Joseph S Luongo

US Patent:

6340388, Jan 22, 2002

Filed:

Apr 12, 2000

Appl. No.:

09/547615

Inventors:

Joseph S. Luongo - Kingman AZ

Assignee:

Advanced Construction Materials Corp. - Kingman AZ

International Classification:

C04B 3808

US Classification:

106675, 106677, 106680, 106698, 106778, 156 39, 156 45, 156346, 428449, 4285377, 524423, 524444

Abstract:

A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a wallboard composition comprising primarily gypsum, and in a wallboard composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises an optional covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength. Additionally, this invention relates to the unique manufacturing process to produce the wallboard composition of the present invention in order to create a lightweight, strengthened, moisture resistant, and fire retardant wallboard used to cover walls and ceilings in construction applications. Still further, this invention relates to the apparatus for manufacturing the wallboard composition of the present invention, including a method and apparatus for economically converting a standard gypsum wallboard manufacturing facility into a facility for manufacturing wallboard of the present invention.

US Patent:

6391958, May 21, 2002

Filed:

Oct 26, 2000

Appl. No.:

09/696894

Inventors:

Joseph S. Luongo - Kingman AZ

Assignee:

Advanced Construction Materials Corp. - Kingman AZ

International Classification:

C08K 300

US Classification:

524423, 524444, 524445, 524448, 428703

Abstract:

A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state in combination with an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises a covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength. Additionally, this invention relates to the unique manufacturing process to produce the wallboard composition of the present invention in order to create a lightweight, strengthened, moisture resistant, and fire retardant wallboard used to cover walls and ceilings in construction applications. Still further, this invention relates to the apparatus for manufacturing the wallboard composition of the present invention, including a method and apparatus for economically converting a standard gypsum wallboard manufacturing facility into a facility for manufacturing wallboard of the present invention.

US Patent:

6403688, Jun 11, 2002

Filed:

Oct 26, 2000

Appl. No.:

09/696895

Inventors:

Joseph S. Luongo - Kingman AZ

Assignee:

Advanced Construction Materials Corp. - Kingman AZ

International Classification:

C08K 330

US Classification:

524423, 524444

Abstract:

A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state in combination with an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises a covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength. Additionally, this invention relates to the unique manufacturing process to produce the wallboard composition of the present invention in order to create a lightweight, strengthened, moisture resistant, and fire retardant wallboard used to cover walls and ceilings in construction applications. Still further, this invention relates to the apparatus for manufacturing the wallboard composition of the present invention, including a method and apparatus for economically converting a standard gypsum wallboard manufacturing facility into a facility for manufacturing.

US Patent:

20010001218, May 17, 2001

Filed:

Dec 8, 2000

Appl. No.:

09/732852

Inventors:

Joseph Luongo - Kingman AZ, US

International Classification:

B29C039/20
B29C071/00
B29D009/00
B32B005/16
B32B013/08
C08K003/30
C08K003/38
C08L003/02
C08L003/10
C08L013/02

US Classification:

264/042000, 264/045600, 264/135000, 264/261000, 264/333000, 156/042000, 156/043000, 156/044000, 156/045000, 156/346000, 425/00400C, 425/308000, 425/404000, 425/449000, 428/305500, 428/307300, 428/307700, 428/308400

Abstract:

A novel construction board composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a construction board composition comprising primarily gypsum, and in a construction board composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum construction board formulations, thus reducing the weight while maintaining the strength of the construction board structure. In a preferred embodiment, the lightweight, strengthened gypsum construction board of the present invention also comprises an optional covering veneer that is applied to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength. Additionally, this invention relates to the unique manufacturing process to produce the improved gypsum construction board composition of the present invention in order to create a lightweight, strengthened, moisture resistant, and fire retardant construction board used to cover walls in construction applications. Still further, this invention relates to the apparatus for manufacturing the construction board composition of the present invention, including a method and apparatus for economically converting a standard gypsum construction board manufacturing facility into a facility for manufacturing the improved gypsum construction board of the present invention.

US Patent:

20020017222, Feb 14, 2002

Filed:

Apr 9, 2001

Appl. No.:

09/828994

Inventors:

Joseph Luongo - Kingman AZ, US

International Classification:

C04B011/00
C04B012/04

US Classification:

106/611000, 106/631000

Abstract:

A novel construction board composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a construction board composition comprising primarily gypsum, and in a construction board composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum construction board formulations, thus reducing the weight while maintaining the strength of the construction board structure. In a preferred embodiment, the lightweight, strengthened gypsum construction board of the present invention also comprises an optional covering veneer that is applied to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength.

US Patent:

63193124, Nov 20, 2001

Filed:

Dec 23, 1999

Appl. No.:

9/471448

Inventors:

Joseph S. Luongo - Kingman AZ

Assignee:

Advanced Construction Materials Corp. - Kingman AZ

International Classification:

B32B 1708
C04B 1100
C04B 1604
C04B 2424

US Classification:

106675

Abstract:

A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a wallboard composition comprising primarily gypsum, and in a wallboard composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises an optional covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength. Additionally, this invention relates to the unique manufacturing process to produce the wallboard composition of the present invention in order to create a lightweight, strengthened, moisture resistant, and fire retardant wallboard used to cover walls and ceilings in construction applications. Still further, this invention relates to the apparatus for manufacturing the wallboard composition of the present invention, including a method and apparatus for economically converting a standard gypsum wallboard manufacturing facility into a facility for manufacturing wallboard of the present invention.

US Patent:

62519794, Jun 26, 2001

Filed:

Aug 13, 1999

Appl. No.:

9/374589

Inventors:

Joseph S. Luongo - Kingman AZ

Assignee:

Advanced Construction Materials Corp. - Kingman AZ

International Classification:

C08K 300

US Classification:

524423

Abstract:

A novel wallboard composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state in combination with an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum wallboard formulations, thus reducing the weight while maintaining the strength of the wallboard structure. In a preferred embodiment, the lightweight, strengthened wallboard of the present invention also comprises a covering veneer that is applied to the top ply of the face paper to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength. Additionally, this invention relates to the unique manufacturing process to produce the wallboard composition of the present invention in order to create a lightweight, strengthened, moisture resistant, and fire retardant wallboard used to cover walls and ceilings in construction applications. Still further, this invention relates to the apparatus for manufacturing the wallboard composition of the present invention, including a method and apparatus for economically converting a standard gypsum wallboard manufacturing facility into a facility for manufacturing wallboard of the present invention.