Abstract:
A water-resistant gypsum fiber product comprising siloxane and coated with a coating comprising alkali metal organosiliconate is provided. A method of making a gypsum fiber product in which siloxane is cross-linked at the surface of the product is also provided. A fuel-efficient method for making the product and reducing the amount of siloxane dust released is provided as well.
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:
The application concerns a gypsum board (10) and a method of producing it whereby the board comprises a gypsum core (20) and at least one mat (12) being provided on the core. The mat has outer (14) and inner (18) surfaces and comprises a first region (30) adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness, and a second region (32) adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness. The first region has more hydrophilicity than the second region, more wettability than the second region, and/or less density than the second region.
Abstract:
Disclosed is a method of preparing a mat-faced cementitious article composite. A mat-faced article (e.g., board) is formed and the composite is formed upon application of a finish composition (e.g., hydrophobic). In one aspect, the matfaced gypsum article comprises a mat having an inner surface adjacent to a cementitious core first surface and an opposite outer mat surface. An aqueous cementitious finish composition is applied to the outside mat surface to form the matfaced cementitious article composite. Desirably, the finish composite can suitably be applied by a roller assembly comprising a finish roller. In some embodiments, the finish roller has an uneven surface, including for example, grooves or depressions (e.g., circumferential or longitudinal) defined therein.
Abstract:
Embodiments of a system and a method for continuously manufacturing a joint compound can be used to produce ready mix joint compound. The system includes means for continuously mixing wet and dry joint compound ingredients together and means for homogenizing multiple volumetric units of mixed joint compound to reduce variation in at least one joint compound material property (e.g., viscosity) across multiple successively produced volumetric units of mixed joint compound (relating to standard commercial packaging sizes for joint compound, such as five-gallon pails, for example) relative to the material property of the respective multiple volumetric units before passing through the means for homogenizing.
Abstract:
A gypsum slurry includes water, a hydraulic component including stucco and a polycarboxylate dispersant. The dispersant has two repeating units wherein the first repeating unit is an olefinic unsaturated mono-carboxylic acid repeating unit or an ester or salt, and the second repeating unit is a vinyl or allyl group bound to a polyether by an ether linkage. The slurry can be made into a gypsum panel.
Abstract:
A production line (10) and process including a moving carrier web (14) for transporting the panel, and a device (93) for controlling thickness of a formed, but not yet set, fiber reinforced cementitious panel slurry on the web (14). The thickness control device (93) may include an angled rigid plate (95) for contacting a downstream end (202) of the angled plate (95) with the slurry on the moving carrier web (14) and a mounting stand (97) for mounting the angled rigid plate (95). The thickness control device (93) may include a flat horizontal plate (201) at a fixed height over the moving carrier for contacting the entire lower surface of the horizontal plate (201) with a facer (444) on the slurry on the moving carrier web (14). Or, the thickness control device (93) may include the angled plate (93) and include the horizontal plate (201) that contacts the facer (444).
Abstract:
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. These waterproof gypsum panels have many uses, such as, tile backer board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, interior wall and ceiling, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, preferably 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. Preferably a pre-coated non-woven glass fiber mat is employed to provide the inorganic mineral fibers for the surface reinforcement.
Abstract:
One or more of these or other problems are improved using a method of making a strong gypsum panel which includes a method for forming a hardened shell structure at the interface of a foamed bubble and a gypsum slurry. A strengthening component is selected from the group consisting of set accelerators, water soluble polyphosphate salts, blends of water soluble polyphosphate salts with starch, boric acid, fibers, glycerin or combinations thereof. The strengthening component is combined with a foaming agent and with water to form an aqueous soap mixture. Foam is generated from the aqueous soap mixture, and added to a gypsum slurry. Allowing the strengthening component to contact the soap bubbles prior to addition of the foam to the gypsum slurry allows the strengthening component to preferentially contact the soap film rather than be dispersed through the entire slurry.