The present invention relates to a process for manufacturing a wood-based board, a wood-based board as use of a liquid coating composition comprising at least one particulate filler material and at least one binder for in-line coating of wood-based boards.

The present invention relates to a process for manufacturing a wood-based board, a wood-based board as use of a liquid coating composition comprising at least one particulate filler material and at least one binder for in-line coating of wood-based boards.

A low strength backfill material having a 28 days compressive strength less than approximately 2.0 MPa is provided. The backfill is suitable for use in areas with dense underground utilities due to its high excavatability and good thermal conductivity. The backfill includes a cementitious binder of approximately 1 weight percent to approximately 10 weight percent and fine aggregates in an amount of approximately 40 to approximately 75 weight percent. Filler is provided at 20 microns to approximately 100 microns for high flowability. A density-controlling agent of 0.0001-5 weight percent is used such that the density of a cured backfill material is approximately 1600 kg/m.sup.3 to 2000 kg/m.sup.3. Thermally conductive particles having a size range of approximately 0.01 microns to 500 microns in an amount of approximately 0.1 to 10 weight percent are evenly dispersed throughout the backfill.

A low strength backfill material having a 28 days compressive strength less than approximately 2.0 MPa is provided. The backfill is suitable for use in areas with dense underground utilities due to its high excavatability and good thermal conductivity. The backfill includes a cementitious binder of approximately 1 weight percent to approximately 10 weight percent and fine aggregates in an amount of approximately 40 to approximately 75 weight percent. Filler is provided at 20 microns to approximately 100 microns for high flowability. A density-controlling agent of 0.0001-5 weight percent is used such that the density of a cured backfill material is approximately 1600 kg/m.sup.3 to 2000 kg/m.sup.3. Thermally conductive particles having a size range of approximately 0.01 microns to 500 microns in an amount of approximately 0.1 to 10 weight percent are evenly dispersed throughout the backfill.

A drying-type joint compound, a setting-type joint compound, and/or a ready-mixed, setting-type joint compound can include a phospholipid dedusting agent. For example, a drying-type joint compound can include: (a) a primary filler at 50 weight percent (wt %) to 98 wt % on a dry basis, wherein the primary filler includes one of calcium carbonate, calcium sulfate dihydrate, and talc, and a mixture thereof (b) a secondary filler at up to 25 wt % on a dry basis; (c) a binder at 1 wt % to 15 wt % on a dry basis; (d) a polymer thickener at 0.05 wt % to 3 wt % on a dry basis; (e) a phospholipid dedusting agent at 0.01 wt % to 3 wt % on a dry basis; (f) an additive up to 10 wt % o on a dry basis; and (g) water at a weight ratio of water to dry components of 1:6 to 2:1.

A drying-type joint compound, a setting-type joint compound, and/or a ready-mixed, setting-type joint compound can include a phospholipid dedusting agent. For example, a drying-type joint compound can include: (a) a primary filler at 50 weight percent (wt %) to 98 wt % on a dry basis, wherein the primary filler includes one of calcium carbonate, calcium sulfate dihydrate, and talc, and a mixture thereof (b) a secondary filler at up to 25 wt % on a dry basis; (c) a binder at 1 wt % to 15 wt % on a dry basis; (d) a polymer thickener at 0.05 wt % to 3 wt % on a dry basis; (e) a phospholipid dedusting agent at 0.01 wt % to 3 wt % on a dry basis; (f) an additive up to 10 wt % o on a dry basis; and (g) water at a weight ratio of water to dry components of 1:6 to 2:1.

The embodiments herein are directed to dry wall waste mixtures, formed under pressure into example embodiments referred to herein as dry wall waste blocks (DWBs) and/or gypsum wallboard waste blocks (GWWBs) and tile structures. DWBs/GWWBs mixtures in particular, often incorporate a higher percentage in the composite mixtures from about 60% up to 85% of dry wall waste than other mixtures and beneficially often incorporates substantially all of the wallboard facing paper as part of the composite mixture. That is, waste processing is simplified by comingling core and paper layers in the final product. DWBs/GWWBs mixtures utilize demolition and construction waste, replacing a high percentage of Portland cement with waste-derived binder.

The embodiments herein are directed to dry wall waste mixtures, formed under pressure into example embodiments referred to herein as dry wall waste blocks (DWBs) and/or gypsum wallboard waste blocks (GWWBs) and tile structures. DWBs/GWWBs mixtures in particular, often incorporate a higher percentage in the composite mixtures from about 60% up to 85% of dry wall waste than other mixtures and beneficially often incorporates substantially all of the wallboard facing paper as part of the composite mixture. That is, waste processing is simplified by comingling core and paper layers in the final product. DWBs/GWWBs mixtures utilize demolition and construction waste, replacing a high percentage of Portland cement with waste-derived binder.

Ceiling tiles and wallboards can be produced with vesicle dedusting agent. For example, a ceiling tile can comprise: a dried base mat that includes: (a) mineral wool; (b) binder; (c) a vesicle dedusting agent at about 0.01 to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles; (d) optionally cellulosic fiber; (e) optionally perlite; (f) optionally glass fiber; and (g) optionally calcium sulfate dihydrate. For example, a wallboard produced from a slurry comprising: (a) calcium sulfate hemihydrate at 70 to 95 wt %; (b) a vesicle dedusting agent at about 0.01 to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles; (c) optionally cellulose fibers at about 0.5 to about 3 wt %; (d) optionally at least one dispersant at about 0.01 to about 2 wt %; and (e) water at a ratio of water to dry components of about 1:6 to about 20:1.

Ceiling tiles and wallboards can be produced with vesicle dedusting agent. For example, a ceiling tile can comprise: a dried base mat that includes: (a) mineral wool; (b) binder; (c) a vesicle dedusting agent at about 0.01 to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles; (d) optionally cellulosic fiber; (e) optionally perlite; (f) optionally glass fiber; and (g) optionally calcium sulfate dihydrate. For example, a wallboard produced from a slurry comprising: (a) calcium sulfate hemihydrate at 70 to 95 wt %; (b) a vesicle dedusting agent at about 0.01 to about 10 wt %, wherein the vesicle dedusting agent comprises vesicles; (c) optionally cellulose fibers at about 0.5 to about 3 wt %; (d) optionally at least one dispersant at about 0.01 to about 2 wt %; and (e) water at a ratio of water to dry components of about 1:6 to about 20:1.