CA1150465A - Weather resistant boards or mouldings of wood fibre materials and its process for production - Google Patents
Weather resistant boards or mouldings of wood fibre materials and its process for productionInfo
- Publication number
- CA1150465A CA1150465A CA000337295A CA337295A CA1150465A CA 1150465 A CA1150465 A CA 1150465A CA 000337295 A CA000337295 A CA 000337295A CA 337295 A CA337295 A CA 337295A CA 1150465 A CA1150465 A CA 1150465A
- Authority
- CA
- Canada
- Prior art keywords
- base material
- weather
- weather resistant
- resistant board
- board
- 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
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
- E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/06—Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N5/00—Manufacture of non-flat articles
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
Abstract
ABSTRACT OF THE DISCLOSURE
Weather resistant boards (for instance, particle boards, facade covering boards, and wall elements) and mouldings (for instance, containers, vessels, prefabricated building elements, and roof elements) of resin-impreg-nated wood fibres and/or other particle materials are provided herein. In the manufacturing process, the base fibres are coated with a solidly ad-hering outer coating of a vulcanizable weather-resistant rubber, or other elastomer, suitable for vulcanizing, without the addition of any adhesive binding medium. The process for the production applies the principle that the condensation of the adhesive agents in the laid-down batt of the fibre-particle mixture on at least one side of that batt as well as the vulcan-ization of the coating material are performed simultaneously, under the same physical conditions (pressure, temperature, time). By using the usual hot pressing machines, weather-resistant boards and mouldings can be produced in one single production run. The final product is an integral united material, in which the base and the coating material are impregnated one into the other within a facing area.
Weather resistant boards (for instance, particle boards, facade covering boards, and wall elements) and mouldings (for instance, containers, vessels, prefabricated building elements, and roof elements) of resin-impreg-nated wood fibres and/or other particle materials are provided herein. In the manufacturing process, the base fibres are coated with a solidly ad-hering outer coating of a vulcanizable weather-resistant rubber, or other elastomer, suitable for vulcanizing, without the addition of any adhesive binding medium. The process for the production applies the principle that the condensation of the adhesive agents in the laid-down batt of the fibre-particle mixture on at least one side of that batt as well as the vulcan-ization of the coating material are performed simultaneously, under the same physical conditions (pressure, temperature, time). By using the usual hot pressing machines, weather-resistant boards and mouldings can be produced in one single production run. The final product is an integral united material, in which the base and the coating material are impregnated one into the other within a facing area.
Description
This invention relates to a method for the production of weather-resistant boards and to the weather-resistant boards so produced.
Many wood fibre materials for the building industry are limited to interior use since they are not sufficiently weather resistant to be used externally. However, since these products, i.e., particle boards, fibre boards, insulating boards, plywood, etc. are considered to be ideal and inexpensive building materials because of their economy, their insula-- tion properties and their lightness, the art has been faced with the problem of providing the necessary weather resistancy and aging stability by altering the nature and composition of the raw materials and binding agents as well as by applying coating the outer skin. The first aim not only is to prevent water from penetrating into the board, but also to keep off atmospheric humidity. Any attempts to solve this problem solely by the type of and modification of, the usual glue mixtures, and by adding hydro-phobic agents andjor anti-bacterial agents, have not provided any reliable results, since it was also desired that the positive properties of the material, e.g. low costs, light weight, heat insulation, bursting strength and standard glueing, should be retained. Such properties are impaired when, for instance, too large quantities of binding materials or mineral admixtures are used, which were expedients recently attempted to achieve sufficient weather resistancy. Therefore, measures heretofore used to provided such weather resistance of the structural composition within limits are coupled with an effective surface protection.
Accordingly, up to the present time, neither materials nor methods have been found which would guarantee that the required long lasting pro-tection would remain effective against atm,ospheric influences to maintain the board resistant to mechanical damage or destruction within an acceptable economic scope. In this respect, coating the board by liquid preserving 6~;
agents is becoming more obsolete, since, the industry has been successful in developing products which have high resistance to moisture, W - and heat radiation etc. and which avoids to a large extent cracking or em-brittlement. Another economic process has been provided in which synthetic-resin-soaked papers are pressed on during the standard production of boards or mouldings. This, however, results in thin and susceptible surface coatings which are liable to crack because of the brittleness of the mater-ial as soon as the base material expands. This danger would be overcome by laminating previously produced weather-resistant, impact-resistant, and crack resistant materials, e.g., sheet metals, asbestos cement, or syn-thetic foils to the board. These, however, might peel-off under the per-manent strain of and influence of the weather as the differences of the expansion-coefficients due to heat radiation result in the destruction of the glue joint and cause blistering.
According up to the present time, no process exists for use on wood-fibre materials, plywood materials or other fibre ~aterials, even those which have previously been made moisture resistant to the greatest possible extent, which can be surface coated with an insoluable layer.
Thus, aims of the present invention are to provide such a building board which is economical to produce; which is resistant to weather influences;
which is substantially non-ageing; which can follow all fiuctuations of the base material without significant embrittling or cracking; which shows high abrasion-resistance; which has impact resistant capacities to mechani-cal influences of any kind; and which has been made substantially non-inflammable.
By one aspect of this invention, ,a weather-resistant board is provided comprising: an impregnable base material cons-tituted by a mixture of an organic and inorganic base material, e.g. a lignocellulosic or other-.f ' J~
wise prepared organic and/or inorganic raw material and a mineral material in the form of at least one of fibres and particles and a curable resin;
and an outer material constituted by a vulcanizable, weather-resistant elssto~eric material; the outer material being in vulcanized form, and being both adhered to one surface of the base material and penetrated and impregnated into that surface of the base material.
By one variant thereoE, the base material is a mixture of ligno-cellulosic fibres and mineral fibres.
By another variant thereof, the outer material is adhered to two mutually opposed faces thereof.
By another variant, the outer material completely encases -the board.
By yet a further variant, the elastomeric material is at least one of a natural vulcanizable rubber and a synthetic vulcanizable rubber.
By still another variant, the organic base and the inorganic base materials are also admixed with an adhesive agent.
By another variant the organic base and the inorganic base materials are in precompressed form.
By still another variant, the board is in heat pressed form.
~o By a further variant, the outer material is provided with a further surface coating.
By a variation thereof, the further surface coating comprises aluminum powder, aluminum foil, color pigments or grainy material.
By still another variation, the further surface coating is in the form of a relief ornamental structure.
The board may be either flat or i~ molded shaped form. Thus, the board may be molded by bending, whereby the elasticity and flexibility of the outer skin takes over the function of a hinge. The board may alternatively be formed as wall, roof, or other building elements, with openings therein for doors and/or windows. Still further, it may be formed as vessels or containers.
. By another aspect of this invention a process is provided for preparing a weather resistant board comprising: laying down a batt of or-ganic base material, e.g. of lignocellulose-containing and mineral-contain-ing materials in the form of a mixture of at least one of fibres and par-ticles and a curable resin, either on a movable carrier followed by apply-ing a layer of a vulcanizable weather-resistant elastomeric material or on a layer of a vulcanizable, weather-resistant elasto~neric material, to provide a composite; and subjecting the so-formed composite to the in-fluence of heat and pressure, whereby the vulcanizable material becomes in vulcanized form and is both adhered to one surface of the batt and pene-trated and impregnated into that surface of the batt.
By one variant thereof, the base material is laid down on the movable charging platform.
In another variant thereof, the base material is laid down on a layer of the vulcanizable rubber which is on the movable charging platform.
By one variant thereof, the process includes the preliminary step of laying down a first layer of a parting material on the movable charging platform.
By another variant thereof, the process includes the preliminary step of slightly prepressing the lignocellulosic fibres.
As noted above, the provision of weather-resistant boards or mouldings of particle board fibre board or plywood materials of aspects of this invention is based on the fact that, for a long time, rubber has proved to be reliable as a weather- and moisture-resistant coating mater-ial. The originally available natural rubber may be replaced by synthetic .. ..
rubbers, thus improving the application properties. By adding stabilizing agents and further additives, the brittleness and cracking under the in-fluence of rain, ozone, light radiation, W radiation and heat radiation has been substantially reduced so that today, for instance, roof films of synthetic rubber are expected to last 50 years without any damage. m e highly useful products of the group of elastomers especially with regard to elasticity, hardness and abrasion resistance may be modified beyond their specific characteristics by altering the chemical composition and the type - and quantity of added filling materials. me outer coating of the particle board first of all has to meet the condition of protecting against de-structive weather influences and mechanical damages. The double faced coating, can be provided for higher surface stability, or it may provide a hinge or protecting edges. The rubber should have the usual expansion characteristics of shrinkage without cracking. Therefore, a hard and viscous rubber composition can be used, which will-result in a protection layer of optimum impact resistance and abrasion resistance after the full vulcanization process. Furthermore, it may be reinfbrced by wool shearing fleece, and other tissue, as well as admixtures of other mineral fibres and/or other metallic fibres.
The essence of the present invention, however, does not rely on the use of highly weather-resistant synthetic rubber mixtures for outer coating. The essence of this invention is the fact that this coating pene-trates into the base material of wood fibres and thus results in an in-soluable composition during the first and only production run, without the necessity of any binding medium in the form of adhesive agents. Tnese weather-resistant boards or mouldings consist of a compound laminated material, ready for any use as wall elements or roof elements in the build-ing industry, the boards b~ing protected on one or several sides or even ., ~
,. .
~ ~ r' ~
edge protected. It may also be formed into pressed containers or vessels suitable to keep and to transport therein liquids or other wet materials.
The process for the manufacture of these weather resistant boards or mouldings of wood fibres and particle materials according to aspects of this invention is based on the interrelationship of the two following procedures, under interacting conditions, so that they are carried out sub-stantially simultaneously:
1. Compressing of the particle fibre mixture of the base mater-ial and hardening of the adhesive agents contained therein; and
Many wood fibre materials for the building industry are limited to interior use since they are not sufficiently weather resistant to be used externally. However, since these products, i.e., particle boards, fibre boards, insulating boards, plywood, etc. are considered to be ideal and inexpensive building materials because of their economy, their insula-- tion properties and their lightness, the art has been faced with the problem of providing the necessary weather resistancy and aging stability by altering the nature and composition of the raw materials and binding agents as well as by applying coating the outer skin. The first aim not only is to prevent water from penetrating into the board, but also to keep off atmospheric humidity. Any attempts to solve this problem solely by the type of and modification of, the usual glue mixtures, and by adding hydro-phobic agents andjor anti-bacterial agents, have not provided any reliable results, since it was also desired that the positive properties of the material, e.g. low costs, light weight, heat insulation, bursting strength and standard glueing, should be retained. Such properties are impaired when, for instance, too large quantities of binding materials or mineral admixtures are used, which were expedients recently attempted to achieve sufficient weather resistancy. Therefore, measures heretofore used to provided such weather resistance of the structural composition within limits are coupled with an effective surface protection.
Accordingly, up to the present time, neither materials nor methods have been found which would guarantee that the required long lasting pro-tection would remain effective against atm,ospheric influences to maintain the board resistant to mechanical damage or destruction within an acceptable economic scope. In this respect, coating the board by liquid preserving 6~;
agents is becoming more obsolete, since, the industry has been successful in developing products which have high resistance to moisture, W - and heat radiation etc. and which avoids to a large extent cracking or em-brittlement. Another economic process has been provided in which synthetic-resin-soaked papers are pressed on during the standard production of boards or mouldings. This, however, results in thin and susceptible surface coatings which are liable to crack because of the brittleness of the mater-ial as soon as the base material expands. This danger would be overcome by laminating previously produced weather-resistant, impact-resistant, and crack resistant materials, e.g., sheet metals, asbestos cement, or syn-thetic foils to the board. These, however, might peel-off under the per-manent strain of and influence of the weather as the differences of the expansion-coefficients due to heat radiation result in the destruction of the glue joint and cause blistering.
According up to the present time, no process exists for use on wood-fibre materials, plywood materials or other fibre ~aterials, even those which have previously been made moisture resistant to the greatest possible extent, which can be surface coated with an insoluable layer.
Thus, aims of the present invention are to provide such a building board which is economical to produce; which is resistant to weather influences;
which is substantially non-ageing; which can follow all fiuctuations of the base material without significant embrittling or cracking; which shows high abrasion-resistance; which has impact resistant capacities to mechani-cal influences of any kind; and which has been made substantially non-inflammable.
By one aspect of this invention, ,a weather-resistant board is provided comprising: an impregnable base material cons-tituted by a mixture of an organic and inorganic base material, e.g. a lignocellulosic or other-.f ' J~
wise prepared organic and/or inorganic raw material and a mineral material in the form of at least one of fibres and particles and a curable resin;
and an outer material constituted by a vulcanizable, weather-resistant elssto~eric material; the outer material being in vulcanized form, and being both adhered to one surface of the base material and penetrated and impregnated into that surface of the base material.
By one variant thereoE, the base material is a mixture of ligno-cellulosic fibres and mineral fibres.
By another variant thereof, the outer material is adhered to two mutually opposed faces thereof.
By another variant, the outer material completely encases -the board.
By yet a further variant, the elastomeric material is at least one of a natural vulcanizable rubber and a synthetic vulcanizable rubber.
By still another variant, the organic base and the inorganic base materials are also admixed with an adhesive agent.
By another variant the organic base and the inorganic base materials are in precompressed form.
By still another variant, the board is in heat pressed form.
~o By a further variant, the outer material is provided with a further surface coating.
By a variation thereof, the further surface coating comprises aluminum powder, aluminum foil, color pigments or grainy material.
By still another variation, the further surface coating is in the form of a relief ornamental structure.
The board may be either flat or i~ molded shaped form. Thus, the board may be molded by bending, whereby the elasticity and flexibility of the outer skin takes over the function of a hinge. The board may alternatively be formed as wall, roof, or other building elements, with openings therein for doors and/or windows. Still further, it may be formed as vessels or containers.
. By another aspect of this invention a process is provided for preparing a weather resistant board comprising: laying down a batt of or-ganic base material, e.g. of lignocellulose-containing and mineral-contain-ing materials in the form of a mixture of at least one of fibres and par-ticles and a curable resin, either on a movable carrier followed by apply-ing a layer of a vulcanizable weather-resistant elastomeric material or on a layer of a vulcanizable, weather-resistant elasto~neric material, to provide a composite; and subjecting the so-formed composite to the in-fluence of heat and pressure, whereby the vulcanizable material becomes in vulcanized form and is both adhered to one surface of the batt and pene-trated and impregnated into that surface of the batt.
By one variant thereof, the base material is laid down on the movable charging platform.
In another variant thereof, the base material is laid down on a layer of the vulcanizable rubber which is on the movable charging platform.
By one variant thereof, the process includes the preliminary step of laying down a first layer of a parting material on the movable charging platform.
By another variant thereof, the process includes the preliminary step of slightly prepressing the lignocellulosic fibres.
As noted above, the provision of weather-resistant boards or mouldings of particle board fibre board or plywood materials of aspects of this invention is based on the fact that, for a long time, rubber has proved to be reliable as a weather- and moisture-resistant coating mater-ial. The originally available natural rubber may be replaced by synthetic .. ..
rubbers, thus improving the application properties. By adding stabilizing agents and further additives, the brittleness and cracking under the in-fluence of rain, ozone, light radiation, W radiation and heat radiation has been substantially reduced so that today, for instance, roof films of synthetic rubber are expected to last 50 years without any damage. m e highly useful products of the group of elastomers especially with regard to elasticity, hardness and abrasion resistance may be modified beyond their specific characteristics by altering the chemical composition and the type - and quantity of added filling materials. me outer coating of the particle board first of all has to meet the condition of protecting against de-structive weather influences and mechanical damages. The double faced coating, can be provided for higher surface stability, or it may provide a hinge or protecting edges. The rubber should have the usual expansion characteristics of shrinkage without cracking. Therefore, a hard and viscous rubber composition can be used, which will-result in a protection layer of optimum impact resistance and abrasion resistance after the full vulcanization process. Furthermore, it may be reinfbrced by wool shearing fleece, and other tissue, as well as admixtures of other mineral fibres and/or other metallic fibres.
The essence of the present invention, however, does not rely on the use of highly weather-resistant synthetic rubber mixtures for outer coating. The essence of this invention is the fact that this coating pene-trates into the base material of wood fibres and thus results in an in-soluable composition during the first and only production run, without the necessity of any binding medium in the form of adhesive agents. Tnese weather-resistant boards or mouldings consist of a compound laminated material, ready for any use as wall elements or roof elements in the build-ing industry, the boards b~ing protected on one or several sides or even ., ~
,. .
~ ~ r' ~
edge protected. It may also be formed into pressed containers or vessels suitable to keep and to transport therein liquids or other wet materials.
The process for the manufacture of these weather resistant boards or mouldings of wood fibres and particle materials according to aspects of this invention is based on the interrelationship of the two following procedures, under interacting conditions, so that they are carried out sub-stantially simultaneously:
1. Compressing of the particle fibre mixture of the base mater-ial and hardening of the adhesive agents contained therein; and
2. Compressing and vulcanizing of the cover layer or layers coated mixture of natural rubber and/or synthetic rubber, or other elasto-mers, suitable filling materials and admixtures thereof.
The condensation and tempering or hardening of the resins and/or other adhesive agents as well as the vulcanization takes place under suitable conditions of pressure, temperature (175C) and time. The dura-tion of the vulcanizing temperature is dependent on accelerators and fil-ling materials within the material, and the thickness of the coating.
These all vary and can be adjusted to the hardening period of the filling materials. The vulcanizing steps for the covering layers or layers on the one hand and the compressing of the base materials on the other hand, should synchronized so that both processes may be carried out substantially simultaneously. Both material components are put into the shaping heat press tools together and in the selected order to match the structure of the finished compound material and are processed in one and the same manu-facturing run to the final board-like compound material or mouldings with weather resistant outer skins. ~or this process, the same tools and plant installations can be used as are required or as one already availa-ble for the production of customary particle boards or mouldings.
In order to obtain a plain one-sided weather resistant coated particle board, for instance, the outer coating is generally applied by spraying onto the mixture of fibre/particle/adhesive agents. If necessary, a parting component (for instance tin sheets and other plates or talc in powdered form). The outer coating can be supplied either in pre-fabricated unvulcanized films, or built up successively by mechanically spraying, pouring, sprinkling and so forth, in the required quantity. After laying down on the batt and, if desired slightly pre-compressing it, the heat pressing follows and the further processing in the usual manner for the production of particle boards.
Of course, this process herein may be carried out in a different sequence and with a different number and quantity of ingredients used, so that for instance the weather resistant cover layer, which is to be vul-canized, is coated or applied on last and on top of and/or on both sides respectively. Furthermore, the mixture of fibre-particles and adhesive agents, with or without addition heat, may undergo a separate pre-com-pression primarily in order to prepress a moulding before the mixture for outer coating is put on and the final pressing follows.
Finally, according to further modifying aspects of this invention, a decorating, reflecting or other surface coating or texture can be vul-canized onto the weather-resistant board for instance, aluminum powder or foil, colour pigments or grainy materials may be used either at the be-ginning or the end of the coating procedure and may be incorporated into the process. The weather-resistant surface may be given a relief ornamen-tal structure provided the pressing tools have been fitted out accordingly.
This weather-resistant coating provided by vulcanization is not limited to compound materials of fibre, or particle-like base materials, since it may be used for plywood or wooden strip boards and in principle also on several outer surfaces and even only partly on the surface. Final-ly, also other lignocellulose-containing organic and the inorganic, i.e.
mineral-containing base materials may be used herein provided they can re-ceive a weather-resistant outer coating of unvulcanized rubber or other elastomers and maybe be manufactured into boards or mouldings.
In the accompanying drawings, Figure 1 is a section of two forms of weather resistant boards of aspects of this invention;
Figure 2 is a section of a board of an aspect of this invention in the form of a facia board;
Figure 3 is a section of a board of two other aspects of this invention in the form of a shaped vessel;
Figure 4 is a section of a board of another aspect of this invention including a window opening thereinj Figure 5 is a schematic flow diagram illustrating the process of one aspect of this invention;
and Figure 6 is a schematic flow diagram illustrating the process of another aspect of this invention.
As seen in Figure 1, the lef~ hand side shows, in cross-secti~n, an upper-coated weather resistant board while the right hand side shows in cross-section, a double-faced coated weather resistant board. The base material 1 consists essentially of a lignocellulose-containing and the mineral-containing fibre-particle/adhesive agents mixture, and the outer coating 2 consists essentially of a weather-resistant, vulcanizable syn-thetic rubber mixture. The outer coating 2 is both adhered to the outer surface of the base material 1 and penetra~es and impregnates into the base material 1 at the region 3. Thus, the weather-resistant board com-prises an integral uniting of the base material 1 and the rubber coating 2 after the rubber coating 2 has been vulcanized.
Figure 2 shows, in cross section, the weather resistant board of another aspect of this invention in the form of a base material 1 and a vulcanized outer rubber layer 2. The board is shown as being bent com-pletely around (at the right hand side) so that the outer rubber layer 2 extends around the side edges and a portion of the bottom. The elasticity of the outer rubber layer enables the corners 4 to act as hinges.
On the left hand side, the board is shown as being bent for form a step, with the elasticity of the outer coating enabling the outer and inner corners 4 to act as hinges. If necessary, a wooden slat 5 can be secured to the inner face behind the step.
In Figure 3, a premolded vessel having the cross section of a bottom 15, side walls 16 and a rim 17 is provided formed of the single faced board consisting of the base material 1 and the outer coating 2 (shown on ~ie lcft hand side), or alternatively of the double faced board consisting of the base material 1 and the outer coatings 2 (shown on the right hand side). After or during the molding operation, the rubber surface 2 is vulcanized.
The board in Figure 4 is shown in the form of a premolded pre-fabricated building element for use in a wall having a profile consisting of main wall portion 18, edge portion 19 and a window opening 20.
Figure 5 provides a description of the process according to one aspect of this invention for the manufacture of weather-resistant boards and mouldings according to another aspect of this invention. A parting agent (e.g. talc in powdered form) 1 is first applied, as by spraying, onto the charging platform 10. Then the granulated mixture of the unvulcanized rubber 7 is applied, and finally a mixture of fibre particles/adhesive _9_ ~5~5 agents 8 is applied thereon, to provide an uncompressed batt 9, having an unvulcanized rubber film 7a on one face thereof. The batt 9 is subjected to compression and heat on the hot press 12. This simultaneously provides a condensation of the adhesive agents in the fibre particle mixture 1 and vulcanization of the weather-resistant vulcanizable outer rubber coating 2.
The outer rubber coating 2 penetrates and is impregnated into the base matexial 1 and this results in the integrated, united board.
Figure 6 shows another aspect of an alternative manufacturing process of another aspect of this invention. Here the parting agent 6 is first sprayed onto the charging platform 10. Then the fibre particles/ad-hesive mixture 8 is applied to form a batt 9. Finally the outer rubber coating is applied on the form of an unvulcanized film of rubber 11. The further processing is as described for Figure 5.
., ~ ,. .
The condensation and tempering or hardening of the resins and/or other adhesive agents as well as the vulcanization takes place under suitable conditions of pressure, temperature (175C) and time. The dura-tion of the vulcanizing temperature is dependent on accelerators and fil-ling materials within the material, and the thickness of the coating.
These all vary and can be adjusted to the hardening period of the filling materials. The vulcanizing steps for the covering layers or layers on the one hand and the compressing of the base materials on the other hand, should synchronized so that both processes may be carried out substantially simultaneously. Both material components are put into the shaping heat press tools together and in the selected order to match the structure of the finished compound material and are processed in one and the same manu-facturing run to the final board-like compound material or mouldings with weather resistant outer skins. ~or this process, the same tools and plant installations can be used as are required or as one already availa-ble for the production of customary particle boards or mouldings.
In order to obtain a plain one-sided weather resistant coated particle board, for instance, the outer coating is generally applied by spraying onto the mixture of fibre/particle/adhesive agents. If necessary, a parting component (for instance tin sheets and other plates or talc in powdered form). The outer coating can be supplied either in pre-fabricated unvulcanized films, or built up successively by mechanically spraying, pouring, sprinkling and so forth, in the required quantity. After laying down on the batt and, if desired slightly pre-compressing it, the heat pressing follows and the further processing in the usual manner for the production of particle boards.
Of course, this process herein may be carried out in a different sequence and with a different number and quantity of ingredients used, so that for instance the weather resistant cover layer, which is to be vul-canized, is coated or applied on last and on top of and/or on both sides respectively. Furthermore, the mixture of fibre-particles and adhesive agents, with or without addition heat, may undergo a separate pre-com-pression primarily in order to prepress a moulding before the mixture for outer coating is put on and the final pressing follows.
Finally, according to further modifying aspects of this invention, a decorating, reflecting or other surface coating or texture can be vul-canized onto the weather-resistant board for instance, aluminum powder or foil, colour pigments or grainy materials may be used either at the be-ginning or the end of the coating procedure and may be incorporated into the process. The weather-resistant surface may be given a relief ornamen-tal structure provided the pressing tools have been fitted out accordingly.
This weather-resistant coating provided by vulcanization is not limited to compound materials of fibre, or particle-like base materials, since it may be used for plywood or wooden strip boards and in principle also on several outer surfaces and even only partly on the surface. Final-ly, also other lignocellulose-containing organic and the inorganic, i.e.
mineral-containing base materials may be used herein provided they can re-ceive a weather-resistant outer coating of unvulcanized rubber or other elastomers and maybe be manufactured into boards or mouldings.
In the accompanying drawings, Figure 1 is a section of two forms of weather resistant boards of aspects of this invention;
Figure 2 is a section of a board of an aspect of this invention in the form of a facia board;
Figure 3 is a section of a board of two other aspects of this invention in the form of a shaped vessel;
Figure 4 is a section of a board of another aspect of this invention including a window opening thereinj Figure 5 is a schematic flow diagram illustrating the process of one aspect of this invention;
and Figure 6 is a schematic flow diagram illustrating the process of another aspect of this invention.
As seen in Figure 1, the lef~ hand side shows, in cross-secti~n, an upper-coated weather resistant board while the right hand side shows in cross-section, a double-faced coated weather resistant board. The base material 1 consists essentially of a lignocellulose-containing and the mineral-containing fibre-particle/adhesive agents mixture, and the outer coating 2 consists essentially of a weather-resistant, vulcanizable syn-thetic rubber mixture. The outer coating 2 is both adhered to the outer surface of the base material 1 and penetra~es and impregnates into the base material 1 at the region 3. Thus, the weather-resistant board com-prises an integral uniting of the base material 1 and the rubber coating 2 after the rubber coating 2 has been vulcanized.
Figure 2 shows, in cross section, the weather resistant board of another aspect of this invention in the form of a base material 1 and a vulcanized outer rubber layer 2. The board is shown as being bent com-pletely around (at the right hand side) so that the outer rubber layer 2 extends around the side edges and a portion of the bottom. The elasticity of the outer rubber layer enables the corners 4 to act as hinges.
On the left hand side, the board is shown as being bent for form a step, with the elasticity of the outer coating enabling the outer and inner corners 4 to act as hinges. If necessary, a wooden slat 5 can be secured to the inner face behind the step.
In Figure 3, a premolded vessel having the cross section of a bottom 15, side walls 16 and a rim 17 is provided formed of the single faced board consisting of the base material 1 and the outer coating 2 (shown on ~ie lcft hand side), or alternatively of the double faced board consisting of the base material 1 and the outer coatings 2 (shown on the right hand side). After or during the molding operation, the rubber surface 2 is vulcanized.
The board in Figure 4 is shown in the form of a premolded pre-fabricated building element for use in a wall having a profile consisting of main wall portion 18, edge portion 19 and a window opening 20.
Figure 5 provides a description of the process according to one aspect of this invention for the manufacture of weather-resistant boards and mouldings according to another aspect of this invention. A parting agent (e.g. talc in powdered form) 1 is first applied, as by spraying, onto the charging platform 10. Then the granulated mixture of the unvulcanized rubber 7 is applied, and finally a mixture of fibre particles/adhesive _9_ ~5~5 agents 8 is applied thereon, to provide an uncompressed batt 9, having an unvulcanized rubber film 7a on one face thereof. The batt 9 is subjected to compression and heat on the hot press 12. This simultaneously provides a condensation of the adhesive agents in the fibre particle mixture 1 and vulcanization of the weather-resistant vulcanizable outer rubber coating 2.
The outer rubber coating 2 penetrates and is impregnated into the base matexial 1 and this results in the integrated, united board.
Figure 6 shows another aspect of an alternative manufacturing process of another aspect of this invention. Here the parting agent 6 is first sprayed onto the charging platform 10. Then the fibre particles/ad-hesive mixture 8 is applied to form a batt 9. Finally the outer rubber coating is applied on the form of an unvulcanized film of rubber 11. The further processing is as described for Figure 5.
., ~ ,. .
Claims (21)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. Weather resistant board comprising: an impregnable base material constituted by mixture of an organic and an inorganic base mater-ial in the form of at least one of fibres and particles and a curable resin; and an outer material constituted by a vulcanizable, weather-re-sistant elastomeric material; said outer material being in vulcanized form and being both adhered to one surface of said base material and penetrated and impregnated into the same surface of said base material.
2. The weather resistant board of claim 1 wherein said base material is a lignocellulose fibrous material and a mineral fibrous material.
3. The weather resistant board of claims 1 or 2 wherein said outer material is adhered to two mutually opposed faces thereof.
4. The weather resistant board of claims 1 or 2 wherein said outer material completely encases said board.
5. The weather resistant board of claims 1 or 2 wherein said elastomeric material is at least one of a natural vulcanizable rubber and a synthetic vulcanizable rubber.
6. The weather resistant board of claims 1 or 2 wherein said base material is also admixed with an adhesive agent.
7. The weather resistant board of claim 1 wherein said base material is in slightly precompressed form.
8. The weather resistant board of claims 1 or 2 which is in heat pressed form.
9. The weather resistant board of claims 1 or 2 wherein the outer material is provided with a further surface coating.
10. The weather resistant board of claims 8, 1 or 2 wherein the outer material is provided with a further surface coating and wherein said further surface coating comprises aluminum powder, aluminum foil, color pigments or grainy material.
11. The weather resistant board of claims 1 or 2 wherein the outer material is provided with a further surface coating and further wherein said further surface coating is in the form of a relief ornamental structure.
12. The weather resistant board of claims 1 or 2 in flat form.
13. The weather resistant board of claims 1 or 2 in shaped molded form.
14. A process for preparing a weather resistant board comprising:
laying down a batt of a mixture of organic materials and in-organic base materials in the form of a mixture of at least one of fibres and particles and a curable resin, either on a movable charging platform and then laying down a vulcanizable weather-resistant elastomer material thereon, or a vulcanizable weather-resistant elastomeric material which has been laid down on said movable charging platform, to provide a composite;
and subjecting the so-formed composite to the influence of heat and pres-sure;
whereby said outer material becomes in vulcanized form and is both adhered to one surface of said base material and is penetrated into and impregnated into the said surface of said base material.
laying down a batt of a mixture of organic materials and in-organic base materials in the form of a mixture of at least one of fibres and particles and a curable resin, either on a movable charging platform and then laying down a vulcanizable weather-resistant elastomer material thereon, or a vulcanizable weather-resistant elastomeric material which has been laid down on said movable charging platform, to provide a composite;
and subjecting the so-formed composite to the influence of heat and pres-sure;
whereby said outer material becomes in vulcanized form and is both adhered to one surface of said base material and is penetrated into and impregnated into the said surface of said base material.
15. The process of claim 14 wherein said base material comprised lignocellulosic material and mineral material.
16. The process of claims 14 or 15 wherein said base material is laid down directly on said movable charging platform.
17. The process of claims 14 or 15 wherein said base material is laid down on a layer of said vulcanizable rubber which is on said mova-ble charging platform.
18. The process of claims 14 or 15 wherein said base material is laid down directly on said movable charging platform including the pre-liminary step of laying down a first layer of a parting material on said movable charging platform.
19. The process of claims 14 or 15 wherein said base material is laid down on a layer of said vulcanizable rubber which is on said movable charging platform including the preliminary step of laying down a first layer of a parting material on said movable charging platform.
20. The process of claims 14 or 15 wherein said base material is laid down directly on said movable charging platform including the step of prepressing said batt of said base material
21. The process of claims 14 or 15 wherein said base material is laid down on a layer of said vulcanizable rubber which is on said movable charging platform including the step of prepressing said batt of said base material.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP78100902A EP0009053B1 (en) | 1978-09-15 | 1978-09-15 | Method of manufacture of weatherproof boards or other elements from wood fibre material and boards or elements formed by this method |
| EP78100902.2 | 1978-09-15 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1150465A true CA1150465A (en) | 1983-07-26 |
Family
ID=8185922
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000337295A Expired CA1150465A (en) | 1978-09-15 | 1979-09-12 | Weather resistant boards or mouldings of wood fibre materials and its process for production |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP0009053B1 (en) |
| CA (1) | CA1150465A (en) |
| DE (1) | DE2862199D1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4608960A (en) * | 1982-12-16 | 1986-09-02 | Reinhard Hering | Panels or moulded elements designed as heat-exchangers |
| US4999064A (en) * | 1985-06-28 | 1991-03-12 | Exxon Chemical Patents, Inc. | Process for producing weather resistant construction elements |
| FR3091496A1 (en) * | 2019-01-03 | 2020-07-10 | Chloé de La Chaise | Tablecloth for forming a fabric which can replace leather and method of manufacturing such a fabric |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3581300D1 (en) * | 1984-03-28 | 1991-02-21 | Reinhard Friedrich Hering | METHOD FOR THE ELASTOMER COATING OF MINERAL MATERIALS AND PRODUCT PRODUCED BY THIS METHOD. |
| GB8516373D0 (en) * | 1985-06-28 | 1985-07-31 | Exxon Chemical Patents Inc | Upgrading of composites |
| DE4100796C2 (en) * | 1991-01-12 | 1995-06-14 | Kurt Dipl Ing Karl | Lightweight element |
| DE4307522A1 (en) * | 1993-03-10 | 1994-09-15 | Ludwig Plack | Multi-layer heat-insulating and vibration-damping component and method for its production |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DD36020A (en) * | ||||
| DE967328C (en) * | 1942-04-26 | 1957-10-31 | Suedostholz G M B H Metz & Co | Process for the production of synthetic wood panels |
| AT227139B (en) * | 1960-12-30 | 1963-04-25 | Oesterr Amerikan Magnesit | Method and device for the continuous production of wood wool lightweight panels with a support layer |
| AT260509B (en) * | 1962-07-12 | 1968-03-11 | Oesterreichische Homogenholz G | Process for the finishing of at least one surface of press plates |
| DE1936681U (en) * | 1966-03-03 | 1966-04-14 | Huels Chemische Werke Ag | WEATHER RESISTANT LIGHTWEIGHT PANEL. |
-
1978
- 1978-09-15 DE DE7878100902T patent/DE2862199D1/en not_active Expired
- 1978-09-15 EP EP78100902A patent/EP0009053B1/en not_active Expired
-
1979
- 1979-09-12 CA CA000337295A patent/CA1150465A/en not_active Expired
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4608960A (en) * | 1982-12-16 | 1986-09-02 | Reinhard Hering | Panels or moulded elements designed as heat-exchangers |
| US4999064A (en) * | 1985-06-28 | 1991-03-12 | Exxon Chemical Patents, Inc. | Process for producing weather resistant construction elements |
| FR3091496A1 (en) * | 2019-01-03 | 2020-07-10 | Chloé de La Chaise | Tablecloth for forming a fabric which can replace leather and method of manufacturing such a fabric |
Also Published As
| Publication number | Publication date |
|---|---|
| EP0009053A1 (en) | 1980-04-02 |
| DE2862199D1 (en) | 1983-04-14 |
| EP0009053B1 (en) | 1983-03-09 |
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| MKEX | Expiry |