333 results about "Stucco" patented technology

An improved moisture management system for installation over doors and windows in buildings that included exterior, stucco-covered, curtain walls comprising an integrally formed, three sided, elongated track including a base, an upright front wall that includes at its base weep holes for the removal of entrained moisture as well as a longitudinal forward extending finish stop above the weep holes, and an upright rear wall at opposing elongated edges of the base, and, extending angularly downward from the outside of the base, and integrally formed therewith, a drip plate that permits ready drainage of water exiting the moisture management system through the weep holes in the upright front wall. Preferably, elongated striations in the front faces of both the front and rear upright walls as well as holes in the upright front wall above the finish stop provide improved adherence of sealants and adhesives used in the installation process.

This invention provides low dust low density gypsum wallboard products having high total core void volumes, corresponding to low densities in the range of about 10 to 30 pcf. The wallboards have a set gypsum core formed between two substantially parallel cover sheets, the set gypsum core preferably having a total void volume from about 80% to about 92%, and made from a slurry including stucco, pregelatinized starch, and a naphthalenesulfonate dispersant. The combination of the pregelatinized starch and the naphthalenesulfonate dispersant also provides a glue-like effect in binding the set gypsum crystals together. The wallboard formulation, along with small air bubble voids (and water voids) provides dust control during cutting, sawing, routing, snapping, nailing or screwing down, or drilling of the gypsum-containing products. This invention also provides a method of making the low dust low density gypsum products including the introduction of soap foam in an amount sufficient to form a total void volume, including air voids, preferably from about 80% to about 92% in the set gypsum core, corresponding to a set gypsum core density from about 10 pcf to about 30 pcf. The wallboards produced by the method generate significantly less dust during working.

A moisture management system for installation over doors and windows in buildings that included exterior, stucco-covered, curtain walls comprising an integrally formed, three sided, elongated track including a base having weep holes therein, an upright front wall and an upright rear wall at opposing elongated edges of the base, and, extending angularly downward from the outside of the base, and integrally formed therewith, a drip plate that permits ready drainage of water entering the moisture management system through the weep holes in the base. Elongated striations in the front faces of both the front and rear upright walls as well as holes in the front upright wall provide adherence of sealants and adhesives used in the installation process.

Polymerization of siloxane is improved using a gypsum-based slurry that includes stucco, Class C fly ash, magnesium oxide and an emulsion of siloxane and water. This slurry is used in a method of making water-resistant gypsum articles that includes making an emulsion of siloxane and water, then combining the slurry with a dry mixture of stucco, magnesium oxide and Class C fly ash. The slurry is then shaped as desired and the stucco is allowed to set and the siloxane polymerizes. The resulting product is useful for making a water-resistant gypsum panel having a core that includes interwoven matrices of calcium sulfate dihydrate crystals and a silicone resin, where the interwoven matrices have dispersed throughout them a catalyst comprising magnesium oxide and components from a Class C fly ash.

Simulated stone, masonry, and brick textured products such as siding having a foam backing or with the hollow parts injected with foam or molded with foam in one or more steps, obtained when specially selected materials are properly admixed and formed via molding techniques. The foam backing is applied to the product in either a one or two step process. The foam backing may be used on panels, wall structures, and other products that may have contoured and textured surfaces and may simulate the appearance of conventional building and construction materials including, but not limited to, stone, brick, masonry, concrete, stucco, wood, other conventional building materials, and combinations of any of these materials are disclosed. The foam backing provides improves thermal insulation, improved sound reduction, improved rigidity, and improved dimensional stability. The disclosed invention is not limited to products in the building or construction industries and may be applied in the manufacture of a wide variety of products in other industries.

The invention generally provides a light weight composite gypsum board including a foamed low density set gypsum core, a top non-foamed (or reduced-foamed) bonding high density layer and a bottom non-foamed (or reduced-foamed) bonding high density layer, a top cover sheet bonded to the foamed low density set gypsum core by the top non-foamed (or reduced-foamed) bonding high density layer, and a bottom cover sheet bonded to the foamed low density set gypsum core by the bottom non-foamed (or reduced-foamed) bonding high density layer. The foamed low density set gypsum core and the non-foamed (or reduced-foamed) bonding high density layers are made from a gypsum slurry including stucco, pregelatinized starch present in an amount of about 0.5-10% by weight based on the weight of stucco, preferably a naphthalenesulfonate disperant present in an amount of about 0.1-3.0% by weight based on the weight of stucco, and preferably sodium trimetaphosphate present in an amount of about 0.12-0.4% by weight based on the weight of stucco. Other slurry additives can include accelerators, binders, paper fiber, glass fiber, and other known ingredients. The foamed low density set gypsum core is prepared having a density of less than about 30 pcf using soap foam in the gypsum-containing slurry. The combination of components provide a composite gypsum board having light weight and high strength. A method of making the composite gypsum board is also provided.

A panel is provided that includes stucco, water and a dispersant component having dispersing properties and comprising a comb-branched polymer with polyether side chains, naphthalene sulfonate-formaldehyde condensate or melamine sulfonate-formaldehyde condensate. A polycondensation component is also included in the slurry that includes three repeating units. A method of making the gypsum panel includes combining stucco, water and a first dosage of a first dispersant to form a slurry, the first. A second dosage of a second dispersant is added to the slurry. Properties of the gypsum slurry are tested and it is formed into a product. The product sets and properties of the product are identified. The first dosage or the second dosage is changed based on the properties of the slurry or product.

The invention generally provides gypsum-containing slurries including stucco, a hydroxyethylated starch, naphthalenesulfonate dispersant, and sodium trimetaphosphate. The naphthalenesulfonate dispersant is present in an amount of about 0.1%-3.0% by weight based on the weight of dry stucco. The hydroxyethylated starch is present in an amount of from about 0.5% by weight to about 10% by weight based on the weight of dry stucco in the formulation. The sodium trimetaphosphate is present in an amount of about 0.1%-0.4% by weight based on the weight of dry stucco. Other slurry additives can include accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, lightweight gypsum wallboard, and a method of making lightweight gypsum wallboard.

The invention generally provides gypsum-containing slurries including stucco, naphthalenesulfonate dispersant, and pregelatinized starch. The naphthalenesulfonate dispersant is present in an amount of about 0.1%-3.0% by weight based on the weight of dry stucco. The pregelatinized starch is present in an amount of at least about 0.5% by weight up to about 10% by weight of pregelatinized starch by weight based on the weight of dry stucco in the formulation. Other slurry additives can include trimetaphosphate salts, accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, gypsum wallboard, and a method of making gypsum wallboard.

The invention generally provides gypsum-containing slurries including stucco, naphthalenesulfonate dispersant, and pregelatinized starch. The naphthalenesulfonate dispersant is present in an amount of about 0.1%-3.0% by weight based on the weight of dry stucco. The pregelatinized starch is present in an amount of at least about 0.5% by weight up to about 10% by weight of pregelatinized starch by weight based on the weight of dry stucco in the formulation. Other slurry additives can include trimetaphosphate salts, accelerators, binders, paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, gypsum wallboard, and a method of making gypsum wallboard.

A cementitious product for applications such as stucco, plaster coating, fireproof coatings, casting / molding applications and flooring. The product is a blend of magnesium oxide and magnesium chloride. Suitable fillers such as bottom ash, fly ash, clinker and other pulverized materials may be added. Fibrous materials, foaming agents and surfactants may also be added to achieve product characteristics for specific application. Processes for blending the selected ingredients are also disclosed.

Effective use of dispersants in wallboard containing foam results from a method where stucco is mixed with a first dispersant and a first quantity of water to form a gypsum slurry. A soap is blended with a second dispersant and a second quantity of water to make a foam. Subsequently, the foam is combined with the slurry. Choice of different first and second dispersants and their relative amounts allows control of the size distribution of the foam bubbles in the slurry and the resulting voids in the gypsum core. Use of the same dispersant in both the mixer and the foam water provides a boost in efficacy of the dispersant.

A gypsum composition comprising water, stucco, clay, an amine compound, a polyoxyalkylene, and a comb-branched copolymer is disclosed. The gypsum composition has improved fluidity. A method for preparing the gypsum composition is also disclosed. The method comprises mixing the components to form a slurry, casting the slurry into a product, and drying the product.

A system for sealing the gaps that occur along the perimeter of a building envelope, particularly along with installation of an exterior finish system channel, or screed, as occurs in the installation and application of stucco. It is common to have gaps occur between the channel, base plate, and foundation of the building envelope. The system utilizes a foam sealing element in combination with the channel, caulking, a fiberglass netting that is installed along the bottom of the channel and the face of the foundation, and, an adhesive sealant that seals and adheres the fiberglass netting to the foundation. The system includes several embodiments for use in either new construction or as an aftermarket product.

The invention generally provides gypsum-containing slurries including stucco, trimetaphosphate salt, and naphthalenesulfonate dispersant, wherein the trimetaphosphate salt is present in an amount of at least about 0.12% by weight based on the weight of stucco. Other slurry additives can include accelerators, binders, starch, and paper fiber, glass fiber, and other known ingredients. The invention also comprises the gypsum-containing products made with such slurries, for example, gypsum wallboard, and a method of making gypsum wallboard.

A flexible control joint for use in plastering and stucco applications. Various embodiments of the flexible control joint may be used to form screed walls for different thicknesses of plaster materials applied to adjoining walls or other structures. The walls or other structures may be of similar or dissimilar constructions. Various embodiments of the control joint may be used to form corner arrangements or T-arrangements to achieve desired design effects.

Products and methods that may enhance the manufacturing, structure, appearance, assembly, or installation of synthetic building or construction products. In particular, exemplary embodiments include panels, wall structures, and other panel assemblies that may have contoured or textured surfaces to simulate the appearances of other building or construction products. For instance, exemplary embodiments of panels, wall structures, and other panel assemblies may have contoured and textured surfaces that may simulate the appearances of conventional building or construction materials including, but not limited to, stone, bricks, masonry, concrete, stucco, wood, other conventional building materials, and combinations of any of these materials.

A fastener including a body having a predetermined axial length, wherein the body includes a screw head at one axial end of the body, a threaded portion at an opposite axial end of the body and an unthreaded shank portion extending between the screw head and the threaded portion, and wherein the shank portion has an axial length in excess of at least one-third of the axial length of the fastener body.

Several matching exterior lighting systems for use on property having electrical service wiring. Lighting fixtures are made of pipe or wood, preferably PVC pipe or redwood. Several embodiments can be installed directly in the ground, while other embodiments can be installed on the vertical exterior surface of a building, or on the top of a wall. In all embodiments, the lamp and electrical connections are housed within the same enclosure, and no separate electrical box is needed. The embodiments made of pipe are coated with stucco, brick, stone, tile, wood, aluminum sheet, or copper sheet, to protect the pipe from environmental degradation. The preferred coating is stucco, and the invention includes a new method of applying stucco to a circular cylinder and manufacturing an article. All embodiments have elongated rectangular windows parallel both to the florescent light bulb, and to the axis of the cylinder, with translucent lenses to allow light to escape. The circular embodiments each have a single lens that covers all of the windows. In several embodiments, the florescent light and light bulbs can be accessed by removing the top of the light and lifting out the lamp which is hung from the top.

A composite building material includes at least one membrane, a spacer material bonded to one face of the membrane, and a lath bonded to an opposite face of the membrane. The components of the composite building material are installed simultaneously as an integral unit within a wall, roof or like assembly. The lath is preferably made of plastic or metal and is used to support cementitious material such as stucco, mortar, plaster, concrete and the like. The spacer material provides ventilation and drainage passages and is preferably provided as separate or integrally-formed spacer elements, an openwork mat, a corrugated material, or the like. Preferably, the membrane is building paper, tar paper, roofing felt, house-wrap material or like weather-resistive material. A wall / roof assembly and a method of assembling a wall / roof structure are also disclosed.

In a method of making a gypsum slurry, a polycarboxylate dispersant, a modifier and a hydraulic material comprising stucco are selected for use in the slurry. These components are then combined with water to form a slurry, where the modifier is added to the slurry prior to formation of a slurry phase by the water, the stucco and the dispersant. The modifier has been shown to be less effective when added after the dispersant and stucco have been contacted in an aqueous slurry. In a preferred embodiment, an amount of stucco is obtained and the modifier and dispersant are selected. A predissolved solution of a dispersant and modifier is prepared in water to form a solution prior to the addition of the stucco. After mixing the solution, the stucco is added to form the slurry. Optionally, the slurry is then shaped into a product and allowed to set.

Screed joints for use in plastering and stucco applications. Various embodiments of screed joints for forming screed walls for different thicknesses of plaster materials applied to adjoining walls or other structures are disclosed. The walls or other structures may be of similar or dissimilar constructions.

Simulated stone, masonry and brick textured products such as siding panels are obtained when specially selected materials are properly admixed and formed via molding techniques. For instance, exemplary methods of manufacturing embodiments of panels, wall structures, and other products that may have contoured and textured surfaces and may simulate the appearances of conventional building or construction materials including, but not limited to, stone, bricks, masonry, concrete, stucco, wood, other conventional building materials, and combinations of any of these materials are disclosed. Such products are manufactured from suitable molds according to a prescribed process methodology using synthetic polymeric materials in addition to other materials such as coloring and texturing materials. Prerequisite surface textures may be produced that effectively simulate actual stone, masonry and brick panels. Methods described herein may enhance the manufacturing, structure, appearance, assembly, or installation of synthetic building or construction products. In particular, exemplary embodiments include panels, wall structures, and other panel assemblies that may have contoured or textured surfaces to simulate the appearances of other building or construction products. The disclosed invention is not limited to products in the building or construction industries and may be applied in the manufacture of a wide variety of products in other industries.

The invention provides in one embodiment a gypsum-containing slurry including stucco and an aqueous pre-dispersion of a pregelatinized starch. Also provided is a method of making gypsum wallboard by providing a pre-dispersion of the pregelatinized starch in water, and adding the pregelatinized starch pre-dispersion to the gypsum-containing slurry. The pregelatinized starch can have a particle size distribution within the following range: d (0.1)=about 20μ-35μ, d (0.5)=about 60μ-110μ, d (0.9)=about 100μ-220μ.

A recessed electrical box having one or more flanges making it easily adaptable to installation on either a finished or unfinished exterior wall of a building. A preferred embodiment includes an inner and outer flange with the inner flange being easily removable. For installation on an unfinished wall, a hole is made in the exterior substrate and the box inserted until the inner flange is flush with the substrate. Fasteners are driven through holes provided in the inner flange to secure the box to the substrate. Lapped siding or any appropriate siding material, is then installed within the gap and placed flush with the sides of the box. For installation on a finished wall, the inner flange is removed and a hole is made in the exterior substrate and the siding and the box inserted until the outer flange is flush with the siding. Holes are drilled in the outer flange and fasteners inserted therein to secure the recessed electrical box to the siding and substrate. A second embodiment simplifies installation of a recessed electrical box in a retrofit situation on a finished wall and a third embodiment simplifies installation of a recessed electrical box on a substrate that will be finished with stucco.

In a method of making a gypsum slurry, a polycarboxylate dispersant, a modifier and a hydraulic material comprising stucco are selected for use in the slurry. These components are then combined with water to form a slurry, where the modifier is added to the slurry prior to formation of a slurry phase by the water, the stucco and the dispersant. The modifier has been shown to be less effective when added after the dispersant and stucco have been contacted in an aqueous slurry. In a preferred embodiment, an amount of stucco is obtained and the modifier and dispersant are selected. A predissolved solution of a dispersant and modifier is prepared in water to form a solution prior to the addition of the stucco. After mixing the solution, the stucco is added to form the slurry. Optionally, the slurry is then shaped into a product and allowed to set.

A temporary and disposable cover for an electrical box. The cover includes a faceplate, side walls, and flexible tabs projecting inwardly from the side walls. When placed upon an electrical box with a permanent cover, the indents seat behind the sidewalls of the permanent cover and hold the temporary cover thereon. While seated upon the electrical box, the temporary cover protects the permanent cover and the forward portion of the electrical box from spatter, overruns, or any other misdirected applications of stucco mud to the surface surrounding the electrical box. After the stucco has cured, the temporary cover is disposed of. The temporary cover is capable of being manufacture at a low cost per unit, thereby permitting it to be disposed of after the stucco has been cured.

A building façade system adapted to be installed onto an exposed surface of a building and provide a substrate for installation of façade elements (e.g., stone, stucco and the like). The system preferably provides a corrosion-resistant structure adapted to withstand extended environmental exposure. In general, the system includes a highly porous three dimensional matrix filamentous polymeric mat and a fiberglass mesh layer associated therewith. Collectively, the polymeric mat and fiberglass mesh layer are adapted to be installed onto an exposed building wall and provide a substrate onto which desired façade elements may be installed.