Gold Bond Building Products, LLC

The present invention is directed to a method of making such gypsum panel. For instance, the method comprises: providing a first facing material; providing a gypsum slurry including calcium sulfate hemihydrate, water, and a silicon containing compound onto the first facing material; providing a second facing material onto the gypsum slurry to form a continuous gypsum sheet; allowing the calcium sulfate hemihydrate to hydrate to form calcium sulfate dihydrate; cutting the continuous gypsum sheet to form a gypsum panel; supplying the gypsum panel to a heating or drying device; and providing a gaseous mixture from the heating or drying device to a regenerative thermal oxidizer.

The present disclosure is directed to a gypsum panel and a method of making such gypsum panel. Further, the present disclosure is directed to a method of processing a reclaimed gypsum panel. The method may include grinding a reclaimed gypsum panel and/or reclaimed gypsum panel pieces into a reclaim composition and separating at least a portion of the reclaimed facing material from the reclaimed gypsum of the reclaim composition. The reclaimed gypsum core of the reclaimed gypsum panel may include a reclaimed water-resistant additive present in a portion of the gypsum core adjacent at least one facing material of the reclaimed gypsum panel in a higher concentration than the center of the thickness of the gypsum core of the reclaimed gypsum panel.

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.

The present invention is directed to a method of making such gypsum panel. For instance, the method comprises: providing a first facing material; providing a gypsum slurry including calcium sulfate hemihydrate, water, and a silicon containing compound onto the first facing material; providing a second facing material onto the gypsum slurry to form a continuous gypsum sheet; allowing the calcium sulfate hemihydrate to hydrate to form calcium sulfate dihydrate; cutting the continuous gypsum sheet to form a gypsum panel; supplying the gypsum panel to a heating or drying device; and providing a gaseous mixture from the heating or drying device to a regenerative thermal oxidizer.

The present disclosure is directed to a gypsum panel and a method of making such gypsum panel. For instance, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core. The gypsum core includes gypsum and a maleic anhydride polymer comprising maleic anhydride repeating units present in an amount of more than 10 wt. % based on the weight of the maleic anhydride polymer. The method of the present disclosure is directed to making the aforementioned gypsum panel by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and a maleic anhydride polymer onto the first facing material and providing a second facing material on the gypsum slurry.

The present invention is directed to a gypsum panel having one or more perforations and a method of making such gypsum panel. For instance, in some aspects, the gypsum panel comprises a gypsum core, a first facing material, and a second facing material. The first facing material, the second facing material, or both may include a multilayer facing material having one or more perforations. Notably, one layer of the multilayer facing material may be a polymer layer.

In the present disclosure, a method of forming a gypsum panel is disclosed. The method comprises: providing a first facing material, forming a starch slurry by combining starch and water at a shear rate of 3,000 rpm or more, providing the starch slurry onto the first facing material, depositing a gypsum slurry comprising stucco and water onto the starch slurry on the first facing material, providing a second facing material on the gypsum slurry, and allowing the stucco to convert to calcium sulfate dihydrate.

The present invention is directed to gypsum panels containing a water resistance enhancement composition and a method of making such gypsum panels. In one embodiment, the gypsum panel comprises a gypsum core, a first facing material, and a second facing material. Notably, the gypsum core may be formed by a gypsum slurry comprising a water resistance enhancement composition including an alkali salt, an ammonium salt, or a combination thereof. The methods of the present invention are directed to making the aforementioned gypsum panels.

A method for improving the air and/or water barrier performance of a building panel is disclosed. The building panel may be a gypsum board or cement board. In particular, the board may have improved resistance to bulk water penetration or permeation while maintaining breathability with respect to water vapor.

The present invention is directed to wallboard assemblies containing a gypsum panel and a method of making such wallboard assemblies. In one embodiment, the wallboard assembly comprises a gypsum panel containing a gypsum core and at least one facing material. The wallboard assembly and/or the gypsum panel may be fire resistant. The methods of the present invention are directed to making the aforementioned wallboard assemblies.