The present invention generally relates to cementitious material that is a precursor of a magnesium oxychloride cement (MOC) and comprises treated carbon fibers comprising a dispersing agent at least partially coating the carbon fibers and processes for the preparation thereof. The present invention is also related to cementitious material that is a precursor of a magnesium oxychloride cement (MOC) and comprises siliconate and processes for the preparation thereof. The present invention further relates to cementitious material (e.g., pourable, extrudable, moldable and formable cementitious material) and cementitious construction material (e.g., boards, structural laminates, etc.) formed from curing the cementitious material.

The present invention generally relates to cementitious material that is a precursor of a magnesium oxychloride cement (MOC) and comprises treated carbon fibers comprising a dispersing agent at least partially coating the carbon fibers and processes for the preparation thereof. The present invention is also related to cementitious material that is a precursor of a magnesium oxychloride cement (MOC) and comprises siliconate and processes for the preparation thereof. The present invention further relates to cementitious material (e.g., pourable, extrudable, moldable and formable cementitious material) and cementitious construction material (e.g., boards, structural laminates, etc.) formed from curing the cementitious material.

An ultra-stable structural laminate with fire resistance and a lateral nail pull strength from 44 to 300 pounds of force and an insulation R value from 1 to 40, the ultra-stable structural laminate of a cementious material with a nano-molecular veneer and a foam component catalytically reacted into an expanded closed cell foam having a thickness from ⅛.sup.th inch to 8 inches, a density from 1.5 pounds/cubic foot to 3 pounds/cubic foot that self-adheres to the cementitious material forming an ultra-stable structural laminate with fire resistance and a lateral nail pull strength from 44 pounds to 300 pounds of force, an insulation R value from 1 to 40, a resistance to seismic impact for earthquakes over 3.1 on the Richter Scale, a break point from 7 lbs/inch to 100 lbs/inch; and a resistance to wind shear equivalent to a 15 mph downburst.

An ultra-stable structural laminate with fire resistance and a lateral nail pull strength from 44 to 300 pounds of force and an insulation R value from 1 to 40, the ultra-stable structural laminate of a cementious material with a nano-molecular veneer and a foam component catalytically reacted into an expanded closed cell foam having a thickness from ⅛.sup.th inch to 8 inches, a density from 1.5 pounds/cubic foot to 3 pounds/cubic foot that self-adheres to the cementitious material forming an ultra-stable structural laminate with fire resistance and a lateral nail pull strength from 44 pounds to 300 pounds of force, an insulation R value from 1 to 40, a resistance to seismic impact for earthquakes over 3.1 on the Richter Scale, a break point from 7 lbs/inch to 100 lbs/inch; and a resistance to wind shear equivalent to a 15 mph downburst.

A wood or engineered wood structural panel, such as, but not limited to, OSB (“oriented strand board”) or plywood, that is both fire-resistant and water resistant. The panel is factory-coated with a product that provides fire resistance. The treatment gives it a Fire-Resistant (FR) performance (for use in a one- or two-hour rated assembly). The panel also is overlaid or coated in a factory setting with a weather/water resistive barrier (WRB). The structural panel thus combines a fire-resistant structural sheathing and WRB product in one integrated panel produced at a factory prior for installation at a job site.

Floor element comprising a top layer (102) attached to a substrate layer (104), in which the top layer (102) is itself layered, the top layer (102) comprising: —an optional backing layer (122) made of flexible polymer, —a flexible or semi-rigid polymer layer (124), onto or into which optionally at least one reinforcing layer (126) is attached or embedded, and —a finishing layer comprising a decorative layer (132), a wearing layer (134) thereon and optionally a coating (136) thereon; the substrate layer (104) being a rigid substrate layer.

This invention provides low dust low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set gypsum core formed between two substantially parallel cover sheets, the set gypsum core preferably having a total void volume from about 80% to about 92%, and made from a slurry including stucco, pregelatinized starch, and a naphthalenesulfonate dispersant. The combination of the pregelatinized starch and the naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small air bubble voids (and water voids) provides dust control during cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products. This invention also provides a method of making the low dust low density gypsum products including the introduction of soap foam in an amount sufficient to form a total void volume, including air voids, preferably from about 80% to about 92% in the set gypsum core, corresponding to a set gypsum core density from about 10 pcf to about 30 pcf. The wallboards produced by the method generate significantly less dust during working.

This invention provides low dust low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set gypsum core formed between two substantially parallel cover sheets, the set gypsum core preferably having a total void volume from about 80% to about 92%, and made from a slurry including stucco, pregelatinized starch, and a naphthalenesulfonate dispersant. The combination of the pregelatinized starch and the naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small air bubble voids (and water voids) provides dust control during cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products. This invention also provides a method of making the low dust low density gypsum products including the introduction of soap foam in an amount sufficient to form a total void volume, including air voids, preferably from about 80% to about 92% in the set gypsum core, corresponding to a set gypsum core density from about 10 pcf to about 30 pcf. The wallboards produced by the method generate significantly less dust during working.

Composite panels and methods of preparation are described herein. In some embodiments, the composite panel can include a first fiber reinforcement, a polyurethane composite having a first surface and a second surface opposite the first surface, wherein the first surface is in contact with the first fiber reinforcement; and a cementitious material adjacent the first fiber reinforcement opposite the polyurethane composite. The polyurethane composite can be formed from (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, (ii) one or more polyols, and (iii) a particulate filler. The fiber reinforcement can be formed from a woven or non-woven material, such as glass fibers. The composite panel can further include a material, such as a second fiber reinforcement and a cementitious layer, in contact with the second surface of the polyurethane composite. Articles comprising the composite panels are also disclosed.

Composite panels and methods of preparation are described herein. In some embodiments, the composite panel can include a first fiber reinforcement, a polyurethane composite having a first surface and a second surface opposite the first surface, wherein the first surface is in contact with the first fiber reinforcement; and a cementitious material adjacent the first fiber reinforcement opposite the polyurethane composite. The polyurethane composite can be formed from (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, (ii) one or more polyols, and (iii) a particulate filler. The fiber reinforcement can be formed from a woven or non-woven material, such as glass fibers. The composite panel can further include a material, such as a second fiber reinforcement and a cementitious layer, in contact with the second surface of the polyurethane composite. Articles comprising the composite panels are also disclosed.