A system and method for introducing a slurry mixture for making gypsum board is disclosed. The system includes, for example, a mixer, a foam injector, and a canister for mixing and moving a slurry mixture of foam and gypsum slurry. Also included in the system is an apparatus having a funnel body constructed and arranged to further mix the slurry mixture. The funnel body includes a number of baffles projecting from its inner wall towards a center and that are spaced around the inner wall. The baffles induce turbulence into the slurry mixture as the slurry mixture moves towards its outlet, thus further mixing the mixture and reducing the flow rate of the slurry mixture before its exits from the outlet for forming the gypsum board.

Processes are disclosed for producing gypsum-based products from a gypsum slurry. Additives or combinations of additives for improving compressive strength, fluidity and/or set time of the gypsum product are mixed in intimate contact with raw gypsum prior to or during grinding and/or flash calcination to form stucco. The stucco is used to prepare a gypsum slurry which is shaped and sets to form the gypsum product.

The present invention provides structure protection sheets which can not only dramatically reduce a construction period to place protective layers on surfaces of structures such as concrete but also protect structures for a long time. The present invention relates to a structure protection sheet, including: a polymer cement layer on a side facing a structure; and a resin layer on the polymer cement layer, the structure protection sheet having a thickness distribution of not more than ±100 μm.

A system and method for introducing a slurry mixture for making gypsum board is disclosed. The system includes, for example, a mixer, a foam injector, and a canister for mixing and moving a slurry mixture of foam and gypsum slurry. Also included in the system is an apparatus having a funnel body constructed and arranged to further mix the slurry mixture. The funnel body includes a number of baffles projecting from its inner wall towards a center and that are spaced around the inner wall. The baffles induce turbulence into the slurry mixture as the slurry mixture moves towards its outlet, thus further mixing the mixture and reducing the flow rate of the slurry mixture before its exits from the outlet for depositing onto paper to form the gypsum board.

An example plasterboard includes a layer of hardened plaster material having a first surface and an opposed second surface and a layer of molded material having a surface that faces away from the layer of hardened plaster material. The surface of the layer of molded material has one or more raised features. The plasterboard also includes a liner between the first surface of the layer of hardened plaster material and the layer of molded material. Other examples include a method of forming such plasterboards and a method for installing such plasterboards.

Wall panels for building construction may include a corrugated sheet including a first series of peaks on a first side of the corrugated sheet configured for positioning to face a room interior. The corrugated sheet may also include a second series of peaks on a second, opposite side of the corrugated sheet configured for positioning to face a room exterior. A radiant barrier including a material reflective to heat may be secured only to the second series of peaks. The corrugated sheet may form pockets of air between the radiant barrier and the corrugated sheet.

A gypsum slurry mixer output canister is provided, including a canister housing having an upper end, an opposite lower end and defining a canister interior, a cover secured to the upper end, a slurry inlet in operational relationship to the upper end, a spiral block associated with the upper end, and having a helical flow surface depending into the interior. A flow distributor is secured to the lower end and is in fluid communication with the interior, and a slurry outlet is defined by the lower canister housing end.

Herein discussed is a method of sintering a ceramic comprising (a) providing an electromagnetic radiation (EMR) source; (b) (i) providing a layer of intermixed ceramic particles and absorber particles, wherein the absorber particles have a volume fraction in the intermixed particles in the range of no less than 3%; or (ii) providing a first layer comprising ceramic particles and a second layer comprising absorber particles in contact with at least a portion of the first layer, wherein the second layer is farther from the EMR source than the first layer; (c) heating (i) the layer of intermixed particles or (ii) the first layer using EMR; and (d) controlling the EMR such that at least a portion of the ceramic particles are sintered wherein (i) the layer of intermixed particles becomes impermeable or (ii) the first layer becomes impermeable, wherein the absorber particles have greater EMR absorption than the ceramic particles.

The present invention is directed to a gypsum board and a method of making such gypsum board. For instance, the gypsum board comprises a gypsum core, a first facing material, and a second facing material wherein the first facing material and the second facing material sandwich the gypsum core. The gypsum core comprises a first gypsum core section and a second gypsum core section each comprising gypsum, wherein the first gypsum core section comprises a polyol compound and has a density higher than a density of the second gypsum core section.

The present invention is directed to an improved gypsum board and a method of making such gypsum board. For instance, the method comprises: providing a first facing material, depositing a gypsum slurry comprising at least stucco and water on the first facing material, providing a second facing material on the gypsum slurry, and allowing the stucco to convert to calcium sulfate dihydrate, wherein the method further comprises a step of providing a dry starch layer including a dry starch at an interface between the first facing material and the gypsum slurry, the second facing material and the gypsum slurry, or both.