Method for forming a lightweight cementitious structural product

Details Method for forming a lightweight cementitious structural product Method for forming a lightweight cementitious structural product

1986-11-20

1988-06-21

Swisher, Nancy A. B.

Stock material or miscellaneous articles

Composite

Of inorganic material

106 90, 106 97, 4273761, 428407, 4285377, B32B 1302, C04B 3102, C04B 3144

Patent

active

047525380

ABSTRACT:
A method for producing a lightweight set cementitious product having excellent strength by forming a aqueous cementitious slurry, incorporating therein expandable polystyrene beads which are less than completely expanded, and heating the slurry to drive off excess water, to cause a cementitious mixture to set, and to further and completely expand the polystyrene beads. In a preferred embodiment and aqueous slurry of calcium sulfate hemihydrate is produced including expandable polystyrene beads in a state which they are partially but not fully pre-expanded. The slurry is deposited between two paper cover sheets, and the product is heated to drive off excess water, to set the gypsum to the solid dihydrate state, and to complete the expansion of the polystyrene beads until they reach their fully expanded state, thereby resulting in a strong lightweight gypsum wallboard which has excellent adhesion between the expanded polystyrene beads and the set gypsum.

REFERENCES:
patent: 2017022 (1935-10-01), Roos
patent: 2080009 (1937-05-01), Roos
patent: 2985219 (1961-05-01), Summerfield
patent: 3021291 (1962-02-01), Thiessen
patent: 4011355 (1977-03-01), Mandish et al.
patent: 4238242 (1980-12-01), Park
patent: 4265964 (1981-05-01), Burkhart
patent: 4331734 (1982-05-01), Stegmeier

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