United States Gypsum Company

Knauf Gips Kg

U.S. Gypsum Company

US Government As Represented by the Secretary of the Army

Ashish Dubey

Peter B Groza

Christopher Robert Nelson

Yanfei Peng

Kumar C Natesaiyer

Alfred C Li

James Lynn Davis

James L Davis

Christopher R Nelson

Michael J Porter

Cesar Chan

William A Frank

Timothy D Tonyan

Bartley P Durst

Nicholas Boone

Michael J Roth

Toney K Cummins

Pamela Kinnebrew

William F Heard

Sundararaman Chithiraputhiran

Pamela G Kinnebrew

Qinghua Li

David R Blackburn

David McDonald

Eugene Scott Stivender

Thomas Slawson

Joe W Chambers

Aaron Greengard

D Paul Miller

Paul White

Chris C Lee

James M Ullett

Mark K Hemphill

Jeffrey William Donelan

Marianela Perez-Pena

Naser Aldabaibeh

Lloyd M George

Nicholas McCartney

Rajesh Raitani

David M Bonen

Ryan Stinson

Andrew Henry Bauer

Nicholas D′anna

Pete Groza

Carol F Johnson

David Bruce Mcdonald

Paul Miller

Water-resistant gypsum products may be produced using a novel catalyst that includes calcium aluminate cement and/or calcium sulfoaluminate cement. For example, a water-resistant gypsum panel may have a core comprising: interwoven matrices of calcium sulfate dihydrate crystals and a silicone resin, wherein the interwoven matrices have dispersed throughout them a siloxane polymerization catalyst comprising (a) 55 wt % to 100 wt % calcium aluminate cement and/or calcium aluminate cement and (b) 0 wt % to 45 wt % and magnesium oxide, wherein the weight ratio of the siloxane polymerization catalyst to the calcium sulfate dihydrate is 0.01-5:100. The water-resistant gypsum panel may have an absence of one or more of: Portland cement, limestone, aragonite, calcite, dolomite, and slaked lime.

Calcium aluminate cement and calcium sulfoaluminate cement catalysts in gypsum panels and use thereof

Beads of materials such as activated alumina, zeolite and silica gel, are used as chloride salt absorbers. The beads are mixed with high-salt gypsum. After mixing for a short time, the mixtures are dried, and the beads and the powder are separated by using a sieve or other physical separation device resulting in a low-salt gypsum which can be used as a gypsum source to make gypsum wallboard.

Methods of removing chloride from gypsum having high level of chloride salt

A production line and process including a moving carrier web for transporting the panel, and a device for controlling thickness of a formed, but not yet set, fiber reinforced cementitious panel slurry on the web. The thickness control device may include an angled rigid plate for contacting a downstream end of the angled plate with the slurry on the moving carrier web and a mounting stand for mounting the angled rigid. The thickness control device may include a flat horizontal plate at a fixed height over the moving carrier for contacting the entire lower surface of the horizontal plate with a facer on the slurry on the moving carrier web. Or, the thickness control device may include the angled plate and include the horizontal plate that contacts the facer.

Apparatus and process with a vibratory angled plate and/or fixed horizontal plate for forming fiber-reinforced cementitious panels with controlled thickness

Continuous method including mixing water and cementitous powder to form slurry; mixing the slurry and reinforcement fibers in a single pass horizontal continuous mixer to form fiber-slurry mixture, the mixer including an elongated mixing chamber having a reinforcement fiber inlet port, and upstream of the fiber inlet port is an inlet port to introduce water and cementitous powder together as one stream or at least two inlet ports to introduce water and dry cementitous powder separately as separate streams into the chamber, a rotating horizontal shaft/s within the chamber, part of the chamber for mixing the fibers and slurry and moving the fiber-slurry mixture to a mixture outlet; discharging the fiber-slurry mixture from the mixer outlet; forming and setting the fiber-slurry mixture on a moving surface; cutting the set mixture into fiber reinforced concrete panels and removing the panels from the moving surface.

Continuous methods of making fiber reinforced concrete panels

A method in which a stream of dry cementitious powder passes through a first conduit and aqueous medium stream passes through a second conduit to feed a slurry mixer to make cementitious slurry. The cementitious slurry passes through a third conduit and a reinforcement fiber stream passes through a fourth conduit to feed a fiber-slurry mixer which mixes the slurry and discrete fibers to make a stream of fiber-slurry mixture. An apparatus for performing the method is also disclosed.

Continuous mixer and method of mixing reinforcing fibers with cementitious materials

Self-consolidating geopolymer compositions utilizing fly ash and inorganic mineral including alkaline earth metal oxide as cementitious reactive components and include cement set retarder. The alkaline earth metal oxide is preferably calcium oxide (also known as lime or quicklime) and/or magnesium oxide. The inorganic minerals including alkaline earth metal oxide have an alkaline earth metal oxide content preferably greater than 50 wt. %, more preferably greater than 60 wt. %, even more preferably greater than 70 wt. %, and most preferably greater than 80 wt. %, for example greater than 90 wt. %. The cementitious reactive powder may optionally also include one or more aluminous cements and one or more source of calcium sulfates. The cementitious reactive powders are activated with an alkali metal chemical activator selected from alkali metal salt and/or alkali metal base. Methods for making the compositions are also disclosed.

Self-consolidating geopolymer compositions and methods for making same

A slurry feed apparatus for depositing a slurry upon a moving forming web having a direction of travel, including: a headbox mounted transverse to the direction of travel of the moving web, having a back wall, sidewalls, a concave transverse front wall, an open top, and an open bottom for directing slurry onto the forming web; a moveable dam releasably attached to the back wall, a seal attached to a bottom wall of the dam; and a headbox support system extending from opposed the sidewalls. Also disclosed is a continuous process for depositing a uniform layer of a cementitious slurry containing reinforcing fibers from the headbox onto a traveling web.

Headbox and forming station for fiber-reinforced cementitious panel production

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.

Hydrophobic finish compositions with extended flow time retention and building products made thereof

A method in which a stream of dry cementitious powder from a dry powder feeder passes through a dry cementitious powder inlet conduit to feed a first feed section of a fiber-slurry mixer. An aqueous medium stream passes through at least one aqueous medium stream conduit to feed a first mixing section the fiber-slurry mixer. A stream of reinforcing fibers passes from a fiber feeder through a reinforcing fibers stream conduit to feed a second mixing section of the fiber-slurry mixer. The stream of dry cementitious powder, aqueous medium stream, and stream of reinforcing fibers combine in the fiber-slurry mixer to make a stream of fiber-cement mixture which discharges through a discharge conduit at a downstream end of the mixer.

Method for producing fiber reinforced cementitious slurry using a multi-state continuous mixer

A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar and repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium aluminate cement, a calcium sulfate and a chemical activator with water.

Dimensionally stable geopolymer composition and method

Cementitious binder compositions for cementitious products including a hydraulic cement-based reactive powder blend, an inorganic flow control agent, and a metal-based dimensional movement stabilizing agent including at least one member of the group of lithium salt and lithium base, and methods for making the cementitious binder compositions.

Self-desiccating, dimensionally-stable hydraulic cement compositions with enhanced workability

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.

A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar, patching materials for road repairs and other repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium sulfoaluminate cement, a calcium sulfate and a chemical activator with water.

Disclosed are cementitious articles with hydrophobic finish. In some embodiments, the article is a waterproof gypsum panel that is 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 are useful in many applications, such as, for example, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having superior water durability and extremely low surface absorption. The flexible and hydrophobic cementitious finish of the invention can include Class C fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), and other optional additives.

Cementitious article comprising hydrophobic finish

A freeze-thaw durable, dimensionally stable, geopolymer composition including: cementitious reactive powder including thermally activated aluminosilicate mineral, aluminate cement preferably selected from at least one of calcium sulfoaluminate cement and calcium aluminate cement, and calcium sulfate selected from at least one of calcium sulfate dihydrate, calcium sulfate hemihydrate, and anhydrous calcium sulfate; alkali metal chemical activator; and a freeze-thaw durability component selected from at least one of air-entraining agent, defoaming agent, and surface active organic polymer; wherein the composition has an air content of about 4% to 20% by volume, more preferably about 4% to 12% by volume, and most preferably about 4% to 8% by volume. The compositions are made from a slurry wherein the water/cementitious reactive powder weight ratio is 0.14 to 0.45:1, preferably 0.16 to 0.35:1, and more preferably 0.18 to 0.25:1. Methods for making the compositions are also disclosed.

Freeze-thaw durable geopolymer compositions and methods for making same

Growing community of inventors

Grayslake, IL, United States of America

Ashish Dubey