A manufacturing method of a ceramic formed body, including: a mixing step in which a raw material for forming a ceramic formed body is dryly mixed, and then, a liquid is added to the obtained dry mixture to wetly mix the mixture; a kneading step in which a mixture obtained in the mixing step is kneaded; an injection step in which supercritical carbon dioxide in the state of supercritical fluid is injected into a kneaded product obtained in the kneading step; and a forming step in which a forming raw material containing the supercritical carbon dioxide obtained in the kneading step and the injection step is extruded to form the ceramic formed body.

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.

The invention concerns a method for producing gypsum boards, wherein a liquefier for the gypsum slurry is foamed with gas to provide a foam having a water content of less than 85 wt.-%, then incorporated into a gypsum/water mixture and the mixture thus obtained is applied on a two dimensional substrate. The incorporation of the liquefier in foamed form allows for a significant reduction of the amount of liquefier required to provide a desired flowability of the gypsum/water mixture, thus allowing the production of gypsum boards with similar characteristics with less liquefier. The invention further concerns gypsum board prepared using this process, apparatuses for producing gypsum boards using this process and the use of a corresponding liquefier foam to minimize the amount of liquefier required to establish a desired flowability of a gypsum/water mixture.

The invention concerns a method for producing gypsum boards, wherein a liquefier for the gypsum slurry is foamed with gas to provide a foam having a water content of less than 85 wt.-%, then incorporated into a gypsum/water mixture and the mixture thus obtained is applied on a two dimensional substrate. The incorporation of the liquefier in foamed form allows for a significant reduction of the amount of liquefier required to provide a desired flowability of the gypsum/water mixture, thus allowing the production of gypsum boards with similar characteristics with less liquefier. The invention further concerns gypsum board prepared using this process, apparatuses for producing gypsum boards using this process and the use of a corresponding liquefier foam to minimize the amount of liquefier required to establish a desired flowability of a gypsum/water mixture.

Disclosed is a composite gypsum board comprising a set gypsum core disposed between face (e.g., Manila) and back (e.g., Newsline) cover sheets. The set gypsum core is formed from a core slurry comprising stucco, water, and optional additives, such as foaming agent, migrating starch, accelerator, retarder, dispersant, etc. A dense layer formed from a dense layer slurry comprising stucco, water, fiber (e.g., paper fiber), and optionally, strength-enhancing starch, is disposed between the core and the face paper. The dense layer slurry contains a greater concentration of fiber, and optionally, strength-enhancing starch, than the core slurry, but the concentration of one or more other additives (e.g., accelerator, retarder, dispersant, or combinations thereof) is lower or the same in the dense slurry as compared with the core slurry. Also disclosed is a method of making board using one board mixer. In embodiments, paper fiber is added to water to form a suspension. The suspension is introduced, while in a non-laminar state, into the dense slurry. Further disclosed is apparatus, such as an extractor and an additive injection system, which can be a part of a cementitious slurry mixing and dispensing assembly.

Disclosed is a composite gypsum board comprising a set gypsum core disposed between face (e.g., Manila) and back (e.g., Newsline) cover sheets. The set gypsum core is formed from a core slurry comprising stucco, water, and optional additives, such as foaming agent, migrating starch, accelerator, retarder, dispersant, etc. A dense layer formed from a dense layer slurry comprising stucco, water, fiber (e.g., paper fiber), and optionally, strength-enhancing starch, is disposed between the core and the face paper. The dense layer slurry contains a greater concentration of fiber, and optionally, strength-enhancing starch, than the core slurry, but the concentration of one or more other additives (e.g., accelerator, retarder, dispersant, or combinations thereof) is lower or the same in the dense slurry as compared with the core slurry. Also disclosed is a method of making board using one board mixer. In embodiments, paper fiber is added to water to form a suspension. The suspension is introduced, while in a non-laminar state, into the dense slurry. Further disclosed is apparatus, such as an extractor and an additive injection system, which can be a part of a cementitious slurry mixing and dispensing assembly.

A building construction product with an electroconductive surface, the building construction product comprising a core with one or more surfaces covered by an electroconductive paper comprising carbon fibers, the electroconductive paper being attached to the one or more surfaces of the core. Methods and materials for producing the building construction products with an electroconductive surface and products and methods for shielding an area from electromagnetic waves.

A building construction product with an electroconductive surface, the building construction product comprising a core with one or more surfaces covered by an electroconductive paper comprising carbon fibers, the electroconductive paper being attached to the one or more surfaces of the core. Methods and materials for producing the building construction products with an electroconductive surface and products and methods for shielding an area from electromagnetic waves.

The present invention relates to calcium-containing, porous, mineral materials having a sulfate content of not more than 1.5% by weight and a biopolymer content in the range of 0.001 to 5.00% by weight, each relative to the total weight of the materials, a method for producing these materials with the aid of biopolymers as stabilizers and the use of biopolymers for producing sulfate-poor calcium-containing, porous, mineral materials.