Strengthened, light weight wallboard and method and apparatus for making the same

• US 6,251,979 B1
• Filed: 08/13/1999
• Issued: 06/26/2001
• Est. Priority Date: 11/18/1998
• Status: Expired due to Fees

• Current Assignee: Innovative Technologies Enterprises Corporation
• Original Assignee: Advanced Construction Materials Corporation
• Inventors: Luongo, Joseph S.
• Primary Examiner(s): Cain, Edward J.
• Application Number:
  US09/374,589
• Time in Patent Office: 683 Days
• Field of Search: 524/423, 524/442, 524/445, 524/449
• US Class Current: 524/423
• CPC Class Codes: B28B 11/24 for curing, setting or hardening processes for influencing or modifying the setting or hardening ability of mortars, concrete or artificial stone compositions, in general C04B40/00
• CPC Class Codes: B28B 15/00 General arrangement or layout of plant ; Industrial outlines or plant installations
• CPC Class Codes: B28B 19/0092 to webs, sheets or the like, e.g. of paper, cardboard
• CPC Class Codes: B28B 23/0087 Lightweight aggregates for making lightweight articles
• CPC Class Codes: B29C 67/245 for making articles of indefinite length
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 14/365 Gypsum synthetic gypsum C04B18/0445, C04B18/064
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/0062 Gypsum-paper board like materials
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 22/0013 Boron compounds
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/2682 Halogen containing polymers, e.g. PVC
• CPC Class Codes: C04B 24/282 Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 24/38 Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 26/02 Macromolecular compounds
• CPC Class Codes: C04B 28/14 containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 40/0028 : Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/0263 : Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C08K 2003/3045 : Sulfates
• CPC Class Codes: C08K 3/30 : Sulfur-, selenium- or tellurium-containing compounds
• CPC Class Codes: C08K 7/22 : Expanded, porous or hollow particles
• CPC Class Codes: C08L 75/04 : Polyurethanes
• CPC Class Codes: E04C 2/043 : of plaster E04C2/049 takes precedence

Abstract

A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state in combination with an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises a covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength. Additionally, this invention relates to the unique manufacturing process to produce the wallboard composition of the present invention in order to create a lightweight, strengthened, moisture resistant, and fire retardant wallboard used to cover walls and ceilings in construction applications. Still further, this invention relates to the apparatus for manufacturing the wallboard composition of the present invention, including a method and apparatus for economically converting a standard gypsum wallboard manufacturing facility into a facility for manufacturing wallboard of the present invention.

Claims

1. A composition suitable for use in the manufacture of construction materials comprising:

an expanded mineral present at about 5% to about 47.5% by weight, said expanded mineral being water-permeable;

calcium sulfate present at 0% to about 23% by weight; and

at least one self-crosslinking tacky polymer present at about 1% to about 40% by weight.

2. The composition of claim 1, wherein said self-crosslinking tacky polymer is selected from the group consisting essentially of modified aliphatic polymer, polyurethane, vinyl acetate, sodium silicate, and polyvinyl chloride.

3. The composition of claim 1, wherein at least one of said self-crosslinking tacky polymers comprise polyurethane present at about 5% to about 40% by weight.

4. The composition of claim 1, wherein at least one of said self-crosslinking tacky polymers comprise vinyl acetate present at about 1% to about 40% by weight.

5. The composition of claim 1, wherein said at least one self-crosslinking tacky polymer comprises polyvinyl chloride present at about 1% to about 15% by weight.

10. The composition of claim 1, said expanded mineral being present at about 25% to about 47.5% by weight.

6. A composition suitable for use in the manufacture of construction materials, comprising:

a dry powder mineral substrate selected from the group of minerals comprising calcium sulfate, perlite, and combinations thereof; and

a synthetic binder, said synthetic binder further comprising a self-crosslinking permanently tacky polymer, starch, and borate.

7. The composition of claim 6, wherein said self-crosslinking permanently tacky polymer comprises vinyl acetate.

8. The composition of claim 7, wherein said vinyl acetate is present at about 1% to about 40% by weight.

9. The composition of claim 6, wherein said starch is present at about 0.001% to about 15%, and said borate is present at about 0.001% to about 10%.

11. A composition suitable for use in the manufacture of construction grade wallboard, said composition forming a rigid core situated between two paper cover sheets, said composition comprising:

an expanded mineral present at about 5% to about 47.5% by weight, said expanded mineral being water-permeable;

calcium sulfate present at 0% to about 23% by weight; and

at least one self-crosslinking tacky polymer present at about 1% to about 40% by weight.

12. The composition of claim 11, wherein said self-crosslinking tacky polymer is selected from the group consisting essentially of modified aliphatic polymer, polyurethane, vinyl acetate, sodium silicate, and polyvinyl chloride.

13. The composition of claim 11, wherein at least one of said self-crosslinking tacky polymers comprise polyurethane present at about 5% to about 40% by weight.

14. The composition of claim 11, wherein at least one of said self-crosslinking tacky polymers comprise vinyl acetate present at about 1% to about 40% by weight.

15. The composition of claim 11, wherein said at least one self-crosslinking tacky polymer comprises polyvinyl chloride present at about 1% to about 15% by weight.

16. The composition of claim 11, said expanded mineral being present at about 25% to about 47.5% by weight.