公开(公告)号：US10737981B2

公开(公告)日：2020-08-11

申请号：US15711583

申请日：2017-09-21

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Samar Emami ,  Salvatore C. Immordino ,  Robert H. Negri ,  David D. Pelot ,  Jeffrey F. Grussing ,  Juan Carlos Ruiz Castañeda ,  Christopher R. Nelson ,  John Jason Roxburgh ,  Srinivas Veeramasuneni

IPC: C04B28/14 ,  C04B38/02 ,  C04B22/04 ,  C04B22/10 ,  C04B40/00 ,  C04B22/06 ,  C04B22/14 ,  C04B38/10 ,  C04B111/00

Abstract: A gypsum-based composition of calcium sulfate hemihydrate with (a) alum and calcium carbonate and/or (b) zeolite and sodium percarbonate for making foamed gypsum slurry. A method to make foamed gypsum slurry from the composition. A method to make foamed gypsum product from the composition. A cavity wall having a cavity filled with the foamed gypsum product.

公开(公告)号：US11414352B2

公开(公告)日：2022-08-16

申请号：US16292988

申请日：2019-03-05

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： David D. Pelot ,  Samar Emami ,  Robert H. Negri ,  Juan Carlos Ruiz Castaneda ,  Christopher R. Nelson ,  John J. Roxburgh ,  Edgar R. De La Rosa Cruz ,  Jorge A. Garcia Torres ,  Miguel Gama Goicochea ,  Antonio Contreras ,  Juan Huitzil

IPC: C04B28/14 ,  C04B24/04 ,  C04B24/26 ,  C04B24/12 ,  C04B22/06 ,  C04B22/16 ,  C04B22/14 ,  C04B18/02 ,  C04B38/02 ,  C04B40/00 ,  C04B24/38 ,  C04B111/00 ,  C04B103/44 ,  C04B111/40 ,  C04B103/10 ,  C04B103/40

Abstract: Method of making foamed gypsum slurry having 15 to 90 volume percent gas bubbles including: passing first slurry including water and on dry basis 50 to 98 wt. % calcium sulfate hemihydrate, 1 to 50 wt. % calcium carbonate, and 0.1 to 10 wt. % cellulose thickener via a first hose to a Wye connector conduit first inlet opening at Rate C and passing alum solution via a second hose to a second inlet opening of the conduit at Rate D to create combined mixed stream passing from the conduit to a static mixer for mixing for Time 3 to activate at least a portion of the calcium carbonate and alum to generate CO2 and create the foamed gypsum slurry; transferring the slurry from the mixer to a cavity between two wall boards via a third hose. Allowing the slurry in the cavity to expand, harden and dry.

公开(公告)号：US10646837B2

公开(公告)日：2020-05-12

申请号：US16361551

申请日：2019-03-22

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Ashish Dubey ,  Peter B. Groza ,  Christopher R. Nelson

IPC: B28B3/22 ,  B01F7/00 ,  B28B1/52 ,  B28B5/02 ,  B28C5/12 ,  B28C5/14 ,  B28C5/40 ,  B29B7/48 ,  B29C48/67 ,  B29C48/00 ,  B29B7/42 ,  B29C48/40 ,  B29C48/57 ,  B01F3/12 ,  B01F7/04 ,  B01F7/06 ,  B01F7/08 ,  B01F13/10 ,  B01F15/02

Abstract: A method in which a stream of dry cementitious powder from a dry powder feeder passes through a dry cementitious powder inlet conduit to feed a first feed section of a fiber-slurry mixer. An aqueous medium stream passes through at least one aqueous medium stream conduit to feed a first mixing section the fiber-slurry mixer. A stream of reinforcing fibers passes from a fiber feeder through a reinforcing fibers stream conduit to feed a second mixing section of the fiber-slurry mixer. The stream of dry cementitious powder, aqueous medium stream, and stream of reinforcing fibers combine in the fiber-slurry mixer to make a stream of fiber-cement mixture which discharges through a discharge conduit at a downstream end of the mixer.

公开(公告)号：US10272399B2

公开(公告)日：2019-04-30

申请号：US15663104

申请日：2017-07-28

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Ashish Dubey ,  Peter B. Groza ,  Christopher R. Nelson

IPC: B28B3/22 ,  B01F7/00 ,  B01F3/12 ,  B01F7/04 ,  B01F7/06 ,  B01F7/08 ,  B01F13/10 ,  B01F15/02 ,  B28C5/12 ,  B28C5/14 ,  B28B1/52 ,  B28B5/02 ,  B28C5/40 ,  B29B7/48

Abstract: A method in which a stream of dry cementitious powder from a dry powder feeder passes through a dry cementitious powder inlet conduit to feed a first feed section of a fiber-slurry mixer. An aqueous medium stream passes through at least one aqueous medium stream conduit to feed a first mixing section the fiber-slurry mixer. A stream of reinforcing fibers passes from a fiber feeder through a reinforcing fibers stream conduit to feed a second mixing section of the fiber-slurry mixer. The stream of dry cementitious powder, aqueous medium stream, and stream of reinforcing fibers combine in the fiber-slurry mixer to make a stream of fiber-cement mixture which discharges through a discharge conduit at a downstream end of the mixer.

公开(公告)号：US11224990B2

公开(公告)日：2022-01-18

申请号：US15663007

申请日：2017-07-28

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Ashish Dubey ,  Peter B. Groza ,  Christopher R. Nelson

IPC: B28C7/04 ,  B28C5/40 ,  B28C5/12 ,  B28B5/02 ,  B28B3/22 ,  B01F7/00 ,  B01F7/08 ,  B28C5/14 ,  B01F7/04 ,  B29B7/48 ,  B28B1/52 ,  B29B7/90 ,  B29C48/67 ,  B29B7/72 ,  B29B7/44 ,  B01F3/12 ,  B28B13/02 ,  B01F15/02 ,  B01F3/20 ,  B05C1/08

Abstract: Continuous method including mixing water and cementitous powder to form slurry; mixing the slurry and reinforcement fibers in a single pass horizontal continuous mixer to form fiber-slurry mixture, the mixer including an elongated mixing chamber having a reinforcement fiber inlet port, and upstream of the fiber inlet port is an inlet port to introduce water and cementitous powder together as one stream or at least two inlet ports to introduce water and dry cementitous powder separately as separate streams into the chamber, a rotating horizontal shaft/s within the chamber, part of the chamber for mixing the fibers and slurry and moving the fiber-slurry mixture to a mixture outlet; discharging the fiber-slurry mixture from the mixer outlet; forming and setting the fiber-slurry mixture on a moving surface; cutting the set mixture into fiber reinforced concrete panels and removing the panels from the moving surface.

公开(公告)号：US11173629B2

公开(公告)日：2021-11-16

申请号：US15662932

申请日：2017-07-28

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Ashish Dubey ,  Peter B. Groza ,  Christopher R. Nelson

IPC: B28C7/04 ,  B28C5/12 ,  B01F7/00 ,  B28B19/00 ,  B01F13/10 ,  B01F7/04 ,  B28C5/14 ,  B28C5/40 ,  B28C9/00 ,  B28B1/52 ,  B28B13/02 ,  B01F15/02 ,  B01F3/12 ,  B05C1/08

Abstract: A method in which a stream of dry cementitious powder passes through a first conduit and aqueous medium stream passes through a second conduit to feed a slurry mixer to make cementitious slurry. The cementitious slurry passes through a third conduit and a reinforcement fiber stream passes through a fourth conduit to feed a fiber-slurry mixer which mixes the slurry and discrete fibers to make a stream of fiber-slurry mixture. An apparatus for performing the method is also disclosed.

公开(公告)号：US10981294B2

公开(公告)日：2021-04-20

申请号：US15663044

申请日：2017-07-28

Applicant: UNITED STATES GYPSUM COMPANY

Inventor： Ashish Dubey ,  Peter B. Groza ,  Christopher R. Nelson

IPC: B28B5/02 ,  B28B19/00 ,  B05C3/18 ,  B05C11/02 ,  B28B1/52 ,  C04B14/42 ,  C04B28/14 ,  C04B40/00 ,  B29L31/10

Abstract: A slurry feed apparatus for depositing a slurry upon a moving forming web having a direction of travel, including: a headbox mounted transverse to the direction of travel of the moving web, having a back wall, sidewalls, a concave transverse front wall, an open top, and an open bottom for directing slurry onto the forming web; a moveable dam releasably attached to the back wall, a seal attached to a bottom wall of the dam; and a headbox support system extending from opposed the sidewalls. Also disclosed is a continuous process for depositing a uniform layer of a cementitious slurry containing reinforcing fibers from the headbox onto a traveling web.