Certainteed Gypsum, Inc.

Bpb Limited

Saint-gobain Placo S.a.s.

Bpb Limited, a U.k. Corporation

Michael P Fahey

Robert J Hauber

Mark E Hennis

Gerald Boydston

Christopher J Sanders

Matthew J Chowing

Troy R Stuart

Bryan Wiltzius

John Bridenstine

Nathan Gregory Frailey

Gerald D Boydston

Matthew J Chowning

A method for producing building boards includes unwinding a facing sheet from a supply roll of facing sheet over top of a forming table that includes a series of nozzles. A volume of cementitious material is deposited from a slurry mixing device to the unwound facing sheet. Pressurized air is supplied from an air source to the series of nozzles, whereby a cushion of air is created between the unwound facing sheet and the forming table.

Apparatus and method for constructing building boards using low friction surfaces

Disclosed is a fastening system and method for securing a sheathing board to an associated framing member. The system includes a feedband for retaining a series of fasteners and a powered drill for sequentially driving the fasteners. The feedband is made from a membrane of a polymeric compound. As the fastener is driven into the sheathing board, a portion of the membrane tears away from the surrounding feedband and becomes seated beneath the fastener. This acts to seal the penetration point and prevent water intrusion and otherwise prevents deterioration of the sheathing board.

Method for forming a seal between a fastener and associated sheathing board

Disclosed is a gypsum board forming device which provides improved slurry spread. The device includes a forming table with an arcuate or angled profile that promotes a uniform slurry spread. An arcuate or angled hinge plate can also be included to further promote the uniform distribution of slurry prior to an extrusion plate.

Gypsum board forming device with improved slurry spread

Disclosed is a fastening system that is adapted for securing a sheathing board to an associated framing member. The system includes a feedband for retaining a series of fasteners and a powered drill for sequentially driving the fasteners. The feedband is made from a membrane of a polymeric compound. As the fastener is driven into the sheathing board, a portion of the membrane tears away from the surrounding feedband and becomes seated beneath the fastener. This acts to seal the penetration point and prevent water intrusion and otherwise prevents deterioration of the sheathing board.

Fastening system for sheathing board

Disclosed is a gypsum board forming device which provides improved slurry spread. The device includes a forming table with an arcuate or angled profile that promotes a uniform slurry spread. An arcuate or angled hinge plate can also be included to further promote the uniform distribution of slurry prior to an extrusion plate. As a result of the improved slurry spread, gypsum board with increased strength and durability can be created.

A multilayer gypsum board forming device, and a gypsum additive delivery system in which additives are delivered to one or more layers of a multi layered gypsum board panels, including engineered polymers, includes at least one additive assembly connected in-line with a first gypsum delivery receptacle for providing an additive fluid feed into the stream of a first gypsum slurry being transported through said first gypsum delivery receptacle for homogenously adding an additive to the first gypsum slurry, and a second gypsum delivery receptacle transporting a second gypsum slurry, in fluid communication with the mixer providing the first gypsum slurry, having a different set of characteristics from those of the first gypsum slurry. At least one outer surface including a polymeric compound or wax emulsion additive entrained therein essentially encases the core gypsum within two facing layers.

Apparatus for targeted delivery of additives to varying layers in gypsum panels

A method of manufacture of multilayer gypsum board, and a gypsum additive delivery system, including wet gypsum board passing through a board forming station in which additives are delivered to one or more layers of a multi layered gypsum board panels, such as engineered polymers, providing a better and more water resistance surface. Preferably, the gypsum board has a first layer of a mixture of set gypsum having an outer surface and a polymeric compound or wax emulsion additive entrained therein and impregnated in a thin sheet of randomly aligned inorganic fibers to essentially encase the core gypsum within two facing layers.

Method for targeted delivery of additives to varying layers in gypsum panels

Gypsum board having inorganic fiber, preferably glass fiber, preferably glass fiber, includes providing face sheets which have been completely impregnated with a gypsum slurry so as to penetrate through said random interstices between the inorganic fibers and to thereby cover the board surfaces with gypsum slurry. The gypsum board product is formed by passing the wet gypsum board through a board forming station having double forming plates, an upper forming plate having at least a portion thereof being set at a predetermined angle relative to a lower forming plate and having a separation between the forming plates defining a predetermined dimension substantially equal to the desired thickness of the manufactured gypsum board product. The method provides a multilayer gypsum board having a polymeric compound added to unset gypsum so as to provide a gypsum board ready for finishing.

Method of manufacture of glass reinforced gypsum board and apparatus therefor

A gypsum board forming device having a gypsum forming station including two laterally disposed edger shoes, and at least one laterally disposed edger bar clamping element on the edger bar. In one embodiment a laterally extending forming plate extends over the top surface of the formed gypsum board, the forming plate including a plurality of micropore conduits through which pressurized water is supplied to provide a film of smoothing water over the top surface of the gypsum board. In another embodiment the edger shoes have a flapper mechanism for retaining unset slurry skimmed off the surface of the gypsum board by the edger bar.

Gypsum board forming device

A multilayer gypsum board having face sheets comprising inorganic fiber, preferably randomly oriented glass fiber, which have been completely impregnated with a gypsum slurry so as to penetrate through the random interstices between the inorganic fibers and to thereby coat the board surfaces with gypsum slurry. The multilayer gypsum board may have a polymeric compound added to unset gypsum the compound may comprise any of the following: polyacrylamide, polymethylacrylamide, polyvinyidene chloride (PVDC), polyamide, poly (hexamethylene adipamide), polyvinylchloride (PVC), polyethylene, cellulose acetate, polyisobutylene, polycarbonate, polypropylene, polystyrene, polychloroprene, styrene, butadiene, natural rubber, poly (2,6 dimethyl pentene oxide), poly (4-methyl-1-pentene) and polydimethyl siloxane. The multilayer gypsum board may comprise a first layer of a mixture of set gypsum having an outer surface and the polymeric compound additive entrained within the set gypsum and being impregnated in a thin sheet of randomly aligned inorganic fibers so as to essentially encase the core gypsum within two facing layers having a combination set gypsum and polymeric compound.

Growing community of inventors

St. Petersburg, FL, United States of America

Michael P Fahey