Gold Bond Building Products, LLC

National Gypsum Properties, LLC

Joseph J Bailey

Eli Stav

R G Iyer

Ma-Ikay Miatudila

Brian G Randall

Richard P Weir

Karen Fey

Bradley J Busche

Gopalakrisnan Sethuraman

Michael N Blades

Thomas R Wilson

Jeff Hawk

Tommy Wilson

Bradley G Busche

Jie Ling

Veda Evans

Brad Busche

Gopalakrishnan Sethuraman

David G Peterson, Jr

Gene Whittington

Craig Robertson

Matthew M Hilken

Elizabeth Burgess

Chris Fewox

The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board, and a method of making such gypsum board. For instance, the method comprises: providing a first encasing layer and a first sound damping layer on the first encasing layer wherein the sound damping layer includes at least 50 wt. % of a first sound damping polymer; depositing a gypsum slurry comprising stucco and water on the sound damping layer to form a gypsum core; providing a second encasing layer on the gypsum slurry; and allowing the stucco to convert to calcium sulfate dihydrate.

Sound damping gypsum board and method of constructing a sound damping gypsum board

The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board. The gypsum board comprises a gypsum core including gypsum and a sound damping polymer. The gypsum core includes a first gypsum layer surface and a second gypsum layer surface opposing the first gypsum layer surface. In addition, a first encasing layer is disposed on the first gypsum layer surface and a second encasing layer is disposed on the second gypsum layer surface.

A sound damping wallboard for installation on an installed wallboard, a sound damping wallboard system, and a method of constructing a sound damping wallboard on a building structure are disclosed. The sound damping wallboard includes a gypsum layer having a gypsum layer inner surface and a gypsum layer outer surface, a first sound damping layer disposed at the gypsum layer inner surface and having a first sound damping layer inner surface opposite the gypsum layer inner surface, a first encasing layer disposed at the gypsum layer outer surface, a second encasing layer disposed at the first sound damping layer inner surface, and a second sound damping layer disposed at the second encasing layer opposite the first sound damping layer inner surface.

Sound damping wallboard and method of constructing a sound damping wallboard

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.

Cementitious panels with swellable materials and methods of providing a moisture or water barrier in cementitious panels using swellable materials

In general, the present invention is directed to a building panel, such as a gypsum board, comprising a core having a first side and a second side opposing the first side and at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment. The panel satisfies at least one of the following: the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 or the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16. The panel may also exhibit at least a Level 3 finish.

Antimicrobial coating for building panel

The present invention is directed to a gypsum board and a method of making such gypsum board. For instance, the gypsum board comprises a gypsum core, a first facing material, and a second facing material wherein the first facing material and the second facing material sandwich the gypsum core. The gypsum core comprises a first gypsum core section and a second gypsum core section each comprising gypsum, wherein the first gypsum core section comprises a polyol compound and has a density higher than a density of the second gypsum core section.

Gypsum board containing a polyol compound

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%.

Method of manufacturing gypsum board with improved fire resistance

Provided are wallboard panels that include a foam material layer and a core material, with one or more sheets of facer material and/or one or more sheets of backing material. The foam material layer may include one or more pores having an open pore geometry. Additionally, provided are methods of manufacturing such wallboard panels.

Wallboard with foam material layer

In general, the present invention is directed to the use of particular phosphorus containing compounds for making a gypsum board. The phosphorus containing compound may be a phosphite or a phosphate having a certain formula. In this regard, the present invention is directed to a slurry for making a gypsum board wherein the slurry includes such phosphorus containing compound. The present invention is also directed to a method of making a gypsum board from the slurry as well as a resulting gypsum board.

Gypsum board and gypsum slurry formed using a phosphorus containing compound

A slurry for manufacturing gypsum board is disclosed. The slurry comprises calcined gypsum, water, a foaming agent, and a thickening agent. The thickening agent of the present disclosure acts to improve the cohesiveness of the slurry without adversely affecting the setting time of the slurry, the paper-to-core bond (wet and dry), or the head of the slurry by acting as a defoaming agent or coalescing agent. Examples of suitable thickening agents include cellulose ether and co-polymers containing varying degrees of polyacrylamide and acrylic acid. A gypsum board and method of forming the slurry and the gypsum board are also disclosed. The gypsum board comprises a gypsum layer formed from the slurry.

Gypsum wallboard slurry and method for making the same

Provided are cementitious panels that include a cementitious core material and a plurality of sheets of facing material surrounding the cementitious core material, in which at least one of the plurality of sheets of facing material includes a polymeric-film. The polymeric film may include a thermoplastic composition that has a polymeric matrix including one or more polymeric materials. Additionally, the thermoplastic composition may optionally include a filler material. Additionally, provided are methods of manufacturing such cementitious panels.

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Charlotte, NC, United States of America

Joseph J Bailey