DE1619258A1 - Process for the production of insulating cardboard and insulating cardboard produced by this process - Google Patents

Description

H. SEILER - J. PFENNING 1619258 ¹ eÄ.irW; Dec 1966

Graduated engineers r «■ I-S O ρ ■ oldenburgallee ίο Pf / an

PA YB N TAN WALTB TELEPHONE: 3Ö4BB21 / 22

Telägrahim-Adjrei "": rope defense patent

■ JOHNS-MAEYILLE GORH) COUNCIL ΙΟΙ " 22 East 40th Street, 16 Mew Xorit, Hew ■ Toric »TJSA

"Process for the production of τοπ insulating cardboard and insulating cardboard produced according to this method ¹¹

For this registration, the priority of the corresponding

FSA registration Ser. ETo. 515 t> 49 of December 22 , 19b5 in claims. taken. ,

The invention relates to, and relates to, insulating paperboard in particular an improvement in the foamed pearls, Fibers and bituminous material contain tide η Isolierpäppenart. These have been commercially available for a number of years Cardboard is a highly satisfactory insulating material, .der excellent for use as roof insulation cardboard is suitable because it provides good thermal insulation ·, sufficiently fire and water resistant and economical can be produced. However, like many others, she has a lot suitable building materials, certain properties, the improvement of which would be desirable.

While the strength of the cardboard for its first use is appropriate, it becomes iti to a certain extent in its handling, transport, laying and roof repairs Scope of improper handling and is something in terms of breaking or tearing

sensitive. 'Accordingly, it would be desirable to have the rigidity the cardboard as well as its shock and pressure resistance. In addition, it would be desirable to improve the gap strength Cardboard to increase its resistance to high wind loads, which are striving 'the roof and the roof insulation boards to lift off the roof wing, to improve. In addition, it would be desirable to have the Zuäand or the To improve the texture of the surface of the cardboard, which light up as a result of the small particles that have accumulated on it foamed perlite has a tendency to be rather sticky and to get crumbly. This state is made by the trio effect the packaging material on the cardboard during its packing and unpacking, as well as by handling and pushing, that the cardboard experiences in the course of its transport is made worse. In addition, the loose particles are never used to glue the cardboard to the roof used adhesive interfering, una are for the the cardboard processing workers uncomfortable.

The problem of how the physical properties of the cardboard improving is more difficult than it may initially seem. To make the cardboard with the right strength, Fire resistance, the appropriate thermal insulation value, the appropriate water absorption resistance and others To provide desirable physical properties must be between the various components of the paperboard a balance must be maintained. Do this one Relatively low density paperboard "in general

009885/1696 _{BAD oreGINAt}

in the range of about 0.144 Ws 0.192 g / ccm (9 - 12'ib / eu.ft.) required. that are economical on a continuous basis It would be undesirable to use ingredients that reduce the amount of void in the paperboard of the cavities either in · * or between the foamed Periite particles were decreasing or any of the necessary impair the physical properties of the paperboard or make it difficult to manufacture. In view of on the manufacture of the cardboard that the use of a die Constituents of the paperboard containing aqueous pulp, the use of an ingredient increasing the drainage time of a soJ-Chen pulp would not be desirable. Another proof of the difficulty in improving it of the physical properties of the paperboard is the Fact - the industry ate extensive experimentation with the most varied of compositions and binding systems to have come to the conclusion that the ·. optimal composition for inducing the in these Paperboard practical, existing overall most desirable properties was achieved with the compositions of the commercial paperboard. ,

In the case of such a cardboard, the foamed perlitteixchen contribute to some important properties. Since they x are light, they act as a filler or inflatable material around the Keep the density of the cardboard at a low value. By

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Using about $ 60 to $ 70 foamed perlite particles, based on the weight of the paperboard, which itself has a density of about 0.048 to 0.080 g / ccm (3 to 5 lb / cu.ft.), densities of 0.160 or 0.176 g / ccm (10 or 11 lb / cu.ft.) were achieved. Generally used in the production of Isolierpappen used foamed perlite mass such a grain size (such grade) that the majority of the particles falls through a sieve with a clear mesh size of 0.83 mm (20 mesh screen) and a smaller but more substantial one Part of it falls through a sieve with a mesh size of 0.15 mm or less (100 mesh or finder). Since they are inorganic, foamed perlite particles contribute to the fire resistance of the cardboard. Furthermore they have excellent thermal insulation properties, and they contribute effectively to the insulation value of the cardboard.

The fibers in commercial cardboard are cellulose fibers, which are mainly used because of the strength they give the cardboard, but also because they act as a filling material that helps the foamed perlite mass to keep the density of the cardboard at the desired value the cardboard are available in significant quantities. Newsprint fibers are commonly used, usually in the range of about 1 to 20 % of the weight of the paperboard, because they are readily available and easily felted to help hold the foamed perlite particles in place.

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Bas la den. Commercially available cardboard existing kituminous Material leads to water absorption resistance and also helps the lasers; thereby ,, the material of the To hold the composition together in cardboard or sheet form. Although other sizing or binding material probably does its job in a more suitable way Way, were generally asphalt or other bituminous compounds preferred because they are relatively cheap, readily available ahd and to "adequately accomplish their assigned task" In general, asphalt is in quantities of about 5 to 1OjS the weight of the cardboard present.

might seem that a method of increasing the Strength of such a periteal roof insulation cardboard in the use of a binding material with high strength instead of asphalt, but this is not very practical because most binders, to make the cardboard effective with a higher strength provided as they are already on Q-round of the asphalt should be used in such large quantities, that 'the cardboard could not be produced economically.

Also, by replacing the asphalt it becomes such Binding material is used, the water absorption resistance of the cardboard is generally reduced to a large ϊβϋ, whereby, if the binding material is organiscli,

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when using sufficiently large amounts of the binder in addition, the fire resistance of the cardboard is reduced. To make the cardboard with the desired density and strength, To provide fire resistance and the appropriate insulating properties, the quantities of foamed perlite particles, which represent the inorganic material present in the cardboard, and the cellulose fibers present in the cardboard approximately at the values of these in the above-described commercial quantities Perlite fiber asphalt paperboard existing components so that the amount of binding and / or layering material that can be used is limited. For the There was trade, so there was little reason to produce periitic Cardboards. Of this kind to hope that any noticeable have improved properties of economic importance, without concurrently one or more other To impair properties to an economically undesirable extent.

The object on which the invention is based therefore exists in it, an insulating cardboard made of perlite fiber bitumen material with create improved physical properties.

Another goal of the invention is such cardboard has certain improved physical properties and in which no substantial loss of any of the desired properties of commercial cardboard occurs, ■

00988SY1696 ... / 7

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Another object of the invention is to provide such a cardboard Appropriate fire and water absorption resistance.

Another object of the invention is such. Cardboard that can be manufactured economically and its manufacture . does not require any major changes to the existing manufacturing facilities.

In summary, according to the invention, a method for Manufacture of insulating cardboard on a sewing machine, for example on a fourdrinier board machine (Fourdrinier machine), and. generated with the help of this process brought novel cardboard in proposal, in which the Solids in the finished product consist of foamed perlite particles, fibers, bituminous material and starch, characterized in that. the components are in the following areas in terms of weight:

foamed perlite particles 40 # - 75 # fibers, 15 fi - 55 fi

bituminous material. 3 $ »- 10 ^ and strength 0.3% - b $>.

Da-starch is known when used in fibrous Compositions in substantial amounts are effective

Binder would normally be expected any "increased strength that they bring about in a cardboard made of perlite, fibers and bituminous material could, by the adverse effects it would cause, be more than outweighed, Da Strength is organic, it would be expected that it would reduce the fire resistance of the paperboard and, since it is hygroscopic, they would also be expected to reduce the water absorption resistance of the paperboard would. Also, starch is common, known for its adverse effect on drainage, provided it in means of freely draining, continuously operating devices, such as a Fourdrinier board machine (Fourdrinier machine). However, unlike These expectations, when using starch in the manner described below, result in the paperboard product significantly improved and did not affect the process to any significant extent.

While according to the previously known state of the art containing both starch and bituminous material Compositions are known, it is clear that no suggestion is made that starch in a pearlitic insulating cardboard and certainly not in the invention used small amounts with bituminous material as

0098 8 S / 1696 ^BAD Qwginal

~ ⁹ ~ 1819258

Part of the binder system can be used. Of the themselves.' Prior art appears to relate to both starch and laser paperboard containing bituminous material to be limited to descriptions of means of strength bound, ans c tu. ie .use na mil · exii ^ m jixxumenmaterial impregnated cardboard, from cardboard in which the binding 'effect one of the ingredients is only temporarily effective, and of paperboard, in which either the starch or the bituminous material or both in comparison to the composition according to the invention in much. are present in large quantities. Examples of such ■ descriptions are USA patents 811 778, 1 664 601, 1 912 094 and 3 166 466. Also appears it that the previous state of the art, with Starch and bituminous material in the same cardboard composition has to do not refer to perlitic paperboard, but rather the filling of a fibrous one Composition with sufficient binder describes to essentially the intermediate frame between the Fibers to be filled in, while in the case of cardboard according to the Invention of the bituminous material and the strength in such a quantity and distribution are available, "that the volume of the voids or gaps between "the foamed perlite particles are not essential, is decreased. These voids or spaces contribute to the thermal insulation properties of the Cardboard and must not be filled with binding agent will. ·

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The nature of the invention is based on the following the accompanying drawings explained in more detail. Show it:

Fig. 1 is a graph showing the relationship between the tensile modulus of perit-paser asphalt paperboard and the amount of starch it contains,

Pig. Figure 2 is a graph showing the relationship between the splitting strength of perlite paser asphalt cardboard and the amount of starch it contains,

Pig. 3 is a graph corresponding to Pig. I except that the fiber content of the paperboard composition was reduced in proportion to the amount of starch added to maintain the organic content of the various paperboard samples at substantially the same level in the tensile modulus tests,

Pig. 4 is a graph corresponding to Pig. with the exception that the Pasergehait is the Cardboard composition based on Pig. 3 has been changed,

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Fig.!? a graph of the relationship between the surface hardness of a perlite fiber asphalt cardboard and the amount of starch it contains, '

Pig. & a graph showing the distribution r Area of the tear module for a number in the course of the production of a perlite fiber asphalt cardboard randomly taken samples compared to a corresponding graphic Representation for during the production of perlite fiber asphalt paperboard of the same type, however, samples containing starch, taken indiscriminately, are illustrated, and

FIG. 7 shows a graphic representation corresponding to FIG. 6, However, based on a perut fiber asphalt cardboard which contains asphalt with a softening point much lower than that in the asphalt used to obtain the data for the graph of Figure b.

00988 5/1696 ^{BAD o} «giwal-

In. the following description relate to those specified Percentages of the various ingredients present in the paperboard, unless otherwise stated on the weight of the solids present in the finished paperboard.

In the drawings illustrate the Pig graphs. 1 to 4 the increase in the tensile modulus and the iDpao-tfestigiceit as a result of the presence of Strength. To obtain the graphical representations according to Pig. 1 and 2 used became a Series of paperboards made of foamed perlite particles, cellulose fibers, asphalt and different amounts of starch contained. The final composition of the comparative or reference paperboard which did not contain starch was as follows:

foamed perlite particles öö, y ⁰ Jo

Newsprint fibers. "24, / ^c ß>

Asphalt (softening point 98.9 ° C) b, 4 #

Total: 1OU, U #

The cardboard was made by mixing the ingredients in water for the purpose of making an aqueous slurry

. ° with a solid consistency by weight of about b fl <

^ The asphalt was made as an aqueous emulsion with i? B $ solids
«^ Content added. The ring and ball penetration value (ring

and ball penetration value) of the asphalt was zero at 2b ° G (TY ⁰ I ¹ ). The mixture was then tested in accordance with the TAPPI test T 1üü1 m-bU (TAPPI = Technical

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Association, of the Pulp and Paper Industry- »London) with the designation" Forming Insulating Borad For Physical Tests "built and operated. TAPPI standard hand-held paperboard former formed into a 25.4 mm (} ") thick wet fiber felt and then flattened at room temperature to solidify the material, whereupon the paperboard first a step at about 204 ° C (-4OQ ⁰ I ¹⁾ and then two and a half hours at about 149- ⁰ C (30O was ⁰ JB ¹⁾ dried "the moisture content of the board was in their introduction into the drying apparatus about 23 # to 25 <fi of the total solids of cardboard and process Trocicuhgs-after about 1 $> * The resulting paperboard had a density of about 0.144 g / ccm (9 lb / cu.ft.).

The composition of the comparative cardboard was added strength to produce more samples in the same way, the ge, as described in more detail below, 'starting from 0.3 i> of the weight of the total solids deir paperboard of residual in the paperboard thickness, an increased proportion of starch contained. The starch was added in the form of raw tapioca starch grains which were contained between the other solids when the watery pulp was made. The tapioca starch ^ cöxner were cooked in the drying device / around eir | gel-like boiled

i. ■■■■■ -.- -> -. \ -

To form starch material that acts as a binder.

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The splitting strength of the samples was determined according to that in ASTM C-209 (ASTM = American Society for Testing Materials) entitled "Testing Fibers" under the chapter "Tensile Strength Perpendicular To Surface" described Test procedure determined. The tensile modulus of the P & ppen was determined according to that in ASTM D-1037 entitled "Evaluating The Properties of Building Fiberborads "(Evaluation of the Properties of construction fiber boards) under the chapter "Static Bending" (Static Bending) determined.

As shown in FIG. 1, the tensile modulus of the insulating board increased sharply with only very small amounts of starch in the composition of the board. With the introduction of larger · * - amounts of starch into the composition of the cardboard increased. the tensile modulus continues to increase, but not at the same rate of increase. The growth rate of the Zerreißmoduls per contained in the cardboard starch content seems to decrease starting at about 1.5 i "to 2 # starch in the composition of the board, significantly lower with increase in the starch content .allmählich.

As shown in Fig. 2, the splitting strength of the paperboard increased with only very small amounts of starch in the cardboard very sharply and took it in the presence of added starch further, but not at the same rate of increase; the

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The steepness of the curve decreases markedly at around 2.5% to $ 1.0 starch content and again, although not so sharply, at around $ 3.5> to $ 5.0> starch content, where the curve appears to flatten out. The peel strength increased even with only 0.5 % strength in the composition of the paperboard from 12 psi to 15 psi, which means an increase of $ 25>, and at 1 $ strength in the composition of the paperboard. to 17 psi, which is an increase of more than 40%. A corresponding surprisingly high increase in strength at such a low starch content is also evident from the Pig curve. 1, in which only O, p 5 & strength increased the tensile modulus from 70 psi to 80 psi, which is an increase of more than 14 i <> , and only $ 1 strength increased the tensile modulus to about 89 psi, which is a Increase of more than $ 27> means *

In the case of those in connection with the curves according to Pig. V and 2 The samples produced, the composition of the comparative cardboard, as indicated above, was gradually increasing in thickness Proportions added. In order to produce specimens that are strong in the tested final finished probepa ^ ta contained in gradually increasing amounts. It means that with the increase in the starch content, the percentage amount. any of the remaining pesticide ingredients, assuming of the total amount of solids in the sample as $ 100, im Slightly decreased in contrast to the actual amount.

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So thus became the percentage of organic matter in the cardboard samples gradually increased while the percentage of inorganic material, i.e. the foamed Pearlite particles, was gradually lowered. To eliminate any possibility that the increased strength of strength containing samples to the great. Part on the increased salary based on organic material, additional series of samples were prepared using the same procedure described above produced or tested for the production of the samples and those used for plotting the curves according to FIGS. 3 and 4 Data obtained. The comparison or reference sample contained no starch and was given the same condition as the comparison or reference sample according to Pig. 1 and 2 produced. However, when forming the test specimens with adding starch in gradually increasing amounts a substantially equal amount of newsprint fiber deducted so that the organic matter content of the Samples remained essentially constant. ·

Like in Pig. 3, the tensile modulus of this increased second group of samples with increasing starch content "sharp on, even with the small amount of $ 0.5 starch in the paperboard the tensile modulus from 76 psi to about 89 psi increased, which means an increase of more than 1 '/%, while at 1 ^ starch content, the tensile modulus increased to yy psi, which is an increase of about $ 30. Bie growth rate of the tensile modulus, was with. the addition of more starch less, the curve increasing with a starch content from about i? ^ seems to flatten very negligibly.

009885/1696

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In Fig. 4 the increase in the splitting strength of the paperboard of this second group of samples is illustrated about 4.5 ° / ° or 5 % starch content noticeably flattened. At 0.5 $ starch content, the splitting strength increased from 13 psi to about 15 psi, which means an increase of more than $ 15, while at 1 ° J> starch content the splitting strength increased to about. "1-6.5 psi which means an increase of about 27 ° / ° . ~

The tensile or rupture modulus of an insulating board is of importance with regard to the overall strength and rigidity of the board, in particular with regard to the ability of the board to be able to deal with it in a rougher manner, which is in the ^; Often occurs outdoors in order to be able to withstand the traffic passing over them and to allow tension between widely separated roof surfaces. If the tensile modulus is increased, the chances of breaking or tearing the paperboard as a result of improper handling during handling or transport are largely reduced. The resistance to splitting, as indicated above, is of essential importance for the resistance to blowing away i

as a result of strong winds.

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-. . ■■ -._ ■, ■ - ^r -v.-M., .., r

MtniitX . ι -. '■ "-.; .- ■ .." (

Referring to Fig. 5, the samples prepared for testing the tensile modulus and splitting strength in conjunction with plotting the graphs of Figs. 1 and 2 were also tested to determine the hardness of both their upper and lower surfaces. The hardness data was obtained in accordance with the Brinell hardness test, which was performed by placing a 25 * 4 mm (1 ") diameter steel ball resting on top of the cardboard sample under an initial load of 0.907 kg (2 pounds) An additional load of 5.44 kg (12 pounds) was imprinted on the sample and the resulting indentation measured. The Brinell hardness number multiplied by 1000 equals 2.69 divided by the number of millimeters the material has been indented. The hardness of both surfaces increased with the addition of small amounts of starch it gathers and increased with gradually larger amounts of starch contained in the cardboard, but not at the same rate of increase = comparative cardboard containing no starch, which means an increase of about 19 % . With a starch content of $ 1, the top had a Brinell hardness number of about 60, which means an increase of about 28 j6. The Brinell hardness number for the underside of the comparison or reference cardboard was 56, while she

at 0.5 5 * starch content was about 64, which is an increase '■■■>".'
. of more than 14 ^ means. Bti 1.0 ^ starch content

009886 / part ^L -

the underside has a Brinell hardness number yoü about 71, which is an increase T about 2 ^{compared to the hardness of the same cardboard (a} ß> means, curves for both surfaces never rise; up to about Q, t> i » starch content increases very quickly and then increases The curve for the top of the board flattens out considerably more than the curve for its bottom.

The importance of the hardness of the cardboard is related to their sensitivity, through hard objects, .the trutha the construction of the roof of ar- ·. beiterii are dropped on them to become. Small amounts of starch not only increased the surface hardness of the cardboard, but surprisingly made it the surfaces of the cardboard are essentially free of dust. this seems to be due to the fact that the strength is associated with demasphalt the components of the cardboard on their surfaces holds together, including the tiny stauD ^ - particles that previously made the surface of the cardboard dusty and made the surface of the cardboard more dense, like this that they also correct the particles better in their Hold position. The surface of the cardboard was in place. dusty or crumbly, as it was sometimes when axs uC: ._ ictii- una / or binding material only. Asphalt used became. hard and essentially, smooth.

009 886/18 96 bad öo ^ ^l

According to Pig. 6 was made on a Fourdrinier machine (iourdriniermachine) Perlint fiber asphalt paperboard the following Composition made:

Foamed · Perlite particles 71, 0 i> Newsprint fibers 20, b $

Asphalt (adult point: 98.89 ° 0) ■ 8.4 5 *

Total: 100.0 ° ß>

The ring and ball penetration value was equal to Uuil ^{at 25 ° C (77 0} I ^1). A number of samples from the paperboard production were taken indiscriminately and tested according to ASTM D-1037 discussed above to determine their tensile modulus, with the results rounded down to the nearest even number for convenience. * Pig's dashed line. 6 represents the frequency with which different values of the tensile modulus occurred * The solid line represents the same type of curve, but with respect to cardboard samples taken at random from the production of Perlint Paser asphalt cardboard with the composition listed below?

foamed perlite particles 71.0 %

Newsprint fibers 21.7 f>"'

Asphalt (adult point 9ö, ö9 ° C) ■ b.'b% - Thickness 0.8 Jl

Total: 100.0%

0 0 9 8 8 5/1696 _BAD original

As indicated by, the various compositions, are the components of 'the. first cardboard in the second Cardboard in essentially the same quantities, however, the second cardboard contains a small amount of starch, while the first cardboard contains no 'starch'

The average density of those not containing starch Cardboard samples were 0.179 g / ccm (11.2 lb / cu.ft ») while the average density of the starch-containing cardboard samples Was 0.167 g / ecm (10.4 lb / eu.ft.). Despite the higher The latter cardboard showed the density of the first-mentioned cardboard a significantly higher tensile modulus value, the average The tensile modulus of the majority of the non-starch cardboard samples ranges from about 4.20 to 4.69 kg / cm (60-67 psi) while the average Tensile modulus of the majority of the starch-containing paperboard samples in the range of about 5.18 to 5.95 kg / cm (74-85, psi) appears to be, which is especially true when considering the samples present in the last named low starch represents a significant increase.

In Pig. 7 is the same type of curve as in Pig. 6 shown, however, with regard to paperboard containing asphalt with a much lower softening point than that in US Pat asphalt used based on Mg. 6 samples. To get the one to plot the dashed curve naoh 3? ig. The data used was recorded on a Fourdrinier board machine (Fourdrinier machine) perlite-paser-asphalt-

Ρ & ρρβ of the nachatshendsn teamwork made! ■■ 009885/1 S00 BADORLOiNAL

foamed perlite particles $ 72.0>

Newsprint fibers 22.5 ^

Asphalt (adult point: 48.89 ° C) 5, S>f>

Total: $ 100.0

To get the "when applying the full curve The data used according to Fig. 7 was recorded on a Fourdrinier board machine (! Fourdrinier machine) Perlite fiber asphalt cardboard the following composition produced /

foamed pearlescent tea 70.0 j6

Newsprint Fibers - $ 23.8>

Asphalt (adult point 48.89 ° C) 5.0 #

Strength $ 1.2>

A total of 100.0 ^

The ring and ball penetration value of the asphalt was 2iJ ° C (77 ° F) in the range of 30-60.

• The average density of the samples of both types of paperboard was approximately 0.173 g / ccm (10.8 lb / cu.ft.). It can be seen that although the binding force of the asphalt used in the samples discussed with reference to FIG strength

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1819258

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containing samples a considerably higher and in some Cases had two to three times the tensile modulus of tensile strength not containing the starch samples "This is an excellent improvement brought about by the in that finished cardboard product containing a small amount of starch was made possible. '.

In order to test the resistance of the cardboard to water absorption, cardboard samples were prepared in the same manner / as in connection with the samples using the samples using the curve for plotting the curve 1 and 2, and the samples were prepared in accordance with Chapter. i ^^ on ^^ t ^ ate) in ^ ASTM-Test C-209 with the Iit «§i ^ ^f a} estihg ^ Siruetüral Insulating Board Made Prom Tegetable Pibrwes ¹¹ According to this test method, the samples are first weighed and then immersed in water for two hours, after which they are removed from the water and weighed again to determine the amount of water absorbed over the course of this time. This is used as an additional test same test procedure with the exception that the samples are immersed for a period of 24 hours The table below gives the percentages of water absorption for the two test times for the specified strengths Samples containing a lot of amounts, whereby the starch was added to an equal & round composition. as for those in connection with the aforementioned series of specimen cards

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HergesiaLxed comparison or reference cardboard is used was foamed at a solids content of $ 68.9 Perlite particles, $ 6.4 asphalt and 24.7% newsprint fibers in the comparative board, these being Percentages in the test samples with the addition of starch in gradually increasing amounts for the various Samples gradually decreased slightly. The strength percent.tBa.tz in the samples referred to the weight and was based on the total weight of the solids content of the finished paperboard samples.

Starch content ($) water absorption by volume

sample

1 0.0

2 0.3

3 0.6

4 1.3

5 2.3

6 2.6

7 3.6

8 .4.7

9 5.6

10 5.6.

11 6.5

12 7.6

13 11.1

If one takes into account that starch tends to absorb moisture, it is noteworthy that the water absorption values are so low even when the cardboard contains as much as 11.1 % starch. The asphalt, of course, contributes to the water resistance of the bppe, but it was not expected that the starch would not significantly outweigh the water resistance properties of the asphalt.

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2 hours 24 hours 1.5 4.9 1.7 3.0 1.7 2.8 1.6 3.7 1.6 2.2 2.0 2.5 1.7 3.3 2.3 5.2 1.8 5.9 1.6 4.2 1.9 4.5 2.0 5.4 2.1 5.1

^: ''^:; re-19258 '

Urn containing the high water absorption capacity of no, asphalt or other Schlichtinaterial means starch-bound paperboard this: Art -different cardboard sample were u prepared to illustrate that contained aufgeschäu & te perlite and newsprint fibers in the same relative proportions as in the to obtain the water absorption data for Samples 1-13 used basic composition were present, but the only other constituent part of asphalt contained small amounts of läpioka starch * The results ifaren f0lge0.de 1

Starch content (| £). Water would take up to tolumen

Sample Z hours 24 hours .

14 0.8: 4.8 28.4

15 2, -3 1.0 22.8

16. 3.8 9.0 30.0-

These figures show that _p strength allein.der resistance of the board to water & ufnähme even the smallest amounts, such as $ 0.8 gewiehtsmäßig the Gresamtfeststoffe of cardboard, actually detrimental is.

As is well known, it has previously been established * that one means Starch (10 ^) bound and not containing asphalt , Perlite fiber paperboard an unexpected water resistance insofar times when a long-term soaking in water for

t ■ = ■■. ■ .'- ■■ "'. ■ i ■' ■" ■. ■■■■■ ■ -

a © Bauer 'from dr © i WooTien only slightly © ® softening the Pallte brought about. But such attempts prove it only "that sine Fas © r-Perllt ~ Süärke ^ Papp0 a® big

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5 / 1Sii / ■ '"" ^: y., / 26

Contain amount of water, canoe, without disintegrating, whereby the amount of water is greater than the amount of water absorbed when testing the cardboard according to the ASIM test 0-209. The ASTM test is of far greater importance, since it is based on the fact the absorption properties of the paperboard to Time determined the problem, around which it is, is not so setoj whether a cardboard eiae certain large amount of water for ein® long- time keeping, isatin, without disintegrating, but whether due to a fault or damage in the roofing, water penetrating into an insulating cardboard is essentially kept in this general localized area, instead of XHift> ^^ 4sfr-, & afoÄ.ii ... ..iub @ .o ^ jU ^ n9ablefceit of the cardboard to spread quickly over the entire insulating layer. Since excessive moisture in an insulating cardboard has a detrimental effect on its strength and its insulation value, it is essential that any effects resulting from the binding of moisture into the cardboard at a damaged area of the roofing are kept as close as possible to the local area of the damaged area. The low absorbency of the paperboard according to the invention offers protection against the undesirable spreading of excessive moisture.

Furthermore, the unexpected improvement in the physical properties of roofing boards containing low levels of starch made of perlite fiber bitumen material, starch-free cardboard was made according to the following typical Weight-wise composition made from solid components contained in the finished cardboard product

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1019258

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foamed pearls.? Q, u / jt ^ uung paper fiber 23.8

Asphalt (adult points 4 &, 9 ^Q O) 6.2

All in all:

Further cardboards were produced, the strength according to contained the following composition, in which the Percentages by weight based on the total solids content of the finished cardboard profile are:.

_ foamed perlite particles "" "- === - _Z e i tcngspap i er f äs er η

Asphalt (adult point 48.9 ° 0) 5.0% thickness 1.2 $>

All in all:. , $ 100.0

The compositions of the two cardboard groups give way from each other only by that contained in the second cardboard group small amount of starch and the correspondingly reduced amount of asphalt in this cardboard. Both Paperboard groups were subjected to tests to determine various physical properties. The following Table illustrates the differences in the physical Properties of the two cardboard groups which are quite remarkable when one takes into account that the one in the second papjjtui & rujj ^ b t, ata «ix" veue starch percentage so low

is. '..' ■■. ' . :

. . · ORIGINAL BATHROOM

009885/1696. .... / 2g-

test

Density g / ccm (pfc)

Extreme stress
kg (lbs)

Tensile gap strength
kg / cm ^ (psi)

-2Q-

Insulating cardboard without starch

0.170 (10.6) 4.082 (9.0) 0.47 (6.7)

Shear crack strength

kg / cm2 (psi) 1.07 (15.3)

Compression - 5 ^c f ° -

Solidification kg / cm (psi)

9.31 .-. (133.0)

Water absorption
(in io of YoI. after
3.75 hours)

1.4

Insulating cardboard with starch

0.183 (11.4)

12,156 (26.8)

1.337 (19.1)

2.226 (31.8)

10.78 (154.0) 1.4

While an increase in the density of a paperboard would be expected to increase its strength somewhat, such an increase in strength is generally proportional to the increase in density. So would on this basis since the multiplication of the The density of the improved paperboard containing starch approximates 7.5 is the increase in the extreme load instead the actual value of 12.156 kg / 26.8 pounds) Value of approximately 4.40 kg (9.7 pounds). In the same way it can be shown that the values of the other tested Properties are considerably higher than they are at the increase in the density of the starch containing sample should have expected.

In carrying out the aforementioned tests, the ultimate Load according to the chapter "Transverse Strength" in the ASTM test C-20y and the tensile gap strength

009885/169 6

BATHROOM OBIGlNAL

determined in accordance with Chapter # 1ensile Strength, Perpendiöular ϊο '-, Surface "(tensile strength perpendicular to the surface) in the ASQM test C-209, with the exception that, for the sake of convenience, instead of a sample with the dimensions 15.24 cm × 15.24 cm. (6 "χ 6") a sample of 5.08 cm χ 5.08 cm (2 "χ 2 ^W ) was used. The results from this smaller sample agree with 15.24 cm 15j24 cm (6 "χ fa") specimens exactly matched the test results. ■.; ■ - .. ·

The shear splitting strength was determined by placing the cardboard in a vertical plane was arranged so that a vertical Line through the top. Corner the one diametrically opposite it lower corner connects to it and at the upper corner a load directed vertically downwards

was exercised until the cardboard failed in shear. The compressive strength of the paperboard was determined according to the chapter "Method of Desting for Compressive Strength" in ASTM-Te & t 0-165, while the water absorption | numbers according to the chapter "¥ ster absorption" (water absorption) \ im ΑΒΤΪίτΊϊβΒϊ O-209 with the exception that ^! the samples "bits" of the specified two-day time _: apatine for! a period of 2 _? ? 5 hours »mixed in fiber _# ^ Both © Steppan nattea ^ tinen Ieoli®x value" 0 "

of 0.36 α
Induetrie ι

were aß? iäh®OT, d 25.4 φ »" ■ ■ (> * ') diek, what in the

© »'ar suf riede UE parts tad Anges © & ® & will,

... / 30

The results of the examination of the extreme. Show strain .the largely improved strength of the small amount of starch containing cardboard versus the starch-free cardboard. The tensile strength and the shear strength of the Starch-containing paperboards are considerably taller than those of the starch-free paperboards and show those of the starch-containing ones Paperboard can be expected to perform better when exposed to strong winds that strive, the Lift the cardboard from the roof! In such a Palie would with all probability die Bond between the cardboard panels and the wing of the The roof gives way before the cardboard gives in itself. The compressive strength of the pegpen containing the starch shows that they are subject to the pressure and impact of workers walking over them in the manufacture or repair of a roof withstand. The water absorption data show that the Adding starch "to the roofing felt its water resistance not "affected.

In order to further illustrate the surprising strength of the insulation board according to the invention, tests * were carried out to determine its horizontal shear gap strength . This attempt was made by building a composite three-layer roof using

I ■ ■ ■

^{commercial 11} saturated with asphalt! 5 "pound" -asbest-. Felt over with any steel; the surface in 2 * χ 12 »connection

... / 31

009 885/18 9 6 bad ordinal

: _ 3iV T613258

bound Dactiisoxierpappeti »The asphalt used between the roofing felt layers, between the felt and the cardboard as well as between the cardboard and the wing had a softening ratio of 87.8 ⁰ C (190 ⁰ I ¹ ) Wing! Was loaded with shear loads, while the composite roof containing the insulating cardboard and felt algae was clamped in and held in its normal position. The load was applied by the winch until the roof yielded, which has in this experiment by "failure of the tensile strength of Filalagen at a wind load of 698 kg b (154-0 pounds) showed. The paperboard itself remained intact.

. The importance of examining the horizontal jti.ext is their indication of the strength of the cardboard through the movement of the building and the outer skin (membrane movement) caused by changing humidity and thermal conditions will. The ability of the cardboard to withstand a simulated building movement up to a force of at least bye,!? icg (1: 54-0- pounas) to withstand without splitting oaer Failure to otherwise fail is seen by the industry as a sign considered a more than adequate performance.

The general formula of the insulation board composition according to of the invention according to the weight of the Gesamtbestanö.telle of the finished Cardboard product is as follows

... / 32

BATH ORIGINAL

009885/1696

foamed perlite particles 40 - 75 i °

Pasern $ 15- $ 53

bituminous material 3 - 10 $

Strong, '0.3 - $ 5

This composition is consistent with what is generally accepted by the industry as meeting the many requirements for an economically satisfactory insulation board, yet it gives a much stronger board product as evidenced by the various test results described above. The fibers are preferably cellulosic fibers, such as newsprint fibers, although other types of reinforcing fibers, such as other forms of cellulosic fibers, slag wool fibers, asbestos fibers, and glass fibers, could also be used. Combinations of cellulosic and slag fibers can also be used, as discussed further below. The bituminous material is preferably asphalt because it has been found to suitably function in the paperboard product, to be economical and readily available. Preferably, the asphalt has a softening point of at least 4b, 9 ° C (120 ⁰ F) to enable the manufacture on a continuous molding machine, for example a chine Langsiebpappe nmas (Fourdrinier machine). However, as will be apparent to those skilled in the art, other bituminous materials could also be used. The used

... / 33 00 9 885/1696 _BAD nal

Starch is preferably a taploka starch because it helps a relatively low cooking temperature brings about a suitable firmness, so that it is in the form of raw grains mixed with the other ingredients and Can be cooked on the spot if the Cardboard is in the Iroekunungsanlage. Other types of starch, such as corn starch, would do their job in the cardboard also meet in a suitable manner, and they can be depending on the type without extensive changes to the Also cook equipment in the drying facility, however would these strengths due to their generally higher Cooking temperature in most cases probably in boiled Form can be added, what from the "processing point of view This is not desirable because of the required Cooking unit and the adverse effect that cooked starch has on the drainage time of freely draining Has paperboard manufacturing processes or operations.

In addition to the various test results discussed above, which show that only small amounts of starch are required in the paperboard according to the invention in order to improve its physical properties considerably, and that in addition the rate of increase in the strength gain of the paperboard is markedly lower as soon as the starch content becomes one. low percentage (not more than about 4.5 i "or 5 #) of GesamtfestaJoffe cardboard reached EAE are other reasons why the starch content .werdet not kept up!

^V BAD ORIQiNAL

00988 5/1696 c}

should be considered the upper limit of the range given in the general formula. Insulating cardboard tends to absorb moisture from the air inside the building, the moisture content of the cardboard fluctuating accordingly as the moisture content fluctuates, which results in cyclical moistening and drying! Each time the cardboard dries, it tends to shrink by a tiny amount, which has a detrimental effect on the dimensional stability of the cardboard. It has been found that as the starch content increases, the tendency to shrink due to cyclic wetting and drying is also increased. Furthermore, the perlitic insulating cardboard of the type described here, if they contain too much starch, tend to dry more slowly, since the starch attracts water when it is boiled and does not give it off easily even when exposed to high temperatures. This necessitates a proportional increase in the drying time, which can lead to the drying process becoming very costly, since drying facilities are complex and the period of time during which the cardboard must remain in the drying system has a significant effect on the costs of the manufacturing process. Other starch-related factors that add to the cost of the insulating board and make it desirable to keep the starch content as low as the strength of the board allows, the cost of the starch, the facilities required for its processing, in particular when cooked dia strength

0 0 9 8 8 5/1 6 9 6 bad original

before it is added to the composition of the paperboard, and the reduction in the rate of production caused by the presence of starch in the pulp, particularly when the starch is added in the cooked state. Therefore, the starch content of the finished cardboard product must not be more than about 5 fi , so that the dimensional stability of the cardboard is maintained, the cost of the cardboard is reduced to a minimum and, moreover, the cardboard experiences a highly appropriate improvement in its physical properties, without its other properties Affect properties.

Roof insulation boards may get wet when they are installed, which has the effect that the cellulose fibers, if present in the board, tend to expand. As a result of the drying process, the cellulose fibers tend to shrink back to their original size. Under the influence of sun and wind, the upper exposed surface of the cardboard often dries out before the underside / dries, so that the cellulose fibers on the top tend to shrink back to their original size, while the cellulose fibers on the underside in their expanded state remain looking. This phenomenon causes the edges of the board to bend upwards and a "depth ¹¹ (" cupping ") cardboard occurs. Although this is not a permanent condition (because the cardboard check into their original planar position moved back when the fibers in the entire Cardboard have become dry) and although the

: BADOBMS5NÄL .. ./30 00.9 885/1696

Cupping movement is slight, it can cause the bond between the cardboard and the roof support surface tears apart when using slow-setting cold glue and a sinking occurs before the adhesive has set. A sinking can also affect the attachment A composite outer roof skin over the insulating cardboard make it extremely difficult and the cause is often worse Roofing work. This phenomenon only occurs with cardboard that has sufficient strength to or to allow the edge sections of the cardboard to be lifted off and to be self-supporting like the paperboards according to the invention.

It has been found that where in the composition slag fibers in sufficient amount to effectively add to the strength of the paperboard, a deepening the cardboard is effectively fixed. This is due to the fact that the slag fibers do not expand when they become wet, so that if they are thoroughly dispersed in the composition in such an amount that they will expand the Cardboard on each side effectively prevent the problem of Is deeply resolved. The ones necessary to fulfill this purpose Amounts of mineral fiber vary depending on the type of paser. The formula below is for compositions for cardboard according to the invention containing mineral or slag wool fibers in connection with cellulose fibers exemplary:

... / 37 0 09885/16 9 6

foamed perlite particles 40 ^ - 65

Cellulose fibers 15 # - 25

Slag wool fibers 10? S - 30

Asphalt $ 3 - TO

Strength $ 0.3 - 5

In the example above, the presence of Slag wool fibers require the amount of foamed perlite to be used, since slag wool like the foamed ones Perlite, inorganic, and fire-resistant, and they also contributes to the insulation value of dex cardboard. Preferably the cellulose fibers should not be replaced by slag wool fibers, as the cellulose fibers make the fabrics more effective hold together in batt form as the slag wool fibers. Because of this, there must be a relatively large one in the cardboard Amount of slag wool fibers to be present to stretch to prevent the cardboard or board, as the cellulose fibers tend to expand when they are moistened and that through the non-stretching slag wool fibers counteract the state that is brought about.

The following lOrmel is for an asbestos fiber compound cardboard containing cellulosic fibers according to FIG Invention exemplary *

... / 38

BATH ORIGINAL

009885/1696

foamed pearlite particles 55 $> - 75 $

Cellulose fibers. - 15 # - 25 #

Asbestos fibers 0.5 # - 5 $>

Asphalt 5 # - 10 #

Thickness 0.3 # - 5 #

Since asbestos fibers have more bandage strength than slag wool fibers, is used to combat the tendency of Cardboard, due to the expansion of the cellulose fibers too deep, does not require as much asbestos in the cardboard.

A preferred formula for the non-slag fiber composition of the paperboard in which the constituent amounts in percent by weight of the total solids of the finished cardboard product is as follows

foamed perlite particles 65 $> - 75 $>

Newsprint fibers 15 ^ - 25 ί »

Asphalt 4. £ -. 8 pounds. -.

Strength $ 0.5> - $ 2>

Within this constituent exex there was one in high Dimensions of satisfactory, economical, defensible cardboard manufactured at which the degree of fire and water resistance retained, which the cardboard to be improved had »and which discussed the unexpected increase in the above physical properties showed.

009885/1696 ^ . _oWOlM At

The insulating cardboard according to the invention can be in any desired suitable manner, for example using a suction form process or a freely draining one continuous process, as in a Fourdrinier board machine (Fourdrinier machine) is provided. With regard to the Fourdrinier process (Fourdrinier operation) can the cardboard according to the in the ÜSA patent 3 042 578 process described. In either process, the starch can already be cooked in the Slurry included with the remaining solids or, as discussed above, the pulp in the form of raw, uncut starch grains are added, which are used in the drying system during the drying process. As well as the strength as well as the bituminous material-should too thoroughly dispersed in the aqueous slurry at the time the pulp is introduced into the paperboard machine will. None of the components are suitable for the finished cardboard to be added by impregnation, since this does not result in an even distribution of the constituent in question throughout the cardboard and in the required areas Quantities would lead. Rather, it would lead to that it would be excessive in some places and insufficient in others and on the surfaces of the cardboard would remain too abundant.

It will be understood that in addition to the ingredients specified above, small amounts of other fillers

· ■■ - "■■ '- ... / 40

009885/1696

may be included in the composition as long as they do not affect the properties of the paperboard and are preferably inorganic because of fire resistance. An example of one such ingredient is clay or clay, in an amount up to $ 5> by weight of the total solids in the cardboard could be present without the density appreciably enhance or impair the board otherwise. However, due to its unfavorable effect on rapid drainage, betonite clay is not recommended.

... / 41 0098.85 / 1-696

Claims (1)

At. s ρ r ü c lie 1. A method of making insulating board on a wet machine, Mspielweise on a Fourdrinier machine, in which the solids in the finished product consist of foamed perlite particles, fibers, bituminous material and starch, all of which are considered to be used in the manufacture of cardboard per se are known, characterized in that the components are by weight in the following ranges:. ^a foamed pearlite oo $ 40-75 ^ Fiber $ 15- $ 55> bituminous material 3 56-10 96 Thickness 0.3 # - 5 fi 2 * Method according to claim!, Characterized in that the fibers are cellulose fibers, such as fibers obtained from newsprint, 3 «Method according to claim 1, characterized in that the Fasepn from cellulose fibers and from mineral or Schlackenfaeern exist. ... / 42 009885/1696 4 «Procedure according to. Claim 3 t characterized in that the cellulose fibers are 15 $> - 25 # of the solids of the finished cardboard, while the mineral or slag fibers are 10 $> - 30 # of the solids of the finished cardboard. 5. The method according to claim 3 or '4, characterized in that the mineral or slag fibers contain asbestos fibers which are about 0.5 $> -5 "$> by weight of the total solids amount of the finished product. 6. The method according to any one of claims 1 to 5 »thereby characterized in that the bituminous material consists of asphalt. 7. insulating cardboard, characterized in that it is produced according to the method according to any one of claims T to 6 is. 009885/1696