US4557973A
Expired / Lapsed
US
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Fire resistant gypsum board containing mineral wool fibers and method
Assignee: GYSUM Co
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Filing: 1983-12-28
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Granted: 1985-12-10
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Expires: 2003-12-28
Abstract
Abstract Blown mineral wool fibers are introduced into slurries (such as gypsum board core formulations and steel column fireproofing plaster formulations) by first blending and coating the blown mineral wool with a powdered calcium sulfate to produce a light, open nodulated effect. When mixed into aqueous calcined gypsum slurries, the nodules open up, thoroughly dispersing the mineral wool--calcium sulfate blend in the aqueous slurry and contributing fire resistant properties to the set gypsum product.
Inventors
- 👤 Mohammad H. Ali
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 05:24
CPC Classifications
C; C04; C04B; C04B20/00; C04B20/10; C04B20/1018; C04B20/1055; C04B24/00; C04B24/12; C04B28/00; C04B28/14; C04B28/16; C04B2111/00; C04B2111/00474; C04B2111/00612; C04B2111/0062; C04B2111/20; C04B2111/28; Y; Y10; Y10T; Y10T428/00; Y10T428/29; Y10T428/2982; Y10T428/2991; Y10T428/2993; Y10T428/2996
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
48 words
A gypsum composition suitable for forming the core of a gypsum board which will provide at least a one hour fire resistance rating by laboratory fire test, which comprises: the set solids from a calcined gypsum slurry having distributed therethrough about 1-5% by weight of mineral wool fibers.
Claim 2
Dependent Claim
48 words
A gypsum composition suitable for forming the core of a gypsum board which will provide at least a one hour fire resistance rating by laboratory fire test, which comprises: the set solids from a calcined gypsum slurry having distributed therethrough about 1-5% by weight of mineral wool fibers.
Claim 3
Dependent Claim
18 words
The gypsum composition of claim 1 in which the mineral wool fibers are coated with calcium sulfate solids.
Claim 4
Dependent Claim
25 words
The gypsum composition of claim 1 which includes about 1-10 parts by weight of calcium sulfate solids per each part by weight of wool fibers.
Claim 5
Dependent Claim
37 words
The gypsum composition of claim 1 in which the composition includes about 1-5% by weight of mineral wool fibers and 1-10 parts by weight of calcium sulfate anhydrite II per each part by weight of wool fibers.
Claim 6
Dependent Claim
15 words
The gypsum composition of claim 1 in which the set solids include textile glass fiber.
Claim 7
Dependent Claim
43 words
A plaster blend composition suitable for forming fire resistant gypsum compositions, which comprises calcined gypsum plaster and about 1-10% mineral wool fibers distributed therethrough resultant from blending about 1-10 parts by weight of calcium sulfate per each part by weight of wool fibers.
Claim 8
Dependent Claim
43 words
A plaster blend composition suitable for forming fire resistant gypsum compositions, which comprises calcined gypsum plaster and about 1-10% mineral wool fibers distributed therethrough resultant from blending about 1-10 parts by weight of calcium sulfate per each part by weight of wool fibers.
Claim 9
Dependent Claim
16 words
The plaster blend composition of claim 6 in which the calcium sulfate is calcium sulfate hemihydrate.
Claim 10
Dependent Claim
17 words
The plaster blend composition of claim 6 in which the calcium sulfate is calcium sulfate anhydrite II.
Claim 11
Dependent Claim
17 words
The plaster blend composition of claim 6 in which the calcium sulfate is calcium sulfate soluble anhydrite.
Claim 12
Independent Claim
117 words
A method of forming a fiber reinforced and fire resistant gypsum board wherein a quantity of a mineral fiber is added to a calcined gypsum slurry, the improvement comprising: tumbling together wool fiber and about 1-10 parts by weight of calcium sulfate per each part by weight of wool to form a blend of wool and calcium sulfate feeding the blend to a gypsum board slurry mixer and mixing about 1-5% by weight of wool with water and calcined gypsum to form a slurry; and feeding the slurry to a gypsum board forming line and forming a gypsum board having a core of casty gypsum containing about 1-5% by weight of wool fiber dispersed throughout the core.
Claim 13
Independent Claim
117 words
A method of forming a fiber reinforced and fire resistant gypsum board wherein a quantity of a mineral fiber is added to a calcined gypsum slurry, the improvement comprising: tumbling together wool fiber and about 1-10 parts by weight of calcium sulfate per each part by weight of wool to form a blend of wool and calcium sulfate feeding the blend to a gypsum board slurry mixer and mixing about 1-5% by weight of wool with water and calcined gypsum to form a slurry; and feeding the slurry to a gypsum board forming line and forming a gypsum board having a core of casty gypsum containing about 1-5% by weight of wool fiber dispersed throughout the core.
Claim 14
Dependent Claim
19 words
The method of claim 10 in which the wool is tumbled to form a blend with calcined calcium sulfate.
Claim 15
Dependent Claim
31 words
The method of claim 10 in which a portion of the calcined gypsum feed to the slurry mixer is diverted, tumbled with the wool, and then fed to the slurry mixer.
Claim 16
Dependent Claim
20 words
The method of claim 10 in which the wool is tumbled to form a blend with calcium sulfate anhydrite II.
Claim 17
Dependent Claim
22 words
The method of claim 10 in which the wool is coated with a quarternary ammonium compound before blending it with calcium sulfate.
Claim 18
Dependent Claim
31 words
The method of claim 10 in which about 2% by weight blown mineral wool is tumbled and blended with about 7% calcium sulfate anhydrite II, and fed to the slurry mixer.
Claim 19
Dependent Claim
26 words
An article for use in manufacture consisting essentially of an intimate, intersticial mixture of nodules of blown mineral wool fibers coated with powdered calcium sulfate solids.
Claim 20
Dependent Claim
26 words
An article for use in manufacture consisting essentially of an intimate, intersticial mixture of nodules of blown mineral wool fibers coated with powdered calcium sulfate solids.
Claim 21
Dependent Claim
32 words
The article of claim 16 wherein the weight ratio of calcium sulfate to wool fibers is about 1-10 parts by weight of calcium sulfate to each part by weight of wool fibers.
Claim 22
Dependent Claim
12 words
The article of claim 16 in which said calcium sulfate is anhydrite.
Claim 23
Dependent Claim
12 words
The article of claim 16 in which said calcium sulfate is hemihydrate.
Claim 24
Dependent Claim
12 words
The article of claim 16 in which said calcium sulfate is dihydrate.
Claim 25
Dependent Claim
16 words
The article of claim 16 in which said wool fibers are coated with a softening agent.
Claim 26
Dependent Claim
18 words
The article of claim 16 in which said wool fibers are coated with a quaternary ammonium softening agent.
Claim 27
Dependent Claim
19 words
The article of claim 16 in which said wool fibers are coated with a diamidoamine quaternary ammonium softening agent.
Claim 28
Dependent Claim
39 words
A process of manufacturing an intimate, intersticial mixture of nodules of blown mineral wool fibers and calcium sulfate comprising a tumbling blending of blown mineral wool with calcium sulfate sufficient to coat the wool fibers with powdered calcium sulfate.
Claim 29
Dependent Claim
39 words
A process of manufacturing an intimate, intersticial mixture of nodules of blown mineral wool fibers and calcium sulfate comprising a tumbling blending of blown mineral wool with calcium sulfate sufficient to coat the wool fibers with powdered calcium sulfate.
Claim 30
Dependent Claim
29 words
The process of claim 23 in which the wool fibers are blended with about 1-10 parts by weight of calcium sulfate for each part by weight of wool fibers.
Claim 31
Dependent Claim
16 words
The process of claim 23 in which the wool fibers are coated with a softening agent.
Claim 32
Dependent Claim
19 words
The process of claim 23 in which the wool fibers are coated with a diamidoamine quaternary ammonium softening agent.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-12-09 | 1989-06-10 | 1989-12-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-12-09 | 1993-06-10 | 1993-12-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-12-09 | 1997-06-10 | 1997-12-10 | $7700.00 | Window Closed / Lapsed |