US1978807A

US1978807A - Method of producing laminated products

Info

Publication number: US1978807A
Application number: US597448A
Authority: US
Inventors: Ericsson H Merritt
Original assignee: LAMINATING PATENTS CORP
Current assignee: LAMINATING PATENTS Corp
Priority date: 1932-03-08
Filing date: 1932-03-08
Publication date: 1934-10-30
Anticipated expiration: 1951-10-30

Description

E. H. MERRITT METHOD OF PRODUCING LAMINATED PRODUCTS Filed March 8, 1932 2 Sheets-Sheet 1 INVENTOR 2/ ATTO RaEY Oct. 30, 1934. E. H. MERRITT METHOD OF PRODUCING LAMINATED PRODUCTS Filed Mafch 8, 1952 2 Sheets-Sheet 2 |NVENT?/RV BYW W gATTORNEY -fl m l r MN 3 Q Patented Oct. 30, 1934 PATENT OFFICE METHOD OF PRODUCING LAMINATED PRODUCTS Ericsson H. Merritt, Loekport, N. Y., assignor to Laminating Patents Corporation,

Seattle,

Wasln, a corporation 01' Delaware Application March 8, 1932, Serial No. 597,448

This invention relates to faced mineral board and methods of forming the same, and in its 'more specific aspects to mineral boards faced with veneer, and to methods for bonding veneer and mineral board.

Among the objects of the invention is the pr ovision of an improved product which coinbines fire-resistant qualities with stre gt durability, and appearance, and the provision of particularly effective methods for the formation of such a product.

A further object is to provide a wood faced product having improved fire-resistant properties and presenting an attractive appearance.

Another object is the provision of an improved method for uniting veneer and mineral board.

Other. objects of the invention will in part be obvious and will in part appear hereinafter.

The invention accordingly comprises the several steps and the relation and order of one or more of suchsteps with respect to each of the others, and the article possessing the features, properties; and the relation of elements, which are exemplified in the following detailed disclosure, and the scope of the application of which will be indicated in the claims.

For a fuller understanding of the nature and objects of the invention reference should be had to the following detailed description taken in connection with the accompanying drawings, in

which: r

Figure 1 is a perspective view of an article embodying the invention; 1

Fig. 2 is an enlarged-fragmentary view of a faced mineral board;

Fig. 3 is a similar view of a faced mineral board having a surface coating;

Fig. 4 is a diagrammatic showing of the mode of procedure embodying the invention;

. Fig. 5 is a diagrammatic showingof another mode of procedure embodying the invention; and

Fig. 6 is a diagrammatic showing of a further modification.

Various types of mineral boards are available for structural and-other purposes, and many of wall board comprising mineral board and a facing material, which may desirably be veneer, (which term is utilized herein to describe wooden sheet material) united thereto. It has been found that a synthetic resinous material such, for example, as a phenol-formaldehyde condensation product and similar phenolic condensation products, provides a particularly effective bond yielding a product having especially desirable qualities for insulating and other properties.

A product embodying the invention is illustrated in Fig. 1. This comprises a mineral board base 8 which may desirably be a dense, substantially incompressible board formed from a composition, the principal ingredients of which are asbestos and Portland cement. United to the mineral board by a suitable synthetic resinous adhesive (indicated at 9 in Fig.2), which may desirably be a phenolic condensation product, is a facing 10 of veneer.

This product possesses the fire-resistant properties, sturdiness and stifiness of the mineral board and at the same time presents an exceedingly attractive appearance for use in panels, .walls, trim and other places wherein such com bined qualities are desirable. The synthetic resinous binder adds to, rather than detracts from, the fire-proofing and water-proofing qualities of the product.

If desired, the exposed surface of the facing material may be coated with a phenolic condensation product or other synthetic resinous material, such a coating being indicated at 11 in 'Fig. 3.

As above noted, various types of mineral board. may be utilized. Among these are cement-asbestos boards as mentioned above, gypsum-containing boards, boards composed principally of cement, and many others.

In certain instances, a product comprising mineral board and a facing of paper or textile material united thereto by means of a synthetic resinous adhesive may be provided.

A variety of difliculties are encountered in the uniting of veneer and other facing material to mineral board. Among these are the difllculties in uniting veneer to an incompressible layer having an uneven surface, the tendency toward the formation of bmters due to excessive moisture contained in the mineral board or applied thereto, and difficulties in obtaining a strong bond and in providing a good appearance. Certain features of the invention relate-to the provi ion of a method for uniting such members no whereby the foregoing and other difficulties may be overcome.

By way of example, certain types of procedures are described below.

In the form of procedure illustrated diagrammatically, in Fig. 4 slabs 12 of a dense, substantially incompressible mineral board which may be formed from a composition, the principal ingredients of which are asbestos and Portland cement, are subjected to a smoothing treatment, as for example, in a grinding machine 13, whereby unevenness in one of the surfaces thereof is eliminated. The slabs are thereupon heated to reduce the moisture content, preferably to a point wherein each section will. contain less than 6% moisture- Sections of pre-cut veneer 14 are preferably dried to a pointwhere they contain less than about 6% to 8% moisture by weight. Desirably, sections of both materials may be dried in a veneer drier 15 such, for example, as that'illustrated in the patent to Louis G. Merritt, et al.-No. 1,757,092. Each section of mineral board coming from the drier is passed by a conveyor 16 under a disseminating mechanism 17 whereby an incomplete, potential.- ly reactive, phenolic condensation product is applied to' the smooth surfacethereof inpowdered form. The applying mechanism may desirably be of a type illustrated in the co-pending application of Louis G. Merritt and Ericsson H. Merritt, Serial No. 542,257, filed June 5, 1931. In the present instance the sections are passed under the disseminating mechanism while they still contain a considerable amount of heat, a surface temperature of from 200 to 250 F. being desirable.

The amount of resin applied may desirably run from 8 to 17 pounds per thousand square feet of surface-spread.

The heat tends to cause a certain amount of melting of the resinous particles which tends to cause them to adhere firmly to the surface and to prevent displacement of particles as setforth in the co-pending' application of Ericsson H. Merritt, Serial No. 582,253, filed December 21, 1931.

Sections of veneer coming from the drier are passed either manually or by suitable automatic means to a point beyond the disseminator 17 and disposed against the coated surface of the mineral board sections to form an assembly. Then these assemblies are suitably subjected to heat and pressure as in a veneer press 19. The heat may desirably range from 300 to 360 F.

and the pressurefrom to 500.pounds per square inch, and the bonding treatment continue for from to"4 minutes. In certain instances thepressed panels may be subjected while still hot to a pressure of one-half a pound per square inch and be so held until cooled.

In the event that a coating on the veneer surfaceis desired, this may be desirably formed by providing a layer of potentially reactive synthetic resinous material, such as a phenolic condensation product in powdered form, upon the exposed surface of the veneer either by passing the assemblies under a further disseminating mechanism, by passing the veneer sheets on a parallel conveyor under a'further disseminating mechanism, by running mineral board sheets and veneer sheets alternately under the disseminating mechanism 17 if the same resinous material is to be used, or in any other suitable manner, after which the assemblies will be subjected to bonding conditions.

which, as adapted to the present invention, is

illustrated diagrammatically in Fig. 5"and described below. I

Sheets of mineral board 20 are run on a conveyor 21 under a spraying mechanism 22, whereby there is applied thereto an aqueous solution containing phenol, acaustic alkali, and ammoniav in suitable proportion, such as 56 parts of phenol, 18 parts of 20% caustic soda solu-' tion, and 7 parts of 37% ammonia solution. This may be applied at the rate of 3 pounds per 1,000 square feet of surface area. The mineral board sheets are thereupon run under a spreading mechanism 23, whereby 13 pounds of powdered phenolic condensation product per 1,000 square feet of surface area is applied thereto, and thence under a second spraying mechanism 24, whereby 3 pounds of furfural per 1,000 square feet, of surface area is applied. A sheet of veneer 25 is laid upon the coated surface of the mineral board, and the assembly subjected to heat and pressure in a hot press 26.

Another desirable type of procedure is by spreading liquids and resin, in the manner exemplified immediately above, on veneer sheets 27, and disposing thereagainst a mineral board layer 28 which has been heated to about 250 F. to 300 F., as by a heatingmeans 29, and subjecting the assembly to heat and pressure in a foo hot plate press 30 without any substantial lapse of time. The heating of the mineral board immediately before it is placed in the press eliminates delay in the transferof heat through this material, which is comparatively diflicult for the heat to penetrate, and serves to provide a proper temperature at the glue linesubstantially at the same time as the application of pressure.

It is to be understood that a number of variations in the manner of applying a'liquid or in the liquid applied, as indicated in the abovementioned application of Ericsson H. Merritt, Serial No. 597,447, filed herewith, or otherwise, may be made without departing from the invention.

Many types of resinous materials may be uti-. lized in accordance with the invention. 'Particular reference may be made to. phenolic condensation products, to urea condensation and polymerization products and to synthetic resinous materials containing vinyl acetate and/or vinyl chloride, which are thermo plastic but not thermo setting, i. e., which set upon, cooling after the application of heat.

As an example of a particular type of phenolic condensation product which may desirably. be utilized, in some instances reference .may be made to a resinous material produced in accordance with the following procedure:

Place 200 grams warm phenol in a metal container about 4" diameter by 5" high arranged 'for the attaching of a reflux, and add 20 grams of KOH dissolved in 20 cc. water, add while stirring .300 grams--37% formaldehyde solution. Attach reflux and apply heat until mass boils freely, then remove heat, as action is exothermic, for about 5 minutes or until ceases. Then again apply heat and boil with reflux for a total time of one hour and ten minutes, then remove reflux. The fluid, while a hot, will be rather viscous but still capable of being easily stirred. The fluid should now be stirred while still applying heat to evaporate free water and phenol. When the mass becomes too stiff for stirring, it should be removed from the container and cooled slowly. The total mass of the resin will be approximately370 grams. After complete cooling the mass is hard and brittle and can be broken up and ground to a powder. V

Since certain changes in carrying out the above process, and certain modifications in the article which embody the invention may be made without departing from its scope, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense. I

It is also to be understood-that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which as a matter of'language might be said to fall therebetween.

Having described my invention what I claim as new and desire to secure by'Letters Patent is:

1. The method of joining mineral board and veneer to form a laminated product which comprises applying an adhesive material in discreteparticle form to a surface of one of said members, associating said surface with the surface of another of said members, and subjecting to bonding: conditions.

2. The method of facing mineral board which comprises associating a sheet of facing material therewith with interposed potentially reactive synthetic resinous adhesive in discrete-particle form, and subjecting to heat and pressure.

3. The method of joining mineral board and veneer to form a laminated product, which comprises applying a potentially reactive synthetic resinous adhesive in powdered form to a surface of one of said members, associating said surface with the surface of the other of said members, and subjecting to bonding conditions.

4. The method of joining mineral board and veneer to form a laminated product, which comprises applying a potentially reactive phenolic condensation product in powdered form to a surface of one of said members, associating said surface with the surface of the other of said members, and subjecting to heat and pressure.

. comprises reducing the moisture content of each of. said members to a point where its moisture content is less than 6 to 8% of its weight, applying a potentially reactive synthetic resinous adhesive in powdered form to a surface of one of said members, associating said surface with the surface fthe other of said members, and subjecting to bonding conditions.\

'7. The method of joining mineral board and veneer to form a laminated product, which "comprises smoothing the surface of a mineral board, associating therewith a veneer sheet with interposed potentially reactive synthetic resinous I I adhesive in discrete-particle form, and subjecting to heat and pressure. I

8. The method of joining mineral board and veneer to form a laminated product, which comprises applying a potentially reactive phenolic condensation product in powdered form to the surface of the mineral board, superposing a sheet of veneer, and subjecting to bonding conditions.

9. The method of joining mineral board and veneer to form a laminated product, which comprises applying a potentially reactive phenolic condensation product in powdered form to the surface of the veneer, superposing a sheet of mineral board, and subjecting to bondingconditions. C

10. The method of joining mineral board and veneer to form a laminated product, which veneer to form a laminated product, which Y comprises continuously disseminating a liquid in a given zone, continuously disseminating a po tentially reactive synthetic resinous material in powdered form in a' second zone, and continu ously disseminating a liquid in a third zone, passing mineral board sheets one after another through saidzones, associating a. veneer sheet with each mineral, board sheet, and subjecting to heat and pressure.

12. The method of joining mineral board and veneer to form a laminated product, which comprises applying a potentially reactive synthetic resinous material in discrete-particle form to the surface of a veneer sheet, heating a mineral board sheet,- disposing the mineral board sheet upon said surface, and substantially immediately subjecting the assembly to heat and pressure.

13. The method of joining mineral board and veneer to form a laminated product, which comprises preheating one of said members, applying a potentially reactive synthetic resinous material in powdered form to a surface thereof, associating a surface of the other member with a coated surface, and subjecting to bonding thereof and to impart to the mineral board.

sheet a surface temperature in the neighborhood of 200 to 250 F., substantially immediately thereafter applying a potentially reactive phe- I nolic condensation product in powdered form to said sheet, superposing the veneer sheet, and subjecting to bonding conditions.

15. The method of forming laminated products, which comprises ,passing mineral board sheetsone after another and veneer sheets one after another through a heating and drying zone, passing each mineral board sheet through a zone in which a powdered potentially reactive synthetic resinous material is disseminated, superposing a heated and dried veneer sheet on each mineral board sheet and subjecting each of' the assemblies thus formed to bonding conditions.

16. The method of forming laminated products, which comprises associating a mineral board layer and a veneer layer with interposed potentially reactive synthetic resinous material in discrete-particle form, a coating layer of potentially reactive synthetic resinous material being provided. on the veneer sheet, and subjecting to bonding conditions.

1'7. The method of facing mineral board with wood veneer, which comprises applying to one of said members a potentially reactive synthetic resinous material in powder form in the absence of suflicient moisture to .liquefy the glue or to m'zalaov