Joint compound including recycled constituents and method and system for making the same
AssigneeUniversal Forest Products, Inc.
InventorsFrank Juergen Nordt, Jason A. Everett, Duane L. Whipple, David E. Spring
Life of this patent
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Abstract
A composition of matter for joint or texture compound used in wallboard applications which incorporates an ingredient which has been reclaimed from waste wallboard panel. A method and system for reconstituting the waste wallboard into the joint compound is also provided. Waste wallboard is thereby recycled so that the waste wallboard does not need to be disposed in a landfill.
Claims47
A method for producing a joint compound composition suitable for insertion within a seam between adjacent wallboard panels comprising the steps of:
- providing a waste wallboard panel having a predominantly gypsum core and a paper backing;
- separating the paper backing from the gypsum core, while at the same time reducing the gypsum core to a collection of gypsum pieces, at least some of the pieces being larger than a predetermined mesh size;
- sorting the separated paper backing from the separated collection of gypsum pieces;
- continuously milling only the separated collection of gypsum pieces larger than the predetermined mesh size in a milling chamber while, at the same time, removing the gypsum pieces milled to a size smaller than the predetermined mesh size from the milling chamber;
- and
- mixing the removed gypsum pieces smaller than the predetermined mesh size with at least one of a binder, a preservative and a rheological additive to form a flowable joint compound mixture with a desirable smooth consistency.
A method for producing a joint compound composition suitable for insertion within a seam between adjacent wallboard panels comprising the steps of:
- providing a waste wallboard panel having a predominantly gypsum core and paper backing;
- separating the paper backing from the gypsum core;
- reclaiming a filler constituent from the gypsum core;
- providing a metal detector;
- actuating the metal detector to sense residual metal components remaining in the gypsum core;
- mixing the filler constituent with at least one of a binder, a preservative and a rheological additive;
- and
- alerting a user of the presence of metal components remaining in the gypsum core.
A method for producing a joint compound composition suitable for insertion within a seam between adjacent wallboard panels comprising the steps of:
- providing a waste wallboard panel having a predominantly gypsum core and paper backing;
- separating the paper backing from the gypsum core;
- reclaiming a filler constituent from the gypsum core;
- providing a mixing unit;
- mixing the filler constituent in the mixing unit with at least one of a binder, a preservative and a rheological additive to form a joint compound mixture;
- providing an outlet port on the mixing unit;
- providing a packaging system downstream of the mixing unit;
- fluidly interconnecting the outlet port of the mixing unit to the packaging system;
- and
- providing a pump intermediate the outlet port of the mixing unit and the packaging system for controlling the flow of the joint compound mixture from the mixing unit to the packaging system.
A method for producing a joint compound composition suitable for insertion within a seam between adjacent wallboard panels comprising the steps of:
- providing a waste wallboard panel having a predominantly gypsum core and paper backing;
- separating the paper backing from the gypsum core;
- reclaiming a filler constituent from the gypsum core;
- providing a mixing unit;
- mixing the filler constituent in the mixing unit with at least one of a binder, a preservative and a rheological additive to form a joint compound mixture having an undetermined viscosity;
- providing an outlet port on the mixing unit;
- providing a packaging system downstream of the mixing unit;
- fluidly interconnecting the outlet port of the mixing unit to the packaging system;
- and
- providing a viscometer fluidly interconnected between the mixing unit and the packaging system for indicating the viscosity of the joint compound mixture.
A method for producing a joint compound composition suitable for insertion within a seam between adjacent wallboard panels comprising the steps of:
- providing a waste wallboard panel having a predominantly gypsum core and paper backing;
- separating the paper backing from the gypsum core;
- reclaiming a filler constituent from the gypsum core;
- providing a mixing unit;
- mixing the filler constituent in the mixing unit with at least one of a binder, a preservative and a rheological additive to form a joint compound mixture having an undetermined temperature;
- providing an outlet port on the mixing unit;
- providing a packaging system downstream of the mixing unit;
- fluidly interconnecting the outlet port of the mixing unit to the packaging system;
- and
- providing a thermometer fluidly interconnected between the mixing unit and the packaging system for indicating the temperature of the joint compound mixture.
Dependencies are inferred from the claim text.