюся отделке с использованием краски или других отделочных средств. 5 н. и 27 з.п. ф-лы, 1 ил., 3 табл.

СПОСОБ ИЗГОТОВЛЕНИЯ ГИПСОВОЙ ШТУКАТУРНОЙ ПЛИТЫ И ГИПСОВАЯ ШТУКАТУРНАЯ ПЛИТА, ПОЛУЧЕННАЯ ТАКИМ ОБРАЗОМ

Настоящее изобретение касается гипсовой штукатурной плиты, содержащей первый внешний слой, предпочтительно бумажный слой (111), первый промежуточный слой (112), образованный второй гипсовой суспензией S, центральный слой (113), образованный первой гипсовой суспензией S, второй промежуточный слой (114), образованный третьей гипсовой суспензией S, и второй внешний слой, в частности бумажный слой (115), причем первый промежуточный слой (112) расположен между первым внешним слоем (111) и слоем (113) сердцевины, а второй промежуточный слой (114) расположен между вторым внешним слоем (115) и слоем (113) сердцевины, причем промежуточные слои (112, 114) имеют, по меньшей мере, в основном постоянную толщину от 0,1 до 3 мм, предпочтительно от 0,2 до 1 мм, причем первая гипсовая суспензия содержит по меньшей мере 80% (по массе) всех гипсовых суспензий (S, S, S) и причем первую гипсовую суспензию готовят и вводят с более низким процентным содержанием воды (по массе), чем вторую Sи/или третью Sгипсовую ...

ГИПСОВАЯ ПЛИТА, СОДЕРЖАЩАЯ, ПО МЕНЬШЕЙ МЕРЕ, ОДИН СЛОЙ ОБЛИЦОВОЧНОЙ БУМАГИ С ГРУНТОВОЧНОЙ ЭМУЛЬСИЕЙ, СОДЕРЖАЩЕЙ ПЛАСТИЧЕСКИЕ ПИГМЕНТЫ, ГРУНТОВОЧНАЯ ЭМУЛЬСИЯ И СООТВЕТСТВУЮЩИЙ СПОСОБ ИЗГОТОВЛЕНИЯ

Изобретение относится к области строительных материалов. Гипсовая плита содержит, по меньшей мере, один слой облицовочной бумаги, образующий наружную сторону плиты, и грунтовочную эмульсию, нанесенную на облицовочную бумагу. Грунтовочная эмульсия содержит в качестве отбеливателя пластические пигменты, предпочтительно от 5 до 40 мас.% пластических пигментов. Эмульсию наносят в количестве от 10 до 45 г/м2. При добавлении пластических пигментов обеспечивается придание или восстановление белизны облицовочной бумаги без снижения пористости бумаги. 4 н. и 30 з.п. ф-лы, 7 табл.

СТРОИТЕЛЬНАЯ ПЛИТА И СПОСОБ ИЗГОТОВЛЕНИЯ СТРОИТЕЛЬНОЙ ПЛИТЫ

Изобретение относится к строительной плите с основной частью с пористой поверхностью и нанесенным на пористую поверхность бумажным полотном. Строительная плита содержит основную часть (10) с пористой поверхностью и бумажным полотном (14), нанесенным на пористую поверхность под промежуточным расположением отверждаемого связующего средства (36), при этом связующее средство (36) проникает внутрь бумажного полотна (14), причем нанесенное на основную часть бумажное полотно (14) содержит грунтовочный слой (34), обеспечивающий покрытие связующего средства, проникающего через бумажное полотно (14) и обеспечивающего сцепление между поверхностью бумажного полотна и окрашивающей жидкостью (38), которая с помощью программируемого способа печати, в частности способа струйной печати, может наноситься на поверхность бумажного полотна (14), расположенную на основной части (10) и снабженную грунтовочным слоем (34). Техническим результатом изобретения является разработка такого способа изготовления строительной ...

УСИЛЕННЫЙ ГИПСОКАРТОННЫЙ ЛИСТ С УЛУЧШЕННОЙ ОГНЕСТОЙКОСТЬЮ

Изобретение относится к отделочным облицовочным материалам и касается гипсокартонного листа с улучшенной огнестойкостью. Лист имеет две противоположные поверхности, в одну из которых заделан волокнистый мат. Данный волокнистый мат содержит волокна, сцепленные полимерным связующим веществом. Длина волокон превышает 20 мм, а диаметр превышает 14 мкм. Полимерное связующее вещество является, по существу, не содержащим формальдегида. Изобретение обеспечивает огнестойкость гипсокартонного листа без необходимости во включении в связующее вещество огнестойких добавок, а также обеспечивает изгибную прочность. 2 н. и 22 з.п. ф-лы, 1 табл., 6 пр.

ГИПСОКАРТОННЫЕ ЛИСТЫ И СПОСОБЫ ИХ ИЗГОТОВЛЕНИЯ

Изобретение относится к гипсокартонным листам и способам их изготовления. Гипсокартонный лист содержит сердечник из затвердевшего гипсового материала, проходящий от первой до второй поверхности гипсокартонного листа, и один или несколько непрерывных слоев материала, расположенных внутри сердечника и проходящих вдоль первой оси по существу до двух противоположных кромок гипсокартонного листа. Причем первая и вторая стороны каждого непрерывного слоя материала по существу покрыты затвердевшим гипсовым материалом. Каждый непрерывный слой представляет собой демпфирующий лист, имеющий коэффициент потерь при демпфировании больше, чем коэффициент потерь при демпфировании затвердевшего гипсового материала, причём демпфирующий лист содержит вязкоупругий полимер. Способ изготовления гипсокартонного листа включает сушку влажного сердечника из гипсового материала, в то время как внутри него расположен непрерывный слой материала или его заготовки. Обеспечивается улучшение качества звукоизолирующих гипсокартонных ...

СУСПЕНЗИЯ И ЗВУКОИЗОЛИРУЮЩАЯ ПАНЕЛЬ С ПОНИЖЕННЫМ СОДЕРЖАНИЕМ СВЯЗАННОЙ ВОДЫ

Изобретение относится к составу суспензии для производства стеновой панели и включает один или более наполнителей, одно или более связующих и воду. Один или более наполнителей представляет собой вспученный перлит, на который нанесено по меньшей мере частичное покрытие из пленкообразующего термопластичного полимера. В некоторых воплощениях данного изобретения в качестве связующего или наполнителя применяют кальцинированный или некальцинированный гипс. Одно из воплощений данного изобретения представляет собой стеновую панель, которая включает твердую матрицу кристаллов дигидрата сульфата кальция, связанных со вспученным перлитом. Способ изготовления панели включает получение вспученного перлита и нанесение на него покрытия из пленкообразующего термопластичного полимера. После приготовления вспученного перлита его смешивают с водой, с другими наполнителями и с одним или более связующих для образования суспензии. Суспензию формуют в виде панели и сушат. Изобретение позволяет снизить содержание ...

ИЗДЕЛИЕ ИЗ ВЯЖУЩЕГО МАТЕРИАЛА

... 1. Изделие из вяжущего материала с волокнистым облицовочным покрытием, содержащее вяжущую сердцевину, содержащую водоотталкивающую добавку, нестабильные и стабильные мыла и полифосфат, первый волокнистый мат, содержащий полимерные или минеральные волокна и водоотталкивающее покрытие на по меньшей мере одной поверхности упомянутого мата, при этом водоотталкивающее покрытие находится в контакте с вяжущей сердцевиной, при этом первый волокнистый мат, содержащий поверхность с водоотталкивающим покрытием, выполнен прилепленным к вяжущей сердцевине, и при этом вяжущая сердцевина частично проникает в упомянутый волокнистый мат.2. Изделие по п.1, отличающееся тем, что водоотталкивающее покрытие содержит тальк, воск, гидрофобную смолу, состав на силиконовой основе, жирную кислоту или ее соли, полиэтиленгликоль, углеводородное или фтороуглеродное поверхностно-активное вещество, имеющее, по меньшей мере, 12 атомов углерода, или их комбинации.3. Изделие по п.1, отличающееся тем, что водоотталкивающее ...

КОМПОЗИТНЫЙ СТРОИТЕЛЬНЫЙ КАРТОН С ПЛАСТИКОВЫМ ПОКРЫТИЕМ И СПОСОБ ЕГО ИЗГОТОВЛЕНИЯ

Изобретение относится к строительным материалам и касается композитного строительного картона с пластиковым покрытием и способа его изготовления. Композитный строительный картон может включать один или более слоев суспензии с погруженными волокнистыми матами. Внешнее пластиковое покрытие механически прикреплено к нижележащему слою суспензии. Пластиковый слой химически связан и образует поперечные химические связи с полимерными добавками в слое суспензии. Изобретение обеспечивает создание строительного картона с полимерной матрицей, обеспечивающей улучшенную долговечность и нагрузочную способность. 5 н. и 27 з.п. ф-лы, 15 ил.

ШТУКАТУРНАЯ ПЛИТА И СПОСОБ ЕЕ ИЗГОТОВЛЕНИЯ

... 1. Штукатурная плита, содержащая гипсовую сердцевину, имеющую переднюю поверхность, заднюю поверхность, две противоположные боковые поверхности и две противоположные торцевые поверхности, и покрывающую ее бумагу-основу, которая покрывает переднюю поверхность, заднюю поверхность и две противоположные боковые поверхности гипсовой сердцевины, причем гипсовая сердцевина включает в себя обладающую большой плотностью твердую кромочную часть, включающую боковые поверхности, покрытые бумагой-основой, по меньшей мере одну обладающую большой плотностью часть, содержащую переднюю поверхность или заднюю поверхность, покрытую бумагой-основой и имеющую плотность, по существу, равную плотности обладающей большой плотностью твердой кромочной части, и центральную обладающую низкой плотностью часть, плотность которой ниже, чем плотность обладающей большой плотностью твердой кромочной части и обладающей большой плотностью части, и которая вписана в обладающую большой плотностью твердую кромочную часть и обладающую ...

СПОСОБ ИЗГОТОВЛЕНИЯ ЛЕГКОГО ГИПСОКАРТОНА

... 1. Способ изготовления легкого гипсокартона, в котором в гипсовой сердцевине распределены поры заданного размера, включающий стадии вдувание воздуха в пенообразователь с получением вспененной жидкости, смешивание вспененной жидкости с замешанной смесью, которая содержит обожженный гипс и воду, с получением вспененного жидкого гипсового теста, заливка вспененного жидкого гипсового теста в пространство между верхним и нижним листами обкладочной бумаги для гипсокартона, формование обкладочной бумаги и вспененного жидкого гипсового теста в форму картона, приблизительная нарезка и затем высушивание картонообразного материала, и нарезка высушенного и сформованного материала по размеру изделия, где способ дополнительно включает стадию предварительного добавления агента для регулирования размера пор, распределенных во вспененном жидком гипсовом тесте, к одному из следующих материалов: маточному раствору пенообразователя или смеси маточного раствора пенообразователя и воды, с получением пенообразователя ...

ИЗДЕЛИЕ ИЗ ВЯЖУЩЕГО МАТЕРИАЛА И СПОСОБ ИЗГОТОВЛЕНИЯ ИЗДЕЛИЯ ИЗ ВЯЖУЩЕГО МАТЕРИАЛА

... 1. Изделие из вяжущего материала с волокнистым облицовочным покрытием, включающее вяжущую сердцевину и первый волокнистый мат, содержащий полимерные или минеральные волокна и водоотталкивающее покрытие, расположенное в контакте с вяжущей сердцевиной на, по меньшей мере, одной из поверхностей мата. ! 2. Изделие по п.1, в котором водоотталкивающее покрытие содержит тальк, воск, гидрофобную смолу, состав на силиконовой основе, жирную кислоту или ее соли, полиэтиленгликоль, углеводородное или фтороуглеродное поверхностно-активное вещество, имеющее, по меньшей мере, 12 атомов углерода, или их комбинации. ! 3. Изделие по п.1, в котором водоотталкивающее покрытие образует слой толщиной, по меньшей мере, около 25 мкм. ! 4. Изделие по п.1, в котором полимерные или минеральные волокна представляют собой стекловолокно, полиэфирное волокно или их комбинации. ! 5. Изделие по п.1, которое дополнительно содержит второй волокнистый мат, состоящий из полимерных или минеральных волокон, при этом вяжущая ...

СПОСОБ ОПРЕДЕЛЕНИЯ СТРУКТУРНЫХ ПАРАМЕТРОВ КОМПОЗИЦИОННЫХ СТРОИТЕЛЬНЫХ ПАНЕЛЕЙ

... 1. Способ определения структурных параметров стеновой плиты, включающий:обеспечение значения прочности среднего слоя стеновой плиты между 300 и 800 фунтами на кв. дюйм;определение требуемого значения протаскивания гвоздя на основании толщины указанного типа стеновой плиты;вычисление значения жесткости облицовочной бумаги на основании указанного обеспеченного значения прочности среднего слоя и указанного определенного значения протаскивания гвоздя; ивывод указанного вычисленного значения жесткости облицовочной бумаги на устройство вывода.2. Способ получения стеновой плиты, включающий:определение требуемого значения протаскивания гвоздя на основании типа стеновой плиты;обеспечение значения прочности среднего слоя стеновой плиты между 300 и 800 фунтами на кв. дюйм;определение значения жесткости облицовочной бумаги на основании указанного требуемого значения протаскивания гвоздя и указанного обеспеченного значения прочности среднего слоя;определение массы облицовочной бумаги на основании вычисленного ...

ВЫСОКОПОРИСТАЯ ОБЛИЦОВОЧНАЯ БУМАГА ДЛЯ ГИПСОВЫХ ПЛИТ

ОГНЕСТОЙКАЯ ГИПСОВАЯ ПАНЕЛЬ

... 1. Многослойная гипсовая панель, содержащая ! сердцевину, включающую гипс и устойчивый к высокотемпературной усадке материал, при этом указанная сердцевина сформирована в виде панели, имеющей по меньшей мере две противоположные поверхности и две противоположные кромки; ! расширяющийся слой, покрывающий по меньшей мере часть группы элементов, включающей одну или более указанных поверхностей, одну или более указанных кромок и их комбинации, при этом указанный расширяющийся слой содержит гипсовую матрицу, имеющую плотность выше, чем у указанной сердцевины, и первый вспучивающийся материал; и ! облицовочный материал, покрывающий по меньшей мере часть указанного расширяющегося слоя. ! 2. Панель по п.1, в которой указанный устойчивый к высокотемпературной усадке материал является по меньшей мере одним веществом из группы, состоящей из стекловолокна, белой сажи, диатомита и глины. ! 3. Панель по п.1, в которой указанный первый вспучивающийся материал содержит по меньшей мере одно вещество из группы ...

СТЕНОВАЯ ПАНЕЛЬ СО СТЫКОВОЙ ПЛАНКОЙ И СПОСОБ ЕЕ ИЗГОТОВЛЕНИЯ

... 1. Способ производства стеновой панели (100) для установки на стеновую конструкцию, отличающийся тем, что стеновая панель (100) производится на основании тела (110), которое, по существу, имеет форму прямоугольного параллелепипеда, включающего в себя две противоположные основные стороны (110А, 110В), имеющие относительно большие граничные поверхности и четыре краевых стороны (111, 112, 113, 114), имеющие относительно малые граничные поверхности, содержащий этапы, на которых:механически обрабатывают поверхность первой краевой стороны (111) упомянутых краевых сторон тела (110), причем первая краевая сторона (111) приобретает плоскую поверхностную структуру, которая проходит от первой (110А) до второй (110В) из упомянутых двух основных сторон;наносят первый слой (160) для обработки поверхности на первую краевую сторону (111);размещают первую стыковую планку (120) вдоль первой краевой стороны (111), причем первая стыковая планка (120) содержит;первую дистальную краевую поверхность (220D),первую ...

ОГНЕСТОЙКАЯ ГИПСОВАЯ ПАНЕЛЬ С НИЗКОЙ МАССОЙ И ПЛОТНОСТЬЮ

... 1. Гипсовая панель, содержащая:отвержденный гипсовый средний слой, расположенный между двумя облицовочными листами, причем отвержденная гипсовая композиция получена по меньшей мере из воды, строительного гипса и крахмала;крахмал содержится в количестве от примерно 0,3 до примерно 10% от массы строительного гипса и эффективен для увеличения твердости среднего слоя гипсовой композиции по сравнению с гипсовой композицией без крахмала;строительный гипс содержится в количестве примерно 700 фунтов/тыс.кв.футов, причем строительный гипс и вода содержатся по меньшей мере в количествах, эффективных для создания кристаллической матрицы, по существу состоящей из двуводного гипса;панель имеет плотность от примерно 27 до примерно 35 фунтов/фут(от примерно 433 до примерно 561 кг/м), среднюю твердость среднего слоя по меньшей мере примерно 11 фунтовунтов (примерно 5 кг), согласно ASTM C473, и коэффициент теплоизоляции по меньшей мере примерно 17 мин.2. Огнестойкая гипсовая панель, содержащая:отвержденный ...

КОМПОЗИЦИЯ ДЛЯ СТРОИТЕЛЬНОГО МАТЕРИАЛА И ГИПСОВАЯ ПЛИТА, А ТАКЖЕ СПОСОБ СТРОИТЕЛЬСТВА С ИХ ИСПОЛЬЗОВАНИЕМ И СТЕНА

... 1. Гипсовая плита для защиты от радиоактивного излучения, отличающаяся тем, что она представляет собой облицовочный материал толщиной 5-40 мм и имеющий удельный вес 0,8-2,0, причем гипсовая сердцевина сформована путем схватывания раствора, полученного добавлением 100 вес.ч. сульфата кальция, представляющего собой гидравлический гипс, 80-200 вес.ч. по меньшей мере одного вида либо двух или более видов неорганических наполнителей, выбранных из группы, включающей хлорид бария, оксид титана, оксид бария, карбонат стронция, карбонат бария и сульфат бария, и воды, покрытая одним или двумя листами для покрытия. ! 2. Гипсовая плита по п.1, отличающаяся тем, что лист для покрытия представляет собой полотно из стекловолокна. ! 3. Гипсовая плита по п.1, отличающаяся тем, что лист для покрытия представляет собой картон для покрытия гипсовой плиты. ! 4. Гипсовая плита по п.1, отличающаяся тем, что гипсовая сердцевина дополнительно содержит 1-5 вес.ч. неорганического волокна или органического волокна ...

ОБЛИЦОВАННОЕ МАТОМ ЦЕМЕНТИРУЮЩЕЕ ИЗДЕЛИЕ И СПОСОБ ЕГО ПОЛУЧЕНИЯ

... 1. Облицованное матом цементирующее композитное изделие, включающее:(a) цементирующее ядро;(b) цементирующий слой тонкослойного покрытия в контакте с цементирующим ядром, обладающий плотностью, большей, чем у цементирующего ядра; и(c) волокнистый мат, включающий (i) микроволокна и (ii) непрерывные волокна, имеющие длину приблизительно 0,6 см или более; где волокнистый мат включает внутреннюю поверхность в контакте с цементирующим слоем тонкослойного покрытия.2. Облицованное матом изделие по п.1, отличающееся тем, что и непрерывные волокна, и микроволокна являются стеклянными волокнами.3. Облицованное матом изделие по п.1 или 2, отличающееся тем, что непрерывные волокна имеют диаметр приблизительно 15 мкм или более.4. Облицованное матом изделие по п.3, отличающееся тем, что микроволокна имеют диаметр от приблизительно 0,25 до приблизительно 5 мкм.5. Способ изготовления облицованного матом цементирующего изделия, включающий этапы, на которых:(a) обеспечивают волокнистый мат, имеющий внутреннюю ...

СТРОИТЕЛЬНАЯ ПАНЕЛЬ, ОБЛАДАЮЩАЯ УЛУЧШЕННОЙ ПРОЧНОСТЬЮ КРЕПЛЕНИЯ

ГИПСОКАРТОН ПОВЫШЕННОЙ ПРОЧНОСТИ И СВЯЗАННЫЕ С ЕГО ПРОИЗВОДСТВОМ СПОСОБЫ, СУСПЕНЗИИ И ПОКРОВНЫЕ ЛИСТЫ

ПОКРЫТИЕ С ЗАТРАВОЧНЫМИ КРИСТАЛЛАМИ ДЛЯ ГИПСОВЫХ ОБЛИЦОВОЧНЫХ ПЛИТ

... 1. Обработанный облицовочный материал для применения в гипсовых облицовочных плитах, включающий:облицовочный материал, поверхность которого обработана некоторым количеством затравочных кристаллов, приклеенных к поверхности облицовочного материала, причем затравочные кристаллы выбирают из группы, включающей СаСО, CaSO, BaSO, NaSO, KAl(SO), CaMg(СО), MgCO, KSO, Fe[SO]/FeSO, Al[SO]и гидратированные формы перечисленного.2. Обработанный облицовочный материал для применения в гипсовых облицовочных плитах по п.1, в котором затравочные кристаллы включают CaSOи его гидратированные формы.3. Обработанный облицовочный материал для применения в гипсовых облицовочных плитах по п.2, в котором CaSOнаходится в безводной форме.4. Обработанный облицовочный материал для применения в гипсовых облицовочных плитах по п.2, в котором CaSOнаходится в форме полугидрата.5. Обработанный облицовочный материал для применения в гипсовых облицовочных плитах по п.2, в котором CaSOнаходится в форме дигидрата.6. Обработанный ...

СТРОИТЕЛЬНАЯ ПЛИТА И СПОСОБ ИЗГОТОВЛЕНИЯ СТРОИТЕЛЬНОЙ ПЛИТЫ

... 1. Строительная плита, содержащая основную часть (10) с пористой поверхностью и бумажным полотном (14), нанесенным на пористую поверхность под промежуточным расположением отверждаемого связующего средства (36), отличающаяся тем, что связующее средство (36) проникает внутрь бумажного полотна (14), причем нанесенное на основную часть бумажное полотно (14) содержит грунтовочный слой (34), обеспечивающий покрытие связующего средства, проникающего через бумажное полотно (14) и обеспечивающего сцепление между поверхностью бумажного полотна и окрашивающей жидкостью (38), которая с помощью программируемого способа печати, в частности способа струйной печати, может наноситься на поверхность бумажного полотна (14), расположенную на основной части (10) и снабженную грунтовочным слоем (34).2. Способ изготовления строительной плиты, включающий следующие этапы:- приготовление основной части (10) с пористой поверхностью, в форме плиты,- приготовление бумажного полотна (14) с нанесенным на одну сторону ...

СИСТЕМА И СПОСОБ ДЛЯ ИЗГОТОВЛЕНИЯ ГИПСОКАРТОННОЙ ПЛИТЫ

... 1. Способ изготовления легкой гипсокартонной плиты, в котором используют производственную линию для изготовления плит, содержащую мешалку, формующий стол и сушилки, причем способ включает в себя следующие операции:использование множества вспененных гранул крахмала, причем указанные гранулы образованы за счет процесса экструзии и имеют ориентировочный размер от 1/32″ до 1/64″, при этом гранулы являются только слегка растворимыми при температурах ниже 140°F;добавление гранул в гипсовую суспензию в соотношении ориентировочно от 5% до 50% по объему;перемешивание гипсовой суспензии и гранул внутри мешалки, при этом гранулы становятся полностью капсулированными внутри суспензии;установка первого наружного листа на формующем столе перед мешалкой;выпуск смеси гипса и гранул из мешалки на первый наружный лист;установка верхнего наружного листа поверх смеси гипса и гранул с образованием комбинированной панели; исушка комбинированной панели внутри сушилок при температуре выше чем 140°F, причем указанная ...

КОМПОЗИЦИИ И СПОСОБЫ ПРИМЕНЕНИЯ МИКРОФИБРИЛЛИРОВАННОЙ ЦЕЛЛЮЛОЗЫ В БУМАГЕ ДЛЯ ОБШИВКИ ГИПСОКАРТОНА

ПРОТИВОМИКРОБНАЯ ПРОКЛЕИВАЮЩАЯ ЭМУЛЬСИЯ И ГИПСОВАЯ ПАНЕЛЬ, ПОЛУЧЕННАЯ С ЕЕ ПРИМЕНЕНИЕМ

... 1. Биоцидная проклеивающая эмульсия, содержащая:агент для проклейки в массе; ибиоцидный эмульгатор, где агент для проклейки в массе и биоцидный эмульгатор эмульгированы в воде.2. Биоцидная проклеивающая эмульсия по п.1, отличающаяся тем, что указанный биоцидный эмульгатор представляет собой не содержащее крахмал катионное четвертичное соединение аммония.3. Биоцидная проклеивающая эмульсия по п.1, отличающаяся тем, что указанный агент для проклейки в массе выбран из группы, состоящей из алкенилянтарного ангидрида и алкилкетенового димера.4. Биоцидная проклеивающая эмульсия по п.1, отличающаяся тем, что соотношение агента для проклейки в массе и биоцидного эмульгатора составляет одну часть проклеивающего агента АЯА и от половины до одной части биоцидного эмульгатора.5. Гипсовая панель, содержащая:гипсовый средний слой;по меньшей мере один облицовочный слой, содержащийбумагу, полученную из бумажной массы, которая содержит эмульсию для проклейки бумаги, содержащую эмульсию биоцидного эмульгатора ...

АКУСТИЧЕСКАЯ ПАНЕЛЬ, СОДЕРЖАЩАЯ ПЕРЕПЛЕТЕННУЮ ФИКСИРОВАННУЮ МАТРИЦУ ИЗ ЗАТВЕРДЕВШЕГО ГИПСА И СПОСОБ ЕЕ ИЗГОТОВЛЕНИЯ

... 1. Способ непрерывного изготовления акустической панели, включающий этапы, на которых осуществляют получение смеси, включающей воду, вспениватель и обожженный гипс; разлив смеси с образованием непрерывной ленты; удержание ленты в условиях, достаточных для того, чтобы обожженный гипс образовал переплетенную фиксированную матрицу из затвердевшего гипса; нарезание ленты с образованием предшественника влажной акустической панели; и сушка предшественника влажной панели с получением акустической панели, в котором акустическая панель характеризуется значением нормального случайного звукопоглощения, равным по меньшей мере примерно 0,32, в соответствии с модифицированным ASTM E 1050-98. 2. Способ по п.1, в котором используют смесь, включающую целлюлозное волокно. 3. Способ по п.2, в котором целлюлозное волокно представляет собой бумажное волокно. 4. Способ по п.2, в котором количество целлюлозного волокна составляет от примерно 1 до примерно 12 вес.% от твердого содержимого смеси. 5. Способ по п ...

Установка для изготовления строительных изделий

УСТАНОВКА ДЛЯ ИЗГОТОВЛЕНИЯ СТРОИТЕЛЬНЫХ ИЗДЕЛИЙ, содержащая йонвейер с горизонтальной и вертикальными формуияцими лентами и установл нное над горизонтальной лентой оборудование, состоящее из дозатора, смесителя и устройства для вьщачи массы на ленту транспортера, о т л и- .:-.-Uv-VTAq 1Э Ш-а;тк , TEXjj-rJEfCjiA r ЕКБЛйОТеКА ч а ю щ а 5 с я тем, что, с целью повышения качества готовых изделий и производительности, она снабжена регулировочным клапаном, установлен ным на выходе смесителя, насосом, установленным между выходом регулировочного клапана и входом устройства для выдачи массы, и устройством автоматического контроля работы регулировочного клапана и смесителя, приче 4 регулировочный клапан выполнен в виде коаксиально установленных 1|илиндров , соединенных по тopцaм - эластичного и охватывающего маталлического с отверстием в его боковой стенке для подачи рабочего агента в пространство между стенками цилиндров , а устройство для выдачи массы О) выполнено в виде установленных параллельно ...

Bauplatte

Bauplatte aus einer primär aus Gips aufgebauten Grundplatte und einer im Wesentlichen aus Lehm bestehenden Deckschicht, die Pflanzenfasern enthält, dadurch gekennzeichnet, dass die Grundplatte mit Weißleim behandelt ist, um die Haftung der Deckschicht zu verbessern.

Gypsum plasterboard with adsorbing additives e.g. for gypsum plasterboards, has adsorbing additives and designed as perforated tile with additives applied as coating on side of plasterboard being on inside when in installed condition

The gypsum plasterboard (1) has adsorbing additives and designed as a perforated tile (4). The adsorbing additives are applied as a coating on the side of the plasterboard being on the inside when in an installed condition. The adsorbing additives are removed by a coating.

COATING LAYER BASED ON A FLEECE OR A FABRIC

VERFAHREN ZUM BEFESTIGEN VON UMLEIMERN AN DEN KANTEN VON BAUPLATTEN AUS MINERALISCHEM MATERIAL.

BAUPLATTE AUS GIPS UND VERFAHREN ZU DEREN HERSTELLUNG

Gitternetzlinien auf Bauplatten (Gipskartonplatten, Gipsfaserplatten, OSB/MPF, Holz-Platten)

Aufbringen von Gitternetzlinien (Koordinaten-Linien) auf Baustoffplatten und Steinen,auf Vorder und oder Rückseite;Beispiele: Gipskarton-Platten, Gipsfaser-Platten, OSB- und MPF-Platten, sowie YTong und Gasbeton-Platten und Steine.

BAUELEMENT AUS GLASFASERVERSTAERKTEM GIPS

Chipboard building panels - coated with fibre -reinforced gypsum cont a bonding improving polymer

Fire-rpoof building panels of porous chipboard with good bending strength and good stability suitable for heat and noise insulating wall or ceiling panels obtd by coating the wet chipboard panels on 1 or both sides with a 1-15mm thick gypsum or similar material layer, the gypsum layer being reinforced with 0.5-7 wt.% pref. 1-3 wt.% of glass or rock wool with a fibre length of 3-10mm, pref. 3-6 mm, and also contg. 0.5-7 wt.% pref. 1-4 wt.% of a polymer to improved the bonding between the gypsum and the fibres. Curing agents for the polymer and wetting agents can be added. The coated panel is dried and cured in 1 step. Urea, epoxy or acrylic resin or PVC may be used.

BAUPLATTE

Gipsbauplatte mit beschichteter Glasvlieslage

PLATTENFOERMIGES BAUELEMENT MIT EINEM GIPSKERN UND EINER KARTONUMMANTELUNG

Verfahren zur Herstellung einer mit beschichtetem Glasvlies kaschierten Gipsbauplatte

Fertigbauelement zur Realisierung von Raumecken im Trockenbau

Die Erfindung betrifft ein Fertigbauelement (03) zur Realisierung von Raumecken im Trockenbau mit einer Bauplatte (05) aus Gipskarton, Gipsfasern oder Holzwerkstoffen, die eine zu einer Rückseite (08) weisende Aussparung (09) aufweist, wobei an die Aussparung (09) ein rechter und ein linker Bauplattenabschnitt (10, 11) angrenzen, und wobei die Bauplattenabschnitte (10, 11) relativ zueinander klappbar sind, und wobei eine rechte und eine linke Stabilisierungsleiste (01, 02) vorgesehen sind, und wobei die Stabilisierungsleisten (01, 02) innerhalb der Aussparung (09) jeweils an einem Bauplattenabschnitt (10, 11) befestigt sind, wobei die beiden Stabilisierungsleisten (01, 02) mit einem elastisch verformbaren Verbindungselement (04) verbunden sind.

Verfahren zum Widerstandsfaehigmachen von Furnier- oder Pappe-Deckschichten von Gipsplatten gegen Beschaedigung

Plattenförmiges Bauelement

Process for producing a web-shaped coating material for construction boards and coating material produced according to the process

A process for producing a web-shaped coating material for construction boards, in particular gypsum boards, and coating material produced according to the process are described, glass fibres, preferably in the form of an aqueous dispersion, being deposited on a glass-fibre scrim on a liquid-permeable base and the liquid below the permeable base being extracted by suction and the body formed compacted. An adhesive and other materials can be added to the dispersion water. The fibres can also be deposited in a dry state and then sprayed with an aqueous medium.

ZEMENTHALTIGE BAUPLATTE MIT VERSTÄRKTEN KANTEN

Mit niedrigem Energieaufwand hergestellte Wandplatten und Verfahren zu deren Herstellung

Wandplatten werden mit Verfahren hergestellt, in denen deutlich weniger Energie beim zur Herstellung von Gipsplatten angewandten Energievergleich verbraucht wird. Ein neuer Binder, bestehend in einer Ausführungsform aus Monokaliumphosphat und Magnesiumoxid, wird zusammen mit verschiedenen Füllstoffen verwendet, um eine gesteuerte exotherme Reaktion zu ergeben, um einen Gipsplatten-artigen Kern zu erzeugen, der in einem ausgewählten Material wie aus rezykliertem Papier eingehüllt und auf einem Förderbandsystem hergestellt werden kann, um die Gips-Wandplatten auszusehen und gehandhabt zu werden, aber ohne den großen Energieverbrauch, der ansonsten zur Herstellung von Gips-Wandplatten benötigt wird. Das entstandene Erzeugnis kann in Innen- oder Außenanwendungen eingesetzt werden und besitzt die Feuer- und Schallschutzeigenschaften sowie weitere wichtige Eigenschaften von Gipswänden. Mit dem Energiekostenanstieg verbilligen sich die neuen Wandplatten der vorliegenden Erfindung gegenüber den ...

Plasterboard

Method for producing flame retardant porous products and products produced thereby

Gypsum plasterboard comprising s-triazine-crosslinked starch

Gypsum plasterboard comprising cross-linked starch

A formulation for making plasterboard with paper cover sheets comprises finely divided gypsum, a minor amount by weight of starch and, as crosslinking agent for the starch, a tri-functional reactive s-triazine having substituents at positions 2, 4 and 6 of the triazine ring which are reactive with the starch. A preferred crosslinking agent is 2,4,6-trichloros-triazine, which is preferably partially reacted with the starch before further reaction with the paper cover sheets for the plaster board. The cross linking of the starch increases strength and improves adhesion to the paper cover sheets.

BUILDING COMPONENTS

Gypsum board

Gypsum wallboard comprising a core of set calcium sulfate dihydrate and a paper cover sheet bonded to each surface thereof, each of said paper cover sheets comprising: (A) a major proportion of cellulose fibers; (B) an internal size comprising a cyclic dicarboxylic acid anhydride having the structural formula: wherein R is selected from dimethylene and trimethylene radicals and R' is a hydrophobic group containing 5 or more carbon atoms selected from alkyl, alkenyl, aralkyl and aralkenyl groups, (C) a cationic agent, and (D) a buffering agent which is a salt of a relatively strong base and a relatively weak acid maintaining the paper during forming at a pH of at least 7.

Improvements in or relating to wallboard

... 429,084. Wallboards. PARFITT, A. W., Stafford House, Norfolk Street, Strand, London.-(Gypsum, Lime and Alabastine, Canada, Ltd.; Paris, Ontario, Canada) Feb. 7, 1934, No. 29878. Divided out of 429,379, [Group V]. [Class 20 (iv)] A wallboard, comprising a core of quicksetting cementitious material enclosed in paper liners, 3, 4, is provided on at least two of its meeting edges with a marginal taper in the form of a bevelled surface extending from one face of the board towards the edge thereof. The taper 6<1> may be formed on all the marginal edges of the board, or on only one side and one end of the board. The taper is disposed on the exposed surface of the board. Specification 429,379 is referred to.

Reinforced plasterboard

Improvements in or relating to pre-fabricated units for use in building construction

... 605,397. Building slabs. CONSTANCE, Ltd., C., and ELVIDGE, S. R. C. Dec. 21, 1945, No. 34692. [Class 87 (i)] In the manufacture of a reinforced plaster slab, an open framework 3, 4 covered on one face with expanded metal, wire netting &c. 2 is embedded in plaster in an open mould, the plaster being swept up at the edges 1b to cover the framework. The edges lb may be reinforced with scrim and may be rabbeted at 6. The framework 3, 4 may be of metal, wood, papier mache or synthetic resin and of various sections. The recess 5 may be filled with heat &c. insulating material and covered by paper 5a. In a modification, a framework 13 covered on both faces with expanded metal &c. 12 is, after being embedded in the one layer of plaster, inverted and embedded in a second layer to form a hollow slab which may be filled with heat &c. insulating material. Slabs may be secured on a supporting framework by screws &c. passed through openings 20.

CONSTRUCTION PANEL HAVING IMRPOVED FIXING STRENGTHAND METHOD FOR THE MANUFACTURE THEREOF

CONSTRUCTION PANEL HAVING IMRPOVED FIXING STRENGTHAND METHOD FOR THE MANUFACTURE THEREOF

Improvement brought to prefabricated and the their manufactoring process gypsum blocks.

Plasterboard.

Method of manufacture of panels préfinis and use of those for construction of houses.

Ready-made unit containing plaster in particular for the building and its manufactoring process.

CONSTRUCTION PANEL HAVING IMRPOVED FIXING STRENGTHAND METHOD FOR THE MANUFACTURE THEREOF

VERFAHREN ZUR HERSTELLUNG VON GIPSKARTONBAU- PLATTEN

VERKLEIDUNGSPLATTE, IN PARTICULAR GYPSUM PLASTERBOARD

IN DRY CONSTRUCTION WAY PARTITION AND USE OF A GYPSUM PLASTERBOARD PROVIDED

POROESES MINERALFASERHALTIGES PAPIER

GYPSUM PLASTERBOARD WITH AT LEAST ONE COATING PAPER WITH PLASTIC PIGMENTS AN ABSTENTION CAPER MASS, CAPER MASS AND PERTINENT MANUFACTURING PROCESS

COMPOUND LINING FOR WALL SLABS

PROCEDURE FOR THE PRODUCTION OF BUILDING OF GYPSUM CARDBOARDS PLATES

BUILDING PASTEBOARD OR ASSEMBLY FIXTURE AND PROCEDURE FOR YOUR PRODUCTION

PROCEDURE FOR MAKING ASSEMBLY FIXTURES OF GYPSUM

ON GYPSUM BASIS IN THE ROLLING UP PROCEDURE MANUFACTURE ASSEMBLY FIXTURE RAW PLATE

GYPSUM PLASTERBOARD

BAUPLATTE, INSBESONDERE GIPSKARTONPLATTE

VORRICHTUNG ZUR HERSTELLUNG HOMOGENER PLATTEN BZW.BAENDER AUS GIPSSCHLAEMMEN

MIXTURE FOR THE CORE OF A GIPSPLATTE.

PROCEDURE FOR FASTENING UMLEIMERN TO THE EDGES OF ASSEMBLY FIXTURES FROM MINERAL MATERIAL.

PROCEDURE AND DEVICE FOR THE PACKING OF TWO OR SEVERAL GIPSPLATTEN.

Procedure for the perforation of thin fleeces

WATER-REJECTING AND STEAM-PERMEABLE MULTI-COMPOSITE LAYER FOR OUTSIDE APPLICATIONS

Hydrophobized fiber cement products, methods for production, and uses thereof

The present invention relates hydrophobized fiber cement products and methods for the production thereof as well as uses of such products, in particular in the building industry. In particular, the present invention provides hydrophobized fiber cement product, comprising a fiber cementitious matrix and a hydrophobizing agent uniformly dispersed therein, wherein said hydrophobizing agent comprises at least one hydrophobic silicone resin having a three-dimensional molecular network structure. The present invention further provides processes for producing a hydrophobized fiber cement product with enhanced water impermeability, wherein said process comprises at least the steps of: a) admixing an inorganic curable cementitious matrix with a hydrophobizing agent to form a curable mixture, wherein said hydrophobizing agent comprises at least one hydrophobic silicone resin having a three-dimensional molecular network structure, b) transforming the curable mixture into a shaped body; and c) curing ...

PREGELATINIZED STARCH WITH MID-RANGE VISCOSITY, AND PRODUCT, SLURRY AND METHODS RELATED THERETO

Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise), and an extruded pregelatinized starch. WO 2014/066079 PCT/US2013/064776 TEMPERATURE (-C) C:)) CD C)_ CD__CDC) C > C <, E log/ I-CV/ Iq E C,)N 0 uC~ c)E 4- 4 om nto ...

PREGELATINIZED STARCH WITH MID-RANGE VISCOSITY, AND PRODUCT, SLURRY AND METHODS RELATED THERETO

Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise), and an extruded pregelatinized starch.

Interior building materials

The purpose of this invention is to provide technology that can implement interior building materials typified by gypsum board to which magnets do not attach, wherein the interior building materials: can form a wall face or the like for which magnetic fasteners and magnetic sheets can be used in place of thumb tacks by way of modifying the surface of such interior building materials so that magnets can attach using a simple means that can be used practically; and can be easily cut with a cutter knife or the like, thereby achieving good workability. This purpose is achieved by interior building materials that are characterized in that a plurality of magnetic material plates are disposed and fixed so that adjacent magnetic material plates have a portion that is in contact with each other, or adjacent magnetic material plates are disposed and fixed with a gap having a narrow section therebetween, to at least part of the front face or the back face of the plate-shaped base material to which ...

Composition for building material, plasterboard, and technique, wall, and the like employing or formed from these

... (1) A composition for building materials which comprises 100 parts by weight of a base selected from the group consisting of calcium sulfate, calcium carbonate, calcium hydroxide, and an emulsion of an organic synthetic resin and 50-3,000 parts by weight of an inorganic filler having a true specific gravity of 3.5-6.0 selected from the group consisting of barium chloride, zinc oxide, aluminum oxide, titanium oxide, barium oxide, strontium carbonate, barium carbonate, and barium sulfate. Also provided is (2) a plasterboard having a plaster core produced from a slurry obtained by mixing 100 parts by weight of calcium sulfate, 50-200 parts by weight of the inorganic filler, and water.

Low thermal transmission building material

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.

A method for determining structural parameters of composite building panels

A method of determining face paper properties of all types of wallboard including providing a core strength value of the wallboard, determining a required nail pull value based the wallboard specifications and calculating a face paper stiffness value based on the provided core strength value and the determined nail pull value. The method includes displaying the calculated face paper stiffness value on a display device.

Acoustical panel comprising interlocking matrix of set gypsum and method for making same

Hydraulic binder-based, tapered-edge boards, production method and production line therefor, and light work construction method

Hydraulic binder-based, tapered-edge boards, production method and production line therefor, and light work construction method

METHOD OF RESHAPING A GYPSUM BOARD CORE AND PRODUCTS MADE BY SAME

PAPER-COVERED GYPSUM WALLBOARD

A METHOD AND AN ARRANGEMENT FOR PACKAGING TWO OR MORE PLASTER BOARDS

GYPSUM BOARD HAVING IMPROVED FLEXIBILITY, TOUGHNESS, ABUSE RESISTANCE, WATER RESISTANCE AND FIRE RESISTANCE

Water resistant cementitious article and method for preparing same

A fibrous mat-faced cementitious article comprising (a) a cementitious core, and (b) a first fibrous mat comprising polymer or mineral fibers and a hydrophobic finish on at least one surface thereof, wherein the hydrophobic finish is in contact with the cementitious core, and a method of preparing a fibrous mat-faced cementitious article, as well as a method of preparing a water-resistant cementitious article comprising (a) preparing an aqueous siloxane dispersion, wherein the dispersion comprises about 4 wt. % to about 8 wt. % siloxane, (b) combining the siloxane dispersion with a cementitious mixture to provide a cementitious slurry, (c) depositing the cementitious slurry onto a substrate, and (d) allowing the cementitious slurry to harden, thereby providing a cementitious article.

Shear Panel Building Material

A shear panel building material that includes a first facing membrane, a core matrix disposed on a face of the first facing membrane, and a semi-rigid or rigid material attached to the core matrix. The core matrix can include microspheres having a size of about 200 microns to about 800 microns, sodium silicate, and ethylene vinyl acetate. In one aspect, the shear panel is substantially free from glue and cement.

Low weight and density fire-resistant gypsum panel

An about ⅝ 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.

Microfiber-containing fiber reinforced facer mats and method of making

Fiber-reinforced composite mats are described that include a non-woven web of fibers. The web of fibers may include a first group of fibers having an average fiber diameter from about 8 μm to about 25 μm, and a second group of fibers having an average fiber diameter from about 0.5 μm to about 6.5 μm. A binder bonds together the non-woven web of fibers into the fiber reinforced composite having an air permeability of 250 cfm/ft 2 or less. Also described are gypsum boards that include one or more facers affixed to at least one surface of the gypsum board. The facers may be made from the above, described fiber-reinforced composite mats.

Gypsum Board with Multiple Tapered Edges

A gypsum board with multiple tapered edges has a flat, rectangular main flat body with four tapered edges. The main flat body is a gypsum core sandwiched between two paper sheets. The main flat body may be of any appropriate size, including 4 feet by 4 feet or other sizes. In a method for manufacturing the gypsum board with multiple tapered edges, a quantity of gypsum slurry is fed between two continuous paper sheets with a conveyor system to make a continuous gypsum sheet and longitudinal edges of the continuous gypsum sheet are tapered. The gypsum slurry is partially dried, and then the continuous gypsum sheet is transversely compressed between an upper bracket and a lower bracket to form a transverse tapered impression. The continuous gypsum sheet is cut at the tapered impression, and the transverse tapered edges are enclosed with finishing paper.

Gypsum products with high efficiency heat sink additives

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.

FORMALDEHYDE-FREE HIGHLY WATER AND ABRASION RESISTANT OVERLAY FOR BUILDING PRODUCTS

A paper based overlay is provided. The overlay has a paper impregnated with a resin composition having an acrylic resin having a glass transition temperature in a range of from about −20° C. to about 40° C. and a resin content from about 15 to about 35 wt. % based on the weight of the overlay. The acrylic composition may include wax in the amount of about 0.005 to about 3.5 wt. % based on the weight of the resin composition. A method of producing the overlay is also provided. The overlay is highly water and abrasion resistant with low volatile content. 1. An overlay comprising paper impregnated with a resin composition , wherein said resin composition comprises:a thermoplastic acrylic resin having a glass transition temperature in a range of from about −20° C. to about 40° C., andfrom 0.0001 wt. % to about 3.5 wt. % wax based on the weight of the resin composition,wherein the acrylic resin content in the overlay is in a range of from about 15 wt. % to about 35 wt. % based on the weight of the overlay.2. The overlay of claim 1 , wherein the glass transition temperature is in a range of from about 10° C. to about 35° C.3. (canceled)4. The overlay of claim 1 , wherein the wax has a melt point in a range of from about 15° C. to about 85° C.5. The overlay of claim 1 , comprising wax selected from slack wax claim 1 , paraffin wax claim 1 , Montan wax claim 1 , microcrystalline wax claim 1 , and mixture thereof.6. (canceled)7. The overlay of claim 1 , wherein the acrylic resin content in the overlay is in a range of from about 15.0 wt. % to about 32.5 wt. % claim 1 , based on the weight of the overlay.8. The overlay of claim 1 , wherein the resin composition further comprises a component selected from diols claim 1 , release agents claim 1 , antifoaming agents and wetting agents.9. The overlay of claim 1 , wherein the paper is kraft paper.10. The overlay of claim 9 , wherein the kraft paper has a basis weight in a range of from about 70 to about 90 g/m.11. The overlay of ...

CONSTRUCTION PANELS, MATERIALS, SYSTEMS, AND METHODS

Construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a core having a first surface and an opposed second surface, and an environmental sensor assembly associated with the panel and configured to detect an environmental condition of the panel and wirelessly communicate data on the environmental condition to a reader. 1. A building panel , comprising:a panel having a first surface and an opposed second surface; and 'wherein the environmental sensor assembly is self-supporting and comprises an antenna, a processing module, and a wireless communication module.', 'an environmental sensor assembly associated with the panel and configured to detect an environmental condition of the panel and wirelessly communicate data on the environmental condition to a reader,'}2. The panel of claim 1 , wherein the environmental sensor assembly is configured to detect an environmental condition of the panel selected from a group consisting of moisture claim 1 , temperature claim 1 , and pressure.3. The panel of claim 1 , wherein the environmental sensor assembly comprises a passive radio frequency identification sensor.4. The panel of claim 1 , wherein:the antenna comprises a resistor inductor capacitor tuned circuit operable to convert the environmental condition into an impedance change, andthe processing module is coupled to the antenna and is operable to translate the impedance change into a sensor code by matching antenna impedance to die impedance.5. The panel of claim 1 , wherein:the antenna has an antenna impedance operable to vary based on the environmental condition,the processing module is coupled to the antenna and comprises a tuning module operable to (i) vary a reactive component impedance in order to change a system impedance comprising the antenna impedance and the reactive component impedance, and (ii) produce an impedance value ...

MONOLITHIC ACOUSTICAL SYSTEM

A composite structure for improving the acoustical properties of a low NRC membrane including a sound absorbing layer and a porous, scrim covered, perforated drywall layer. 1. A construction comprising a rigid membrane extending across a wall or ceiling area , the membrane exhibiting an NRC of 0.10 or less when measured from the side of the membrane facing a space to be occupied , a porous sound absorbing layer in contact with or closely adjacent the space facing membrane side , a plurality of perforated drywall sheets covering the sound absorbing layer and attached to the membrane , the perforated drywall being clad on each side with a non-woven porous scrim , adjacent edges of the sides of the drywall panels facing the space to be occupied including the respective scrim being taped and covered with joint compound , the respective scrim and joint compound being covered with an acoustically transparent coating , the combination of the membrane , sound absorbing layer , scrim clad perforated drywall sheets and coating exhibiting an NRC of at least 0.75 when measured from a side facing the space to be occupied.2. The construction of claim 1 , wherein the sound absorbing layer is attached directly to the membrane and the perforated drywall is secured to the membrane.3. The construction of claim 2 , wherein the perforated drywall is attached to parallel furring strips attached to the membrane.4. The construction of claim 3 , wherein the furring strips are mechanically attached to the membrane and the perforated drywall is screw attached to the furring strips.5. The construction of claim 4 , wherein the furring strips provide spaces for reception of the sound absorbing layer.6. The construction of claim 5 , wherein the sound absorbing layer is a rigid board attached to the membrane.7. A method of improving the NRC of a low NRC membrane comprising covering the membrane with a layer of sound absorbing material and covering the sound absorbing material with perforated ...

METHOD OF CONSTRUCTION OF A WALL HEATING PANEL AND A WALL HEATING PANEL

The method of construction of a wall heating panel and a wall heating panel consists in constructing an aluminium multi-channel collector, preferably with one phase transition channel, connecting it inseparably with vertical aluminium heating elements, arranging the heating elements in the grooves of a dry wall construction board, preferably magnesium, and filling the space between the grooves and the heating elements with elastic compound, and then applying paper—aluminium foil laminate onto the whole surface of the board. A wall heating panel consists of an aluminium collector () with stub pipes (), inside the collector there are horizontal parallel phase transition channels () and a water channel (), the phase transition channel () is inseparably connected with the vertical aluminium heating elements () which are inserted into the grooves of the dry wall construction board (), spaces between the grooves and the heating elements are filled with elastic compound () and sealed with paper—aluminium foil laminate (), whereas the top part of the collector () adjoins the bottom surface of the board (). 1. A method for constructing a wall heating panel for a dry wall construction , comprising the steps of:forming, from an aluminium multi-channel profile, a collector having at least one horizontal phase transition channel and a water channel having stub pipes at both ends of the water channel for connecting the collector to a water heating installation;permanently plugging the ends of the at least one phase transition channels;connecting inseparably aluminium vertical heating elements, previously plugged at the top, with the at least one phase transition channel to form a system and checking the system for tightness;removing air from the system and filling the system with a thermodynamic medium in an amount of up to 95% of the system volume and tightly closing the system;inserting the vertical heating elements into previously made grooves of a dry wall construction board, ...

BUILDING PANEL WITH SECTIONS

A building panel with a high degree of isotropy with regard to the load bearing capacity and flexural strength. The building panel includes a first section and a second section, each section including at least one layer, each of the at least one layer having fibers, whereby the fibers are distributed substantially homogeneously throughout each layer, substantially parallel to the main surfaces of the panel and oriented predominantly in the same direction and the sections are firmly joined in transverse direction, and the first section is thinner than the second section. 1. A building panel comprising: a first section and a second section , each including at least one layer , each of the at least one layer comprising fibers; whereby the fibers are distributed substantially homogeneously throughout each layer , substantially parallel to the main surfaces of the panel and oriented predominantly in the same direction; and the sections are firmly joined in transverse direction; and the first section is thinner than the second section.2. The building panel according to claim 1 , characterized in that the first section is the section farthest from a force to be applied.3. The building panel according to claim 1 , characterized in that the first section makes up at least 5% of the thickness of the panel and at most 30% of the thickness of the panel.4. The building panel according to claim 1 , characterized in that the second section has a 2.5 to 10 times greater thickness compared to the first section.5. The building panel according to claim 1 , characterized in that the at least one layer comprises a plurality of lamina comprising fibers in the same orientation.6. The building panel according to claim 1 , characterized in that the building panel has a monolithic appearance.7. The building panel according to claim 1 , characterized in that the building panel comprises a binding material.8. The building panel according to claim 1 , characterized in that the building panel is ...

GYPSUM BOARD SUITABLE FOR WET OR HUMID AREAS

Gypsum board having a core, said core having at least one side covered with a non-woven fabric; characterized in that the inner side of the non-woven fabric, which is in contact with the core of the gypsum board, has a surface roughness Ra of from 25 to 60 micrometers, preferably from 25 to 50 micrometers, advantageously from 25 to 40 micrometers. 166.-. (canceled)67. Gypsum board having a core , said core having at least one side covered with a non-woven fabric; characterized in that the inner side of the non-woven fabric , which is in contact with the core of the gypsum board , has a surface roughness Ra of from 25 to 60 micrometers.68. Gypsum board according to claim 67 , wherein the inner side of the non-woven fabric comprises an embossing pattern having said surface roughness.69. Gypsum board according to claim 68 , wherein the gypsum board contains water resistant agents in its core and/or in its non-woven fabric.70. Gypsum board according to claim 68 , wherein the non woven fabric comprises fibers that are selected from the group consisting of cellulose fibers claim 68 , inorganic or mineral fibers claim 68 , synthetic polymeric fibers claim 68 , and mixtures thereof.71. Gypsum board according to claim 70 , wherein the cellulose based fibers represent at least 25 wt % of the weight of the non woven fabric.72. Gypsum board according to claim 70 , wherein said inorganic or mineral fibers are glass fibers.73. Gypsum board according to claim 70 , wherein the synthetic polymeric fibers are polymer fibers selected from the group consisting of polyamide claim 70 , polyaramide claim 70 , polyethylene claim 70 , polypropylene claim 70 , polyester claim 70 , and mixtures thereof.74. Gypsum board according to claim 68 , wherein the outer side of the non woven fabric claim 68 , which is in contact with the air claim 68 , and has a surface roughness Ra less than 25 micrometers.75. Gypsum board according to claim 68 , wherein the non woven fabric comprises at least one ...

Gypsum Panels, Mats Therefor, and Methods

Methods of making gypsum panels, fiberglass mats, and associated gypsum panels and building sheathing systems are provided. In one aspect, a method of making a gypsum panel includes depositing an aqueous liquid containing a wetting agent onto a fiberglass mat, such that the aqueous liquid penetrates an entire thickness of the fiberglass mat, and depositing a gypsum slurry onto the fiberglass mat onto which the aqueous liquid has been deposited, such that the gypsum slurry penetrates at least a portion of the fiberglass mat. In another aspect, a method of making a gypsum panel includes depositing an aqueous liquid containing a wetting agent onto a fiberglass mat, and depositing a gypsum slurry onto the fiberglass mat onto which the aqueous liquid has been deposited, prior to drying of the aqueous liquid, such that the gypsum slurry penetrates at least a portion of the fiberglass mat. 1. A gypsum panel , comprising:a gypsum core having a first surface and a second surface opposite the first surface;a first fiberglass mat having a first surface associated with the first surface of the gypsum core, such that gypsum of the gypsum core penetrates at least a portion of the first fiberglass mat; anda wetting agent deposited across an entire thickness of the first fiberglass mat, wherein the wetting agent is deposited onto the first fiberglass mat in an uncoated state, such that the wetting agent penetrates the entire thickness of the first fiberglass mat.2. The gypsum panel of claim 1 , wherein the wetting agent is a surfactant.3. The gypsum panel of claim 2 , wherein the surfactant is selected from a group consisting of multifunctional agents comprising acetylenic chemistry claim 2 , ethoxylated low-foam agents claim 2 , siloxane-based surfactants claim 2 , and nonionic superwetting and coalescing surfactants.4. The gypsum panel of claim 2 , wherein the surfactant has a boiling point of 200° C. or lower.5. The gypsum panel of claim 2 , wherein the surfactant has a boiling ...

Polyester Laminated Building Boards With Improved Surface Characteristics

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. 1. A composite , multi-layered building panel comprising:opposed upper and lower fiber mats, the mats being porous and each mat having an interior and an exterior surface;a set gypsum core extending between and bonded to the interior surfaces of the upper and lower fiber mats, the portion of the set gypsum core proximate the upper and lower fiber mats having a density that is greater than the remainder of the set gypsum core;a polyethylene terephthalate (PET) film having an interior and an exterior surface;a polymer adhesive adhering the modified interior surface of the PET film to the exterior surface of the upper fiber mat, whereby the PET film is bonded to the upper fiber mat; andan acrylic coating applied to the exterior surface of the PET film, the acrylic coating providing a surface finish to the composite, multi-layered building panel;wherein the polymer adhesive forms a smooth outer stratum on the upper and lower fiber mats, the outer stratum being substantially free of the fibers that make up the upper and lower fiber mats.2. The building panel of claim 1 , wherein the exterior surface of the PET film includes topological inconsistencies ranging from a depth of about 0.001 inches to about 0.01 inches.3. The building panel of claim 1 , wherein the surface finish is a level 4 or level 5 surface finish.4. A building panel comprising:a first mat having an interior ...

Method for tightening a screw for fastening a construction panel to a support

A method for tightening a screw for fastening a construction panel to a support of the construction panel, in which the fastening screw is screwed through the construction panel and then through at least part of the support, includes a monitoring of a change over time of a tightening torque of the fastening screw, with determination of a first maximum torque value and then of a second minimum torque value, and after determination of the second minimum torque value, a stoppage of the tightening of the fastening screw for a torque value, termed stoppage value, corresponding to a third maximum torque value or being determined after an occurrence of a third maximum torque value.

Building Panels, Systems, and Methods

Gypsum panels, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a gypsum core having a first surface and an opposed second surface, a first facer material associated with the first surface of the gypsum core, and an environmental sensor assembly associated with the gypsum panel and configured to detect an environmental condition of the gypsum panel and wirelessly communicate data on the environmental condition to a reader. 1. A building panel , comprising:a panel core comprising wood, foam, or gypsum, the panel core having a first surface and an opposed second surface; andan environmental sensor assembly disposed wholly within the panel core or between a first facer material associated with the first surface of the panel core and the first surface of the panel core, wherein the environmental sensor assembly is passive and comprises an antenna, a processing module, and a wireless communication module,wherein the environmental sensor assembly is configured to detect an environmental condition of the building panel and wirelessly communicate data on the environmental condition to a reader,wherein the antenna has an antenna impedance operable to vary based on the environmental condition, the processing module is coupled to the antenna and comprises a tuning module operable to (i) vary a reactive component impedance in order to change a system impedance comprising the antenna impedance and the reactive component impedance, and (ii) produce an impedance value representative of the reactive component impedance, and the wireless communication module is coupled to the processing module and is operable to communicate the impedance value representative of the reactive component impedance to the reader, andwherein the data on the environmental condition comprises the impedance value representative of the reactive component impedance.2. The building panel of claim 1 , wherein ...

PLASTER-BASED ACOUSTIC BOARD

A plaster-based board includes a core made of plaster positioned between two coating layers, in which a textile including glass fibers and an organic binder constitutes at least one of the coating layers and/or the textile is embedded in the plaster constituting the core. In the textile, the binder includes one or more organic polymers having a glass transition temperature which varies from −10 to +25° C., measured by differential scanning calorimetry according to the standard ISO 11357-1:2009. 1. A plaster-based board comprising a core made of plaster positioned between two coating layers , and a textile including glass fibers and an organic binder comprising at least one organic polymer exhibiting a glass transition temperature which varies from −10 to +25° C. , said textile constituting one of the coating layers or the two coating layers and/or being embedded in the core made of plaster.2. The board as claimed in claim 1 , wherein the textile is a nonwoven or a fabric.3. The board as claimed in claim 1 , wherein the textile includes at least 80% by weight of glass fibers.4. The board as claimed in claim 1 , wherein the glass fibers are individual glass filaments having a diameter which varies from 5 to 30 μm claim 1 , or strands comprising a plurality of the glass filaments or an assemblage of several base strands.5. The board as claimed in claim 1 , wherein the textile includes up to 20% by weight of fibers different in chemical nature from the glass fibers.6. The board as claimed in claim 1 , wherein the organic polymer is chosen from copolymers of an olefin and of vinyl acetate claim 1 , copolymers of vinyl acetate and of (meth)acrylic acid or of (meth)acrylate claim 1 , copolymers of (meth)acrylate and of a monomer other than vinyl acetate claim 1 , homopolymers of (meth)acrylic acid or of acrylate claim 1 , terpolymers of vinyl acetate claim 1 , of an olefin and of a vinyl ester monomer claim 1 , and acrylonitrile polymers claim 1 , and terpolymers of ...

Interlocking Gypsum Building Surface Products, Methods of Manufacture, and Interlocking Gypsum Building Surface Systems

The present disclosure relates generally to building surface products, for example, panels suitable for forming a building surface. The present disclosure relates more particularly to a building surface product including a gypsum panel with an upper edge that overlaps a lower edge of a neighboring gypsum panel.

BOARD DEWATERING SYSTEM AND METHOD

A cementitious product with strengthened composite structure is provided. Energy-efficient methods for manufacturing such products are provided as well and include dewatering a partially-set cementitious product by applying vacuum, and also creating a concentration gradient across the product thickness. Systems for manufacturing such products are provided as well. 1. A method for manufacturing a cementitious product with strengthened composite structure , the method comprising:preparing a cementitious slurry comprising gypsum and water;forming a cementitious product by depositing the slurry between two paper layers, a face paper layer and a back paper layer;disposing the product over at least one device selected from the group consisting of a scraping device and vacuum box; andstrengthening the composite structure of the product by applying vacuum to the product.2. The method of claim 1 , wherein the product is disposed over at least one vacuum box such that the face paper layer of the product is at least partially in contact with the at least one vacuum box.3. The method of claim 1 , wherein the product is disposed over at least one vacuum box such that the back paper layer of the product is at least partially in contact with the at least one vacuum box.4. The method of claim 1 , wherein the product is disposed over at least one vacuum box such that the face paper layer and the back paper layer of the product are at least partially in contact with the at least one vacuum box.5. The method of claim 1 , wherein the product is partially-set at the step of disposing the product over at least one vacuum box.6. The method of claim 1 , wherein the applied vacuum is sufficient to create a moisture gradient across the product thickness.7. The method of claim 1 , wherein the applied vacuum is sufficient to drain water from the product.8. The method of claim 1 , wherein the vacuum is applied at 10-20 in Hg.10. The method of claim 1 , wherein the vacuum is applied to both ...

GYPSUM COMPOSITION COMPRISING UNCOOKED STARCH HAVING MID-RANGE VISCOSITY, AND METHODS AND PRODUCTS RELATED THERETO

Disclosed are product (e.g., panels), slurry, and methods relating to an uncooked starch having a mid-range peak viscosity (i.e., from about 120 Brabender Units to about 900 Brabender Units). 1. A gypsum board comprising:a set gypsum core disposed between two cover sheets, the core formed from a slurry comprising stucco, water, and at least one uncooked starch having a peak viscosity of from about 120 Brabender Units to about 900 Brabender Units when the viscosity is measured by putting the starch in a slurry with water at a starch concentration of 15% solids, and using a Viscograph-E instrument set at 75 rpm and 700 cmg, where the starch is heated from 25° C. to 95° C. at a rate of 3° C./minute, the slurry is held at 95° C. for ten minutes, and the starch is cooled to 50° C. at a rate of −3° C./minute.2. The gypsum board of claim 1 , wherein the uncooked starch has a bulk density of from about 40 pcf to about 45 pcf.3. The gypsum board of claim 1 , wherein the uncooked starch has a peak viscosity of from about 300 BU to about 875 BU.4. The gypsum board of claim 1 , wherein the uncooked starch is acid-modified.5. The gypsum board of claim 1 , wherein the uncooked starch has a cold water viscosity of less than about 50 centipoise claim 1 , as measured according to the Brookfield viscometer method.6. The gypsum board of claim 1 , wherein the slurry further comprises a dispersant.7. The gypsum board of claim 1 , wherein the slurry further comprises a polyphosphate.8. The gypsum board of claim 7 , wherein the polyphosphate is sodium trimetaphosphate claim 7 , and the slurry further comprises a dispersant.9. The gypsum board of claim 1 , wherein the uncooked starch has a bulk density of from about 35 pcf to about 45 pcf claim 1 , the uncooked starch is acid-modified claim 1 , the uncooked starch has a cold water viscosity of less than about 50 centipoise claim 1 , as measured according to the Brookfield viscometer method claim 1 , and the board has a density of from ...

Phase-Change Materials From Wax-Based Colloidal Dispersions And Their Process Of Making

This invention generally relates to phase-change materials (“PCM” or “PCM materials”) made from colloidally-protected wax-based microstructures. This invention also relates to such PCM materials configured in various physical forms. This invention further relates to a process of configuring such PCM materials for a variety of end-use applications in which dampening of temperature fluctuations by absorption and desorption of heat is desired. This invention further relates to preparing colloidally-protected wax-based microstructures in particulate form that function as PCM materials. 1. A phase change material (PCM) comprising colloidally-protected wax-based (CPWB) microstructures. The present application is a divisional of U.S. patent application Ser. No. 14/927,940, filed Oct. 30, 2015, which claims benefit of U.S. Provisional Patent Application No. 62/072,617, filed Oct. 30, 2014, both of which are incorporated herein by reference in their entireties.This invention generally relates to phase-change materials (“PCM” or “PCM materials”) made from colloidally-protected wax-based microstructures. This invention also relates to such PCM materials configured in various physical forms. This invention further relates to a process of configuring such PCM materials for a variety of end-use applications in which dampening of temperature fluctuations by absorption and desorption of heat is desired. This invention further relates to preparing colloidally-protected wax-based microstructures in particulate form that function as PCM materials.A phase-change material (PCM) is a substance with a high heat of fusion which, melting and solidifying at a certain temperature, is capable of storing and releasing large amounts of energy. Heat is absorbed or released when the material changes from solid to liquid and vice versa; thus, PCMs are classified as latent heat storage (LHS) units. The phase change herein would be the solid-liquid phase change. Depending on the molecular weight and ...

PREGELATINIZED STARCH WITH MID-RANGE VISCOSITY, AND PRODUCT, SLURRY AND METHODS RELATED THERETO

Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise). 1. A board comprising:a set gypsum core disposed between two cover sheets, the core formed from a slurry comprising stucco, water and at least one pregelatinized starch, wherein the starch has a characteristic of a viscosity from about 35 centipoise to about 425 centipoise when the viscosity is measured while the starch is subjected to the conditions according to the VMA method,wherein the pregelatinized starch is in an amount from about 0.5% to about 5% by weight of the stucco,wherein the pregelatinized starch requires an increase in the amount of excess water needed to be added to the slurry to maintain the slurry fluidity at the same level it would be without the pregelatinized starch, that is less than the increase in the amount of excess water needed by a starch having a viscosity characteristic greater than 425 centipoise according to the VMA method, the board having a core hardness of at least about 11 lb, as determined according to ASTM C473.2. The board according to claim 1 , wherein the viscosity characteristic of the pregelatinized starch is from about 35 centipoise to about 200 centipoise according to the VMA method.3. The board according to claim 1 , wherein the water/stucco ratio is from about 0.55 to about 0.8.4. The board according to claim 1 , wherein the board has a density from about 24 pcf to about 35 pcf.5. The board according to claim 1 , wherein the slurry comprises a second type of starch that is (a) not gelatinized claim 1 , (b) is a pregelatinized starch having the characteristic of a viscosity below 35 centipoise according to the VMA method claim 1 , and/or (c) is a pregelatinized starch having the characteristic of viscosity above 425 centipoise according to the VMA method.6. The board according to wherein the second type of starch comprises alkylated starch.7. ...

Pregelatinized starch with mid-range viscosity, and product, slurry and methods related thereto

Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise), and an extruded pregelatinized starch.

Surfactant Composition for Use in Gypsum Wallboard Manufacture

A gypsum composition including calcined gypsum, water, and a foaming agent composition which comprises at least one betaine, either alone or in combination with at least one alkyl sulfate and/or at least one alkyl ether sulfate, is disclosed. The gypsum composition can be used to prepare foamed gypsum wallboard.

Gypsum wallboard with reinforcing mesh

A wallboard panel is provided, including a sheet of face paper, a first layer of gypsum composition having a first density, a web of mesh associated with the first layer of gypsum composition, a second layer of gypsum composition having a second density, the second density being lower than the first density, and a layer of backing paper. An associated method includes providing a sheet of face paper and laying same upon a moving conveyor belt, applying a first layer of gypsum composition slurry upon the sheet of face paper, applying a web of mesh upon the first layer of gypsum composition slurry, applying a second layer of gypsum composition slurry upon the web of mesh, and applying a sheet of backing paper upon the second layer of gypsum composition slurry.

METHODS FOR MAKING GYPSUM BOARDS WITH POLYMER COATING AND GYPSUM BOARDS MADE BY THE METHOD

Methods for making a gypsum board provided with a latex polymer coating layer having a sufficiently low glass transition temperature, a less dense gypsum core layer, and a relatively denser layer of gypsum between the less dense gypsum core layer and the latex polymer coating layer and a gypsum board made by the method. 1. A method of making a gypsum board , comprising:providing a face paper sheet having an inner bond surface and an outer surface, the face paper sheet inner bond surface opposed to the face paper sheet outer surface;applying a polymer coating to the inner bond surface of the face paper sheet, wherein the polymer coating comprises water and latex polymer selected from the group consisting of acrylics, styrene acrylics, acrylic esters, vinyl acrylics, vinyl chloride acrylic, styrene acetate acrylics, ethylene polyvinyl acetate, polyvinyl acetate, styrene butadiene, and combinations thereof and surfactant, the latex polymer having a glass transition temperature (Tg) of 10° C. to about 20° C.;depositing a first layer of relatively dense gypsum slurry comprising water and calcium sulfate hemihydrate directly on the polymer coated inner bond surface of the face paper sheet to form a first layer of relatively dense slurry, wherein all of the surface of the face paper sheet which contacts the relatively dense gypsum slurry is coated with the polymer;mixing water, calcium sulfate hemihydrate and air to make a foamed gypsum slurry, wherein a weight ratio of the water to calcium sulfate hemihydrate being mixed is 0.2-1.5:1;depositing the foamed gypsum slurry directly on the first layer of relatively dense gypsum slurry to form a foamed gypsum core layer to locate the first layer of relatively dense gypsum layer between the gypsum core layer and the face paper sheet inner bond surface;wherein calcium sulfate hemihydrate in the foamed gypsum slurry and calcium sulfate hemihydrate in the relatively dense gypsum slurry convert to calcium sulfate dihydrate, and the ...

ACOUSTIC PLASTERBOARD

A plaster-based board includes a core made of plaster positioned between two coating layers, in which a textile including fibers of a thermoplastic polymer constitutes at least one of the coating layers and/or the textile is embedded in the plaster constituting the core. 1. A plaster-based board comprising a core made of plaster positioned between two coating layers , and a textile including thermoplastic polymer fibers , said textile constituting one of the coating layers or the two coating layers and/or being embedded in the core made of plaster.2. The board as claimed in claim 1 , wherein the textile is a nonwoven or a fabric.3. The board as claimed in claim 1 , wherein the textile includes at least 70% by weight of fibers composed of at least one thermoplastic polymer.4. The board as claimed in claim 1 , wherein the thermoplastic polymer is chosen from polyolefins claim 1 , polyamides claim 1 , homopolymers and copolymers of acrylonitrile claim 1 , polyimides claim 1 , polyesters claim 1 , poly(lactic acid)s claim 1 , polyhydroxyalkanoates claim 1 , vinyl polymers claim 1 , copolymers of ethylene and of a vinyl compound claim 1 , (meth)acrylic acid polymers claim 1 , alkyl (meth)acrylate polymers claim 1 , polycaprolactones claim 1 , polystyrenes claim 1 , polymers of styrene and of an anhydride claim 1 , copolymers of an olefin and of a fluorinated monomer claim 1 , polycarbonates claim 1 , polyketones claim 1 , polyetherketones claim 1 , polyethersulfones claim 1 , polyimides and linear polyurethanes.5. The board as claimed in claim 4 , wherein the thermoplastic polymer is chosen from polypropylene claim 4 , (meth)acrylic acid or (meth)acrylate polymers claim 4 , poly(lactic acid)s claim 4 , polyhydroxyalkanoates claim 4 , PET claim 4 , PBT and polyethylene naphthalate.6. The board as claimed in claim 5 , wherein the thermoplastic polymer is polypropylene claim 5 , a (meth)acrylic acid or (meth)acrylate polymer or PET.7. The board as claimed in claim 1 , ...

HYDROPHOBIZED FIBER CEMENT PRODUCTS, METHODS FOR PRODUCTION, AND USES THEREOF

The present invention relates hydrophobized fiber cement products and methods for the production thereof as well as uses of such products, in particular in the building industry. In particular, the present invention provides hydrophobized fiber cement product, comprising a fiber cementitious matrix and a hydrophobizing agent uniformly dispersed therein, wherein said hydrophobizing agent comprises at least one hydrophobic silicone resin having a three-dimensional molecular network structure. The present invention further provides processes for producing a hydrophobized fiber cement product with enhanced water impermeability, wherein said process comprises at least the steps of: a) admixing an inorganic curable cementitious matrix with a hydrophobizing agent to form a curable mixture, wherein said hydrophobizing agent comprises at least one hydrophobic silicone resin having a three-dimensional molecular network structure, b) transforming the curable mixture into a shaped body; and c) curing the curable mixture to form a uniformly hydrophobized fiber cement product. 1. A hydrophobized fiber cement product , comprising a fiber cementitious matrix and a hydrophobizing agent uniformly dispersed therein , wherein said hydrophobizing agent comprises at least one hydrophobic silicone resin having a three-dimensional molecular network structure.2. The hydrophobized fiber cement product according to claim 1 , wherein said hydrophobic silicone resin is an alkyl alkoxy silicone resin.3. The hydrophobized fiber cement product according to claim 1 , wherein said hydrophobic silicone resin is an alkyl triethoxy silicone resin.4. The hydrophobized fiber cement product according to claim 1 , wherein said hydrophobic silicone resin is an octyl triethoxy silicone resin.5. The hydrophobized fiber cement product according to claim 1 , wherein said hydrophobic silicone resin is is liquid at ambient temperature in its substantially pure form.6. The hydrophobized fiber cement product ...

GYPSUM PRODUCTS WITH IMPROVED GLASS FIBER MAT

A gypsum product with improved elasticity and increased nail-pull strength is provided, the product made with a glass fiber mat in which glass fibers are cross-linked with a polymeric resin. Further embodiments provide methods for making the glass fiber mats and gypsum products. 1. A gypsum product comprising a gypsum core sandwiched between at least one glass fiber mat in which glass fibers are cross-linked with a polymeric resin.2. The gypsum product of claim 1 , wherein the polymeric resin is selected from the group consisting of a polyacrylate claim 1 , polyester claim 1 , polystyrene claim 1 , acrylo-polyester and acrylo-polystyrene.3. The gypsum product of claim 1 , wherein the amount of the polymeric resin is at about 10 lbs/MSF of the glass fiber mat.4. The gypsum product of claim 1 , wherein the polymeric resin is an acrylo-polyester cross-lined with the glass fibers by hydroxyl functional groups.5. The gypsum product of claim 1 , wherein the glass fibers are pre-pressed claim 1 , post-pressed or both.6. A glass fiber mat with pre-pressed randomly oriented glass fibers in which the pre-pressed glass fibers are cross-linked with a polymeric resin.7. The glass fiber mat of claim 6 , wherein the polymeric resin is selected from the group consisting of a polyacrylate claim 6 , polyester claim 6 , polystyrene claim 6 , acrylo-polyester and acrylo-polystyrene.8. The glass-fiber mat of claim 6 , wherein the glass fibers are further post-pressed.9. A method for making a gypsum product claim 6 , the method comprising:forming a gypsum slurry;obtaining a glass fiber mat;soaking the glass fiber mat in an aqueous polymeric resin solution;causing glass fibers in the glass fiber mat to cross-link by curing the resin; andforming a gypsum product by covering the gypsum slurry on at least one side with the glass fiber mat in which glass fibers are cross-linked with the polymeric resin.10. The method of claim 9 , wherein the curing of the resin is accomplished by exposing the ...

GYPSUM PANELS, MATS THEREFOR, AND METHODS

Methods of making gypsum panels, fiberglass mats, and associated gypsum panels and building sheathing systems are provided. In one aspect, a method of making a gypsum panel includes depositing an aqueous liquid containing a wetting agent onto a fiberglass mat, such that the aqueous liquid penetrates an entire thickness of the fiberglass mat, and depositing a gypsum slurry onto the fiberglass mat onto which the aqueous liquid has been deposited, such that the gypsum slurry penetrates at least a portion of the fiberglass mat. In another aspect, a method of making a gypsum panel includes depositing an aqueous liquid containing a wetting agent onto a fiberglass mat, and depositing a gypsum slurry onto the fiberglass mat onto which the aqueous liquid has been deposited, prior to drying of the aqueous liquid, such that the gypsum slurry penetrates at least a portion of the fiberglass mat. 1. A method of making a gypsum panel , comprising:depositing an aqueous liquid comprising a wetting agent onto a first surface of a first fiberglass mat, such that the aqueous liquid penetrates an entire thickness of the fiberglass mat;depositing a gypsum slurry onto the first surface of the first fiberglass mat onto which the aqueous liquid has been deposited, such that the gypsum slurry penetrates at least a portion of the first fiberglass mat; andallowing the gypsum slurry to set to form a gypsum core.2. The method of claim 1 , wherein the wetting agent is a surfactant.3. The method of claim 2 , wherein the surfactant is selected from a group consisting of multifunctional agents based on acetylenic chemistry claim 2 , ethoxylated low-foam agents claim 2 , siloxane-based surfactants claim 2 , and nonionic superwetting and coalescing surfactants.4. The method of claim 2 , wherein the surfactant is present in the aqueous liquid in an amount of about 0.05 percent to about 1 percent claim 2 , by weight of the liquid.5. The method of claim 2 , wherein the surfactant has a boiling point of ...

Partition Having Increased Fixing Strength

A partition is adapted to support a fixture and has a front surface to which the fixture may be affixed and a back surface that faces away from the fixture. The partition comprises a plasterboard and a reinforcing board, the reinforcing board being located between the plasterboard and the front surface, and the plasterboard comprising at least 1 wt % fibre and at least 1 wt % polymer is additive. 1. A partition that is adapted to support a fixture , the partition having a front surface that is for affixing a fixture thereto and a back surface that is for facing away from the fixture , the partition comprising a plasterboard and a reinforcing board , the reinforcing board being located between the plasterboard and the front surface , and the plasterboard comprising at least 1 wt % fibre and at least 1 wt % polymeric additive.2. A partition according to claim 1 , characterised in that the ability of the partition to retain a screw is 1.5 times greater than that of the plasterboard alone.3. A partition according to having a screw pull-out strength greater than 1000 N.4. A partition according to claim 1 , wherein the plasterboard and the reinforcing board are glued together.5. A partition according to claim 4 , wherein the glue is a viscoelastic glue.6. A partition according to claim 1 , wherein the plasterboard and the reinforcing board are connected with double sided glue tape.7. A partition according to claim 1 , wherein the plasterboard and the reinforcing board are secured to each other by means of mechanical fixings.8. A partition according to claim 7 , wherein the plasterboard and the reinforcing board are secured to each other by means of screw fixings.9. A partition according to claim 7 , wherein the reinforcing board is offset relative to the plasterboard in the plane of the partition.10. A partition according to claim 7 , wherein the reinforcing board has a thickness in the range 6-19 mm.11. A partition according to claim 7 , wherein the reinforcing board ...

APPARATUS AND METHOD FOR CASTING A STUCCO SLURRY LAYER OF DEFINED WIDTH ONTO A LINER FOR PRODUCTION OF GYPSUM PLASTERBOARDS

The invention concerns an apparatus for furnishing a liner with a layer of stucco slurry, comprising at least:

HIGH SOLIDS COATINGS FOR BUILDING PANELS

Described herein is a coating composition suitable for application to a building panel. The coating composition comprises inorganic pigment, liquid carrier, and a humectant comprising a first ester-containing compound. The liquid carrier may be present in an amount ranging from about 10 wt. % to about 30 wt. % based on the total weight of the coating composition. Described herein are also building panels coated with the coating composition and methods of their production. 1. A building system comprisinga first building panel positioned adjacent to a second building panel, and a seam formed between the first and second building panels;a seam-filling material applied to the seam;{'claim-text': ['a binder having a pH of at least about 7.0 and a Tg of at least 20° C.;', 'a pigment; and', 'a viscosity modifier;'], '#text': 'a coating applied to the first and second building panels and the seam-filing material, the coating comprising:'}wherein the pigment and binder are present in a weight ratio of at least about 5:1.2. The building system according to claim 1 , wherein the Tg of the binder is at least 30° C.3. The building system according to claim 1 , wherein the binder is a styrene acrylic copolymer.4. The building system according to claim 1 , wherein the styrene acrylic copolymer has a pH ranging from about 7.5 to about 9.5. The building system according to claim 1 , wherein the binder is polyvinyl acetate.6. The building system according to claim 5 , wherein the polyvinyl acetate has a pH of about 7.0.7. The building system according to claim 1 , wherein the viscosity modifier comprises a humectant and a dispersant.8. The building system according to claim 7 , wherein humectant and the dispersant are present in a weight ratio ranging from about 1:1 to about 4:1.9. The building system according to claim 7 , wherein the humectant is selected from the group consisting of ester-containing humectants including sugar-based esters and glycol-based esters.10. The building ...

Plaster boards and methods for making them

One aspect of the disclosure is a plaster board having a first edge and an opposed second edge, and a third edge and an opposed fourth edge. The plaster board includes a first layer of hardened plaster material including a first surface and an opposed second surface, and a second layer of hardened plaster material including a first surface and an opposed second surface. The second layer of hardened plaster material is stacked against the first layer such that their first surfaces face one another. The first layer and the second layer together define the first, second, third, and fourth edges of the plaster board. The plaster board also includes a viscoelastic polymer disposed between the first surfaces of the first and second layers of hardened plaster material. The viscoelastic polymer does not extend substantially to the first, second, third, and fourth edges of the plaster board.

MAGNET RECEPTIVE PANELS AND METHODS

Provided are building panels comprising at least one magnet receptive element, methods for making such panels, and kits and methods for attaching objects to a panel without nails or screws. 1. A building panel comprising: a pattern of one or more magnet receptive elements , the one or more magnet receptive elements applied to at least one surface of the building panel and/or embedded into the building panel.2. The building panel of claim 1 , wherein the pattern includes at least one of a disjointed pattern claim 1 , a discontinuous pattern claim 1 , a continuous pattern claim 1 , a grid claim 1 , an array claim 1 , being geometrically spaced claim 1 , randomly spaced claim 1 , and spaced in at least one direction.3. The building panel of claim 1 , wherein the building panel is a wallboard panel.4. The building panel of claim 1 , wherein the pattern is a disjoined grid pattern of at least two rows claim 1 , a first row of magnet receptive elements and a second row of magnet receptive elements claim 1 , and wherein the magnet receptive elements in the first row and the magnet receptive elements in the second row differ in their composition from each other.5. The building panel of claim 1 , wherein the one or more magnet receptive elements comprise a ferromagnetic material.6. The building panel of claim 1 , wherein the one or more magnet receptive elements include at least one of magnet receptive tape claim 1 , magnet receptive sheet claim 1 , magnet receptive paint claim 1 , magnet receptive coating claim 1 , foil claim 1 , shim claim 1 , magnetic tape claim 1 , magnetic sheet claim 1 , magnetic paint claim 1 , and magnetic coating.7. The building panel of claim 1 , wherein the one or more magnet receptive elements are a magnet.8. The building panel of claim 1 , wherein the one or more magnet receptive elements are attractive to the magnet which comprises at least one of an alnico magnet claim 1 , a magnet made from a ferromagnetic material claim 1 , a rare-earth ...

HYDROPHOBIC FINISH COMPOSITIONS WITH EXTENDED FLOW TIME RETENTION AND BUILDING PRODUCTS MADE THEREOF

Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention have many uses, such as, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives. 2. The hydrophobic finish composition of claim 1 , wherein the carboxylic acids or salts of carboxylic acids are not a polycarboxylate superplasticizer.3. The hydrophobic finish composition of claim 1 , having an absence of polycarboxylate ether.4. The hydrophobic finish composition of claim 1 , wherein the extended flow time retention agent comprises citric acid or a citric acid salt.5. The hydrophobic finish composition of claim 1 , wherein the extended flow time retention agent is at least one member selected from the group consisting of tricarboxylic acids claim 1 , dicarboxylic acids claim 1 , sugar acids claim 1 , aldonic acids claim 1 , aldaric acids claim 1 , uronic acids claim 1 , aromatic carboxylic acids claim 1 , amino carboxylic acids claim 1 , alpha hydroxy acids claim 1 , beta hydroxy acids claim 1 , sodium salts of said acids claim 1 , and potassium salts of said acids.69-. (canceled)10. The hydrophobic finish composition of claim 1 , wherein the film-forming polymer comprises at least one member selected from the group consisting of acrylic polymers and copolymers claim 1 , ...

Gypsum board from gypsum having high level of chloride salt and a perforated sheet and methods associated therewith

Gypsum boards formed from synthetic gypsum and other gypsum sources having high chloride salt concentrations. The gypsum boards may include a set gypsum board core layer between a front and back paper cover sheets. The back paper cover sheet has a plurality of perforations extending therethrough. Methods of making the gypsum boards, and a wall system for employing the gypsum boards, are also provided. The concentration of the chloride anion in aqueous gypsum slurry used to make the set gypsum board core layer and to perform the methods of the invention may range from about 500 ppm to about 3000 ppm, typically from about 500 ppm to about 2000 ppm per 1,000,000 parts by weight calcium sulfate hemihydrate, more typically from about 500 ppm to about 1500 ppm per 1,000,000 parts by weight calcium sulfate hemihydrate.

MEMBRANE-READY FIBROUS FACED GYPSUM PANELS, APPARATUS, AND METHODS

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. 1. A method of making an unattached , membrane-ready , exterior gypsum panel , comprising:depositing a gypsum slurry onto a surface of a first fibrous mat;depositing a second fibrous mat onto a surface of the gypsum slurry opposite the first fibrous mat, such that a surface of the second fibrous mat contacts the gypsum slurry, to form a gypsum sandwich structure;drying the gypsum sandwich structure;applying an adhesive coating composition to a surface of the first fibrous mat opposite the gypsum slurry, such that the adhesive coating covers at least a portion of the surface of the first fibrous mat; anddrying the adhesive coating composition to form a material coating on the first fibrous mat and form a membrane-ready gypsum panel, wherein the material coating comprises a substantially smooth outer surface.2. The method of claim 1 , wherein the first fibrous mat has a mat coating on the surface of the first fibrous mat opposite the gypsum slurry.3. The method of claim 1 , wherein the second fibrous mat has a mat coating on the surface of the second fibrous mat opposite the gypsum slurry.4. The method of claim 1 , wherein applying the adhesive coating composition occurs after drying the gypsum sandwich structure.5. The method of claim 1 , wherein applying the adhesive coating composition occurs before drying the gypsum sandwich structure.6. The method of claim 1 , wherein the adhesive coating composition is applied such that the outer surface has a finish from about a level 1 finish to about a level 5 finish.7. The method of claim ...

Coating and binder compositions for gypsum boards

An adhesive binder composition for adhering a paper sheet to a gypsum article with a gypsum layer having at least one paper sheet on a major surface thereof. The adhesive binder composition includes a polymeric adhesive and at least one surfactant. The adhesive binder composition resides at a boundary between the gypsum layer and the paper sheet.

HIGH SOLIDS COATINGS FOR BUILDING PANELS

Described herein is a coating composition suitable for application to a building panel. The coating composition comprises inorganic pigment, liquid carrier, and a humectant comprising a first ester-containing compound. The liquid carrier may be present in an amount ranging from about 10 wt. % to about 30 wt. % based on the total weight of the coating composition. Described herein are also building panels coated with the coating composition and methods of their production. 1. A coated building panel comprising:a body comprising a first major surface and a side surface that intersects the first major surface; a binder having a pH of at least about 7.0 and a Tg of at least 20° C.;', 'a pigment; and', 'a viscosity modifier;, 'a coating applied to at least one of the first major surface or the side surface, the coating comprisingwherein the pigment and binder are present in a weight ratio of at least about 5:1.2. The coated building panel according to claim 1 , wherein the Tg of the binder is at least 30° C.3. The coated building panel according to claim 1 , wherein the binder is a styrene acrylic copolymer having a pH ranging from about 7.5 to about 9.4. (canceled)5. The coated building panel according to claim 1 , wherein the binder is polyvinyl acetate having a pH of about 7.0.6. (canceled)7. The coated building panel according to claim 1 , wherein the viscosity modifier comprises a humectant and a dispersant present in a weight ratio ranging from about 1:1 to about 4:1.811.-. (canceled)12. The coated building panel according to claim 1 , wherein the pigment is selected from one or more of titanium dioxide claim 1 , calcium carbonate claim 1 , alumina trihydrate claim 1 , and diatomaceous earth.1332.-. (canceled)33. A coated building panel comprising:a body comprising a first major surface and a side surface that intersects the first major surface; a binder;', 'a pigment; and', 'a viscosity modifier comprising a humectant and a dispersant present in a weight ratio ...

Treatment Composition Containing A Mold Inhibiting Agent and A Water Repellent Having Reduced Foaming Properties

The present disclosure is generally directed to a mold inhibiting composition. The mold inhibiting composition can be used to treat various different substrates, including building material products, such as facing layers for wallboard. In general, any suitable paper product may be treated with the composition. The composition contains a mold inhibiting agent in combination with a defoamer. The mold inhibiting agent may comprise a pyrithione. The defoamer, on the other hand, may comprise an oil based defoamer containing metal oxide particles, such as silica particles. The mold inhibiting composition can be combined with a water repellent and applied to a substrate without excessive amounts of foam or froth being formed. The defoamer is selected so as to not interfere with the resulting water absorption properties of the product. 1. A building material product comprising:a core comprising gypsum, the core including a first face and a second and opposite face;a first facing layer adhered to the first face and a second facing layer adhered to the second face of the core, each of the first and second facing layers comprising a paper layer; a water repellent agent;', 'a mold inhibiting agent; and', 'a defoamer, the defoamer comprising an oil carrier and a defoaming agent, the defoamer being present on the facing layer in an amount greater than about 5 grams per MSF., 'a water repellent and mold inhibiting composition applied to at least one of the facing layers, the water repellent and mold inhibiting composition comprising2. A building material product as defined in claim 1 , wherein the defoamer is present on the facing layer in an amount of from about 10 grams per MSF to about 50 grams per MSF.3. A building material product as defined in claim 1 , wherein the oil carrier comprises a hydrocarbon oil.4. A building material product as defined in claim 1 , wherein the oil carrier comprises mineral oil claim 1 , vegetable oil claim 1 , or a white oil.5. A building material ...

Self-Sealing Fasteners, Building Panels, Systems, and Methods

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. 1. A fastener , comprising:an elongated fastener body having a first end and an opposed second end, with an external surface extending between the first end and the second end; anda coating material disposed on at least a portion the external surface,wherein the coating material displays a viscosity of less than 1 Pa·s, measured at a shear rate of 1000 Hz and at a temperature of 150° F.2. The fastener of claim 1 , wherein the coating material displays a viscosity of less than 1×10Pa·s claim 1 , measured at a shear rate of 1000 Hz and at a temperature of 150° F.3. The fastener of claim 1 , wherein the coating material comprises a pressure-sensitive hot melt.4. The fastener of claim 3 , wherein the pressure-sensitive hot melt comprises a polymer selected from a group consisting of styrene block copolymers claim 3 , styrene-butadiene-styrene claim 3 , styrene-isoprene-styrene claim 3 , styrene-ethylene/butylene-styrene claim 3 , styrene-ethylene/propylene adhesives claim 3 , ethylene-vinyl acetate claim 3 , ethylene-acrylate copolymers claim 3 , polyolefins claim 3 , polybutene-1 claim 3 , amorphous polyolefin claim 3 , polyamides claim 3 , polyesters claim 3 , polyurethanes claim 3 , including reactive or thermoplastic polyurethanes claim 3 , polycaprolactone claim 3 , polycarbonates claim 3 , fluoropolymers claim 3 , silicone rubbers claim 3 , and thermoplastic elastomers.5. ...

PREGELATINIZED STARCH WITH MID-RANGE VISCOSITY, AND PRODUCT, SLURRY AND METHODS RELATED THERETO

Disclosed are product (e.g., panels), slurry, and methods relating to a pregelatinized starch having a mid-range viscosity (i.e., from about 20 centipoise to about 700 centipoise), and an extruded pregelatinized starch. 120-. (canceled)21. A method of making a board comprising:(a) mixing at least water, stucco, and at least one extruded pregelatinized starch to form a slurry, wherein the extruded pregelatinized starch is formed by modifying and extruding a wet starch having a water content less than about 25% wherein the modifying at least partially hydrolyzes the starch via acid and/or enzyme modification, the slurry having a water/stucco ratio of from about 0.4 to about 1.1,(b) disposing the slurry between a first cover sheet and a second cover sheet to form a wet assembly,(c) cutting the wet assembly into a board, and(d) drying the board;{'sup': '−1', 'the extruded pregelatinized starch having (i) a cold water solubility greater than about 30% when measured at 25° C., and (ii) a cold water viscosity of a 10 wt. % slurry of the starch in water when measured at 25° C. and at a shear rate of 100 sfor 1 min of from about 120 centipoise to about 300 centipoise.'}22. The method according to claim 21 , wherein the extruded pregelatinized starch has a cold water solubility of from about 30% to about 75%.23. The method according to claim 22 , wherein the extruded pregelatinized starch has a cold water solubility of from about 50% to about 75%.24. The method according to claim 21 , wherein the extruded pregelatinized starch has a particle size of from about 100 microns to about 400 microns.25. The method according to claim 22 , wherein the extruded pregelatinized starch has a particle size of from about 100 microns to about 400 microns.26. The method according to claim 21 , wherein the extruded pregelatinized starch is in an amount of from about 0.1% to about 5% by weight based on the weight of stucco.27. The method according to claim 24 , wherein the extruded ...

Apparatus and Method for Constructing Building Boards Using Low Friction Surfaces

Discloses is an apparatus and method for utilizing air along a building board forming line for the purpose of reducing friction between the board and the underlying forming tables. The device employs a series of air nozzles that are formed within the face of the forming tables. An air source delivers pressurized air to the nozzles. As completed or partially completed boards travel along the forming tables, an air cushion is created to reduce the friction between the board and the underlying table. The pressurized air can also be used to transport the boards and promote the even distribution of slurry during formation. The various components of the present invention, and the manner in which they interrelate, are described in greater detail hereinafter. 1. A method for producing building boards , the method comprising:utilizing a supply roll of a facing sheeting, a slurry mixing device, a fluid source, and a forming table including a series of nozzles;unwinding the facing sheet over top of the forming table;depositing a volume of cementitious material from the mixing device to the unwound facing sheet; andsupplying a pressurized fluid from the fluid source to the series of nozzles, whereby a pressurized fluid cushion is created between the unwound facing sheet and the forming table, the fluid cushion reducing the frictional forces otherwise generated between the facing sheet and the forming table.2. The method of claim 1 , wherein the fluid source supplies pressurized air in bursts at a set frequency.3. The method of claim 1 , further comprising vibrating the deposited cementitious material via the pressurized air bursts.4. The method of claim 1 , wherein the nozzles are angled and the method further comprises moving the unwound facing sheet via the fluid cushion.5. The method of claim 1 , further comprising supplying the pressurized fluid at greater pressures at selection locations upon the forming table so as to promote even distribution of the deposited ...

CONSTRUCTION PANELS, MATERIALS, SYSTEMS, AND METHODS

Construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a core having a first surface and an opposed second surface, and an environmental sensor assembly associated with the panel and configured to detect an environmental condition of the panel and wirelessly communicate data on the environmental condition to a reader. 1. A building panel , comprising:a panel comprising a panel core and having a first surface and an opposed second surface; andan environmental sensor assembly disposed wholly within the panel core or between the panel core and a facer material of the panel and configured to detect an environmental condition of the panel and wirelessly communicate data on the environmental condition to a reader,wherein the environmental condition of the panel comprises temperature, pressure, or both.2. The panel of claim 1 , wherein the environmental sensor assembly comprises an antenna claim 1 , a processing module claim 1 , and a wireless communication module.3. The panel of claim 1 , wherein the environmental sensor assembly comprises a passive radio frequency identification sensor.4. The panel of claim 2 , wherein:the antenna comprises a resistor inductor capacitor tuned circuit operable to convert the environmental condition into an impedance change, andthe processing module is coupled to the antenna and is operable to translate the impedance change into a sensor code by matching antenna impedance to die impedance.5. The panel of claim 2 , wherein:the antenna has an antenna impedance operable to vary based on the environmental condition,the processing module is coupled to the antenna and comprises a tuning module operable to (i) vary a reactive component impedance in order to change a system impedance comprising the antenna impedance and the reactive component impedance, and (ii) produce an impedance value representative of the ...

Construction Panel Having Improved Fixing Strength

A gypsum product has a first polymeric additive and a second polymeric additive distributed therein, wherein the first polymeric additive is a synthetic polymer and the second polymeric additive is starch. 2. The gypsum panel according to claim 1 , wherein the total amount of the polyvinyl acetate and native starch is greater than 4 wt. % to less than 20 wt % relative to the gypsum.3. The gypsum panel according to claim 1 , wherein the fibres are glass fibres.4. The gypsum panel according to claim 3 , wherein the fibres are present in an amount of 3-10 wt % relative to the gypsum.5. The gypsum panel according to claim 1 , wherein the starch is a migratory starch. This application is a continuation application of pending U.S. application Ser. No. 15/523,966, filed May 3, 2017, entitled “Construction Panel Having Improved Fixing Strength”; which itself is the U.S. National Stage entry of International Application No. PCT/GB2015/053538, filed Nov. 19, 2015, which claims priority to GB Application No. 1420674.2, filed Nov. 20, 2014. These prior applications are incorporated herein by reference in their entirety.The present invention relates to panels for use in building construction. In particular, the present invention relates to panels for providing partitions to which items such as sinks, televisions, or radiators may be affixed.Light-weight panels such as plasterboard (e.g. gypsum plasterboard), polystyrene board and fibreboard are commonly used to provide partitions within buildings. Their advantages for this application include the fact that they are light and quick to install.However, in certain cases, such light-weight panels may have the drawback that they are not strong enough to support fixtures (e.g. sinks, televisions, radiators, fire extinguishers, shelves and any other item that requires attachment to the panel). In such cases, the weight of the fixture may cause the fixing means (e.g. screws) to be pulled out of the panel, such that the fixture falls ...

UTILITY MATERIALS INCORPORATING A MICROPARTICLE MATRIX FORMED WITH A SETTING AGENT

A composition, utility material, and method of making a utility material is disclosed. A composition having an improved setting time may include a plurality of microparticles mixed with a sodium silicate binder and an isocyanate setting agent, where the microparticle composition has a setting time of less than or equal to one hour. A utility material may be a wallboard that includes the composition. 1a wallboard having a first facing membrane and a second facing membrane; and 'microparticles and at least one binder;', 'a core matrix disposed between the first facing membrane and the second facing membrane, wherein the core matrix includeswherein a majority of the microparticles in the core matrix of the wallboard are structurally intact; andwherein a water content of the wallboard is less than 5%.. A utility material comprising: This application claims the benefit of U.S. Provisional Patent Application No. 61/198,554, filed on Nov. 4, 2008, which is incorporated by reference herein in its entirety.The present invention relates generally to various utility and/or building materials, such as wallboard, sound attenuation materials, shear panels, casting materials, etc., and more particularly to utility and/or building materials incorporating a microparticle-based core matrix. Accordingly, the present invention involves the fields of chemistry, manufacturing engineering, construction, and materials science.Many different types of building or utility materials, such as wallboard insulation, blown-in insulation, acoustical or sound dampening/absorbing materials, etc., exist in the art. These are all designed to provide a specific function within a structure. In addition, the composition of ingredients or components making up these utility materials varies greatly. Although there are many different available compositions making up the many different utility materials, relatively few of these incorporate microparticles, such as naturally occurring cenospheres or ...

SHEAR PANEL BUILDING MATERIAL

A shear panel building material that includes a first facing membrane, a core matrix disposed on a face of the first facing membrane, and a semi-rigid or rigid material attached to the core matrix. The core matrix can include microspheres having a size of about 200 microns to about 800 microns, sodium silicate, and ethylene vinyl acetate. In one aspect, the shear panel is substantially free from glue and cement. 1a first facing membrane;a second facing membrane;a rigid material situated between the first facing membrane and the second facing membrane, said rigid material being self-supporting; and from about 25 wt % to about 60 wt % of microparticles based on wet formulation,', 'from about 20 wt % to about 36 wt % sodium silicate, and', 'from about 2 wt % to about 6 wt % of a vinyl acetate,, 'a core matrix disposed between said first and second facing membranes, said core matrix includingwherein the rigid material is held in place with respect to the first and second facing membranes by the core matrix.. A shear panel building material comprising: This application is a continuation application of U.S. patent application Ser. No. 13/176,692, filed Jul. 5, 2011, which is a continuation of U.S. patent application Ser. No. 12/238,379, filed on Sep. 25, 2008, which is a continuation-in-part of U.S. patent application Ser. No. 12/077,951, filed on Mar. 21, 2008, which claims the benefit of U.S. Provisional Patent Application No. 60/919,509, filed on Mar. 21, 2007, and of U.S. Provisional Patent Application No. 60/961,130, filed on Jul. 17, 2007, and of U.S. Provisional Patent Application No. 61/002,367, filed on Nov. 7, 2007, and U.S. Provisional Patent Application No. 61/081,951, filed on Jul. 18, 2008, all of which are each incorporated by reference herein in their entireties.The present invention relates generally to building materials, and more particularly to shear panels or shear-type building materials. Accordingly, the present invention involves the fields of ...

BUILDING ASSEMBLY INCLUDING A WEATHER RESISTANT BARRIER, A SHEET FOR USE AS A WEATHER RESISTANT BARRIER, A LIQUID COATING COMPOSITION AND METHODS OF MAKING THE FOREGOING

A weather resistive barrier (WRB) for the exterior protection of building substrates can have a water vapor permeability that decreases with increasing temperature. In an embodiment, the WRB includes a coating comprising a LCST polymer, and may further include a second polymer. The WRB can be part of a building assembly, part of a sheet, or a sheet itself, the sheet having an air permeability of less than 0.02 L/(s m) at a pressure of 75 Pa. Furthermore a liquid coating composition can include a LCST polymer and a second polymer, wherein the liquid coating composition can be adapted that a solid coating formed by the liquid coating composition has an air permeability of less than 0.02 L/(s m) at a pressure of 75 Pa and a water vapor permeability that decreases with increasing temperature. 1. A building assembly comprising a building substrate and a weather resistive barrier (WRB) , the WRB having a water vapor permeability that decreases with increasing temperature in a temperature range from 5° C. to 60° C. at 25% relative humidity (RH).2. The building assembly of claim 1 , wherein the WRB comprises a coating including a lower critical solution temperature (LCST) polymer.3. The building assembly of claim 2 , wherein the coating further comprises a second polymer different from the LCST polymer.4. The building assembly of claim 2 , wherein the LCST polymer includes a hydroxyalkyl cellulose claim 2 , a poly(alkylacrylamide) claim 2 , a poly(vinyl methyl ether) claim 2 , a polyetheramine claim 2 , or any combination thereof.5. The building assembly of claim 4 , wherein the LCST polymer includes a hydroxypropylcellulose claim 4 , Poly(N-isopropylacrylamide) claim 4 , poly(N-(tert-butyl)acrylamide) claim 4 , a monoamine of a poly(ethylene propylene) copolymer claim 4 , or any combination thereof.6. The building assembly of claim 2 , wherein an amount of the LCST polymer in the coating is at least 0.5 wt % based on the total weight of the coating.7. The building assembly ...

Building Element

A building element (for example plasterboard) is described, and comprises a wirelessly or magnetically readable identifier. Since the identifier is wirelessly or magnetically readable, it is possible to determine the type of the plasterboard (or other building element) after installation, without damaging the plasterboard or any decoration applied to it. 134-. (canceled)35. A plasterboard building element comprising an identifier , wherein said identifier is magnetically readable.36. A plasterboard building element according to claim 35 , wherein said identifier comprises a pattern of magnetically detectable material.37. A plasterboard building element according to claim 35 , wherein said magnetically detectable material comprises magnetic paint.38. A plasterboard building element according to claim 35 , wherein said identifier is printed.39. A plasterboard building element according to claim 35 , wherein said magnetically detectable material comprises strips of metal.40. A plasterboard building element according to claim 35 , wherein said identifier extends continuously across at least one surface of said building element.41. A plasterboard building element according to claim 35 , wherein said identifier is located in a discrete area of said building element.42. A plasterboard building element according to claim 35 , wherein said building element comprises plasterboard claim 35 , said plasterboard comprising a gypsum core sandwiched between a face layer and a backing layer.43. A plasterboard building element according to claim 42 , wherein said identifier is located on an inner surface of at least one of said face layer and said backing layer claim 42 , adjacent to said gypsum core.44. A plasterboard building element according to claim 35 , wherein said identifier uniquely identifies the building element.45. A plasterboard building element according to claim 35 , wherein said identifier identifies at least one material characteristic of the building element.46. A ...

Concrete panel board

A concrete panel board is provided. The panel board includes: a substrate board; a primer layer applied to the substrate; a thinset mortar layer applied to the primer layer; a plaster layer applied to the thinset mortar layer; and a sealant layer applied to the plaster layer.

Foam modifiers for gypsum slurries, methods, and products

Disclosed is a foam modifier, e.g., useful for gypsum or cement slurries. The foam modifier comprises a fatty alcohol that is added to a gypsum or cement slurry that includes foaming agent, such as an alkyl sulfate surfactant. The fatty alcohol can be a C 6 -C 16 fatty alcohol in some embodiments. The use of such a foam modifier can be used, for example, to stabilize the foam, reduce waste of foaming agent, improve void size control in the final product, and improve the gypsum board manufacturing process.

GYPSUM WALLBOARD PRODUCED USING A HIGH WATER-TO-STUCCO RATIO

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. 1. A fire resistant gypsum board comprising:a set gypsum composition disposed between two cover sheets, the set gypsum composition comprising an interlocking matrix of set gypsum formed from a slurry comprising at least stucco and water;the slurry having a water-to-stucco ratio from about 0.7 to about 2.0; and{'sup': 3', '3, 'the board having a density from about 24 lbs/ftto about 40 lbs/ft, and when at a thickness of about ⅝ inch, a nail pull resistance of at least about 70 lbs of force as determined according to ASTM C473-09, and a Fire Endurance Index (FEI) greater than about 52 minutes.'}2. The fire resistant gypsum board of claim 1 , wherein the set gypsum composition comprises gelatinized starch in an amount greater than about 1% by weight based on the weight of the stucco.3. The fire resistant gypsum board of claim 1 , wherein the set gypsum composition comprises a thickener.4. The fire resistant gypsum board of claim 3 , wherein the thickener is silica fume claim 3 , Portland cement claim 3 , fly ash claim 3 , clay claim 3 , fine cellulosic particles claim 3 , or a high molecular weight polymer claim 3 , or any mixture thereof.5. The fire resistant gypsum board of claim 4 , wherein the thickener is less than about 10% by weight based on the weight of the stucco.6. The fire resistant gypsum board of claim 4 , wherein the high molecular weight polymer is polyacrylamide.7. The fire resistant gypsum board of claim 1 , wherein the composition further comprises high thermal expansion particles.8. The fire resistant gypsum board of claim 7 , wherein the high thermal expansion particles are vermiculite.9. The fire resistant gypsum board of claim 8 , wherein vermiculite is less than about 5% by weight based on the ...

TAPERED PLASTERBOARDS AND METHODS FOR MAKING THEM

Disclosed herein are plaster boards having a first surface and an opposing second surface, and 1. A plasterboard comprising:a first surface and an opposing second surface, anda first edge and an opposing second edge that bound the first surface and the second surface,the first surface comprising a first section and a second section, the first section being raised compared to the second section, the second section abutting the second edge,the second surface comprising a first section and a second section that are separated by a boundary between the first edge and the second edge, the first section of the second surface being substantially parallel to the first section of the first surface, the second section of the second surface sloping toward the first surface from the boundary toward the second edge.2. The plasterboard of claim 1 , wherein the second section of the second surface abuts the second edge.3. The plasterboard of claim 1 , wherein the first section of the first surface is substantially parallel to the second section of the first surface.4. The plasterboard of claim 1 , wherein the first section of the first surface and the second section of the first surface are separated by a step-shaped boundary.5. The plasterboard of claim 4 , wherein the step-shaped boundary is substantially perpendicular to the first section of the first surface and the second section of the first surface.6. The plasterboard of claim 1 , wherein the first section of the first surface and the second section of the first surface are separated by a sloped boundary.7. The plasterboard of claim 1 , wherein the first section of the first surface is raised above the second section of the first surface by at least 0.01 inches claim 1 , e.g. claim 1 , at least 0.02 inches.8. The plasterboard of claim 1 , wherein the first section of the first surface is raised above the second section of the first surface by no more than 0.1 inches claim 1 , e.g. claim 1 , no more than 0.05 inches.9. The ...

BUILDING PRODUCTS COMPOSITES AND METHODS

Methods of manufacturing composites are provided, including combining dihydrate calcium sulfate whiskers, hemihydrate calcium sulfate stucco, and water to form a slurry, and setting the slurry to form a composite having a natural porosity of about 60 volume percent or greater. Composites are also provided, including dihydrate calcium sulfate whiskers and dihydrate calcium sulfate crystals, and having a natural porosity of about 60 volume percent or greater. 1. A method of manufacturing a composite , comprising:combining dihydrate calcium sulfate whiskers, hemihydrate calcium sulfate stucco, and water to form a slurry; andsetting the slurry to form a composite having a natural porosity of about 60 volume percent or greater.2. The method of claim 1 , wherein the dihydrate calcium sulfate whiskers and the hemihydrate calcium sulfate stucco are combined in amounts from about 1 percent by weight whiskers to about 35 percent by weight whiskers and from about 65 percent by weight stucco to about 99 percent by weight stucco claim 1 , as measured on a dry basis.3. The method of claim 1 , wherein the dihydrate calcium sulfate whiskers comprise wet dihydrate calcium sulfate whiskers that have been dewatered to about 50 percent water to about 70 percent water.4. The method of claim 1 , further comprising:combining hemihydrate calcium sulfate stucco and water to form a slurry of dihydrate calcium sulfate crystals; andageing the slurry under ambient conditions to form dihydrate calcium sulfate whiskers in water.5. The method of claim 4 , further comprising:removing at least a portion of the water from the dihydrate calcium sulfate whiskers in water to form dewatered calcium sulfate whiskers.6. The method of claim 1 , wherein the dihydrate calcium sulfate whiskers have a mean aspect ratio of at least about 2.7. The method of wherein the dihydrate calcium sulfate whiskers have a mean aspect ratio from about 10 to about 20.8. The method of claim 1 , wherein the composite has a ...

GYPSUM PANELS, SYSTEMS, AND METHODS

Gypsum panels, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a gypsum core having a first surface and an opposed second surface, a first facer material associated with the first surface of the gypsum core, and an environmental sensor assembly associated with the gypsum panel and configured to detect an environmental condition of the gypsum panel and wirelessly communicate data on the environmental condition to a reader. 1. A gypsum panel , comprising:a gypsum core having a first surface and an opposed second surface; andan environmental sensor assembly disposed wholly within the gypsum core or between a first facer material associated with the first surface of the gypsum core and the first surface of the gypsum core,the environmental sensor assembly being configured to detect an environmental condition of the gypsum panel and wirelessly communicate data on the environmental condition to a reader.2. The gypsum panel of claim 1 , wherein the environmental sensor assembly is configured to detect an environmental condition of the panel selected from moisture claim 1 , temperature claim 1 , and pressure.3. The gypsum panel of claim 1 , wherein the environmental sensor assembly comprises a passive radio frequency identification sensor.4. The gypsum panel of claim 1 , wherein the environmental sensor assembly is passive and comprises an antenna claim 1 , a processing module claim 1 , and a wireless communication module.5. The gypsum panel of claim 4 , wherein:the antenna comprises a resistor inductor capacitor tuned circuit operable to convert the environmental condition into an impedance change, andthe processing module is coupled to the antenna and is operable to translate the impedance change into a sensor code by matching antenna impedance to die impedance.6. The gypsum panel of claim 4 , wherein:the antenna has an antenna impedance operable to vary based on the ...

Gypsum panels, systems, and methods

Gypsum panels and methods of making the same are provided. A gypsum panel includes a gypsum core containing set gypsum and unexpanded perlite ore, wherein the unexpanded perlite ore is present in the gypsum core in an amount greater than any other component, other than the gypsum.

GYPSUM PRODUCTS COMPRISING SILICA GEL

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 the inclusion of silica gel. 1. A gypsum board comprising:a set gypsum composition disposed between two cover sheets, the set gypsum composition comprising an interlocking matrix of set gypsum formed from a slurry comprising stucco, water, and metal silicate;the set gypsum composition comprising silica gel; and{'sup': 3', '3, 'the gypsum board having a density from about 15 lbs/ftto about 42 lbs/ftand a Fire Endurance Index greater than about 53 minutes.'}2. The gypsum board of claim 1 , wherein the metal silicate is sodium silicate claim 1 , potassium silicate claim 1 , lithium silicate claim 1 , or a combination thereof.3. The gypsum board of claim 1 , wherein the metal silicate (in an active basis) is in an amount from about 0.01% to about 1% by weight based on the weight of stucco.4. The gypsum board of claim 1 , wherein prior to addition to the slurry claim 1 , the metal silicate is included in a solution having a pH from about 5 to about 10.5. The gypsum board of claim 1 , wherein the metal silicate has a SiOto metal oxide ratio from about 0.5 to about 5.0.6. The gypsum board of claim 1 , wherein the set gypsum composition further comprises vermiculite in an amount less than about 5% by weight based on the weight of the stucco.7. The gypsum board of claim 1 , wherein the gypsum board has a silica gel to metal silicate weight ratio from about 1 to 1 to about 99 to 1.8. The gypsum board of claim 1 , wherein the gypsum board has a silica gel to metal silicate weight ratio greater than about 99 to 1.9. The gypsum board of claim 1 , wherein the gypsum board has a density from about 15 lbs/ftto about 35 lbs/ft.10. The gypsum board of claim 1 , wherein the gypsum board has a dry weight of less than about 2000 lbs/1000 ftwhen at a thickness of about ⅝ ...

Phase-Change Materials From Wax-Based Colloidal Dispersions And Their Process Of Making

This invention generally relates to phase-change materials (“PCM” or “PCM materials”) made from colloidally-protected wax-based microstructures. This invention also relates to such PCM materials configured in various physical forms. This invention further relates to a process of configuring such PCM materials for a variety of end-use applications in which dampening of temperature fluctuations by absorption and desorption of heat is desired. This invention further relates to preparing colloidally-protected wax-based microstructures in particulate form that function as PCM materials.

Flour binder for gypsum board, and related methods, product, and slurries

Disclosed is an acid-modified flour and a method of making the acid-modified flour. The acid-modified flour is desirably prepared using a dry milling process. A starting flour is combined with a strong acid to form a mixture. The mixture is heated. A neutralizer is added to increase the pH of the mixture. If desired, the mixture can be dried and any agglomerates can be removed. The acid-modified flour can be used as a binder in a slurry for preparing one or more gypsum layers in a gypsum board.

Gypsum board containing high absorption paper and related methods

Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains at least one set gypsum layer sandwiched between two cover sheets. The set gypsum layer is formed from at least stucco and water. The stucco material generally includes a high salt impurity content, for example, when the stucco is calcined from certain sources of low-quality synthetic gypsum. For example, in some embodiments, the salts are chloride salts, e.g., sodium chloride (NaCl), potassium chloride (KCl), magnesium chloride (MgCl2), and/or calcium chloride (CaCl2)). At least one of the cover sheets is composed of high absorption paper, which enhances the bond between the set gypsum layer and the cover sheet.

Exterior Wall Assembly Systems

An attachment strip for attaching lath to a wall and a system for attaching lath to a wall with increased water resistive characteristics. The attachment strip has protruding teeth on an attachment plate that holds the lath in place, and a mounting plate that secures the lath furring strip against the wall and framing. In addition, since attachment strip, instead of the lath directly, is secured to the sheathing, fewer mounting devices are needed compared to when a lath is directly secured to a sheathing, where substantially more mounting devices would be needed. Thus in this arrangement, fewer penetrations are created when installing the lath. Additional water resistive features, such insulation layers, and a drainage space surrounded by two water resistive barriers, create space that not only increases insulation, but protects the inner layers of a wall from damage. 1. An attachment strip for attaching a lath to a wall , comprising:a mounting plate configured for placement completely flush against said wall;a mounting device for securing said mounting plate to said wall;an attachment plate configured to secure said lath directly to said attachment plate, said attachment plate configured to project away from said wall, said attachment plate substantially perpendicular to said mounting plate, said attachment plate having a vertical edge; and,at least one protruding tooth projecting from said vertical edge of said attachment plate, said at least one protruding tooth configured to secure said lath to said attachment strip, wherein said at least one protruding tooth is configured to project away from said wall;wherein said at least one protruding tooth comprises at least one groove adjacent to said vertical edge of said attachment plate, said at least one groove configured to hold said lath in a pre-set position;whereby mounting said lath over said at least one protruding tooth prevents said lath from easily detaching from said attachment strip;whereby mounting said ...

Low weight and density fire-resistant gypsum panel

An about ⅝ 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.

Dry wall and method of making same

Drywall made with a pre-formed facer layer, pre-formed to have a well-defined depression along the side edge portion of the drywall. When the pre-formed paper is applied to the drywall core, the resulting sheet of drywall has a well-defined depressed edge portion for receiving mud and drywall tape. The facer layer is pre-formed by passing the semi-solid paper slurry beneath an embossing roller which includes a raised circumferential rib on each side of the roller, and preferably at least one raised crossbar. As the semi-solid paper slurry passes beneath embossing roller, a depressed side edge is formed along each side edge portion of the paper, and preferably a wider lateral depression is formed across the width of the paper every 8, 10 or 12 feet along the length of paper as it is pressed by roller.

GYPSUM BOARD

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. 123-. (canceled)24. A composite gypsum board comprising:a core comprising set gypsum formed from at least water and stucco, the core having a substantially flat shape and a generally uniform thickness, the core defining first and second board faces in opposing relation;a sheet disposed in bonding relation along the first board face, the sheet made of a material that has a thickness greater than about 0.017 inches, possesses a thermal conductivity that is less than about 0.1 w/(m.k.), and is applied to a back side of the composite gypsum board; and{'sup': '2', 'the composite gypsum board having a dry weight of less than about 1750 lbs/1000 ftwhen at a thickness of about ⅝inch.'} Gypsum products can be manufactured using a slurry formed from at least water and stucco. The stucco, which is calcium sulfate hemihydrate (CaSO.½HO), reacts with water to form gypsum, which is calcium sulfate dihydrate (CaSO.2HO). The two water molecules in crystallized gypsum are chemically bound to the calcium sulfate in what is often termed “crystallized water.”Gypsum wallboard is generally a composite board comprising a core , face sheet/liner , and back sheet/liner (). In a wallboard assembly, the face sheet of the wallboard is exposed to the exterior, and the back sheet is placed inside a cavity defined by two wallboards (). Gypsum wallboards are commonly used in drywall construction of interior walls and ceilings, and should be able to withstand both fire and excessive temperatures. As a result, gypsum wallboards are manufactured using specifications that maximize fire endurance/ ...

Method of Manufacturing Gypsum Board with Improved Fire Resistance

The present disclosure is directed to a method of manufacturing gypsum board as well as the resulting gypsum board. The method comprises providing a gypsum slurry with a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. As a result, the gypsum board includes gypsum and a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. The gypsum board exhibits an area shrinkage of less than 10%. 122-. (canceled)23. A method for manufacturing a gypsum board , the method comprising:providing a gypsum slurry and a shrinkage-reducing additive comprising a silica,wherein the gypsum board exhibits an area shrinkage of less than 20%.24. The method according to claim 23 , wherein the silica comprises colloidal silica claim 23 , precipitated silica claim 23 , or a mixture thereof.25. The method according to claim 23 , wherein the silica comprises colloidal silica.26. The method according to claim 23 , wherein the silica comprises precipitated silica.27. The method according to claim 23 , wherein the shrinkage-reducing additive has a particle size of less than 1 nanometer.28. The method according to claim 23 , wherein the gypsum board exhibits an area shrinkage of less than 10%.29. A gypsum board comprising:gypsum and a shrinkage-reducing additive comprising a silica,wherein the gypsum board exhibits an area shrinkage of less than 20%.30. The gypsum board according to claim 29 , wherein the silica comprises colloidal silica claim 29 , precipitated silica claim 29 , or a mixture thereof.31. The gypsum board according to claim 29 , wherein the silica comprises colloidal silica.32. The gypsum board according to claim 29 , wherein the silica comprises precipitated silica.33. The gypsum board according to claim 29 , wherein the shrinkage-reducing additive has a particle size of less than 1 nanometer.34. The gypsum board according to claim 29 , wherein the gypsum board exhibits an area shrinkage of less ...

GYPSUM PANELS, SYSTEMS, AND METHODS

Methods of making gypsum panels, and the panels and systems of panels prepared by such methods are provide. The methods include forming a first gypsum slurry by combining stucco, water, and a siliconate and setting the first gypsum slurry to form at least part of a core of the gypsum panel. 1. A method of making a gypsum panel , comprising:forming a first gypsum slurry by combining stucco, water, a siloxane, and a siliconate; andsetting the first gypsum slurry to form at least part of a core of the gypsum panel,wherein a ratio of siloxane to siliconate in the first gypsum slurry is from about 1:1 to about 1:50.2. The method of claim 1 , wherein the ratio of siloxane to siliconate in the first gypsum slurry is from about 1:2 to about 1:30.3. The method of claim 1 , wherein the siliconate is present in the first gypsum slurry in an amount of from about 3 lb/msf to about 50 lb/msf claim 1 , for a gypsum panel having a thickness of about ¼ inch to about 1 inch.4. The method of claim 1 , wherein the siliconate is present in the first gypsum slurry in an amount of from about 10 lb/msf to about 30 lb/msf claim 1 , for a gypsum panel having a thickness of about ¼ inch to about 1 inch.5. The method of claim 1 , wherein the siloxane is present in the first gypsum slurry in an amount of from about 0.01 lb/msf to about 20 lb/msf claim 1 , for a gypsum panel having a thickness of about ¼ inch to about 1 inch.6. The method of claim 1 , wherein the siloxane is present in the first gypsum slurry in an amount of from about 0.01 lb/msf to about 5 lb/msf claim 1 , for a gypsum panel having a thickness of about ¼ inch to about 1 inch.7. The method of claim 1 , wherein the siliconate comprises sodium or potassium methylsiliconate claim 1 , sodium or potassium ethyl siliconate claim 1 , propylsiliconate claim 1 , isopropylsiliconate claim 1 , butylsiliconate claim 1 , octylsiliconate claim 1 , phenylsiliconate claim 1 , or any combination thereof.8. The method of claim 1 , wherein the ...

ANTIMICROBIAL SIZE EMULSION AND GYPSUM PANEL MADE THEREWITH

Disclosed is an emulsion of an internal paper size and a biocidal emulsifying agent, such as a cationic non-starchy quaternary ammonium compounds, that is introduced into a paper-making furnish to produce an anti-microbial paper. The antimicrobial paper is useful as facing for gypsum panels. A method of making the paper includes emulsifying the internal size with a biocide before introducing the size to the paper furnish. A method of making a microbial growth resistant gypsum panel that incorporates the antimicrobial paper is also disclosed. 1. A mold-resistant gypsum panel comprising:a gypsum core;at least one facer comprisingpaper made from a furnish that includes a paper sizing emulsion comprising an emulsion of a biocidal emulsifying agent and an internal sizing agent, wherein the biocidal emulsifying agent is a non-starchy quaternary ammonium compound, and wherein the internal sizing agent and biocidal emulsifying agent are emulsified in water.2. The mold-resistant gypsum panel of wherein said emulsion is free of additional emulsifying agents.3. The mold-resistant gypsum panel of wherein said internal sizing agent is selected from the group consisting of alkenyl succinic anhydride and alkyl ketene dimer.4. The mold-resistant gypsum panel of wherein said internal sizing agent is alkenyl succinic anhydride.5. The mold-resistant gypsum panel of wherein the biocidal emulsifying agent is a non-starchy cationic quaternary ammonium compound.6. The mold-resistant gypsum panel of claim 1 , wherein said non-starchy quaternary ammonium compound is at least one selected from the group consisting of alkyl dimethyl benzyl ammonium chloride claim 1 , alkyl dimethyl ethyl benzyl ammonium chloride claim 1 , dialkyl dimethyl ammonium chloride claim 1 , didecyl dimethyl ammonium chloride claim 1 , and combinations thereof.7. The mold-resistant gypsum panel of claim 1 , wherein said biocidal emulsifying agent is selected from the group consisting of dequalinium chloride claim 1 , ...

Gypsum panels, systems, and methods

Gypsum panels and methods of making gypsum panels are provided. Methods of making gypsum panels include: depositing a first gypsum slurry onto a first surface of a first fiberglass mat; allowing the first gypsum slurry to set to form at least a portion of a gypsum core; and applying a substantially continuous barrier coating comprising a polymer binder to a second surface, opposite the first surface, of the first fiberglass mat, in an amount of from about 1 lb/MSF to about 40 lb/MSF, such that the substantially continuous barrier coating has an average thickness of from about 1 micron to about 100 microns, wherein the substantially continuous barrier coating eliminates at least 99 percent of pin holes present in the exposed second surface of the first fiberglass mat.

Treatment Composition Containing A Mold Inhibiting Agent and A Water Repellent Having Reduced Foaming Properties

The present disclosure is generally directed to a mold inhibiting composition. The mold inhibiting composition can be used to treat various different substrates, including building material products, such as facing layers for wallboard. In general, any suitable paper product may be treated with the composition. The composition contains a mold inhibiting agent in combination with a defoamer. The mold inhibiting agent may comprise a pyrithione. The defoamer, on the other hand, may comprise an oil based defoamer containing metal oxide particles, such as silica particles. The mold inhibiting composition can be combined with a water repellent and applied to a substrate without excessive amounts of foam or froth being formed. The defoamer is selected so as to not interfere with the resulting water absorption properties of the product. 1. A process for producing a paper with mold and moisture inhibiting properties , comprising:forming a paper web from an aqueous suspension of pulp fibers; a water repellent dispersion containing a water repellent agent, the water repellent dispersion being present in the water repellent and mold inhibiting composition in an amount from about 3% to about 10% by weight,', 'a mold inhibiting composition comprising a mold inhibiting agent and a defoamer, the defoamer comprising an oil carrier and a defoaming agent, the mold inhibiting composition being present in the water repellent and mold inhibiting composition in an amount from about 7% to about 20% by weight, the defoamer being present in the water repellent and mold inhibiting agent in an amount of at least about 0.1% by weight, and', 'water; and, 'applying to a side of the paper web a water repellent and mold-inhibiting composition, the water repellent and mold-inhibiting composition comprising'}thereafter drying the paper web to form a paper product.2. The process of claim 1 , further comprising laminating the paper product to a core comprising gypsum to form a dry wall product.3. The ...

Gypsum-Based Panel

A panel has a gypsum matrix, in which the following additives are embedded: glass fibre in an amount greater than 1 wt % relative to the gypsum and a synthetic polymeric binder in an amount greater than 2.5 wt % relative to the gypsum. The glass fibre and synthetic polymeric binder are present in a weight ratio of at least 2 parts binder to one part fibre. The amount of sand present in the gypsum matrix lies in the range 0-0.5 wt % relative to the gypsum. The amount of cellulosic fibre present in the gypsum matrix lies in the range 0-2 wt % relative to the gypsum. 113-. (canceled)14. A panel having a gypsum matrix , the gypsum matrix having the following additives embedded therein:glass fibre in an amount greater than 1 wt % relative to the gypsum;a synthetic polymeric binder in an amount greater than 2.5 wt % relative to the gypsum;the glass fibre and synthetic polymeric binder being present in a weight ratio of at least 2 parts binder to one part fibre;wherein the amount of sand present in the gypsum matrix lies in the range 0-0.5 wt % relative to the gypsum;and further wherein the amount of cellulosic fibre present in the gypsum matrix lies in the range 0-2 wt % relative to the gypsum.15. A panel according to claim 14 , the panel being provided with a facing on at least one side.16. A panel according to claim 14 , wherein the glass fibre is dispersed throughout the gypsum matrix.174. A panel according to claim claim 14 , wherein the polymeric binder is polyvinyl acetate.18. A panel according to claim 14 , wherein the amount of acrylic resin present in the gypsum matrix lies in the range 0-1 wt % relative to the gypsum.19. A panel according to claim 14 , wherein the amount of calcium carbonate present in the gypsum matrix lies in the range 0-1 wt % relative to the gypsum.20. A panel according to claim 14 , wherein the total weight of the additives embedded in the gypsum matrix is less than the weight of the gypsum in the gypsum matrix.21. A panel according to ...

System and Method for the Production of Gypsum Board Using Starch Pellets

The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum. 1. A method of producing lightweight gypsum board , the method utilizing a board production line including a mixer , a forming table , and dryers , the method comprising:providing a plurality of starch pellets, the pellets being of a uniform size and being only slightly soluble at temperatures below approximately 130° F., the pellets being more soluable at elevated temperatures;adding the pellets to a gypsum slurry in a pellet to gypsum ratio of between approximately 5/100 to 50/100 by volume;blending the gypsum slurry and pellets within the mixer whereby the pellets become fully encapsulated within the slurry;supplying a first facing sheet to the forming table prior to the mixer;discharging the blended gypsum and pellets from the mixer and onto the first facing sheet;supplying a top facing sheet over the blended gypsum and pellets to form a composite panel;drying the composite panel within the dryers to a temperature in excess of approximately 130° F., the drying causing the pellets to dissolve and the residual moisture to be removed from the board, whereby the dissolved pellets provide starch to the gypsum slurry and create voids within the set gypsum.2. A method of producing building board , the method utilizing starch , stucco , and water , the method comprising:combining the starch with air to form aerated starch pellets, the aerated pellets being slightly soluble at temperatures below approximately ...

PANELIZED EIFS STUCCO-SIDING SYSTEM AND METHOD

A panelized EIFS stucco siding system with a locking edge. The device is a pre-finished stucco siding panel system that can be installed in any weather condition without extra preparation or consideration. The system has “SL” trim lock system that can be installed by professionals or can be used by the DIY (do-it-yourselfer). It provides a weather tight cladding system that adds beauty and insulation value to the building envelope. 1. A panelized EIFS stucco siding system comprising: a front-face comprising a pre-finish-surface with integrated primary drainage;', 'a rear-face with integrated secondary drainage; and', 'a thickness; and, 'a body having;'}, 'at least one pre-finished panel assembly, each said at least one pre-finished panel assembly including;'}a dual integrated drainage system comprising the primary drainage and secondary drainage; andwherein said panelized EIFS stucco siding system comprises a plurality of said at least one pre-finished panel assembly installed in functional combination without a thermally conducting bridge within each panel and between panels;wherein said body is defined by said front-face, said rear-face separated by said thickness, said rear-face mounted adjacent a host-building in-use; andwherein said integrated drainage system is integrated into each said body such that when in combination said panelized EIFS stucco siding system being installed and locked modularly on said host-building is protected from damage due to environmental elements.2. The panelized EIFS stucco siding system of claim 1 , wherein said integrated drainage system comprises an exterior channel.3. The panelized EIFS stucco siding system of claim 2 , wherein the exterior channel is sloped from center towards one or more outer edges of the panel.4. The panelized EIFS stucco siding system of claim 1 , wherein the body is mountable to said host-building via a nail-anchor-strip and at least one fastener.5. The panelized EIFS stucco siding system of claim 4 , ...

Sizing composition for wet use chopped strand glass fibers

A sizing composition including water, a polyvinylpyrrolidone film former, a silane coupling agent, a lubricant, and a surfactant is provided. The polyvinylpyrrolidone film former constitutes from 30 wt. % to 50 wt. % of the dry solids of the sizing composition. Wet use chopped strand glass fibers for use in reinforcing gypsum board are also provided. The wet use chopped strand glass fibers include chopped glass fibers having the sizing composition applied thereto. The sizing composition improves fiber bundle integrity, fiber flow rate, fiber flow rate consistency, and dispersibility of the wet use chopped strand glass fibers in a gypsum matrix or slurry.

BOARD AND METHOD OF MANUFACTURING A BOARD

A board includes at least a substrate which is formed at least of a gypsum-based and/or cement-based basic material layer with a compressive strength of 30 kg/cm2 and a resin-based covering provided on at least one side of the substrate, in the form of a laminate layer directly pressed onto the substrate. 149.-. (canceled)50. A board , wherein it consists at least of a substrate which is formed at least of a gypsum-based or cement-based basic material layer with a compressive strength of 30 kg/cm2 and a resin-based covering provided on at least one side of the substrate , in the form of a laminate layer directly pressed onto the substrate.51. The board of claim 50 , wherein the directly pressed laminate layer is a layer which is pressed with a pressure of more than 25 kg/cm2.52. The board of claim 50 , wherein the basic material layer has a compressive strength of at least 70 kg/cm2.53. The board of claim 50 , wherein the basic material layer has a compressive strength in the order of magnitude of 90 kg/cm2 or more.54. The board of claim 50 , wherein the directly pressed laminate layer is a layer which has been pressed with a pressure of more than 30 kg/cm2 claim 50 , and that the compressive strength of the board is higher than that value.55. The board of claim 50 , wherein the basic material layer is a so-called highly compacted gypsum and/or cement board.56. The board of claim 50 , wherein the basic material layer contains reinforcement material claim 50 , such as reinforcement fibers.57. The board of claim 56 , wherein the fibers are present in the basic material layer substantially over the entire thickness of this layer.58. The board of claim 56 , wherein the fibers consist of synthetic fibers in general and/or natural fibers in general and/or wood fibers and/or paper fibers and/or carbon fibers and/or glass fibers.59. The board of claim 50 , wherein the aforementioned resin-based covering is situated at that side of the board which is intended for forming the ...

PLASTER BOARDS AND METHODS FOR MAKING THEM

The present disclosure relates to plaster boards and methods for making them. For example, one aspect of the disclosure is a plaster board comprising one or more continuous layers of material disposed within a body of hardened plaster material, the first side and second side of each continuous layer of material being substantially covered by the hardened plaster material. In certain such embodiments, each continuous layer of material includes a polymer (e.g., a damping polymer) disposed on a carrier sheet. Another aspect of the disclosure relates to a method for making a plaster board that involves drying a wet body of plaster material while a continuous layer of material or precursor therefor is disposed within it. 1. A plaster board having a first surface and an opposed second surface , the plaster board comprisinga body of hardened plaster material extending from the first surface of the plaster board to the second surface of the plaster board, andone or more continuous layers of material disposed within the body, each continuous layer of material having a first side and an opposed second side, the first side and second side of each continuous layer of material being substantially covered by the hardened plaster material.2. The plaster board of claim 1 , wherein the plaster material comprises a base material that is a gypsum material.3. The plaster board of claim 1 , wherein each continuous layer of material is a sheet comprising a carrier sheet having a polymer disposed thereon.4. The plaster board of claim 1 , wherein each continuous layer of material is a damping sheet comprising a carrier sheet having a damping polymer disposed thereon claim 1 , each damping sheet having a damping loss factor that is greater than a damping loss factor of the hardened plaster material.5. The plaster board of claim 4 , wherein the carrier sheet comprises a fiberglass mat claim 4 , a fiberglass fabric claim 4 , a sheet of foamed polymer claim 4 , a paper sheet or a woven or non- ...

NONWOVEN WITH TWO-PART BINDER SYSTEM

Disclosed herein is a binder system for nonwoven fiber mats that provides desirable properties to the nonwoven mat including desirable porosity, desirable surface properties e.g., desirable wettability and/or moisture resistance, and enhanced tensile strength. The system includes a two-part binder that includes (1) a formaldehyde-free carbohydrate-based binder and (2) a formaldehyde-free hydrophobic acrylic-based hinder. 1. A nonwoven fiber mat comprising:randomly oriented fibers; and a formaldehyde-free carbohydrate-based binder, and', 'a formaldehyde-free hydrophobic acrylic-based binder,, 'a two-part binder system applied to at least a portion of the randomly oriented fibers, wherein the binder system comprises{'sup': 2', '3, 'wherein, when the mat has a basis weight of about 0.015 lb/ft(about 75 gsm) and about 20% by weight solids of the two-part binder system based on the total weight of the nonwoven fiber mat, the mat has a Frazier permeability of about 650 to about 715 CFM (about 18.4 to about 20.2 m/min).'}2. The nonwoven fiber mat of claim 1 , wherein the mat has a basis weight of about 0.012 to about 0.018 lb/ft(about 60 to about 88 gsm).3. The nonwoven fiber mat of claim 1 , wherein the nonwoven fiber mat comprises from about 10% to about 30% by weight solids of the two-part binder system based on the total weight of the nonwoven fiber mat.4. The nonwoven fiber mat of claim 1 , wherein the carbohydrate-based binder comprises a carbohydrate and a crosslinking agent.5. The nonwoven fiber mat of claim 4 , wherein the carbohydrate comprises a polysaccharide having a dextrose equivalence of 2 to 20.6. The nonwoven fiber mat of claim 4 , wherein the carbohydrate comprises a water soluble polysaccharide.7. The nonwoven fiber mat of claim 4 , wherein the carbohydrate comprises maltodextrin claim 4 , dextrin claim 4 , starch claim 4 , modified starch claim 4 , starch derivative claim 4 , or combinations thereof.8. The nonwoven fiber mat of claim 4 , wherein the ...

SYSTEM, METHOD AND APPARATUS FOR SUBSTANTIALLY AIRTIGHT AREA SEPARATION WALL

An area separation wall (ASW) may include gypsum liner panels and structural elements located between adjacent ones of the gypsum liner panels. A sealing material may be located between the gypsum liner panels and the structural elements, and between adjacent ones of the structural elements. The sealing material may form seals therebetween, such that the ASW is substantially airtight when assembled. In addition, the ASW may include a fire rating of at least 2 hours in compliance with ANSI/UL 263. 1. An area separation wall (ASW) , comprising:a plurality of gypsum liner panels;a plurality of horizontal structural elements configured to receive adjacent gypsum liner panels within an elongated track having a base and flanges extending from the base; andsealing material adhered to an interior of each of the flanges of the elongated tracks of the horizontal structural elements by an adhesive layer disposed between the sealing material and the interior of each of the flanges of the elongated tracks of the horizontal structural elements, such that the sealing material is disposed between the gypsum liner panels and each of the flanges of the elongated tracks of the horizontal structural elements when the adjacent gypsum liner panels are inserted into the elongated tracks of the horizontal structural elements to provide a substantially airtight seal between the gypsum liner panels and the horizontal structural elements, wherein the ASW, upon inserting the adjacent gypsum liner panels into the elongated tracks of the horizontal structural elements, comprises:a fire rating of at least 2 hours in compliance with ANSI/UL 263; and{'sup': 2', '2, 'an air permeance of not greater than 0.44 cfm/ftunder a pressure differential of 0.3 in water (1.5 7psf) (2.25 L/s·m@ 75 Pa).'}2. The ASW of claim 1 , wherein the air permeance is not greater than 0.38 cfm/ft claim 1 , under a pressure differential of 0.3 in water (1.57 psf) claim 1 , when tested with the method prescribed by ASTM E2357 ...

Apparatus and Method for Constructing Building Boards Using Low Friction Surfaces

Discloses is an apparatus and method for utilizing air along a building board forming line for the purpose of reducing friction between the board and the underlying forming tables. The device employs a series of air nozzles that are formed within the face of the forming tables. An air source delivers pressurized air to the nozzles. As completed or partially completed boards travel along the forming tables, an air cushion is created to reduce the friction between the board and the underlying table. The pressurized air can also be used to transport the boards and promote the even distribution of slurry during formation. The various components of the present invention, and the manner in which they interrelate, are described in greater detail hereinafter. 1. A board forming device with low friction surfaces comprising:a gypsum slurry mixing device including a slurry outlet;a first forming table having a series of nozzles;a first plenum chamber associated with the first forming table and in fluid communication with the nozzles;a first air source supplying pressurized air to the first plenum chamber and the series of nozzles;a lower supply roll supplying a bottom facing sheet to the first forming table, the slurry outlet supplying slurry over the bottom facing sheet;a second forming table having a series of nozzles;a second plenum chamber associated with the second forming table and in fluid communication with the nozzles;a second air source supplying pressurized air to the second plenum chamber and the series of nozzles;wherein the pressurized air supplied to the nozzles reduces the friction between the bottom facing sheet and the first and second forming tables.2. A board forming device comprising:a gypsum slurry mixing device including a slurry outlet;a forming table having an upper surface, a length and a width, a series of nozzles placed along with length and width of the forming table;a plenum associated with the forming table and in fluid communication with the ...

System and Method for the Production of Gypsum Board Using Starch Pellets

The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum. 19-. (canceled)10. A system for the production of lightweight gypsum board , the system comprising:a board production line having upstream and downstream ends, the production line including two supply rolls for first and second facing sheets;a first supply of starch pellets;a second supply of stucco;a mixer for combining the starch pellets and the stucco with water to form a slurry, the mixer blending the pellets and the slurry such that the pellets become fully encapsulated within the slurry, the mixer including an outlet for depositing the blended pellets and slurry between the first and second facing sheets to create a panel.11. The system as described in further comprising a series of board dryers located downstream of the production line for drying the panel.12. The system as described in wherein drying the panel within the dryers causes the pellets to dissolve and the gypsum slurry to set claim 11 , whereby the dissolved pellets provide starch to the gypsum slurry and create voids within the set gypsum.1324-. (canceled)25. A method of producing lightweight gypsum board claim 11 , the method utilizing a board production line including a mixer claim 11 , a forming table claim 11 , and dryers claim 11 , the method comprising:providing a plurality of starch pellets, the pellets being of a uniform size and being only slightly soluble at temperatures below approximately 130° F., the pellets being more ...

System and Method for the Production of Gypsum Board Using Starch Pellets

The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum. 1. A method of producing lightweight gypsum board , the method utilizing a board production line including a mixer , a forming table , and dryers , the method comprising:providing a plurality of starch pellets, the pellets being of a uniform size and being only slightly soluble at temperatures below approximately 130° F., the pellets being more soluable at elevated temperatures;adding the pellets to a gypsum slurry in a pellet to gypsum ratio of between approximately 5/100 to 50/100 by volume;blending the gypsum slurry and pellets within the mixer whereby the pellets become fully encapsulated within the slurry;supplying a first facing sheet to the forming table prior to the mixer;discharging the blended gypsum and pellets from the mixer and onto the first facing sheet;supplying a top facing sheet over the blended gypsum and pellets to form a composite panel;drying the composite panel within the dryers to a temperature in excess of approximately 130° F., the drying causing the pellets to dissolve and the residual moisture to be removed from the board, whereby the dissolved pellets provide starch to the gypsum slurry and create voids within the set gypsum.2. A method of producing building board , the method utilizing starch , stucco , and water , the method comprising:combining the starch with air to form aerated starch pellets, the aerated pellets being slightly soluble at temperatures below approximately ...

Plastic Coated Composite Building Boards and Method of Making Same

Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength. 1. A composite structural panel comprising:a slurry layer with an embedded mat, the mat consisting essentially of fibers that are bound together by a hot melt thermoplastic.2. The composite structural panel as described in wherein the fibers are organic.3. The composite structural panel as described in wherein the fibers are inorganic.4. The composite structural panel as described in wherein the fibers are continuous.5. The composite structural panel as described in wherein the fibers are non continuous.6. The composite structural panel as described in wherein the hot melt thermoplastic is applied in a layer that follows the topography of the underlying mat.7. The composite structural panel as described in wherein the hot melt thermoplastic is applied in a smooth layer.8. The composite structural panel as described in wherein the hot melt thermoplastic is applied in a layer having a thickness of between 0.1 to 10 mils.9. The composite structural panel as described in wherein the hot melt thermoplastic is formed from ethylene vinyl acetate (EVA).10. The composite structural panel as described in wherein the hot melt thermoplastic is formed from ethylene methyl acrylonitrile (EAA).11. The composite structural panel as described in wherein the hot melt thermoplastic is translucent.12. The composite structural panel as described in wherein the hot melt thermoplastic is colored.13. A composite structural panel comprising:first and second gypsum slurry layers, wherein the second slurry layer has a higher density than the ...

Gypsum panels, systems, and methods

Gypsum panels and methods of making the same are provided herein. The gypsum panels include a barrier coating on a second surface of a coated fiberglass mat, the second surface comprising a coated surface, with the barrier coating comprising an acrylic binder and a filler in an amount of from about 50 to about 75 percent solids by volume of the barrier coating, the barrier coating being deposited in an amount of from about 46 lb/msf to about 60 lb/msf, dry weight. Sheathing systems of at least two such gypsum panels are also provided.

GYPSUM BOARDS MADE WITH HIGH PERFORMANCE BIO-BASED FACERS AND METHOD OF MAKING THE SAME

A gypsum panel that incorporates a plant fiber other than paper is disclosed. The plant fiber material may be in the form of a facing material adhered to at least one side of the gypsum panel or in the form of loose fibers integrated with the gypsum panel as a matrix or both. Further, the plant fiber may be combined with conventional gypsum panel additives, is fully recyclable and environmentally sustainable. The present invention further relates to a method of making such a gypsum panel. 1. A gypsum panel having a facing material on at least one side comprising plant fiber other than paper.2. The gypsum panel of claim 1 , wherein the facing material comprises a nonwoven plant fiber.3. The gypsum panel of claim 1 , wherein the plant fiber comprises flax.4. The gypsum panel of claim 1 , wherein the plant fiber comprises hemp5. The gypsum panel of claim 1 , wherein the plant fiber is selected from the group consisting of flax claim 1 , hemp claim 1 , jute claim 1 , kenaf claim 1 , abaca claim 1 , sabai grass claim 1 , esparto grass claim 1 , straw claim 1 , bagasse claim 1 , milkweed floss fibers claim 1 , bamboo claim 1 , and pineapple leaf fibers.6. The gypsum panel of claim 1 , wherein the plant fiber is blended with a polymer.7. The gypsum panel of claim 6 , wherein the polymer is selected from the group consisting of polyester claim 6 , polypropylene claim 6 , polyethylene claim 6 , polybutylene claim 6 , nylon claim 6 , polyaramids claim 6 , polyethylene terephthalate claim 6 , modified polyethylene terephthalate claim 6 , polyesteramides claim 6 , polylactic acid-based polymers claim 6 , terpolymers based on polylactic acid claim 6 , polyglycolic acid claim 6 , polycaprolactone claim 6 , polyalkylene carbonates claim 6 , polyhydroxybutyrate (PHB) claim 6 , aliphatic-aromatic copolyesters claim 6 , aliphatic polyesters claim 6 , starch claim 6 , and succinate-based aliphatic polymers.8. The gypsum panel of claim 6 , wherein the polymer is a mono-component fiber. ...

System and method of interlocking wall panels

An interconnectable wall panel system and method of forming and assembling the same are provided. A plurality of wall panels are provided that are interconnectable in a predetermined manner and arrangement, and wherein the wall panels comprise features for enhancing ease and accuracy of assembly. Wall panel members of the present disclosure are suitable for use in constructing modular building units, such as bathroom pods.

Plasterboards and methods for making them

An example plasterboard includes a layer of hardened plaster having a first surface and an opposed second surface, a layer of polymer material having particles of one or more cementitiously-active substances mixed therein, and a liner between the first surface of the layer of hardened plaster and the layer of polymer material. Another example is a method of forming such a plasterboard. The method includes loading an extruder with the polymer material having the particles of one or more cementitiously active substances mixed therein, extruding the polymer material through a die to form the layer of polymer material on a surface of the liner, contacting with a layer of wet plaster material, the liner having the polymer material applied thereon such that the surface of the liner faces away from the wet plaster material, and drying the layer of wet plaster material to form the layer of hardened plaster.

PLASTERBOARDS AND METHODS FOR MAKING THEM

An example plasterboard includes a layer of hardened plaster material having a first surface and an opposed second surface and a layer of molded material having a surface that faces away from the layer of hardened plaster material. The surface of the layer of molded material has one or more raised features. The plasterboard also includes a liner between the first surface of the layer of hardened plaster material and the layer of molded material. Other examples include a method of forming such plasterboards and a method for installing such plasterboards. 1. A plasterboard comprising:a layer of hardened plaster material having a first surface and an opposed second surface;a layer of molded material having a surface that faces away from the layer of hardened plaster material, the surface of the layer of molded material having one or more raised features; anda liner between the first surface of the layer of hardened plaster material and the layer of molded material.2. The plasterboard of claim 1 , wherein the hardened plaster material comprises a gypsum material.3. The plasterboard of claim 1 , wherein the first surface of the layer of hardened plaster material and/or the liner have shapes that substantially conform to the one or more raised features of the layer of molded material.4. The plasterboard of claim 1 , wherein the surfaces of the liner and/or the layer of hardened plaster material do not substantially conform to the surface texture of the layer of molded material.5. The plasterboard of claim 4 , wherein the surfaces of the liner and/or the layer of hardened plaster material are substantially flat.6. The plasterboard of claim 1 , wherein the molded material is a polymeric material or is a substantially inorganic material.7. The plasterboard of claim 1 , wherein the one or more raised features cover at least 75% of a surface of the liner that faces away from the first surface of the layer of hardened plaster material.8. The plasterboard of claim 1 , wherein ...

Stucco Composite Building Panel

A Stucco Composite Building Panel is disclosed, in which a sheet of exterior wall sheathing and a cement board are attached together to form an improved sheet of building material for the construction of exterior stucco walls. This composite building panel reduces the amount of individual layers required to build a conventional stucco wall by providing an exterior wall building panel that is mounted directly to the stud framing that is ready for a finish layer of stucco to be applied. 1. A composite building panel comprising: a sheet of exterior wall sheathing and a layer of cementitious board , wherein the cement board is laminated to one side of the sheathing forming a stucco wall building material sheet with shear strength that is ready to receive a finish layer of stucco replacing the base coat of conventional stucco methods.2. The composite building panel of claim 1 , wherein a water resistant coating is applied to the sheathing to protect the wall from moisture.3. The composite building panel of claim 1 , wherein claim 1 , the adhesive that bonds the cement board to the sheathing contains a water resistant acrylic.4. The composite building panel of claim 1 , wherein a sheet of black builders paper is laminated in between the cement board and the sheathing to function as a water resistant barrier.5. The composite building panel of claim 1 , wherein a sheet of black builders paper is laminated to the back of the sheathing to function as a water resistant barrier.6. The composite building panel of claim 1 , wherein a sheet of spunbond olefin fiber such as Tyvek is laminated in between the cement board and the sheathing to function as a water resistant barrier.7. The composite building panel of claim 1 , wherein a sheet of spunbond olefin fiber such as Tyvek is laminated to the back of the sheathing to function as a water resistant barrier.8. The composite building panel of claim 1 , wherein claim 1 , the method of installation includes a moisture resistant ...

Cementitious Panels with Swellable Materials and Methods of Providing a Moisture or Water Barrier in Cementitious Panels Using Swellable Materials

Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel. 169-. (canceled)70. A cementitious panel , comprising;a core layer comprising a cementitious material;a plurality of sheets of facing material surrounding the core layer, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material; andoptionally, a first dense layer comprising a cementitious material defining an interface between the core layer and the first sheet of facing material, and optionally, a second dense layer comprising a cementitious material defining an interface between the core layer and the second sheet of facing material; andone or more swellable materials, wherein the core layer, the first dense layer, the second dense layer, the first sheet of facing material, and/or the second sheet of facing material comprises at least one of the one or more swellable materials.71. The cementitious panel of claim 70 , wherein the core layer comprises at least one of the one or more swellable materials claim 70 , the one or more swellable materials of the core layer comprising from 0.1 wt. % to 90 wt. % of the core layer claim 70 , based on the total weight of the core layer claim 70 ,72. The cementitious panel of claim 70 , wherein the first dense layer claim 70 , the second dense layer claim 70 , or both comprise at least one of the one or more swellable materials claim 70 , the one or more swellable materials comprising from 0.1 wt. % to 90 wt. % based on the total weight of the first dense layer; the second dense layer claim 70 , or both.73. The cementitious panel of claim 70 , wherein the swellable material comprises particles and/or discrete domains of a ...

SHEAR PANEL BUILDING MATERIAL

A shear panel building material that includes a first facing membrane, a core matrix disposed on a face of the first facing membrane, and a semi-rigid or rigid material attached to the core matrix. The core matrix can include microspheres having a size of about 200 microns to about 800 microns, sodium silicate, and ethylene vinyl acetate. In one aspect, the shear panel is substantially free from glue and cement. 1a first facing membrane;a second facing membrane;a rigid material situated between the first facing membrane and the second facing membrane, said rigid material being self-supporting; and from about 25 wt % to about 60 wt % of microparticles based on wet formulation,', 'from about 20 wt % to about 36 wt % sodium silicate, and', 'from about 2 wt % to about 6 wt % of a vinyl acetate,, 'a core matrix disposed between said first and second facing membranes, said core matrix includingwherein the rigid material is held in place with respect to the first and second facing membranes by the core matrix.. A shear panel building material comprising: This application is a continuation application of U.S. patent application Ser. No. 13/176,692, filed Jul. 5, 2011, which is a continuation of U.S. patent application Ser. No. 12/238,379, filed on Sep. 25, 2008, which is a continuation-in-part of U.S. patent application Ser. No. 12/077,951, filed on Mar. 21, 2008, which claims the benefit of U.S. Provisional Patent Application No. 60/919,509, filed on Mar. 21, 2007, and of U.S. Provisional Patent Application No. 60/961,130, filed on Jul. 17, 2007, and of U.S. Provisional Patent Application No. 61/002,367, filed on Nov. 7, 2007, and U.S. Provisional Patent Application No. 61/081,951, filed on Jul. 18, 2008, all of which are each incorporated by reference herein in their entireties.The present invention relates generally to building materials, and more particularly to shear panels or shear-type building materials. Accordingly, the present invention involves the fields of ...

FIBER-REINFORCED COATED MATS AND MAT-FACED PANELS AND METHODS

Fiber-reinforced coated mats and fiber-reinforced coated mat-faced panels are provided herein, along with methods for making the same. Fiber-reinforced coated mats include a mat with a fiber-reinforced coating on one surface. Fiber-reinforced coated mat-faced panels include a fiber-coated mat and a panel material in contact with a surface of the mat opposite the fiber-reinforced coating. Methods include applying a fiber-reinforced coating to a surface of a mat to form a coated mat and drying the coated mat to cure the fiber-reinforced coating. Some methods also include combining the mat with a panel material to form a mat-faced panel. 1. A method of making a fiber-reinforced coated mat-faced panel , comprising:applying a fiber-reinforced coating to a first surface of a first mat to form a coated first mat;drying the coated first mat to cure the fiber-reinforced coating; andcombining the first mat with a panel material to form a mat-faced panel.2. The method of claim 1 , wherein the fiber-reinforced coating comprises fibers and a coating base.3. The method of claim 2 , wherein the coating base comprises resin claim 2 , latex claim 2 , or a combination thereof.4. The method of claim 2 , wherein the fibers are selected from the group consisting of: nylon fibers claim 2 , polyester fibers claim 2 , polypropylene fibers claim 2 , glass fibers claim 2 , wood cellulose fibers claim 2 , aramid fibers claim 2 , acrylic fibers claim 2 , polyvinyl chloride fibers claim 2 , polyvinyl acetate fibers claim 2 , polyolefin fibers claim 2 , polyurethane fibers claim 2 , fire resistant or flame retardant polymer fibers claim 2 , single-crystal calcium sulfate anhydrite whiskers claim 2 , single-crystal magnesium aluminate whiskers claim 2 , single-crystal magnesium silicate whiskers claim 2 , single-crystal calcium silicate whiskers claim 2 , and combinations thereof.5. The method of claim 2 , wherein the fibers have a nominal length from about 1/16 inch to 1.5 inch claim 2 , and an ...

SYSTEM AND METHOD OF INTERLOCKING WALL PANELS

An interconnectable wall panel system and method of forming and assembling the same are provided. A plurality of wall panels are provided that are interconnectable in a predetermined manner and arrangement, and wherein the wall panels comprise features for enhancing ease and accuracy of assembly. Wall panel members of the present disclosure are suitable for use in constructing modular building units, such as bathroom pods. 1. A method of forming a modular building unit , comprising:providing a plurality of pre-formed wall panels operable to be interconnected;wherein a first pre-formed wall panel of the plurality of pre-formed wall panels comprises a first end and a second end and a planar surface extending between the first end and the second end;the planar surface of the first pre-formed wall panel comprising a plurality of female receiving members comprising a predetermined distribution along the planar surface;the first pre-formed wall panel comprising a plurality of studs on an opposing side of the first pre-formed wall panel from the planar surface;a second pre-formed wall panel of the plurality of pre-formed wall panels comprising a first end and a second end and a planar surface extending between the first end and the second end, the first end of the second pre-formed wall panel comprising a plurality of male extensions, the male extensions being sized and operable to be received within the plurality of female receiving members;providing a plurality of support elements on the second preformed wall panel, wherein each of the plurality of support elements comprises a stud provided on an opposing side of the second preformed wall panel from the planar surface of the second preformed wall panel;wherein the at least one of the plurality of male extensions members is joined to or co-formed with at least one stud of the second pre-formed wall panel and wherein the pair of horizontal members are connected to the at least one stud;inserting the plurality of male ...

Low weight and density fire-resistant gypsum panel

An about ⅝ 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.

Method and means for making a wall by means of securing drywall panels to a background

Method for making a wall with the aid of drywall panels (1, 1a, 1b) and a background (2, 12, 25), wherein the drywall panels are provided with edge coupling profiles (3, 4, 6, 13, 14, 16) on their edges, which are arranged to be secured to the background and, subsequently, coupled to each other. The drywall panels may also be provided with a rear coupling profile (24). The drywall panels can be hooked together or coupled to each other by means of transverse sliding. The edge coupling profiles may also comprise anti-adhesive extensions (31), forming anti-adhesive edge areas (32) at the front side of the drywall panel on which stucco mass does not adhere. The measures according to the invention are intended to provide drywall panels which, after use, can be disassembled easily and cleanly so that the drywall panels can be reused as drywall panels, resulting in that the environment is not burdened with gypsum waste caused by damaged, broken and destroyed drywall panels.

GYPSUM PANELS, SYSTEMS, AND METHODS

Gypsum panels and methods for their manufacture are provided herein. The gypsum panels include a gypsum core having a first surface and a second opposed surface and a first fiberglass mat associated with the first surface of the gypsum core, such that gypsum from the gypsum core penetrates at least a portion of the first fiberglass mat. 1. A method of making a gypsum panel , comprising:depositing a first gypsum slurry onto a first surface of a first fiberglass mat, such that the first gypsum slurry penetrates at least a portion of the first fiberglass mat; andallowing the first gypsum slurry to set to form at least a portion of a gypsum core,wherein the first gypsum slurry comprises an aqueous polymeric or inorganic binder, in an amount effective to enhance penetration of the slurry.2. The method of claim 1 , wherein the gypsum panel comprises the binder in an amount of from about 0.5 lb/1000 ftto about 50 lb/1000 ft claim 1 , on a dry basis.3. The method of claim 1 , wherein the binder comprises a latex binder.4. The method of claim 1 , wherein the binder comprises at least one of styrene-butadiene-rubber (SBR) claim 1 , styrene-butadiene-styrene (SBS) claim 1 , ethylene-vinyl-chloride (EVCl) claim 1 , poly-vinylidene-chloride (PVdCl) and poly(vinylidene) copolymers claim 1 , modified poly-vinyl-chloride (PVC) claim 1 , poly-vinyl-alcohol (PVOH) claim 1 , ethylene-vinyl-acetate (EVA) claim 1 , poly-vinyl-acetate (PVA) and polymers and copolymers containing units of acrylic acid claim 1 , methacrylic acid claim 1 , their esters and derivatives thereof (acrylic-type polymers).5. The method of claim 1 , wherein the first gypsum slurry comprises a wetting agent in an amount effective to bring a slurry surface tension of the first gypsum slurry to from about 30 dyne/cm to about 60 dyne/cm.6. The method of claim 5 , wherein the wetting agent comprises a surfactant having a boiling point of 200° C. or lower.7. The method of claim 1 , wherein the first gypsum slurry is ...

Asymmetrical Laminate Panel and Method of Manufacture

The present disclosure relates generally to plaster wall panels, for example, suitable for covering interior wall frames. The present disclosure relates more particularly to a plaster wall panel including a first plaster layer, a second plaster layer, and a damping layer disposed between the first and second plaster layers. The first plaster layer has a first thickness and is composed of a first plaster material that has a first material property. The second plaster layer has a second thickness and is composed of a second plaster material that has a second material property. The first thickness is smaller than the second thickness, and the first and second material properties are different. 1. A plaster wall panel comprising:a first plaster layer having a first thickness and being composed of a first plaster material having a first material property;a second plaster layer having a second thickness and being composed of a second plaster material having a second material property, wherein the first thickness is smaller than the second thickness and wherein the first and second material properties are different; anda damping layer disposed between the first plaster layer and the second plaster layer.2. The plaster wall panel according to claim 1 , wherein at least one of the first plaster material and second plaster material comprises a base material that is a gypsum material.3. The plaster wall panel according to claim 1 , wherein at least one of the first plaster material and second plaster material comprises a base material that is lime or a cement.4. The plaster wall panel according to claim 1 , wherein the first thickness is in a range from 3% to 75% of the second thickness.5. The plaster wall panel according to claim 1 , wherein the elastic modulus of the first plaster material is in a range from 150% to 1000% of the elastic modulus of the second plaster material.6. The plaster wall panel according to claim 1 , wherein the density of the first plaster material is ...

GYPSUM PANELS, SYSTEMS, AND METHODS

Gypsum panels, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a gypsum core having a first surface and an opposed second surface, a first facer material associated with the first surface of the gypsum core, and an environmental sensor assembly associated with the gypsum panel and configured to detect an environmental condition of the gypsum panel and wirelessly communicate data on the environmental condition to a reader. 1. A gypsum panel , comprising:a gypsum core having a first surface and an opposed second surface;a first facer material associated with the first surface of the gypsum core; andan environmental sensor assembly associated with the gypsum panel and configured to detect an environmental condition of the gypsum panel and wirelessly communicate data on the environmental condition to a reader,wherein the environmental sensor assembly is self-supporting and comprises an antenna, a processing module, and a wireless communication module.2. The gypsum panel of claim 1 , wherein the environmental sensor assembly is configured to detect an environmental condition of the panel selected from a group consisting of moisture claim 1 , temperature claim 1 , and pressure.3. The gypsum panel of claim 1 , wherein the environmental sensor assembly comprises a passive radio frequency identification sensor.4. The gypsum panel of claim 1 , wherein:the antenna comprises a resistor inductor capacitor tuned circuit operable to convert the environmental condition into an impedance change, andthe processing module is coupled to the antenna and is operable to translate the impedance change into a sensor code by matching antenna impedance to die impedance.5. The gypsum panel of claim 1 , wherein:the antenna has an antenna impedance operable to vary based on the environmental condition,the processing module is coupled to the antenna and comprises a tuning module operable to (i) ...

Plastic Coated Composite Building Boards and Method of Making Same

Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength. 1. A composite structural panel comprising:a slurry layer with an embedded mat, the mat consisting essentially of fibers that are bound together by a hot melt thermoplastic.2. The composite structural panel as described in wherein the fibers are organic.3. The composite structural panel as described in wherein the fibers are inorganic.4. The composite structural panel as described in wherein the fibers are continuous.5. The composite structural panel as described in wherein the fibers are non continuous.6. The composite structural panel as described in wherein the hot melt thermoplastic is applied in a layer that follows the topography of the underlying mat.7. The composite structural panel as described in wherein the hot melt thermoplastic is applied in a smooth layer.8. The composite structural panel as described in wherein the hot melt thermoplastic is applied in a layer having a thickness of between 0.1 to 10 mils.9. The composite structural panel as described in wherein the hot melt thermoplastic is formed from ethylene vinyl acetate (EVA).10. The composite structural panel as described in wherein the hot melt thermoplastic is formed from ethylene methyl acrylonitrile (EAA).11. The composite structural panel as described in wherein the hot melt thermoplastic is translucent.12. The composite structural panel as described in wherein the hot melt thermoplastic is colored.13. A composite structural panel comprising:first and second gypsum slurry layers, wherein the second slurry layer has a higher density than the ...

Gypsum Plasterboard

The invention concerns a gypsum plasterboard () comprising at least an upper gypsum layer () having a first density, first hardness and first thickness and a lower gypsum layer () having a second density, a second hardness and a second thickness. The first density is lower than the second density and/or the first hardness is lower than the second hardness, and the first thickness is lower than the second thickness. The plasterboard according to the invention are heavy or dense plasterboards with an enhanced fixing ability. 1. A gypsum plasterboard comprising at least an upper gypsum layer having a first density , first hardness and first thickness and a lower gypsum layer having a second density , a second hardness and a second thickness , wherein the first density is lower than the second density and/or wherein the first hardness is lower than the second hardness and wherein the first thickness is lower than the second thickness.2. The gypsum plasterboard of claim 1 , characterised in that a ratio of the first thickness to the second thickness is lower than 1:1.05 claim 1 , preferably lower than 1:2 claim 1 , further preferably lower than 1:4 and/or higher than 1:50 claim 1 , preferably higher than 1:20.3. The gypsum plasterboard of claim 1 , characterised in that the first thickness is higher than 0.5 mm and/or lower than 5.0 mm.4. The gypsum plasterboard of claim 1 , characterised in that the first density is ≤880 kg/m claim 1 , preferably ≤800 kg/mand/or the second density is ≥880 kg/m claim 1 , preferably ≥920 kg/m claim 1 , further preferably ≥1000 kg/m.5. The gypsum plasterboard of claim 1 , characterised in that a ratio of the first density to the second density is ≤0.9 claim 1 , preferably ≤0.75.6. The gypsum plasterboard of claim 1 , characterised in that the first hardness is >13 mm claim 1 , preferably ≥14 mm and/or the second hardness is ≤12 mm claim 1 , preferably ≤13 mm.7. The gypsum plasterboard of claim 1 , characterised in that a ratio of the first ...

Self-Sealing Fasteners, Building Panels, Systems, and Methods

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. 1. A building panel , comprising:a panel core having a first surface and a second opposed surface;a mat associated with the first surface of the panel core, and forming an external surface of the panel; anda plurality of dots of a coating material disposed in a grid on the external surface of the panel, wherein the grid comprises columns of dots equidistantly spaced,wherein the coating material comprises a polyurethane, polyamide, or ethylene-vinyl acetate.2. The building panel of claim 1 , wherein the coating material has a tack such that the coating material will not block an adjacent panel.3. The building panel of claim 1 , wherein the building panel is a gypsum panel in which the panel core comprises gypsum and the mat is a fiberglass mat claim 1 , wherein gypsum of the gypsum core penetrates a remaining portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated.4. The building panel of claim 1 , wherein the coating material is present in an amount of from 0.0001 lb/ftto 0.0025 lb/ft.5. The building panel of claim 1 , wherein each dot of the plurality of dots contains the coating material in an amount of from about 0.05 g to about 0.5 g.6. The building panel of claim 1 , wherein each dot of the plurality of dots contains the coating material in an amount of from about 0.05 g to about 0.2 g.7. The building panel of claim ...