US4094694A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Water-resistant gypsum composition and products, and process of making same
Assignee: United States Gypsum Co
•
Filing: 1977-05-16
•
Granted: 1978-06-13
•
Expires: 1997-05-16
Abstract
Abstract An improved water-resistant cementitious composition and products made therefrom are provided by forming an aqueous cementitious slurry, as for example of calcined gypsum and adding to the slurry a composition in the form an aqueous emulsion of asphalt and wax, a minor proportion of polyvinyl alcohol and a minor proportion of a borate compound, that is, one having an anion comprising boron and oxygen, as for example borax. The slurry is set in conventional manner by heating and drying. The resulting product has a high degree of water-resistance while utilizing less asphalt and wax composition than required with conventional asphalt-wax emulsions thereby accomplishing a large savings in raw material costs. Additionally, the use of a small amount of the borate compound permits a smaller amount of the relatively expensive polyvinyl alcohol to be used without a reduction in the water-resistance of the final product. Alternatively, an amount of asphalt and wax composition may be utilized equal to or greater than that conventionally used, but obtaining a much greater degree of water-resistance.
Inventors
- 👤 William J. Long
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 12:07
CPC Classifications
C; C04; C04B; C04B28/00; C04B28/14; C04B2111/00; C04B2111/20; C04B2111/27
Claims Analysis
Total Claims: 48
Claim 1
Independent Claim
115 words
A water-resistant cementitious composition consisting essentially of a set mass of hydrated gypsum crystals, and a waterproofing composition, said waterproofing composition comprising asphalt and wax originally added as an emulsion, a borate-containing compound and polyvinyl alcohol, the dry weight percent of the total of said asphalt and said wax based on the dry weight of said cementitious composition being at least about 1.6%, said polyvinyl alcohol being present in an amount of at least 0.015 weight percent based on the dry weight of said cementitious composition, and said borate-containing compound being present in an amount effective to cooperate with said polyvinyl alcohol and said asphalt and wax to enhance the water-resistance of said cementitious composition.
Claim 2
Dependent Claim
115 words
A water-resistant cementitious composition consisting essentially of a set mass of hydrated gypsum crystals, and a waterproofing composition, said waterproofing composition comprising asphalt and wax originally added as an emulsion, a borate-containing compound and polyvinyl alcohol, the dry weight percent of the total of said asphalt and said wax based on the dry weight of said cementitious composition being at least about 1.6%, said polyvinyl alcohol being present in an amount of at least 0.015 weight percent based on the dry weight of said cementitious composition, and said borate-containing compound being present in an amount effective to cooperate with said polyvinyl alcohol and said asphalt and wax to enhance the water-resistance of said cementitious composition.
Claim 3
Dependent Claim
23 words
A water-resistant composition according to claim 1, wherein said borate-containing compound is present in an amount of at least about 0.002 weight percent.
Claim 4
Dependent Claim
13 words
A water-resistant composition according to claim 2, wherein said borate-containing material is borax.
Claim 5
Dependent Claim
23 words
A water-resistant composition according to claim 2, wherein said polyvinyl alcohol is present in an amount of at least about 0.05 weight percent.
Claim 6
Dependent Claim
25 words
A water-resistant composition according to claim 2, wherein said polyvinyl alcohol is formed of polyvinyl acetate hydrolyzed to a degree of at least about 87%.
Claim 7
Dependent Claim
25 words
A water-resistant cementitious composition according to claim 2, wherein said polyvinyl alcohol is formed of polyvinyl acetate hydrolyzed to a degree greater than about 99%.
Claim 8
Dependent Claim
30 words
A water-resistant composition according to claim 2, wherein the proportion by weight of said asphalt to said wax is from about 1:1 to about 10:1 based on total dry solids.
Claim 9
Dependent Claim
23 words
A water-resistant composition according to claim 2, wherein the ratio of asphalt to wax is from about 4.8:1 to about 5.2:1 by weight.
Claim 10
Dependent Claim
32 words
A water-resistant composition according to claim 2, wherein the total amount of said waterproofing composition is no greater than about 15% by weight of said hydrated gypsum based on dry solids content.
Claim 11
Independent Claim
123 words
A method for producing a set water-resistant cementitious composition which comprises admixing with an aqueous slurry consisting essentially of calcined gypsum a waterproofing composition, and setting said slurry, said waterproofing composition comprising an emulsion of asphalt and wax, a borate-containing compound and polyvinyl alcohol, the dry weight percent of the total of said asphalt and said wax based on dry weight of said cementitious composition being at least about 1.6%, said polyvinyl alcohol being present in an amount of at least about 0.015 weight percent based on the dry weight of said cementitious composition, and said borate-containing compound being present in an amount effective to cooperate with said polyvinyl alcohol and said asphalt and wax to enhance the water-resistance of said cementitious composition.
Claim 12
Independent Claim
123 words
A method for producing a set water-resistant cementitious composition which comprises admixing with an aqueous slurry consisting essentially of calcined gypsum a waterproofing composition, and setting said slurry, said waterproofing composition comprising an emulsion of asphalt and wax, a borate-containing compound and polyvinyl alcohol, the dry weight percent of the total of said asphalt and said wax based on dry weight of said cementitious composition being at least about 1.6%, said polyvinyl alcohol being present in an amount of at least about 0.015 weight percent based on the dry weight of said cementitious composition, and said borate-containing compound being present in an amount effective to cooperate with said polyvinyl alcohol and said asphalt and wax to enhance the water-resistance of said cementitious composition.
Claim 13
Dependent Claim
22 words
A method according to claim 10, wherein said borate-containing compound is present in an amount of at least about 0.002 weight percent.
Claim 14
Dependent Claim
12 words
A method according to claim 11, wherein said borate-containing material is borax.
Claim 15
Dependent Claim
22 words
A method according to claim 11, wherein said polyvinyl alcohol is present in an amount of at least about 0.05 weight percent.
Claim 16
Dependent Claim
24 words
A method according to claim 11, wherein said polyvinyl alcohol is formed of polyvinyl acetate hydrolyzed to a degree of at least about 87%.
Claim 17
Dependent Claim
25 words
A water-resistant cementitious composition according to claim 11, wherein said polyvinyl alcohol is formed of polyvinyl acetate hydrolyzed to a degree greater than about 99%.
Claim 18
Dependent Claim
30 words
A water-resistant composition according to claim 11, wherein the proportion by weight of said asphalt to said wax is from about 1:1 to about 10:1 based on total dry solids.
Claim 19
Dependent Claim
23 words
A water-resistant composition according to claim 11, wherein the ratio of asphalt to wax is from about 4.8:1 to about 5.2:1 by weight.
Claim 20
Dependent Claim
32 words
A water-resistant composition according to claim 11, wherein the total amount of said waterproofing composition is no greater than about 15% by weight of said hydrated gypsum based on dry solids content.
Claim 21
Dependent Claim
121 words
A cementitious slurry for forming a water-resistant cementitious composition, said slurry consisting essentially of an aqueous mixture of calcined gypsum crystals, and a waterproofing composition, said waterproofing composition comprising an aqueous emulsion of asphalt and wax, a borate-containing compound and polyvinyl alcohol, the dry weight percent of the total of said asphalt and said wax based on dry weight of said cementitious composition being at least about 1.6%, said polyvinyl alcohol being present in an amount of at least about 0.015 weight percent based on the dry weight of said cementitious composition, and said borate-containing compound being present in an amount effective to cooperate with said polyvinyl alcohol and said asphalt and wax to enhance the water-resistance of said cementitious composition.
Claim 22
Dependent Claim
121 words
A cementitious slurry for forming a water-resistant cementitious composition, said slurry consisting essentially of an aqueous mixture of calcined gypsum crystals, and a waterproofing composition, said waterproofing composition comprising an aqueous emulsion of asphalt and wax, a borate-containing compound and polyvinyl alcohol, the dry weight percent of the total of said asphalt and said wax based on dry weight of said cementitious composition being at least about 1.6%, said polyvinyl alcohol being present in an amount of at least about 0.015 weight percent based on the dry weight of said cementitious composition, and said borate-containing compound being present in an amount effective to cooperate with said polyvinyl alcohol and said asphalt and wax to enhance the water-resistance of said cementitious composition.
Claim 23
Dependent Claim
30 words
A cementitious slurry according to claim 19, wherein said borate-containing compound is present in an amount of at least about 0.002 weight percent of the dried and set gypsum composition.
Claim 24
Dependent Claim
13 words
A cementitious slurry according to claim 20, wherein said borate-containing material is borax.
Claim 25
Dependent Claim
23 words
A cementitious slurry according to claim 20, wherein said polyvinyl alcohol is present in an amount of at least about 0.05 weight percent.
Claim 26
Dependent Claim
25 words
A cementitious slurry according to claim 20, wherein said polyvinyl alcohol is formed of polyvinyl acetate hydrolyzed to a degree of at least about 87%.
Claim 27
Dependent Claim
25 words
A cementitious slurry composition according to claim 20, wherein said polyvinyl alcohol is formed of polyvinyl acetate hydrolyzed to a degree greater than about 99%.
Claim 28
Dependent Claim
30 words
A cementitious slurry according to claim 20, wherein the proportion by weight of said asphalt to said wax is from about 1:1 to about 10:1 based on total dry solids.
Claim 29
Dependent Claim
23 words
A cementitious slurry according to claim 20 wherein the ratio of asphalt to wax is from about 4.8:1 to about 5.2:1 by weight.
Claim 30
Dependent Claim
32 words
A cementitious slurry according to claim 20, wherein the total amount of said waterproofing composition is no greater than about 15% by weight of said hydrated gypsum based on dry solids content.
Claim 31
Independent Claim
129 words
A method for forming a cementitious slurry for setting to form a water-resistant cementitious composition, consisting essentially of forming a mixture of calcined gypsum crystals, and adding a waterproofing composition to said slurry, said waterproofing composition comprising an emulsion of asphalt and wax, a borate-containing compound and polyvinyl alcohol, the dry weight percent of the total of said asphalt and said wax being at least about 1.6% based on the dry weight of said cementitious composition, said polyvinyl alcohol being present in an amount of at least about 0.015 weight percent based on the dry weight of said cementitious composition, and said borate-containing compound being present in an amount effective to cooperate with said polyvinyl alcohol and said asphalt and wax to enhance the water-resistance of said cementitious composition.
Claim 32
Independent Claim
129 words
A method for forming a cementitious slurry for setting to form a water-resistant cementitious composition, consisting essentially of forming a mixture of calcined gypsum crystals, and adding a waterproofing composition to said slurry, said waterproofing composition comprising an emulsion of asphalt and wax, a borate-containing compound and polyvinyl alcohol, the dry weight percent of the total of said asphalt and said wax being at least about 1.6% based on the dry weight of said cementitious composition, said polyvinyl alcohol being present in an amount of at least about 0.015 weight percent based on the dry weight of said cementitious composition, and said borate-containing compound being present in an amount effective to cooperate with said polyvinyl alcohol and said asphalt and wax to enhance the water-resistance of said cementitious composition.
Claim 33
Dependent Claim
28 words
A method according to claim 28, wherein said borate-containing compound is present in an amount of at least about 0.002 weight percent of the dry set gypsum composition.
Claim 34
Dependent Claim
12 words
A method according to claim 29, wherein said borate-containing material is borax.
Claim 35
Dependent Claim
22 words
A method according to claim 29, wherein said polyvinyl alcohol is present in an amount of at least about 0.05 weight percent.
Claim 36
Dependent Claim
27 words
A method according to claim 29, wherein said polyvinyl alcohol is formed of polyvinyl acetate hydrolyzed to a degree of from 97% to greater than about 99%.
Claim 37
Dependent Claim
24 words
A method composition according to claim 29, wherein said polyvinyl alcohol is formed of polyvinyl acetate hydrolyzed to a degree greater than about 99%.
Claim 38
Dependent Claim
29 words
A method according to claim 29, wherein the proportion by weight of said asphalt to said wax is from about 2:1 to about 10:1 based on total dry solids.
Claim 39
Dependent Claim
22 words
A method according to claim 29, wherein the ratio of asphalt to wax is from about 4.8:1 to about 5.2:11 by weight.
Claim 40
Dependent Claim
31 words
A method according to claim 29, wherein the total amount of said waterproofing composition is no greater than about 15% by weight of said hydrated gypsum based on dry solids content.
Claim 41
Dependent Claim
43 words
A method according to claim 11, wherein said asphalt and wax are first formed into an aqueous emulsion together with said borate-containing compound and said emulsion is then added to said slurry, and wherein said polyvinyl alcohol is separately added to said slurry.
Claim 42
Dependent Claim
10 words
A water-resistant composition according to claim 2, comprising gypsum wallboard.
Claim 43
Dependent Claim
14 words
A cementitious slurry according to claim 20, which is suitable for forming gypsum wallboard.
Claim 44
Dependent Claim
43 words
A method according to claim 29, wherein said asphalt and wax are first formed into an aqueous emulsion together with said borate-containing compound and said emulsion is then added to said slurry, and wherein said polyvinyl alcohol is separately added to said slurry.
Claim 45
Dependent Claim
64 words
A water resistant cementitious composition, as in claim 1, wherein said polyvinyl alcohol is present in an amount of from at least about 0.015 to about 0.13 weight percent, based on the dry weight of said cementitious composition, and said borate containing compound is present in an amount of at least about 0.002 weight percent based on te dry weight of said cementitious composition.
Claim 46
Dependent Claim
61 words
A method as in claim 11, wherein said polyvinyl alcohol is present in an amount of from at least about 0.015 to about 0.13 weight percent, based on the dry weight of said cementitious composition, and said borate containing compound is present in an amount of at least about 0.002 weight percent based on the dry weight of said cementitious composition.
Claim 47
Dependent Claim
61 words
A cementitious slurry, as in claim 19, wherein said polyvinyl alcohol is present in an amount of from at about 0.015 to about 0.13 weight percent, based on the dry weight of said cementitious composition, and said borate containing compound is present in an amount of at least about 0.002 weight percent based on the dry weight of said cementitious composition.
Claim 48
Dependent Claim
61 words
A method, as in claim 28, wherein said polyvinyl alcohol is present in an amount of from at least about 0.015 to about 0.13 weight percent, based on the dry weight of said cementitious composition, and said borate containing compound is present in an amount of at least about 0.002 weight percent based on the dry weight of said cementitious composition.
References Cited (Backward Citations)
US1658605A
Cited
US2198776A
Cited
US3520708A
Cited
US3645763A
Cited
US3753748A
Cited
US3867161A
Cited
US3935021A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-06-12 | 1981-12-12 | 1982-06-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-06-12 | 1985-12-12 | 1986-06-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-06-12 | 1989-12-12 | 1990-06-13 | $7700.00 | Window Closed / Lapsed |