Slurry and acoustical panel with reduced bound water

Stock material or miscellaneous articles – Composite – Of silicon containing

Reexamination Certificate

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C428S446000, C428S500000, C106S287100, C106S287230, C106S409000, C106S499000, C264S232000, C264S007000, C264S134000

Reexamination Certificate

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07875358

ABSTRACT:
A composition for a slurry for manufacture of a building panel includes one or more fillers, one or more binders and water. One or more fillers is an expanded perlite at least partially covered with a film-forming, thermoplastic polymer coating Some embodiments use calcined or uncalcined gypsum as a binder or filler. One embodiment is a building panel that includes a solid matrix of calcium sulfate dihydrate crystals bound to expanded perlite.A method of making the panel includes acquiring expanded perlite and coating it with film-forming, thermoplastic polymer coating. After the expanded perlite is prepared, it is combined with water other optional fillers and one or more binders to form a slurry. The slurry is shaped into a panel and allowed to dry.

REFERENCES:
patent: 2634208 (1953-04-01), Miscall et al.
patent: 3407138 (1968-10-01), Harper et al.
patent: 4212755 (1980-07-01), Ruff et al.
patent: 4302344 (1981-11-01), Ruff et al.
patent: 5964934 (1999-10-01), Englert
patent: 2004/0209071 (2004-10-01), Carbo et al.

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