Abstract:
The invention provides a curable, formaldehyde free coating composition comprising a composition comprising a polyacid copolymer crosslinked with a hydroxyl group-containing compound and calcium aluminosilicate powder, panels coated with the coating composition, and a method of coating a panel with the coating composition.
Abstract:
Effective use of dispersants in wallboard containing foam results from a method where stucco is mixed with a first dispersant and a first quantity of water to form a gypsum slurry. A soap is blended with a second dispersant and a second quantity of water to make a foam. Subsequently, the foam is combined with the slurry. Choice of different first and second dispersants and their relative amounts allows control of the size distribution of the foam bubbles in the slurry and the resulting voids in the gypsum core. Melamine sulfonate condensate and polycarboxylate dispersants are preferred dispersants.
Abstract:
An acoustical panel is made by applying a thin, acoustically- transparent coating to an acoustical base mat. A pulp is made from one or more fillers, a fibrous filler, a binder and water. A thickener solution is prepared from a thickener and water. A portion of the pulp and the thickener solution are mixed under high shear conditions to degrade the fibrous filler and form a smooth coating. The coating is applied to and distributed over a base mat and the coated base mat is then cut and dried to form a coated acoustical panel. The panel is free of visible mineral nodules on the surface of the coating. Optionally, the pulp is a portion of a pulp used to make the base mat. Other embodiments include the use of recycled dust or fine particles of the acoustical panel obtained from cutting or shaping the base mat or coated panels.
Abstract:
A coating for application to the surface of an interior building product comprises: a resin formulation such as a melamine formaldehyde resin characterized by its ability to strengthen the interior building product when applied as a coating to the building product; and an aldehyde scavenger selected from the group consisting of; tetraethylene pentamine, propionamide, caprolactam, ammonium hydroxide, sodium bisulfate, sodium metabisulfite, ammonium primary phosphate, ammonium secondary phosphate, a combination of ammonium primary phosphate and ammonium secondary phosphate, a combination of ammonium primary phosphate, ammonium secondary phosphate and a sulfite, a polyvinyl alcohol; adipic dihydrazide and a combination of a polyvinyl alcohol and adipic dihydrazide.
Abstract:
An acoustical panel is made by applying a thin, acoustically- transparent coating to an acoustical base mat. A pulp is made from one or more fillers, a fibrous filler, a binder and water. A thickener solution is prepared from a thickener and water. A portion of the pulp and the thickener solution are mixed under high shear conditions to degrade the fibrous filler and form a smooth coating. The coating is applied to and distributed over a base mat and the coated base mat is then cut and dried to form a coated acoustical panel. The panel is free of visible mineral nodules on the surface of the coating. Optionally, the pulp is a portion of a pulp used to make the base mat. Other embodiments include the use of recycled dust or fine particles of the acoustical panel obtained from cutting or shaping the base mat or coated panels.
Abstract:
A gypsum slurry is described that includes water, a hydraulic component comprising at least 50% calcined gypsum by weight based on the dry weight of the hydraulic component, foam, a defoamer and a polycarboxylate dispersant In some embodiments of the invention, the defoamer is combined with the dispersant prior to being added to the gypsum slurry The defoamer and dispersant can be added as a physical mixture, wherein the defoamer is attached onto the dispersant polymer, or a combination thereof In some embodiments, a gypsum building panel is made from the gypsum slurry.