Abstract:
Disclosed are methods relating to an extruded pregelatinized, partially hydrolyzed starch prepared by mixing at least water, non-pregelatinized starch, and acid to form a starch precursor. The acid can be a weak acid that substantially avoids chelating calcium ions or a strong acid in a small amount. In the method, pregelatinization and acid-modification of the starch precursor occurs in one step in an extruder. Also disclosed are methods of preparing board using the starch prepared according to the methods, as well as starches and boards prepared by various methods of the invention.
Abstract:
A slurry distributor for use in a continuous manufacturing process includes an inlet opening and a shaped duct adapted to receive a flow of slurry provided at the inlet opening. The shaped duct has a parabolic guide surface adapted to redirect the flow of slurry. An outlet opening in fluid communication with the shaped duct is adapted to discharge the flow of slurry from the slurry distributor.
Abstract:
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.
Abstract:
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.
Abstract:
A gypsum composition, board, and method of producing a gypsum board with increased fire endurance are described. The set gypsum-containing composition can be used to prepare a gypsum board having fire endurance, based on particular water-to-stucco ratios.
Abstract:
A multi-piece mold for use in a method for making a slurry distributor includes a plurality of mold segments adapted to be removably secured together. The mold segments are configured such that, when the mold segments are assembled together, the assembled mold segments define a substantially continuous exterior surface adapted to be a negative image of an interior flow region of a slurry distributor molded thereupon. Each mold segment has a maximum cross-sectional area in a plane substantially transverse to a direction of movement of the mold segment along a removal path out of a respective opening of the molded slurry distributor. The maximum cross-sectional area of each mold segment is up to about 150% of the smallest area of the interior flow region of the molded slurry distributor through which the mold segment traverses when moving along the respective removal path.
Abstract:
A noncombustible exterior structural wall of a building, where the noncombustible wall includes a steel frame with a plurality of vertically oriented support studs, a plurality of noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels with an absence of an air/weather membrane.
Abstract:
A reduced weight, reduced density gypsum panel that includes high expansion vermiculite with fire resistance capabilities that are at least comparable to (if not better than) commercial fire rated gypsum panels with a much greater gypsum content, weight and density.
Abstract:
This invention provides gypsum wallboards with a unique microstructure where the walls between voids are enhanced in thickness and strength to substantially improve the strength and handling properties of the wallboards. A method of making lightweight gypsum wallboards is also provided.
Abstract:
Disclosed is a gypsum board comprising a set gypsum core disposed between two cover sheets. The set gypsum core is formed from a slurry comprising stucco, water, and at least one pregelatinized starch having a viscosity of from about 20 cP to about 300 cP as measured according to the VMA method described herein. The starch is present in an amount of greater than 10% by weight of the stucco. In preferred embodiments, the board has good strength properties even at lower densities, such as about 31 pcf or less. Also disclosed are a related method of making a gypsum wallboard and a slurry.