CA1049822A - Manufacture of fibrous artefacts - Google Patents

Manufacture of fibrous artefacts

Info

Publication number
CA1049822A
CA1049822A CA253,131A CA253131A CA1049822A CA 1049822 A CA1049822 A CA 1049822A CA 253131 A CA253131 A CA 253131A CA 1049822 A CA1049822 A CA 1049822A
Authority
CA
Canada
Prior art keywords
fibres
process according
slurry
layer
forming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA253,131A
Other languages
French (fr)
Inventor
John E. Occleshaw
Edward L.J. Harris
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tac Construction Materials Ltd
Original Assignee
Tac Construction Materials Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tac Construction Materials Ltd filed Critical Tac Construction Materials Ltd
Application granted granted Critical
Publication of CA1049822A publication Critical patent/CA1049822A/en
Expired legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Paper (AREA)
  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE

The invention provides a process for producing a fibre-reinforced board product from an aqueous slurry by forming a layer on the surface of a rotary sieve, from which the layer is subsequently removed, the process including the step of forming the aqueous slurry from water, an inorganic binder and from ? to 20% by weight of vitreous fibres (referred to the finished product) together with a minor proportion of auxiliary non-asbestos fibres preferably cellulosic, having a Canadian Standard Freeness in the range 20 - 300°. The process may also include a preliminary step of opening the auxiliary non-abestos fibres to a Canadian Standard Freeness of 20- 300° before forming the slurry.

Description

This invention relates to the manufacture of fibrous artefacts such as boards and sheets by processes including the step of forming a layer on the surface of a rotary sieve from an aqueous slurry.
Such processes have hitherto been carried out using a slurry including asbestos fibre and cement, optionally with modifying agents, fillers and the like, which serve to control the density of the final product. In the most commonly used processes, asbestos and cement are mixed and beaten with a large proportion of water to form a thin slurry, which is then stored while being agitated in a container known as a 'stuff chest". This constitutes a reservoir from which supplies of a slurry are taken, diluted with water and fed to one or more vats in each of which a sieve cylinder is rotated.
Each of these cylinders picks up the slurry as a continuous, thin wet layer, excess water draining through the meshes of the sieve, and the layer is applied to an endless conveyor belt by which it is carried to a rotating cylinder to which it is transferred and on which it is wound.
The coating on the cylinder builds up layer by layer ¦ until the required thickness is reached. To make a flat sheet, the layered product on the cylinder (which is then usually known as a forming bowl) is cut axially 1 25 when it has reached the required thickness.
j ~Iowever, attempts to completely replace the asbestos ¦ fibre with vitreous fibre have been unsatisfactory because I the physical characteristics of vitreous fibre are so very different from those of asbestos, making the formation of a coherent sheet on the rotary sieve extremely difficult, if not impossible.
According to the present invention, we provide a process for producing a fibre-reinforced board product from an aqueous slurry by forming a layer on the surface of a rotary sieve, from which the layer is subsequently removed, the process including the step of forming the
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aqeous slurry from water, an inorganic binder and from ~ to 20% of vitreous fibres, together with a minor proportion of auxiliary non-asbestos ~ibre having a Canadian Standard Freeness in the range 20 to 300. The percentage of vitreous fibre is referred to the finished product.
The express~on "Canadian Standard Freeness" (CSF) in the present context refers to the standard sheet forming test as commonly applied throughout the papermaking industry and wherein, for example, raw cellulose pulp exhibits a CSF of 700 - 900 and a very highly opened papermaking cellulose pulp exhibits a CSF of about 300.
The vitreous fibre may be glass fibre, or mineral wool, or a mixture of these. The term "mineral wool"
includes both slag and rock wool. I~here glass fibre is used, the staple length is preferably of the order of 2~ cm or less, 1~ cm being especially preferred.
The mineral wool may be pretreated to reduce its staple length, if necessary, for example by subjecting it to a milling treatment.
The inorganic binder may be a hydraulic binder such as O.P. cement and in such a case it is preferred that - the vitreous fibre be either alkali-resistant or at least treated to reduce its susceptibility to alkaline attack. The binder may also include a pulverised fuel ash.
- The auxiliary non-asbestos fibre is preferably cellulosic ~~ and will usually be in the form of a pulp; if so the process may include a preliminary refining treatment i 30 to confer upon the pulp the desired degree of openness ~` equivalent to a Canadian Standard Freeness value in -the range 20 to 300, 150 being very suitable in practice.
It will be appreciated that in a conventional papermaking process CSF values of less than 300 are generally regarded as very low. In contrast, we find that the present process operates well ~ith CSF values of 150 or even lower. Ho~e~er, provided that the surface area characteristlcs ' ` ' , ' '"
.
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of the auxiliary non-asbestos fibre are at least similar to those OI ashestos or cellulosic fibre, other materials may be used in the present process.
Although "minor proportion" includes up to 49~ by weight, other requirements, for example, non-combustibility requirements, may limit the proportion to a very much smaller figure, say to 5 or 10%.
Optionally, the process may also include the step of adding to the slurry density modifying agents such as perlite, china clay and/or diatomite, so as to bring the density of the finished artefact into the range appropriate for a particular end use.
It is also possible to add free silica-containing materials for the specific purpose of reacting with substantially all of any free lime released when the binder sets.
This is particularly relevant to processes using hydraulic cement as the binder and where the binder is caused to set by autoclaving. Free lime would of course tend to degrade the vitreous fibre component of the artefact if no attempt to minimise its effects was made.
Material stripped from the rotary sieve is naturally in a wet condition and the process will normally include causing the binder to set, for example, by air drying, autoclaving or stoving, i.e. heating in an oven to produce the finished product. Optionally, the wet products may be profiled and/or cut or trimmed prior to causing the binder to set. After setting the binder, the boards may be sanded or otherwise prepared for sale and/or use.
The invention also includes board products made by a process according to the invention.
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in order that the invention to be better understood, four preferred embodiments of it will now be described by way of example.

Example 1 A slurry was made from:-% by weight Alkali resistant glass fibre (1 1/4 cm staple length) 2 Alkali resistant mineral wool fibre (pretreated by milling) 10 Bleached kraft pulp (refined to - 130-150 CSF) 5 - Ordinary Portland cement 50 Diatomite 13 Perlite 10 , China Clay 10 The furnish was mixed with water in a pilot plant scale Hollander beater, 125 litres of water being needed for 27 -kg. beater charge. The mixing time was of the order of 10-15 minutes, including 5 minutes after adding the glass fibre to the other ingredients. This was to ensure thorough disper-sion of the glass fibre. The water temperature was in the ; range of 30-35C.
The slurry was then run on a vat machine and processed into boards which were air matured for seven days and oven dried at 100C for 24 hours. The average Modulos of Rigidity (at a standard density of about 720 Kg/m3) figures obtained from all the runs on this basic furnish varied from 5.5-5.8 N/mm depending upon the machine running conditions used. These 30 figures met the British Standard Specification 3536 for ,.. ~. . ..

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- - , ................... : . - :
. .. . , , ,: ~ ., . : , Insulation Boards. The impact strength of the boards exhibited significant increases over conventional asbestos-based boards but the interlaminar bond and stiffness of the boards were not as good. Equivalent or improved performances were ob-tained in tests for Freeze/Thaw Stability, Water Absorption and Dimensional Stability.
Example 2 A slurry was made from ordinary Portland cement (50% by weight) and a mixture of approximately equal parts of fibrous cellulose and inorganic filler (mainly china clay), as des-cribed in relation to Example 1.
Boards made on the vat machine from this slurry had an average MOR of 4.98 N/mm at a dry density of 870 Kg/m .

.
Example 3 Flat sheets were made as just described, using a furnish comprising:-1.2 cm staple length alkali resistant glass 1.5% (by Wt.) Kraft pulp (refined to 130-150 CSF) 5%
Ordinary portland cement 93.5%
The products had a density of 1250 Kg/m3 and a modulus of rigidity of 17.1 MN/m .
Example 4 Partition boards were made by the same method from a furnish comprising:-1.2 cm. staple length alkali resistant glass fibre 2.0% (by Wt.) Kraft pulp (refined to 130-150CSF) 8.0~
Ordinary portland cement 89.66%

Pigment 0.34%
The products had a density of 1095Kg/m3 and a modulus of rigidity of 22.2 MN/m .

Claims (11)

The embodiments of the invention in which an exclu-sive property or privilege is claimed are defined as follows:
1. A process for producing a fibre-reinforced board product from an aqueous slurry by forming a layer on the surface of a rotary sieve, from which the layer is subsequently removed, the process including the step of forming the aqueous slurry from water, an inorganic binder and from 1/2 to 20% by weight of vitreous fibres based on the weight of the finished product, together with a minor pro-portion of auxiliary non-asbestos fibres having a Canadian Standard Freeness in the range 20 - 300°.
2. A process according to Claim 1 wherein the auxil-iary non-asbestos fibres are cellulosic.
3. A process according to Claim 1 including a preli-minary step of opening the auxiliary non-asbestos fibres to a Canadian Standard Freeness of 20 - 300° before forming the slurry.
4. A process according to Claim 1, wherein the vitreous fibres are glass fibres having a staple length of the order of 2.5 cm or less.
5. A process according to Claim 4 wherein the glass fibres have a staple length of about 1.25 cm.
6. A process according to Claim 3 wherein the vitreous fibres are of mineral wool.
7. A process according to Claim 6, including the preliminary step of pretreating the mineral wool fibres to reduce their staple length.
8. A process according to any of Claims 1, 2 or 3 wherein the vitreous fibres are mixture of glass and mineral wool fibres.
9. A process according to claim 1 including the step of adding to the slurry a density-modifying filler.
10. A process according to claim 1 including the step of causing the binder to set after removing the layer from the surface of the rotary sieve.
11. A process according to claim 10 wherein the binder is caused to set by autoclaving the wet product.
CA253,131A 1975-05-30 1976-05-21 Manufacture of fibrous artefacts Expired CA1049822A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB2353675A GB1521482A (en) 1975-05-30 1975-05-30 Manufacture of fibrous artefacts

Publications (1)

Publication Number Publication Date
CA1049822A true CA1049822A (en) 1979-03-06

Family

ID=10197222

Family Applications (1)

Application Number Title Priority Date Filing Date
CA253,131A Expired CA1049822A (en) 1975-05-30 1976-05-21 Manufacture of fibrous artefacts

Country Status (18)

Country Link
JP (1) JPS6039525B2 (en)
AU (1) AU508163B2 (en)
BE (1) BE842341A (en)
CA (1) CA1049822A (en)
DE (1) DE2624130A1 (en)
DK (1) DK237076A (en)
EG (1) EG12580A (en)
FR (1) FR2312465A1 (en)
GB (1) GB1521482A (en)
IE (1) IE42700B1 (en)
IT (1) IT1061859B (en)
LU (1) LU75041A1 (en)
NL (1) NL186855B (en)
NO (1) NO149836C (en)
NZ (1) NZ180981A (en)
SE (1) SE417085B (en)
ZA (1) ZA763086B (en)
ZM (1) ZM6176A1 (en)

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE7800706L (en) * 1978-01-20 1979-07-21 Rockwool Ab HYDRAULIC COMPOSITION
GB2040331B (en) * 1978-12-09 1983-01-26 Turner & Newall Ltd Fibrous composites
EP0015538B1 (en) * 1979-03-06 1983-06-08 Kubota Ltd. A glass-fiber-reinforced cement panel and a process for its manufacture
DE3143202A1 (en) * 1981-10-30 1983-05-11 Metzeler Schaum Gmbh, 8940 Memmingen LAMINATE PLATE AND METHOD FOR THE CONTINUOUS PRODUCTION OF A LAMINATE PLATE
JPS59131551A (en) * 1983-01-16 1984-07-28 松下電工株式会社 Manufacture of inorganic hardened body
FR2556386B1 (en) * 1983-12-09 1986-12-26 Everitube INCOMBUSTIBLE PANEL AND MANUFACTURING METHOD THEREOF
DE3409597A1 (en) * 1984-03-15 1985-09-26 Baierl & Demmelhuber GmbH & Co Akustik & Trockenbau KG, 8121 Pähl ASBEST-FREE BUILDING MATERIAL PARTS AND METHOD FOR THEIR PRODUCTION
EP3957616A1 (en) 2021-07-07 2022-02-23 Swisspearl Group AG Fire resistant fibre cement compositions
US20240209664A1 (en) 2022-12-23 2024-06-27 Hefei Midea Refrigerator Co., Ltd. Hinge and opening and closing device

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1421556A (en) * 1973-03-13 1976-01-21 Tac Construction Materials Ltd Board products

Also Published As

Publication number Publication date
IE42700B1 (en) 1980-09-24
GB1521482A (en) 1978-08-16
SE7605917L (en) 1976-12-01
NL7605752A (en) 1976-12-02
FR2312465B1 (en) 1981-09-25
AU508163B2 (en) 1980-03-13
FR2312465A1 (en) 1976-12-24
NO761811L (en) 1976-12-01
NZ180981A (en) 1978-07-28
DK237076A (en) 1976-12-01
IT1061859B (en) 1983-04-30
JPS6039525B2 (en) 1985-09-06
DE2624130A1 (en) 1976-12-16
JPS51147523A (en) 1976-12-17
IE42700L (en) 1977-11-20
BE842341A (en) 1976-11-29
NL186855B (en) 1990-10-16
SE417085B (en) 1981-02-23
AU1445176A (en) 1977-12-08
EG12580A (en) 1979-03-31
NO149836B (en) 1984-03-26
ZA763086B (en) 1977-04-27
LU75041A1 (en) 1977-01-20
ZM6176A1 (en) 1977-10-21
NO149836C (en) 1984-07-04

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