US4238546A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Lightweight gypsum products and methods of making same
Assignee: Ferjon
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Filing: 1979-07-30
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Granted: 1980-12-09
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Expires: 1999-07-30
Abstract
Abstract Disclosed is a method of making lightweight gypsum products wherein expanded substantially monocellular volcanic ash having a loose bulk density of about 0.05 to about 15 pounds per cubic foot is added to calcined gypsum and water to form a slurry. The hydrated gypsum product formed has a bulk density of about 24 to about 45 pounds per cubic foot.
Inventors
- 👤 Harold L. Phillips
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 21:49
CPC Classifications
E; E04; E04C; E04C2/00; E04C2/02; E04C2/04; E04C2/049; C; C04; C04B; C04B14/00; C04B14/02; C04B14/04; C04B14/14; C04B14/16; C04B28/00; C04B28/14; Y; Y10; Y10S; Y10S106/00; Y10S106/01; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249967; Y10T428/249968; Y10T428/249969; Y10T428/29; Y10T428/2982
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
53 words
A gypsum product including a body consisting essentially of hydrated calcium sulfate and expanded substantially monocellular volcanic ash particles in the form of hollow spherical bodies distributed throughout the hydrated calcium sulfate, said body having a bulk density of from about 24 pounds per cubic foot to about 45 pounds per cubic foot.
Claim 2
Dependent Claim
53 words
A gypsum product including a body consisting essentially of hydrated calcium sulfate and expanded substantially monocellular volcanic ash particles in the form of hollow spherical bodies distributed throughout the hydrated calcium sulfate, said body having a bulk density of from about 24 pounds per cubic foot to about 45 pounds per cubic foot.
Claim 3
Dependent Claim
36 words
A gypsum product as defined in claim 1 wherein the loose bulk density of said expanded substantially monocellular volcanic ash particles is between about 0.5 pounds per cubic foot and about 15 pounds per cubic foot.
Claim 4
Dependent Claim
31 words
A gypsum product as defined in claim 1 wherein said expanded substantially monocellular volcanic ash particles comprise from about five percent to about fifty percent of the volume of said body.
Claim 5
Dependent Claim
51 words
A wallboard comprising parallel sheets of paper bonded to opposite major faces of a monolithic core, wherein said core consists essentially of hydrated calcium sulfate and expanded substantially monocellular volcanic ash and has a bulk density of from about 24 pounds per cubic foot to about 45 pounds per cubic foot.
Claim 6
Dependent Claim
51 words
A wallboard comprising parallel sheets of paper bonded to opposite major faces of a monolithic core, wherein said core consists essentially of hydrated calcium sulfate and expanded substantially monocellular volcanic ash and has a bulk density of from about 24 pounds per cubic foot to about 45 pounds per cubic foot.
Claim 7
Dependent Claim
34 words
A wallboard as defined in claim 4 wherein the loose bulk density of said expanded substantially monocellular volcanic ash is between about 0.5 pounds per cubic foot and about 15 pounds per cubic foot.
Claim 8
Dependent Claim
29 words
A wallboard as defined in claim 4 wherein said expanded substantially monocellular volcanic ash comprises from about five percent to about fifty percent of the volume of said core.
Claim 9
Dependent Claim
72 words
In the process of forming wallboard wherein calcined calcium sulfate is mixed with water and additives and formed into a slurry which is then formed into a core between parallel sheets of paper and cured to form a monolithic core of hydrated calcium sulfate, the step of adding expanded substantially monocellular volcanic ash comprising substantially spherical enclosed hollow bodies having an internal gas pressure less than atmospheric to said calcined calcium sulfate.
Claim 10
Dependent Claim
72 words
In the process of forming wallboard wherein calcined calcium sulfate is mixed with water and additives and formed into a slurry which is then formed into a core between parallel sheets of paper and cured to form a monolithic core of hydrated calcium sulfate, the step of adding expanded substantially monocellular volcanic ash comprising substantially spherical enclosed hollow bodies having an internal gas pressure less than atmospheric to said calcined calcium sulfate.
Claim 11
Dependent Claim
33 words
The process defined in claim 7 wherein said expanded substantially monocellular volcanic ash is added in amounts sufficient to constitute from about five percent to about fifty percent by volume of said slurry.
Claim 12
Dependent Claim
41 words
The process defined in claim 7 wherein said expanded substantially monocellular volcanic ash has a loose bulk density of from about 0.5 pounds per cubic foot to about 15 pounds per cubic foot prior to mixing with said calcined calcium sulfate.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-12-09 | 1984-06-09 | 1984-12-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-12-09 | 1988-06-09 | 1988-12-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-12-09 | 1992-06-09 | 1992-12-09 | $7700.00 | Window Closed / Lapsed |