EP0427274A1 - Strukturieren von einer Mineralfaserakustikplatte mit einer Schleuderstrahlmaschine - Google Patents

Strukturieren von einer Mineralfaserakustikplatte mit einer Schleuderstrahlmaschine Download PDF

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Publication number
EP0427274A1
EP0427274A1 EP90121427A EP90121427A EP0427274A1 EP 0427274 A1 EP0427274 A1 EP 0427274A1 EP 90121427 A EP90121427 A EP 90121427A EP 90121427 A EP90121427 A EP 90121427A EP 0427274 A1 EP0427274 A1 EP 0427274A1
Authority
EP
European Patent Office
Prior art keywords
fiberboard
housing
particulate material
roof
wheel
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.)
Withdrawn
Application number
EP90121427A
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English (en)
French (fr)
Inventor
Alan L. Boyd
Fred L. Migliorini
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Celotex Corp
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Celotex Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Celotex Corp filed Critical Celotex Corp
Publication of EP0427274A1 publication Critical patent/EP0427274A1/de
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C3/00—Abrasive blasting machines or devices; Plants
    • B24C3/08—Abrasive blasting machines or devices; Plants essentially adapted for abrasive blasting of travelling stock or travelling workpieces
    • B24C3/10—Abrasive blasting machines or devices; Plants essentially adapted for abrasive blasting of travelling stock or travelling workpieces for treating external surfaces
    • B24C3/14—Apparatus using impellers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/06—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for producing matt surfaces, e.g. on plastic materials, on glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B28B11/0818—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for roughening, profiling, corrugating
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/16—Special fibreboard
    • D21J1/20—Insulating board

Definitions

  • This invention relates to a method and apparatus for producing an acoustical firberboard, and more particularly is directed to the surface texturing of a mineral ceiling panel with a wheel blast machine.
  • Shaped products made from fibers and a binder which are typically acoustical in nature, i.e., capable of attenuating sound, are well known in the art and are widely used today. Examples of such shaped products include ceiling panels and tiles, wall boards, screen dividers, construction panels, and the like.
  • the conventional process for making these products involves use of fourdrinier-type machine wherein an aqueous mixture comprising the fiber and binder is cast on a forming screen, and subsequently consolidated and dewatered. Normally, the formed board is passed to an oven for final drying.
  • the present invention therefore provides a method of decoratively texturing the surface of a fiberboard which comprises: (a) conveying the fiberboard in a horizontal position through a closed housing having entry and exit slots for the fiberboard, and (b) decoratively texturing the top surface of the fiberboard while the fiberboard is within the housing by: (i) discharging particulate material downwardly against a region of the surface of the fiberboad to abrade the surface, a portion of the spent particulate material thereby being deposited on the surface of the fiberboard (ii) blowing the spent particulate material off the surface, and (iii) discharging additional particulate material downwardly against the surface to complete the abrasion, whereby removal of the spent particulate material from the first discharge prevents masking of the surface and contributes to the formation of a decorative and uniform patter over the entire fiberboard surface.
  • the board product which is texturized by the method of the invention may be formed continously by conventional wet processes wherein a water slurry of the board-forming ingredients is deposited upon a moving wire screen.
  • the invention may also involve an operation whereby boards are formed in a cast process without water drainage from the product. After consolidation and drying, the board is abraded on either one of its two major surfaces.
  • apparatus for decoratively texturing the surface of a fiberboad which comprises: (a) a housing having entry and exit slots for fiberboard, (b) means for continously conveying fiberboard to be decoratively textured through the housing, (c) a first means for discharging particulate material in the housing against a region of the surface of the fiberboard to abrade the surface, (d) a means for directing an air stream in the housing to remove from the fiberboard surface spent particulate material from the first discharging means, and (e) a second means for discharging particulate material in the housing against the fiberboard surface to complete the decorative texturing, whereby removal of the spent particulate material from the first discharging means prevents masking of the surface and contributes to the formation of a decorative and uniform pattern over the entire fiberboard surface.
  • the first and second abrasive discharging means each preferably comprise at least one centrifugal blasting wheel mounted in the roof of the housing to cause a portion of the fiberboard surface to be uniformly impacted.
  • the second discharging means is located downstream along the production line from the first such means in order to abrade the remaining fiberboard surface untreated by said first means. Air blown from a device such as an air knife removes spent particulate material left on the surface after its abrasion by the first discharging means. This removal allows the production of a highly decorative and uniform pattern of the surface of the fiberboard.
  • a fiberboard sheet material which may comprise inorganic and/or organic fibrous material and preferably consists of mineral fibers, a binder and the other board-forming ingredients, is produced in a conventional manner, such as on a wet board forming machine, e.g., a Fourdrinier or a cylinder machine.
  • a wet board forming machine e.g., a Fourdrinier or a cylinder machine.
  • FIG. 1 there is shown a machine chest 1 containing water to which the mineral fibers, such as conventionally felted mineral wool, are first added.
  • the other ingredients which advantageously consist of aqueous suspensions of perlite and optionally clay, or starch, and of paper, are added to the machine chest.
  • the machine chest agitator 2 is suitably operated to keep the slurry stirred up so that the ingredients are uniformly distributed throughout the slurry.
  • the solids content of the slurry may be from about 2 to 8 weight %.
  • the fiberboard is produced from a slurry containing mineral fibers (e.g., mineral wool) which are nodulated during wet mixing of the slurry's ingredients.
  • mineral fibers e.g., mineral wool
  • the consistency must be sufficiently high, e.g., about 5 to 8, preferably 5.5 to 8, and more preferably 6 to 7.5 weight %.
  • the formation of nodules of mineral fiber during mixing of the slurry may be brought about as described in U. S. patent application Serial No. 210,446, files June 23, 1988, the disclosure of which application is hereby incorporated by reference.
  • the rate and duration of agitation for forming an appropriate content of nodulated wool in the slurry can be readily determined through routine experimentation.
  • the slurry is mixed for about 10 to 60 minutes by means of a rotary agitator (impeller) revolving at a rate of about 100 to 150 revolutions per minute.
  • the mineral wool may be introduced to the slurry in the form of pellets of previously nodulated mineral wool.
  • the slurried composition is transferred by pump 3 through pipe 4 to head box 5.
  • the slurry is subsequently deposited on Fourdrinier wire 7 through orifice 6 of head box 5.
  • the first section 8 of the Fourdrinier wire permits free drainage of water from the material and further drainage is promoted by suction boxes 9 in section 10.
  • a wet felted mat of the mineral fiber composition forms on the machine.
  • the wet laid mat is dewatered by the Fourdrinier machine to a solids content of about 20 to 40 weight percent.
  • the partially dried material is then prepressed to a thickness of about 0.4 to 0.8 inch by a plurality of press rolls 11. It will be appreciated that a single set of press rolls could be employed if desired.
  • the sheet product After being pressed, the sheet product will generally have from about 60 to about 75% water.
  • a coating may be applied to the pressed mat by means of feed-pipe 13 and coater 14.
  • the wet mat After passing through press rolls 11, the wet mat is transferred into dryer 12. At the outlet of the dryer, ther is obtained a board 15 having a moisture content of about 1.0%.
  • the board is cut into smaller panels by saw arrangement 16.
  • Dried boards having widths of 24 in. or more, e.g., 24 to 52 in., can be formed for texturing by the wheel blast machine of the invention.
  • the dried product can be subjected to any suitable conventional finishing apparatus, depending on the applications for which it intended.
  • Such apparatuses may include applicators for applying coatings to protect and/or decorate the product surface, such as bevel coaters, finish spray coaters, printers, multi-color decorative coaters, and the like, and further drying equipment.
  • a fine-textured appearance is created on one of the two major surfaces of the dried board by the wheel blaster 17 of the invention.
  • the board may be advantageously turned over by an inverter 18 to present the smooth screen side for surface treatment.
  • the board is continously passed by suitable conveyor means (e.g., conveyor rollers 19) through the wheel blast machine located on the production line.
  • suitable conveyor means e.g., conveyor rollers 19
  • the housing 20 of the machine has inlet and outlet openings 25 and 26 for board.
  • the process can be run at a line speed of up to 200 lineal feet per minute. However, for optimum pattern uniformity, the line speed through the wheel blast machine generally should be about 150-180 lfpm.
  • the speed of the line can be readily adjusted so that the entire board surface will be uniformly subjected to the action of the abrasive spray from the wheel blaster. Even at quite high line speeds, the present invention makes it possible to produce pleasing and uniform patterns on boards which are much wider than conventionally textured boards. Whereas a typical width of a conventionally textured board is about 2 ft., boards having widths up to 52 in. or more can be readily textured in accordance with the present invention.
  • conveyor rollers 19 carry fibrous board 15 through the housing 20 of the wheel blast machine to abrade and thereby decoratively texture the board surface with abrasive material 21 propelled by first abrasive discharging means 22.
  • the first abrasive discharging means advantageously comprises one or more roof mounted centrifugal blasting wheels 22 located within the blasting chamber directly above the conveyor means for directing the abrasive material downwardly upon the board as it passes through the chamber.
  • more than one blasting wheel is employed, such as the two shown in FIGS.
  • the wheels 22 a , 22 b preferably are staggered in a longitudinally spaced apart relation and in a laterally spaced apart relation to cause the top surface of the board to be uniformly impacted by the abrasive particles centrifugally thrown by the wheels, preferably at an acute angle with respect to said board surface.
  • the desired effect of the spacing is that abrasive thrown by the first wheel onto the board will ricochet without passing through the path of abrasive particles thrown by the next wheel thereby to minimize intereferences with the particles thrown at the surfaces of the boards and also to avoid undesirable cushioning effects.
  • Wheels 22 a , 22 b are advantageously located so as to abrade the outer edges of the board.
  • the machine includes a second abrasive discharging means located within the blasting chamber downstream from the first such means.
  • the second abrasive discharging means advantageously comprises one or more roof mounted centrifugal wheels 23 (two shown in FIGS. 2 and 3) similarly spaced for uniform treatment and texturing of the board surface. Wheels 23 a , 23 b are suitably mounted to treat the interior portion of the board.
  • the throwing wheels may be of conventional type described in the art, and can be obtained from Wheelabrator-Frye, Inc.
  • the surface-treating material 21 may be any abrasive capable of texturing the surface of the board. Both “heavy” abrasives (e.g., metal grit or shot) and “light” abrasives, which are of softer materials than the former type, may be used. “Light” abrasives include such items as glass shot, plastics, walnut shells, pecan shells, corn husks, peach pits, etc. Typically, the surface abrasion removes about 0.01-0.04, preferably .025 - .035, inch of the board surface in producing the desired look. Depending on factors such as the type of abrasive and board being treted as well as the spatial relationship of the wheels and board, the wheels can be operated at various speeds, such as from about 1800 to 3600 rpm.
  • a blower means disposed between the first and second abrasive discharging means removes from the board surface the spent abrasive particles thrown by the former means before exposure of the surface to the second abrasive discharging means.
  • the blower means advantageously comprises a roof mounted device which supplies air under pressure to blow the spent abrasive off the board surface. As illustrated in FIGS. 2 to 4, air under pressure is directed from a suitable source, not shown, to a manifold 24, whereby air is directed downwardly at an angle of less than 90° to gently sweep the abrasive material from the surface.
  • the air manifold may, for example, consist of a compressed air knife or a manifold connected to a centrifugal blower.
  • the air is directed angularly downwardly onto the fiberboard to blow the abrasive particles laterally outwardly from its surface whereby the particles are displaced laterally beyond the board where they can settle downwardly for return by any suitable means to the chamber supplying the blast wheels to again be used.
  • An especially suitable device for supplying air is the FIG. 4 embodiment comprising an elongated pipe 24 having a slit and mounted in housing 20 to extend above the production line and from side to side thereof.
  • a final blow-off device is located within housing 20 to remove residual abrasive material before conventional finishing of the boards.
  • the present invention provides a method and apparatus whereby fiberboard surfaces may be rapidly and economically textured.
  • the invention is seen to provide a method and apparatus for texturing fiberboard with abrasive particles by which method and apparatus the surface of the fiberboard may be uniformly and decoratively abraded without complications from spent abrasive on the board surface.
  • Previous attempts to remove the spent abrasive from the fiberboard surface by employing wipers made of rubber of similar materials were unacceptable. The dragging of these wipers across the abraded surface to scrape off used blast medium left marks on the fiberboard and resulted in product rejects.
  • the formulation utilized in manufacturing the product consists of the following ingredients in the listed percentages by weight: Ingredient % Mineral Wool 65.0 Perlite 21.5 Newsprint 4.0 Starch 9.5 Retention Aid 0.05
  • the ingredients were diluted with water to form a slurry in machine chest 1.
  • the slurry was transformed to head box 5 and next deposited on Fourdrinier wire 7.
  • the slurry was dewatered in a conventional manner on the Fourdrinier machine to form a wet felt or mat of interlocked fibers.
  • the partially dewatered fibrous mat was next passed through a press section comprising pressing rolls 11, which densified the mat and provided a wet mat of uniform thickness (about one inch) with a moisture content of about 65%. After leaving the press section, the wet mat was conveyed to dryer 12.
  • the board product After being dried, the board product was subjected to various conventional finishing steps, which included cutting into appropriate sizes and cleaning. After being flipped over by inverter 18, the board product was then abraded on the screen side by wheel blaster 17 and this side was coated to produce textured fiberboards of the invention.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
EP90121427A 1989-11-09 1990-11-08 Strukturieren von einer Mineralfaserakustikplatte mit einer Schleuderstrahlmaschine Withdrawn EP0427274A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US43381389A 1989-11-09 1989-11-09
US433813 1989-11-09

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EP0427274A1 true EP0427274A1 (de) 1991-05-15

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CA (1) CA2029072A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1015092C2 (nl) * 2000-05-02 2001-11-05 Constructiewerkplaats G C Gr N Samenstel en werkwijze voor het stralen van een metaalproduct.

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2434736A (en) * 1941-03-05 1948-01-20 Certain Teed Prod Corp Apparatus for surfacing sheet material
GB851021A (en) * 1957-04-25 1960-10-12 Lawes Bros Ltd Process for providing plastics material with a matt surface
GB898172A (en) * 1960-01-27 1962-06-06 Henry Cobden Turner Improvements in or relating to the treatment of leather or plastic articles
CH374565A (de) * 1960-01-29 1964-01-15 Fischer Ag Georg Schleuderstrahl-Putzmaschine, insbesondere zum Strahlen von bandförmigem Putzgut
US3269066A (en) * 1963-01-09 1966-08-30 Wheelabrator Corp Method for production of abraded design on work surfaces
CH447864A (de) * 1966-02-14 1967-11-30 Fischer Ag Georg Schleuderstrahl-Putzmaschine zum Strahlen von Halbfabrikaten, insbesondere von Walzgütern, z.B. Blechen und Bändern aus Eisen
US3832809A (en) * 1972-01-05 1974-09-03 Carborundum Co Method for removing wustite scale
EP0108381A1 (de) * 1982-11-08 1984-05-16 The Celotex Corporation Verfahren zum Pressformen im Nassteil und gepresstes Erzeugnis
US4911788A (en) * 1988-06-23 1990-03-27 The Celotex Corporation Method of wet-forming mineral fiberboard with formation of fiber nodules

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2434736A (en) * 1941-03-05 1948-01-20 Certain Teed Prod Corp Apparatus for surfacing sheet material
GB851021A (en) * 1957-04-25 1960-10-12 Lawes Bros Ltd Process for providing plastics material with a matt surface
GB898172A (en) * 1960-01-27 1962-06-06 Henry Cobden Turner Improvements in or relating to the treatment of leather or plastic articles
CH374565A (de) * 1960-01-29 1964-01-15 Fischer Ag Georg Schleuderstrahl-Putzmaschine, insbesondere zum Strahlen von bandförmigem Putzgut
US3269066A (en) * 1963-01-09 1966-08-30 Wheelabrator Corp Method for production of abraded design on work surfaces
CH447864A (de) * 1966-02-14 1967-11-30 Fischer Ag Georg Schleuderstrahl-Putzmaschine zum Strahlen von Halbfabrikaten, insbesondere von Walzgütern, z.B. Blechen und Bändern aus Eisen
US3832809A (en) * 1972-01-05 1974-09-03 Carborundum Co Method for removing wustite scale
EP0108381A1 (de) * 1982-11-08 1984-05-16 The Celotex Corporation Verfahren zum Pressformen im Nassteil und gepresstes Erzeugnis
US4911788A (en) * 1988-06-23 1990-03-27 The Celotex Corporation Method of wet-forming mineral fiberboard with formation of fiber nodules

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1015092C2 (nl) * 2000-05-02 2001-11-05 Constructiewerkplaats G C Gr N Samenstel en werkwijze voor het stralen van een metaalproduct.

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CA2029072A1 (en) 1991-05-10

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