United States Gypsum Company

Naveen Punati

Qinghua Li

Alexander J Donovan

Weixin David Song

Alfred C Li

James Wittbold

Robert H Negri

Richard B Stevens

Chris C Lee

James M Ullett

Mark K Hemphill

William Rago

Jeffrey F Grussing

Pamela L Hargrove

Tyler Kincaid

David D Pelot

Gary Miller

Joseph W Schlude

Mark Antosh

Luis Carrazco

Joseph Swinea

Christian Huch

William J Rago

A joint compound including calcium sulfate hemihydrate and/or at least one filler, wherein a total amount of the at least one filler and/or calcium sulfate hemihydrate is at least about 50 wt % of the joint compound on a dry (water-free) basis, preferably the filler comprises calcium carbonate, calcium sulfate dihydrate, or calcium sulfate anhydrite, or a mixture thereof; binder at up to about 15 wt % of the joint compound on a dry basis; polymer thickener at up to about 3 wt % of the joint compound on a dry basis; plasticizer dedusting agent at about 0.01 to about 3 wt % of the joint compound on a dry (water free) basis; and an additive up to about 10 wt % of the joint compound on a dry basis.

Plasticizer dedusting agents for joint compounds

Disclosed are a composite gypsum board and a method of preparing composite gypsum board. The board contains a set gypsum core sandwiched between two cover sheets. The core is formed from a slurry containing stucco, water, and optional ingredients such as foaming agent, accelerator, retarder, polyphosphate, starch, and dispersant, and core intumescent material. The board also contains at least one skim coat and/or hard edges. A face skim coat layer can be included on one side of the core, facing a face cover sheet. A back skim coat layer can be included on the other side of the core, facing a back cover sheet. Hard edges are known in the art and can be formed, e.g., continuously from a stucco slurry for forming the face and/or back skim coats. Preferably, the back skim coat layer and/or the hard edges are formed from a slurry containing stucco, water, skim coat or edge intumescent material (which have the same desired characteristics), and other optional additives as desired. The skim coat or edge intumescent material can be composed of the same material as the core intumescent material, if desired, but the skim coat and/or edge intumescent material is present in a higher relative concentration in its respective slurry than the amount of core intumescent material in the core slurry. Examples of suitable intumescent materials include expandable vermiculite (e.g., No. 4 or No. 5 according to the US naming system, or combinations thereof), expandable graphite, perlite, or any combination thereof.

Fire resistant gypsum board and related methods

A snap-setting joint compound with reduced calcium sulfate hemihydrate and improved sandability, as well as methods for building wall assemblies and repairing walls with the joint compound.

Setting type joint compound compositions with reduced plaster

A panel for a shaftwall system includes a panel body with a core and at least one outer facing layer and an opposite backing surface. A score line is formed in the facing layer, defining two folded panel portions. The panel is folded along the score line to form a folded edge, and the folded panel portions are arranged so that the backing surfaces of the panel portions contact each other. A companion shaftwall building structure system is provided, including a plurality of the panels defining an enclosure, each panel being a &#xbd;-inch thick wallboard panel having a 'V'-shaped score line defining a pair of panel portions, the score line forms a tapered edge of the folded panel. A plurality of brackets is provided, each bracket defining a panel track dimensioned for slidingly accommodating the folded panel and retaining the panel in place without the use of fasteners.

Shaftwall system using folded panels, and panel

Disclosed are a gypsum board, and related slurries and methods. The gypsum board comprises a gypsum layer disposed between two cover sheets. The gypsum layer comprises a crystalline matrix of set gypsum and expandable graphite. The expandable graphite exhibits volume expansion at high temperatures. Optionally, unexpanded vermiculite can also be included in the gypsum layer to provide an expansion component at even higher temperatures. Because of synergy between the expandable graphite and unexpanded vermiculite in accordance with some embodiments, less vermiculite can be included in the board than in conventional board that contained vermiculite. The board desirably can pass one or more fire-related tests, and is a fire-rated board in some embodiments.

Fire resistant gypsum board comprising expandable graphite and related methods and slurries

A slurry distributor includes a feed conduit and a distribution conduit in fluid communication therewith. The feed conduit includes an entry segment with a feed inlet and a feed entry outlet in fluid communication therewith and extending along a first feed flow axis. The feed conduit includes a shaped duct having a bulb portion in fluid communication with the feed entry outlet. The feed conduit includes a transition segment in fluid communication with the bulb portion and extending along a second feed flow axis in non-parallel relationship with the first feed flow axis. The bulb portion has an area of expansion with a cross-sectional flow area that is greater than a cross-sectional flow area of an adjacent area upstream from the area of expansion. The shaped duct has a convex interior surface in confronting relationship with the feed entry outlet of the entry segment.

Slurry distributor, system, and method for using same

A combined wooden frame support and ceiling system is provided, each support including upper and lower wooden chords and a wooden structure connecting the lower chord to the upper chord for weight bearing purposes. A gypsum wallboard batten strip is attached to the lower chord, and defining a ledge extending from each side of the lower chord. A single thickness of gypsum wallboard panels is used to create a ceiling attached to the support, each panel used to create the ceiling is made from a slurry composition including less than 5% by weight of Grade 4 vermiculite. Upon the support being assembled in the ceiling system, with a plurality of the supports, and having lengths of insulation supported by the ledges of the adjacent supports, the ceiling system resists charring by fire for at least one hour.

One hour fire rated wooden frame members using lightweight gypsum wallboard

Growing community of inventors

Arlington Heights, IL, United States of America

Naveen Punati