US3286785A - High temperature resistant acoustical board - Google Patents

High temperature resistant acoustical board Download PDF

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US3286785A
US3286785A US457984A US45798465A US3286785A US 3286785 A US3286785 A US 3286785A US 457984 A US457984 A US 457984A US 45798465 A US45798465 A US 45798465A US 3286785 A US3286785 A US 3286785A
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weight
mils
impregnant
board
boards
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Richard F Shannon
Jerry L Helser
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Owens Corning
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Owens Corning Fiberglas Corp
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Priority to US457984A priority Critical patent/US3286785A/en
Priority to GB22603/66A priority patent/GB1109867A/en
Priority to BE681419D priority patent/BE681419A/xx
Priority to FR62608A priority patent/FR1480832A/fr
Priority to NL6607067A priority patent/NL6607067A/xx
Priority to US555201A priority patent/US3490065A/en
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • 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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/522—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement for producing multi-layered articles
    • 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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/526—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement by delivering the materials on a conveyor of the endless-belt type
    • 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
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0015—Machines or methods for applying the material to surfaces to form a permanent layer thereon on multilayered articles
    • 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
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
    • C04B41/5035—Silica
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5076—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with masses bonded by inorganic cements
    • C04B41/5089—Silica sols, alkyl, ammonium or alkali metal silicate cements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/88—Insulating elements for both heat and sound
    • E04B1/90—Insulating elements for both heat and sound slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E04B1/941—Building elements specially adapted therefor
    • E04B1/942—Building elements specially adapted therefor slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • E04B2001/8471—Solid slabs or blocks layered with non-planar interior transition surfaces between layers, e.g. faceted, corrugated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2964—Artificial fiber or filament

Definitions

  • the present invention concerns structural, acoustical and thermal insulating boards which are capable of retaining their integrity and dimensional stability at temperatures in excess of 1000 F., and particularly low density siliceousfiber boards possessing an inorganic lamina at one surface and within the voids existing in the fibrous low density structure.
  • Structural and decorative elements formed from interbonded or intermeshed siliceous fibers such as glass, mineral Wool or asbestos fibers
  • these non-combustible elements contribute to flame spread or building collapse as the result of this loss of integrity at temperatures experienced during a fire.
  • these non-combustible elements are commonly employed to mask or seal off such readily com bustible elements as wooden studs, joists,.partitions, decking, and the like.
  • these low density materials perform the desired function in an adequate fashion in both thermally insulating' the combustible materials which they conceal and thereby preventing the transfer of temperatures adequate to initiate combustion, and in physically blocking direct flame transfer.
  • siliceous fiber boards may also weaken concealed non-combustible structural elements such as steel beams or girders and concrete decks, to cause a partial or total collapse of the building structure.
  • thermocouples sense temperatures which would be adequate to ignite combustible building elements or to weaken noncombustible elements such as steel beams or concrete decks.
  • This test yields a fire rat ing based upon the length of endurance of the medium tested under the prescribed conditions. For example, an acoustical board which endured for one hour before per mitting the transfer of temperatures adequate to initiate combustion or cause the collapse of noncombustible elements would receive a one hour rating.
  • a failure is experienced whenever any single thermocouple reaches 325 F., above ambient temperature, or when the average temperature of the thermocouples reaches 250 F., above ambient temperature.
  • the present invention is directed to the provision of low density decorative and structural elements formed from siliceous fibers, which exhibit structural integrity and dimensional stalbility at temperatures in excess of 1000' F., while retaining the acoustical and thermal insulating properties for which they are valued.
  • Another object is the pmovision of methods for the preparation of such low density decorative and structural elements.
  • a further object is the provision of irnpregnants cap-able of imparting the prescribed integrity to such decorative and structural elements.
  • Structural integrity is employed to define the ability to resistthe transfer of heat and flames through apertures resulting fnom tJhe delamination or disintegration of the structure, or through apertures resulting from the separation of the low density boards from their fastenings, suspension systems or from albutting, adjacent boards, upon exposure to temperatures in excess of 1000 F. Consequently, the termstructural integrity contains an aspect of dimensional stability in respect to resistance to shrinkage, expansion and warping or sagging. It should also be noted that the acoustical properties of the structures include both sound absorption and resistance to sound transmission.
  • the former is provided by the low density, void-filled region which is retained at one major surface of the board, while the latter is improved by virtue of the formation of a dense zone which is substantially impervious to sound at the opposite major surface.
  • the insulating values of the boards are enhanced by virtue of the opacifying effect of the dense layer.
  • FIGURE 1 is a fragmentary sectional view of a product prepared in accordance with the invention.
  • FIGURE 2 is a schematic representation of an apparatus suitable for the practice of the methods of the invention.
  • the foregoing objects are achieved by means of the deposition of a thin, continuous inorganic structural phase, or layer, within the voids present within a resin-bonded, low density fibrous medium and immediately adjacent to one of the two major surfaces of the low density fibrous board.
  • the extent of such deposition is limited and controlled in order to prevent the impregnation of the other or opposite major surface, and to thereby retain the desirable thermal and acoustical properties of the low density medium of which the second major surface is composed.
  • an aqueous slurry containing a specific combination of inorganic ingredients formulated to provide the desired structural integrity and dimensional stability is applied to one surface of the low density fibrous element and then deposited within the voids present in the fibrous medium and adjacent to the point of application.
  • a structural layer having a thickness of 15 mils is adequate, while the acoustical-thermal low density zone or layer must have .a thickness of at least 50 mils.
  • the structural layer or impregnated zone normally has a thickness of at least 50 mils while an unimpregnated zone having a thickness of at least 125 mils is preferred.
  • the aqueous component After depositing and positioning the impregnant to the desired depth, the aqueous component is dispelled by drying to leave a strong rigid structural phase or layer.
  • the inventive impregnants contain both inorganic particulate matter, and a binder phase which is capable of interadherring the inorganic particles both at ambient conditions and during exposure t-o temperatures in excess of 1000 F.
  • the binder phase contains between 5 to 95% by weight of colloidal silica and between 5 to 95% by weight of bentonite, and comprises between 2 to 25% by weight of the total solids
  • the impregnant contains between 1 to 20% by weight of colloidal silica and between 1 to by weight of bentonite. It should be noted that references to quantities of colloidal silica relate to the quantities of silica solids, although these compositions are normally employed as dispersions in a liquid carrier medium such as water.
  • the inorganic particles which are intenbonded by the foregoing binder phase include a combination of both materials possessing a'melting point below 2000 F., and materials which melt above that temperature.
  • the lower melting materials are the aluminosilicates of the Group I and II metals, sodium, potassium, calcium, magnesium, and barium, and alnminosilica-tes containing two or more of these metals.
  • the high melting materials comprise certain hydrous aluminum silicates which are subsequently described. This combination is based upon the discovery that the formation of a molten or ceramic phase is highly desirable in the attainment of structural integrity at temperatures experienced during a fire or a fire test;
  • the lower melting materials pro 'vide a new or auxiliary adhesive p'hase upon exposure to temperatures in the range of 1000-25 00 F., which serves to interadhere the higher melting particles and to maintain structural integrity. While structural integrity resulting from a liquid or molten phase may at first appear contradictory, the nature of this liquid must be considered.
  • the Group I and/or Group II metals function as fluxes which facilitate the melting of a portion of the ingredients of the impregnant and form an extremely viscous adhesive. compositions commonly possess viscosities in the range of For example, molten glass 10 to 10" poises and consequently are not highly fluid liquids in the ordinary sense of the word.
  • the value of thermally inert particles interbonded by the described liquid adhesive, over thermally inert but structurally weak imprcgnants is aptly demonstrated by the fire ratings achieved with the inventive impregnants.
  • the previously described binder phase i.e. bentonite and colloidal silica
  • this admixture comprises between 10 to by weight of the higher melting hydrated aluminum silicate particles and between 10 to 90% by weight of the lower melting sodium, potassium, calcium, magnesium and barium aluminosilicates. Consequently, the impregnant composition contains between 7.5 to 90% by weight of both the lower and the higher melting materials.
  • the impregnants generally comprise:
  • impregnants contain:
  • Colloidal silica (solids) 2-6 Bentonite 3-5 Ball clay 30-60 Feldspar 30-60 Colloidalsilica and silica sols are commercially available compositions and materials of this nature, as well as methods for their preparation, are disclosed by US. 2,244,325, 3,083,167, 3,041,140 and 3,128,251.
  • Bentonite is a commonly known clay mineral composed essentially of montmorillonite and beidellite; it is colloidal hydrated aluminum silicate or sodium montmorillonite.
  • the hydrated aluminum silicates employed by the invention are ball clays consisting primarily of kaolinite, illite and montmorillonite, with minor quantities of ferric oxide, finely divided silica and titanium dioxide, and trace amounts of lime, magnesia, soda, and potash. More precisely, they contain between 50-75% by weight of SiO between 15-35% by weight of A1 0 and between 0.5- 10% by weight of Fe O with conventional silica, alumina and iron contents of approximately 57:27:1. Ball clays are distinguished from the more common clays such as kaolin clays, by their lower alumina contents, e.g. 15- 35% as opposed to 37-50% for kaolin clays.
  • the ball clays have a diameter of 10 microns or less.
  • the ball clays have a total alkali and alkaline earth metal content of between 0.5-4% by weight. It should be noted that in references made to the quantity of ingredients present in clays or minerals, the total weight of the composition from which the percentages are derived may contain minor quantities of organic materials. Typical of these hydrated aluminum silicates are the Maryland and Tennessee ball clays generally, and such specific materials as Saxon clay, Yankee ball clay, Rex clay, XB ball clay, pyrophyllite, and the like.
  • the lower melting material is preferably feldspar but one may generally employ the Group I and II metal aluminosilicates of sodium, potassium, calcium, magnesium or barium aluminosilicates, combinations thereof, or aluminosilicates which containtwo or more of the specified metal ions, i.e. Na, K, Ca, Ba or Mg. In addition, these metals are present in a quantity of between 6-20% by weight, and preferably 8-15% by weight.
  • aluminosilicates examples include the feldspars such as orthoclase, albite, hydrophane, microcline,
  • anorthite, anorthoclase, etc. and such "compounds as This may be employed to the rate and depth of impreg nepheline, cancrinite, thomsonite, eucryptite, grossularite, nation.
  • the impregnation depth and rate may alumontite, phillipsite, etc.
  • the majority of also be controlled by means independent of the impregthe particles making up these compositions also have nant. For example, vacuum or mechanically pressurized diameters of no more than microns. 5 impregnation, e.g.
  • a doctor blade may be employed to The examples in the following table provide a number force a highly viscous impregnant to the desired depth of formulations suitable forum in the present invention, within the fibrous substrate.
  • the fibrous in which the quantities of ingredients are expressed as substrate may be pre-treated with a wetting agent, e.g. percentages by weight: sprayed with a solution of an organosilicone fluid, to fa- TABLE 1 Examples
  • Feldspar I in the above table comprised the following cilitate and control the rate and depth of impregnation by quantities of ingredients expressed in percentages by viscous slurries.
  • the wetting agent may be inweight; corporated in the impregnant.
  • the siliceous fibers which make up the low density boards treated in accordance 67.53 36 with the invention frequently contain a water repellant 19. 1 8 2 5 3 which causes the board to resist wetting and penetration g K20 1 by the aqueous slurries which are employed.
  • the board should be either pre-treated with -a wetting agent, or an agent capable of modifying the surface
  • -a wetting agent or an agent capable of modifying the surface
  • tension properties of the slurry should be incorporated in and 3.2% on a 325 mesh (68.2% of the particles posthe slurry.
  • a wetting agent which has proved highly satsessed a diameter of 20 microns or less).
  • Feldspars II isfactory for the above purposes is sodium dioctyl sulfoand III were similar in respect to ingredients and total Succinate having a molecular weight of 444 and available alkali and alkaline earth metal content, i.e.
  • ingredients 28.3; 23.58 such as reinforcements, opacifiers, fillers, wetting agents,
  • anti-foaming agents may be added to the 3.21 g. lnventive impregnants. Typical of such additives are,
  • inventive combinations crons or less (pe rcent) 81.0 93.0 of higher and lower melting materials may be simulated shnnkage 2900 R (percent) by adding fiuxing agents to hydrated aluminum silicates having a'high melting point, e. 2000-3500 F.
  • a fl i agent such sodium Oxide may be that a portion of the aluminum silicate was present as dd d t a b ll l i a it adequate to exert a pyrophyllite. fluxing effect upon only a portion of the clay, e.g.
  • colloidal silica of the foregoing examp s were weight.
  • Such an expedient also results in a molten or p y as aqueous dispersions Containing between ceramic adhesive phase but is more expensive and diffi- 60% by weight of colloidal silica and preferably 40% cult to prepare, since minerals which naturally contain a by weight.
  • H w v t q i ie t d r f r to the fluxing agent content, e.g. feldspar, are readily available. amount of silica solids employed. II. lmpregnlated products.As previously mentioned,
  • the impregnants of the above examples were prepared the products of the invention comprise an acoustical panel, by admixing the ingredients with water to form a slurry. board, or tile formed from siliceous fibers bonded or en- While a slurry containing 2070%, and preferably 50% tangled into a mass having a density in the range of l by Weight f Water 18 preferred in most Cases, the ratio 0 to 30 p.c.f., and possessing two substantially parallel mamust be gauged to yield an impregnant of the viscosity jor surfaces, one of which is impregnated with the invendesired for the specific applicator system and substrate tive compositions. The resultant product retains its deemployed.
  • the viscosity of the impregnant is noryielding highly improved structural integrity, and resistmally increased by increasing the percentage of solids. ance to heat or flame transfer when exposed to high temperatures.
  • the impregnation of the board throughout its entire thickness i.e. the filling of all of the voids present in the board, must obviously be avoided.
  • satisfactory acoustical properties, and some degree of thermal insulation are realized when a low density region having a depth of no more than 50 mils is left upon the unimpregnated surface of the board.
  • an impregnated region having a thickness of no more than mils is adequate to provide structural integrity which permits the board to endure temperatures as high .as 2500 F., without failing. It should be realized that in the case of thicker boards, the temperatures which are experienced by the impregnant are lower as the result of the layer of low density thermal insulation which is present at the outside between the impregnant and the heat source.
  • the acoustical boards comprising glass fibers have an apparent density of from 1 to 30 pounds per cubic foot and are ⁇ from 250 to 3000 mils thick. These boards impregnated to a depth of at least 15 mils with the treating material.
  • Preferred embodiments of the invention comprise fibrous glass boards having a density in the range of 8 to 15 p.c.f., a thickness of from 350 to 1500 mils, and an impregnated region having a thickness of about 50 to; 750 mils and generally about 50 to 200 mils.
  • the uni-mpregnated zone will comprise approximately one-half of the thickness of the board.
  • Examples of such structures comprise a one inch thick board with an impregnated zone or structural layer having a thickness of 50 mils and a 78 inch thick board having an impregnated zone having a thickness of 500 mils.
  • a preferred product comprises a board having a density in the range of 9-13 p.c.f., a thickness of between 350 to 1500 mils, and containing between 0.3 and 0.8 pounds of the impregnant present in each square foot of the impregnated board.
  • boards having densities of between 1 to 30 p.c.f., and a thickness as great as 3 inches have been prepared and have yielded the desired properties.
  • FIGURE 1 provides a fragmentary, sectional view through a fibrous board prepared in accordance with the invention.
  • one surface 11 of the low density, fibrous board 12 has been impregnated to yield a dense layer 13 which serves as a structural member.
  • the dense layer 13 also contains the fibers 14 of which the board 12 is composed, and which provide an additional benefit in reinforcing the dense layer 13.
  • a low density unimpregnated phase 15 is left intact at the opposite surface 16 of the board 12 to provide the desired thermal and acoustical properties.
  • the structural value of the dense layer 13 functions primarily after the fibers of the low density unimpregnated phase 15 have been weakened, softened or melted and following pyrolysis of the resin binder. At such time, the dense layer 13 becomes the primary or sole supporting, spanning, or suspending means and may provide the sole source of structural integrity for the board 12.
  • the dense layer 13 does not remain inert upon exposure to temperatures in the range of 1500 F. or higher.
  • inorganic impregnants resistant to temperatures as high as 3000 F. were employed as the dense layer 13
  • the structures still failed at temperatures far below the melting points of the impregnants. It is believed that such failures were the result of the absence of an adequate binder phase within the impregnants. In essence, the inert impregnants suffered from thermal erosion or the like, lost integrity, and failed. It was found that the use of the inventive binder phase, i.e.
  • the low density fibrous boards employed as the substrate utilized in the above examples and impregnated in the practice of the invention are typified by those disclosed by US. 2,790,741; 2,791,289; 2,882,764; 2,984,312; 3,082,- 143; 3,111,188; 3,118,516; 3,159,235; and similar structures employing glass, mineral wool or asbestos fibers.
  • the binder employed to bond the siliceous fibers together into a low density mass may also contain a fire retardant additive such as clay, asbestine, etc.
  • the fibrous board may be first washed, but not thoroughly impregnated, i.e. without filling the voids throughout the thickness of the board and destroying insulating and acoustical values, with an inorganic material such as a clay slurry, etc. Such measures improve the total fire resistance of the structure although failing to provide adequate structural integrity at high temperatures.
  • the impregnated structures are prepared by depositing a slurry of the inventive impregnant upon one surface of the fibrous board, introducing the impregnant within the voids present upon one surface of the porous board without filling the voids present upon the opposite surface of the board, and drying the impregnant.
  • FIGURE 2 shows a schematic representation of apparatus suitable for the impregnation of low density siliceous fiber substrates.
  • fibrous boards 21 are carried by means of a foraminous conveyor belt 22 beneath a trough 23 which dispenses an impregnating slurry 24 upon the upper surface 25 of the boards 21.
  • the deposited impregnant 226 is then passed beneath a metering knife blade 27 which controls the thickness and consequently the quantity of the deposited impregnant 26.
  • the boards 21 are then passed beneath and in contact with a pressure roll 28 which forces the deposited impregnant within the upper surface of the boards 21.
  • the boards 21 and rforaminous conveyor belt 22 may then be passed over a suction box 29 which serves to draw the impregnant within the boards 21 and may implement or replace the effect of the pressure roll 28.
  • a sprinkler 30 may deposit a wetting agent such as a silicone fluid upon the upper surface 25 of the boards 21 prior to the deposition of the impregnant.
  • a wetting agent such as a silicone fluid
  • the drying of the impregnant may be accomplished by conventional oven treatments.
  • boards having a density of approximately p.c.f., .a thickness of between 350 to 1000 mils, and containing an impregnant layer weighing approximately 0.8 pounds (aqueous slurry, 50% solids) per square foot of the board may be oven dried at a temperature of 400 F., in approximately one hour.
  • the primary sources of control for both the rapidity and the degree of impregnation reside in the matching of the viscosity and/or surface tension of the impregnant in relation to the density of the board, the slurry may be merely metered and evenly deposited upon the upper surface of the board, and will immediately 9 flow to a desired depth within the upper surface of the board, without penetrating to the opposite surface.
  • a slurry having a viscosity of approximately 100-200 centipoises it is preferred to employ a slurry having a viscosity of approximately 100-200 centipoises. In such case, the slurry flows entirely within the board to a depth of approximately 125-180 mils within a matter of 1 to 3 seconds.
  • the present invention provides fire resistant, structural integrity imparting impregnants; acoustical and thermal insulating structural elements capable of retaining their integrity at high temperatures; and methods for the preparation of the foregoing structural elements.
  • the treating materials of this invention can also be used for bonding aggregates such as vermiculite, perlite, glass foam pellets, glass beads and the like to produce products such as high temperature resistant pipe insulation.
  • these treating compositions can be used for near total impregnation coup-led with one or more b ack-coatings to provide novel effects.
  • the coatings can be used for steel and wood decks to provide improved fire ratings.
  • An acoustical and thermal insulating element capable of maintaining structural integrity at temperatures in excess of 1000 F., comprising a plurality of siliceous fibers interbonded into an integral, void-containing mass having a density of between 1 to 30 pounds per cubic foot and shaped in the form of a panel having two substantially parallel major surface and a thickness of between 250 and 3000 mils, and deposited within said voids present between said fibers and adjacent to one of said surfaces and to a depth of at least 15 mils, an impregnant comprising between 75 to 98% by weight of aluminum silicate particles consisting essentially of between to 90% by weight of hydrated aluminum silicate containing between 50 to 75% by weight of SiO and between to 35% by weight of A1 0 and between 10 to 90% by weight of an aluminosilicate of a metal selected from the group consisting of sodium, potassium, calcium, magnesium, barium and combinations of said metals, in which said metal is present in a quantity in excess of 6% by weight, and admixed with
  • siliceous fibers are glass fibers.
  • An acoustical and thermal insulating element capable of maintaing structural integrity at temperatures in excess of 1000 F., comprising a plurality of glass fibers interbonded into an integral void-containing mass having a density of between 8 to 15 pounds per cubic foot and shaped in the form of a panel having two substantially parallel major surfaces and a thickness of between 350 to 1500 mils, and deposited within said voids present between said fibers and adjacent to one of said surfaces and to a depth of at least 15 mils, an impregnant comprising between 75 to 98% by weight of aluminum silicate particles and consisting essentially of between 10 to by weight of hydrated aluminum silicate containing between 50 to 75% by weight of SiO and between 15 to 35% by weight of A1 0 and between 10 to 90% by weight of an aluminosilicate of a metal selected from the group consisting of sodium, potassium, calcium, mag nesium, barium and combinations of said metals, in which said metal is present in a quantity in excess of 6% by weight, and admixed
  • a method for the preparation of acoustical and thermal insulating elements capable of maintaining struc tural integrity at temperatures in excess of 1000 F. comprising applying to one major surface of a panel comprising a plurality of siliceous fibers interbonded into an integral void-containing mass having a density of between 1 to 30 pounds per cubic foot and having two substantially parallel major surfaces and a thickness of between 250 to 3000 mils, an aqueous dispersion of an impregnant comprising between 75 to 98% by Weight of aluminium silicate particles and consisting essentially of between 10 to 90% by weight of hydrated aluminum silicate containing between 50 to 75 by weight of SiO and between 15 to 35% by weight of A1 0 and between 10 to 90% by weight of an aluminosilicate of a metal selected from the group consisting of sodium, potassium, calcium, magnesium, barium and combinations of said metals, in which said metal is present in a quantity in excess of 6% by weight, and between 2 to 25% by weight of a binder phase consisting
  • suction is applied to said second major surface subsequent to the application of said aqueous dispersion to said one major surface.
  • a method for the preparation of acoustical and thermal insulating elements capable of maintaining structural integrity at temperatures in excess of 1000 F., comprising applying to one major surface of a panel comprising a plurality of glass fibers interbonded into an integral void-containing mass having a density of between 8 to 15 pounds per cubic foot and having two substantially parallel major surfaces and a thickness of between 350" to 1500 mills, an aqueous dispersion of an impregnant comprising between 75 to 98% by weight of aluminum silicate particles and consisting essentially of between 10 to 90% by weight of hydrated aluminum silicate containing between 50 and 75% by weight of Si and between 15 to 35% by weight of A1 0 and between to 90% by weight of an aluminosilicate of a metal selected from the group consisting of sodium, potassium, calcium, magnesium, barium and combinations of said metals, in which said metal is present in a quantity in excess of 6% by weight, and between 2 to 25% by weight of a binder phase consisting essentially of between 1 to 20% by weight of coll
  • a heat resistant, integrity-imparting impregnant consisting essentially of an aqueous dispersion of between 2 to by weight of a binder phase consisting essentially of between 1 to 20% by weight of colloidal silica and between 1 to 15% by Weight of bentonite, andbetween to 98% by weight of aluminum silicate particles consisting essentially of between 10 to by weight of hydrated aluminum silicate containing between 5 0 to 75 by weight of SiO and between 15 to 35% by weight of A1 0 and between 10 to 90% by weight of an aluminosilicate of a metal selected from the group consisting of sodium, potassium, calcium, magnesium, barium and combinations of these, in which said metal is present in a quantity in excess of 6% by weight.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Acoustics & Sound (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
US457984A 1965-05-24 1965-05-24 High temperature resistant acoustical board Expired - Lifetime US3286785A (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US457984A US3286785A (en) 1965-05-24 1965-05-24 High temperature resistant acoustical board
GB22603/66A GB1109867A (en) 1965-05-24 1966-05-20 High temperature resistant acoustical board
BE681419D BE681419A (enrdf_load_stackoverflow) 1965-05-24 1966-05-23
FR62608A FR1480832A (fr) 1965-05-24 1966-05-23 Panneaux de construction calorifuges et d'insonorisation
NL6607067A NL6607067A (enrdf_load_stackoverflow) 1965-05-24 1966-05-23
US555201A US3490065A (en) 1965-05-24 1966-06-03 High temperature resistant acoustical board

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US457984A US3286785A (en) 1965-05-24 1965-05-24 High temperature resistant acoustical board

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BE (1) BE681419A (enrdf_load_stackoverflow)
GB (1) GB1109867A (enrdf_load_stackoverflow)
NL (1) NL6607067A (enrdf_load_stackoverflow)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3470977A (en) * 1968-02-21 1969-10-07 Owens Corning Fiberglass Corp Fire resistant glass fiberboard and method of making same
US3490065A (en) * 1965-05-24 1970-01-13 Owens Corning Fiberglass Corp High temperature resistant acoustical board
DE2635736A1 (de) * 1975-08-12 1977-02-17 Rockwool Int Feuerhemmendes plattenmaterial
EP0000402A1 (de) * 1977-07-18 1979-01-24 Saint-Gobain Industries Verfahren zur Herstellung von Isolierbauplatten
USRE34020E (en) * 1980-07-11 1992-08-04 Imperial Chemical Industries Plc Fibrous composite materials and the production and use thereof
US20070125011A1 (en) * 2005-12-06 2007-06-07 Weir Charles R Acoustic partition for removable panel finishing system
DE4338619C5 (de) * 1993-11-11 2007-12-27 Saint-Gobain Isover G+H Ag Beschichtetes Mineralwolleprodukt und Verfahren zu dessen Herstellung
US20110031064A1 (en) * 2009-08-07 2011-02-10 Law Harvey Hui-Xiong Non-combustible sound-absorbing facing
CN111995350A (zh) * 2020-07-17 2020-11-27 北京盈德化工有限公司 一种吸音材料及其制备方法和用途

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2907844A1 (de) * 1979-02-28 1980-09-11 Ibo Beratung Betreuung Aussenwand-waermedaemmung
GB2157560A (en) * 1984-04-24 1985-10-30 Bernard Sidney Sadler Fire-protection material
EP0432326A1 (en) * 1989-12-11 1991-06-19 Kiyohiko Shioya Method of producing polycrystal system compound ceramics
DE19546979A1 (de) * 1995-12-15 1997-07-03 Gruenzweig & Hartmann Temperaturbeständiges Mineralwolleprodukt
GB201114079D0 (en) 2011-06-13 2011-09-28 Neul Ltd Mobile base station

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB822261A (en) * 1954-12-10 1959-10-21 Owens Corning Fiberglass Corp Improvements in and relating to thermally stable bonded siliceous structures
US3017318A (en) * 1962-01-16 High temperature resistant siliceous compositions
US3077413A (en) * 1957-02-27 1963-02-12 Carborundum Co Ceramic fiber products and method and apparatus for manufacture thereof
US3141809A (en) * 1957-06-26 1964-07-21 Johns Manville Fiber Glass Inc Mineral fiber laminate and method of making same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3017318A (en) * 1962-01-16 High temperature resistant siliceous compositions
GB822261A (en) * 1954-12-10 1959-10-21 Owens Corning Fiberglass Corp Improvements in and relating to thermally stable bonded siliceous structures
US3077413A (en) * 1957-02-27 1963-02-12 Carborundum Co Ceramic fiber products and method and apparatus for manufacture thereof
US3141809A (en) * 1957-06-26 1964-07-21 Johns Manville Fiber Glass Inc Mineral fiber laminate and method of making same

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3490065A (en) * 1965-05-24 1970-01-13 Owens Corning Fiberglass Corp High temperature resistant acoustical board
US3470977A (en) * 1968-02-21 1969-10-07 Owens Corning Fiberglass Corp Fire resistant glass fiberboard and method of making same
DE2635736A1 (de) * 1975-08-12 1977-02-17 Rockwool Int Feuerhemmendes plattenmaterial
EP0000402A1 (de) * 1977-07-18 1979-01-24 Saint-Gobain Industries Verfahren zur Herstellung von Isolierbauplatten
USRE34020E (en) * 1980-07-11 1992-08-04 Imperial Chemical Industries Plc Fibrous composite materials and the production and use thereof
DE4338619C5 (de) * 1993-11-11 2007-12-27 Saint-Gobain Isover G+H Ag Beschichtetes Mineralwolleprodukt und Verfahren zu dessen Herstellung
US20070125011A1 (en) * 2005-12-06 2007-06-07 Weir Charles R Acoustic partition for removable panel finishing system
US20110031064A1 (en) * 2009-08-07 2011-02-10 Law Harvey Hui-Xiong Non-combustible sound-absorbing facing
US8167085B2 (en) * 2009-08-07 2012-05-01 Smc Australia Pty Ltd Non-combustible sound-absorbing facing
CN111995350A (zh) * 2020-07-17 2020-11-27 北京盈德化工有限公司 一种吸音材料及其制备方法和用途

Also Published As

Publication number Publication date
GB1109867A (en) 1968-04-18
BE681419A (enrdf_load_stackoverflow) 1966-10-31
NL6607067A (enrdf_load_stackoverflow) 1966-11-25

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