CA1065659A - Method for the manufacture of a mineral fibre - Google Patents

Method for the manufacture of a mineral fibre

Info

Publication number
CA1065659A
CA1065659A CA281,152A CA281152A CA1065659A CA 1065659 A CA1065659 A CA 1065659A CA 281152 A CA281152 A CA 281152A CA 1065659 A CA1065659 A CA 1065659A
Authority
CA
Canada
Prior art keywords
binder
sheet
fibers
watered
weight
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
CA281,152A
Other languages
French (fr)
Inventor
Gunnar Cederqvist
Ulf Aberg
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.)
Rockwool AB
Original Assignee
Rockwool AB
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 Rockwool AB filed Critical Rockwool AB
Application granted granted Critical
Publication of CA1065659A publication Critical patent/CA1065659A/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
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/04Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • 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
    • C04B40/00Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • 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
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/10Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
    • C04B2111/12Absence of mineral fibres, e.g. asbestos

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Paper (AREA)
  • Nonwoven Fabrics (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Inorganic Fibers (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE
An improved sheet material, for example for flooring, is disclosed which is formed of mineral fibers and a binder. The material is manufactured by preparing an aqueous fiber suspension, forming a sheet by a dewatering step, and drying the sheet while subjecting it to an observable comprimation.
The product exhibits equivalent properties to conventional porous asbestos support felts, which are questionable from the viewpoint of health risks.

Description

~0~6~
In manufacturing certain types o~ floor material, a porous sheet, having asbestos as its essential constituent, is used as support felt. Asbestos, however, may create health risks and it has therefore been proposed, in this connection as well as in other connec ions, that the asbestos should be exchanged with artificial mineral wool, for instance stone wool, glass wool or the like, because artificial mineral wool will not create the health risks, produced by the asbestos. Replacing asbestos simply with a corresponding amount of mineral wool, however, will produce a fibrous sheet wherein rigidity against pulling, flexibility and impression resistance are much inferior to the product using asbestos as the fibrous material.
The artificial mineral fibers, in contrast to the asbestos fibers, are quite smooth and require quite a different binding effect than the asbestos. Large quantities of binder, which are obviously uneconomical, and also unsuitable from other points of view, have proved incapable of overcoming this ..
difference in fibrous properties.
In the present invention, however, a method is disclosed whereby a fibrous sheet, based on artificial mineral wool, will exhibit such properties, using reasonable amounts of binder, - such that it may replace the corresponding asbestos products.
The method according to the present invention, however, is not limited to replacing asbestos products.. The invention refers to an aqueous process, where a suspension of artificial mlneral fibers in water lS first prepared, a sheet is formed from the fibrous suspension, and finally this sheet is dried.
According to the lnvention, the sheet is subjected to an observable compression while drying. It has proved expecially advantageous if the compression is subjected and removed so that ~ ; ;
the compression is retained during the major part of the drying procedure, preferably so that it will remain until the sheet is -1- ~ . :

. ' iS~S~
almost completely dry. The reason for obtaining such a decisive positve effect, which greatly supercedes the effect which an increase of density proper will give, may, after studies, be - assumed that the binder drops which in the initial part comprise a given amount of water with one or more binder particles contained therein, will also initially comprise or at - least touch two or more fibers. When the water is removed, of course, the volume of the drop is decreased so that the binder - particles will be released. Then it may happen, and it obviously ` happens to an important extent, that the separate binder particles no longer overlay the distance between the fibers.
Then, also, no binder action will occur.
The circumstances, however, are different if the fibers, - which are in contact with a given binder dispersion drop, are compressed so that the distance will be small. The binder particles remaining after the evaporation of the water will then be able to bind the fibers together. When the drying procedure is finished and deloading takes place, the fiber sheet will expand, but by that time, the binding is already esta-blished. In principle, this effect could be achieved, for instance - by a momentary compression of greater or lesser extent of the fiber sheet after the drying procedure has been finished but before the fiber sheet has been cooled. The effect which is then achieved, however, is much smaller and therefore it seems to be of importance that the binding between the fibers, due to the compression adjacent to each other, takes place concurrent with the removal of the water during the drying procedure.
In order to maximize the effect of the invention, it is required that the compression during the drying be observable.
It should amount to at least 20 percent, and preferably, to at least 40 percent of the thickness of the wet sheet. An especially desirable apparatus for execution of the invention
2.
. ., :
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has proved to be a drying cylinder, which has, in an est~blishe~
way, its major part surrounded by a drying felt or a drylng vira. The drying felt, however, or the drying vira must be so arranged that it can be stretched to such a degree that the - fiber sheet will get the required amount of compression.
A Yankee-type fiber machine has proved to be most favorable, but multiple cylinder machines can be used as well, since it has proved to be of no decisive importance that the pressure be deloaded during the time when the sheet is moved from one cylinder to another one. However, it is of greater importance that the degree of compression on the different cylinders be uniform.
The effects caused by the execution of the invention in the above indicated process, according to what has been found by investigation, is to be regarded as substantially the result of an effective use of the binder. It has also been established that the binder effect, such as it appears in the ready mineral fiber sheet, is further improved by establishing sequential feeding of the binder. Thus, it has proven to be of great value that the binder is added in two steps. Thereby one part of the binder should be added to the fiber suspension from which the sheet is formed. A second part of the binder should there-after be added to the wet sheet after dewatering has been nearly or completely finished.
As binder during the first binder step, latex of an - acrylate polymeric product in the form of a dispersio~ or some binder comparable therewith seems to be optimal. The result will be especially good if the dispersion is brought to a coagualated state before the formation of the sheet. The coagulation can take place in the fiber suspension after the binder dispersion has been added, but it may preferably take place before the addition of the dispersion to the fiber _3 .. . . . .................. . . . . .

,, . . ~ . ~, .. ,. . , . :. , ~656S~ ---~ suspension, because the conditions ~or coa~ulation will be under better control then.
The binder which is added to the fiber suspension must form at least 2 percent but should not exceed 25 percent of the fiber weight. Preferably the amount-of binder should be about 15 percenl of the fiber weight.
In the second binder step, it has been proved that styrene-butadiene-latex or the like will give the best results.
However, it is of decisive importance that this binder be distributed extremely evenly and in the form of small particles.
Spraying with a high degree of finely divided particles has therefore been found to be the most suitable procedure. The cloud of binder particles thereby created, however, is difficult to control in practice, such that it has proved especially advantageous to use electrostatic spraying. -The amo~nt of binder in the second binder addition step should also be at least 2 percent, and at a maximum 25 percent - of the fiber weight. A suitable amount for most purposes will be 10 percent of the fiber weight.
If the amount of binder in the first step is close to the lower limit, then more binder should be added during the second step relative to the amount added in the first step and vice versa. The total amount of binder, therefore, should not be less than 10 percent and, preferably, less than 20 percent of the fiber weight. Alternatively, there are no essential advantages to be gained by using over 40 percent by fiber weight and little advantage in using over 30 percent.
The examples below show how the characteristics of the invention produce an important result regarding the desirable properties for the mineral fiber sheet. ~owever, it is under-stood that the invention may be used in other ways within the scope and spirit of the claims.

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` Example 1 .
A fiber suspension comprising 0.1~ stone wool fibers in water is provided with 15% acrylate latex, based on the fiber weight, said latex having just been brought to a coagulated - state by a lowering of the pH-value using alum solution. The binder containing the fiber suspension is dewaterecl on an even vira "Voith Hydroforme~'. After dewatering to 40~ dry substance about 10~ based on the fiber weight, styrene butadiene latex is sprayed thereon. The sheet was introduced on a drying cylinder havin~ 1 m diameter, with its major part surrounded - by a vira, having a controllable tension. The sheet was dried and tested with respect to pulling rigidity and impression rigidityl). The following results were obtained:

A B
Pulling force in the vira 0.4 kp/cm 20 kp/cm Compression of the dry cylinder 10% 60%

- Pulling rigidity lengthwise 20.5 N/3cm 60 N/3cm crosswise 17.3 N/3cm 53 ~/3cm Impression rigidity durlng loadl) 1.4 mm 0.5 mm after deloading 1.2 mm 0.38 mm )a steel ball 20 mm ~ in diameter supplies a load to the sheet for 5 minutes and the impression is measured. After deloading - for 5 minutes, the impression is again measured.
' ' The sheet, which had been strongly compressed while drying (test B) exhibited essentially better rigidity than the one which had been compressed only nominally (A).

Example_2 In a test conducted principally accordin~ to example 1, the following variations were made regarding the type of binder utilized.
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~n w O ~o .Q~ 5 ~ oO~ (D n ~0
3 ~ (D &' ,~ , z z x ~ ~ lJ
)~

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o o ~ a~ o ~ 1--~ w 3 ~ ~ x P, o o z z 0~o up ~
3 33 ~ n 3 3 (D
O

11)65659 .

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.

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Claims (16)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method for the manufacture of a sheet comprising mineral fibers and a binder comprising the steps of:
(a) providing a layer of an aqueous suspension comprising water, mineral fibers and a binder;
(b) de-watering said layer to form a de-watered sheet comprising said mineral fibers and said binder; and (c) drying said de-watered sheet and simultaneously compressing the de-watered sheet such that the de-watered sheet is compressed at least 20% to produce a dried sheet comprising said mineral fibers and said binder.
2. A method according to claim 1 wherein said compression is such that the de-watered sheet is compressed at least 40%.
3. A method according to claim 1 wherein the compressing of said de-watered sheet is maintained during a major portion of the time of drying thereof.
4. A method according to claim 3 wherein the compressing of said de-watered sheet is maintained until the sheet is at least substantially complete-ly dried.
5. A method according to claim 1 wherein the de-watered sheet is dried and simultaneously compressed by being pressed against the surface of a dryer cylinder.
6. A method according to claim 1 wherein said layer is provided by pro-viding an aqueous suspension comprising water, mineral fibers and a binder and forming said aqueous suspension into a layer thereof.
7. A method according to claim 6 wherein said binder comprises an acrylate resin dispersion.
8. A method according to claim 7 wherein said dispersion is coagulated and added to said aqueous suspension after being coagulated.
9. A method according to claim 7 wherein the binder is present in said suspension in an amount of from 2 to 25% by weight based on the weight of the fibers.
10. A method according to claim 6 wherein a further portion of said binder is added to the de-watered sheet after de-watering thereof and before drying thereof.
11. A method according to claim 10 wherein said further portion of said binder comprises a styrene butadiene latex.
12. A method according to claim 10 wherein said further portion of said binder is sprayed onto said de-watered sheet.
13. A method according to claim 12 wherein the spraying is effected by electrostatic spraying of said binder.
14. A method according to claim 10 wherein said further portion of said binder is added in an amount of from 2 to 25% by weight based on the weight of said fibers.
15. A method according to claim 10 wherein the total amount of said binder is from 10-40% by weight based on the weight of said fibers.
16. A method according to claim 10 wherein the total amount of said binder is from 20-30% by weight based on the weight of said fibers.
CA281,152A 1976-07-23 1977-06-22 Method for the manufacture of a mineral fibre Expired CA1065659A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
SE7608399A SE397338B (en) 1976-07-23 1976-07-23 PROCEDURE FOR MANUFACTURING A PATTERN MAINLY CONSISTING OF MINERAL FIBERS AND BINDERS

Publications (1)

Publication Number Publication Date
CA1065659A true CA1065659A (en) 1979-11-06

Family

ID=20328537

Family Applications (1)

Application Number Title Priority Date Filing Date
CA281,152A Expired CA1065659A (en) 1976-07-23 1977-06-22 Method for the manufacture of a mineral fibre

Country Status (9)

Country Link
BE (1) BE856906A (en)
CA (1) CA1065659A (en)
DE (1) DE2732414A1 (en)
DK (1) DK333677A (en)
FI (1) FI56863C (en)
FR (1) FR2359232A1 (en)
NL (1) NL174573C (en)
NO (1) NO772290L (en)
SE (1) SE397338B (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4389282A (en) * 1982-08-06 1983-06-21 Combustion Engineering, Inc. Ceramic fiber board
DE3314373A1 (en) * 1983-04-20 1984-10-25 Basf Ag, 6700 Ludwigshafen SOUND INSULATION PANELS BASED ON MINERAL FIBERS AND THERMOPLASTIC BINDERS

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE501107A (en) * 1950-02-09
US2772603A (en) * 1950-09-12 1956-12-04 Owens Corning Fiberglass Corp Fibrous structures and methods for manufacturing same
US2905584A (en) * 1955-05-25 1959-09-22 Johnson & Johnson Process for making a unified fibrous web
US3097990A (en) * 1961-01-16 1963-07-16 Armstrong Cork Co Polytetrafluoroethylene saturated crocidolite fiber product
CA958508A (en) * 1970-01-20 1974-12-03 Martyn Aartsen Fibre treatment process
FR2187975B1 (en) * 1972-06-06 1976-08-06 Non Tisses Ste Fse

Also Published As

Publication number Publication date
FR2359232A1 (en) 1978-02-17
FI762350A (en) 1978-01-24
BE856906A (en) 1977-11-14
DK333677A (en) 1978-01-24
NO772290L (en) 1978-01-24
NL174573B (en) 1984-02-01
DE2732414A1 (en) 1978-01-26
SE397338B (en) 1977-10-31
NL7706516A (en) 1978-01-25
NL174573C (en) 1984-07-02
FI56863B (en) 1979-12-31
FR2359232B1 (en) 1983-03-18
FI56863C (en) 1980-04-10

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