In general, the present invention is directed to the use of particular phosphorus containing compounds for making a gypsum board. The phosphorus containing compound may be a phosphite or a phosphate having a certain formula. In this regard, the present invention is directed to a slurry for making a gypsum board wherein the slurry includes such phosphorus containing compound. The present invention is also directed to a method of making a gypsum board from the slurry as well as a resulting gypsum board.

The product is produced from a settable aqueous calcium sulphate dispersion which has a water to solids ratio of less than 0.4 to 1, and has distributed therethrough lightweight hollow bodies having water-impervious surfaces (such as expanded polystyrene beads). The dispersion contains a hydratable cement (such as calcium sulpho aluminate) which is capable of hydration in the presence of the calcium sulphate dispersion. The hydratable cement is such that it reacts with excess water in the dispersion thereby enhancing the water resistance of the resulting product.

A binder composition for use in the manufacture of a nonwoven mat including a low-density fiber, and nonwoven mats made with the binder, are disclosed. The low-density fiber is able to reduce the acoustic openness of the nonwoven mats made therefrom while also capable of being delivered with existing binder technology and equipment.

The present disclosure relates generally to plaster wall panels, for example, suitable for covering interior wall frames. The present disclosure relates more particularly to a plaster wall panel including a first plaster layer, a second plaster layer, and a damping layer disposed between the first and second plaster layers. The first plaster layer has a first thickness and is composed of a first plaster material that has a first material property. The second plaster layer has a second thickness and is composed of a second plaster material that has a second material property. The first thickness is smaller than the second thickness, and the first and second material properties are different.

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.

Gypsum panels and methods for their manufacture are provided herein. The gypsum panels include a gypsum core having a first surface and a second opposed surface and a first fiberglass mat associated with the first surface of the gypsum core, such that gypsum from the gypsum core penetrates at least a portion of the first fiberglass mat.

Plastisol compositions are provided, in which the plastisol compositions include a bio-based plasticizer comprising one or more epoxy groups and a polymeric resin dispersed throughout the bio-based plasticizer. The plastisol composition comprises a flowable material that can be coated onto substrates. Coated fibers including an inorganic fiber indirectly or directly at least partially coated with a plastisol composition comprising a bio-based plasticizer and a polymeric resin dispersed throughout the solidified bio-based plasticizer are also provided. Cementitious boards reinforced with inorganic fibers, such as mesh scrims, that include a solidified bio-based plasticizer coating applied thereto are also provided.

Gypsum panels and methods of making the same are provided. A method of making a gypsum panel includes forming a first gypsum slurry by combining stucco, water, a siliconate, and a phosphate salt or polymer, and setting the first gypsum slurry to form at least part of a core of the gypsum panel, wherein the gypsum panel displays a 2-hour water absorption test weight increase of at least 10 weight percent less than an otherwise identical comparative panel containing no phosphate salt or polymer in its core.

The present invention is directed to a gypsum panel and a method of making such gypsum panel. For instance, in one embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and an alkoxylated compound. In another embodiment, the gypsum panel comprises a gypsum core and a first facing material and a second facing material sandwiching the gypsum core, wherein the gypsum core includes gypsum and a polyol compound and wherein the gypsum panel exhibits a humidified deflection of greater than 0 inches to 0.05 inches. The methods of the present invention are directed to making the aforementioned gypsum panels by providing the first facing material, providing a gypsum slurry comprising gypsum, water, and the respective compound onto the first facing material, and providing the second facing material on the gypsum slurry.

Beads of materials such as activated alumina, zeolite and silica gel, are used as chloride salt absorbers. The beads are mixed with high-salt gypsum. After mixing for a short time, the mixtures are dried, and the beads and the powder are separated by using a sieve or other physical separation device resulting in a low-salt gypsum which can be used as a gypsum source to make gypsum wallboard.