US3459629A - Wood particle board containing vermiculite and method of making same - Google Patents

Wood particle board containing vermiculite and method of making same Download PDF

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Publication number
US3459629A
US3459629A US562195A US3459629DA US3459629A US 3459629 A US3459629 A US 3459629A US 562195 A US562195 A US 562195A US 3459629D A US3459629D A US 3459629DA US 3459629 A US3459629 A US 3459629A
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Prior art keywords
grams
vermiculite
board
ore
wood
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US562195A
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English (en)
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Antoine Kawam
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WR Grace and Co
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WR Grace and Co
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    • 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
    • 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
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/251—Mica
    • 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
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/259—Silicic material

Definitions

  • This invention relates to fire resistant building materials. In one particular aspect it relates to composite fire resistant vermiculite-wood boards.
  • Exfoliated vermiculite because it is readily available and possesses a high degree of thermal resistance has been laminated on the surface of the boards.
  • this invention provides a composite board, comprising a particle board consisting of a mixture of wood particles, and a raw unexpanded vermiculite ore bonded with a suitable binder.
  • Grades l-5 Commercial vermiculite ore is designated by grades and is marketed as Grades l-5.
  • the U8. series size of these grades are as follows: Grade 1, 3-12; Grade 2, 8-16; Grade 3, 1240; Grade 4, 30-70; and Grade 5, 40.
  • verirnculite ore any of these grades of verirnculite ore is applicable to this invention. It is to be understood that where the term unexpanded vermiculite ore is used it means an expandable or exfoliated ore.
  • the wood particles may be in the form of a chip, flake, exclesior, shaving, splinter or sawdust made by grinding tearing, and cutting debarked wood.
  • the ratio of unexpanded vermiculite ore to wood chips depends upon the end use. The higher the vermiculite ore content, the better the heat and fire rating, but the weaker the final structure will be. For applications where structural strength is not required but a high fire resistance is necessary, a higher ratio of vermiculite ore to wood chips can be used.
  • the vermiculite ore content can vary from 10 to 80% based on the weight of the wood chips, with 25% ore and 75% wood suitable for most purposes.
  • binder The type of binder and the amount necessary will depend upon the particular use for which the product is intended.
  • the preferred binders of this invention are those commonly used in particle board preparation; namely, urea formaldehyde, phenol formaldehyde, and to a minor degree milamin-HCHO, and other aminoblasts.
  • paraffin based wax emulsions can be added to the vermiculite ore-wood chips where sizing is necessary.
  • the uses to which the composite board of this invention can be applied are extremely varied.
  • the uses deemed within the scope of the invention are wallboards, sound insulations, heat isulations, decorative panels, table covers, roofing, insulating panels for appliances, acoustical tile, backing for decorative wood paneling, materials for doors, underlayments, insulations in safes and the like.
  • exfoliated vermiculite coated with adhesive is spread out on the bottom of a suitable mold.
  • a layer of unexpanded vermiculite ore, also coated with adhesive is spread upon the exfoliated vermiculite ore wood chips and a binder is spread upon the unexpanded vermiculite ore layer to form a mat.
  • a layer of unexpanded vermiculite ore coated with adhesive may be applied to the mattress layer and a further layer of exfoliated vermiculite, also coated with adhesive, can be applied to the vermiculite ore layer.
  • the assembly is subjected to heat and compression in the usual way to form a board provided on both sides with fire proof layers of exfoliated vermiculite and vermiculite ore and having a center core of Wood chips and vermiculite ore.
  • This laminated board is illustrated in the drawing. It shows the board generally at 10, the facing layers of exfoliated vermiculite at 11 and 12, the unexpanded vermiculite ore layer at 13 and 14, and the center core of vermiculite ore wood chips and binder at 15.
  • EXAMPLE I 1500 grams of wood chips inch x A inch) having a moisture content of 7.2%, and 500 grams of No. 3 unexpanded vermiculite ore were blended together. During the blending, 41.5 grams of a 45% paraflin base wax emulsion was added to the mix in the form of a fine atomizing jet. After adding the wax, 230 grams of urea formaldehyde adhesive containing 65% solids was added. The moisture content of the composite was them 10.5%.
  • the mat was removed from the mold and pressed at 35 ton pressure and 300 F. to inch thickness. The pressure was then lowered to 12 tons and maintained in that condition for 3 minutes. A 4 inch board resulted.
  • This board exhibited excellent fire resistance and the vermiculite ore particles upon contact with a flame, or when submitted to intense heat, expanded and prevented fire propagation.
  • EXAMPLE II A board was prepared as described in Example I, but in place of the unexpanded vermiculite ore, unexpanded perlite was used. This board also exhibited excellent fire 3 resistance and the perlite ore particles upon contact with a flame or submitted to intense heat, expanded and prevented fire propagation.
  • EXAMPLE III Two boards were prepared, (1) 3000 grams of wood chips (moisture content 7.2%) and 100 grams of unexpanded vermiculite ore No. 3 were blended together. During the blending, 83 grams of a 45% paraffin based wax emulsion was sprayed upon the tumbling mass. 460 grams of urea formaldehyde resin adhesive containing 65% solids was added to the wood chip vermiculite ore mix. The total water content of the composite was 400 grams of expanded No. 2 vermiculite ore was blended with 74 grams of urea formaldehyde adhesive and 9 grams of a 45 parafiin based wax emulsion.
  • composition was placed in apress at 300 F. and tons pressure for 3 minutes and compressed to inch thickness, at which time the pressure was dropped to 12 tons and held for an additional 3 minutes.
  • a inch composite board resulted.
  • the second board was prepared by blending 4000 grams of food chips, 83 grams of a paraffin base wax emulsion, and 460 grams of 65 solution of ureaformaldehyde resin adhesive and 9 grams of wax emulsion.
  • the first board contains a center core of wood chips and unexpanded vermiculite ore with surface layers of exfoliated vermiculite
  • the second board contains a core of only wood chips and resin with similar surface layers of exfoliated vermiculite.
  • Both boards were subjected to the hot flame of the tip of an acetylene torch.
  • board (1) which is the board of this invention, no burning or propagation of the flame occurred. After 3 minutes exposure of one side of this board to flame, the other side remained cool to the touch. Damage to the exposed face was only superficial and confined to the area of direct contact.
  • the second board (2) which is similar to the prior art compositions started to char, burn and smoke after 80 seconds of exposure to the flame.
  • EXAMPLE IV 3000 grams of wood chips and 1000 grams of No. 3 unexpanded vermiculite ore were blended together and sprayed with 82 grams of a 45 paraffin wax base emul- 4 sion. 460 grams of a 65% urea-formaldehyde adhesiv was added to the mix.
  • a board was then prepared by spreading evenly 745 grams of the ore adhesive mix on the bottom of a 14 inch square mold and then applying 1600 grams of the wood chip vermiculite and ore composite on top of it and following this by additional layer of 745 grams of the vermiculite ore and formaldehyde resin.
  • This three layered composite was then compressed to 2 inches in a cold press after which it was subjected to 35 tons pressure at 3 minutes at 300 F. and compressed to inch thickness. The pressure was then dropped to 12 tons for an additional 3 minutes.
  • the resulting board was /51 inch.
  • a second board was prepared as the first, differing in that it contained a surface layer of vermiculite ore on only one side. Both boards were subjected to the hot flame of the tip of an acetylene torch and exhibited excellent fire and heat resistance.
  • EXAMPLE V A special product board can be prepared where unusually high fire resistance is required as on ships, airplanes, safes, etc.
  • a five layered composite board was prepared containing the center layer or core 1200 grams of wood chips and 400 grams of No. 3 expanded vermiculite ore blended with 128 grams of urea formaldehyde resin and 16 grams of paraffin base wax.
  • On either side of the core layer was a layer of unexpanded No. 3 vermiculite ore consisting of 300 grams of the ore, 24 grams of urea formaldehyde resin, and 3 grams of the paraflin base wax.
  • the surface layers were exfoliated vermiculite and contained 200 grams of the vermiculite, 16 grams of urea formladehyde resin and 2 grams of paraffin base wax.
  • This board was prepared using the method described in the previous examples. The resulting board is illustrated in the drawing.
  • the board was exposed for 10 minutes to the hot tip of an acetylene torch and exhibited only minor localized effect.
  • the side opposite the torch reached a temperature of to F. No burning, smoking or charring was exhibited on the flame side.
  • a particle board consisting of a mixture of wood particles and unexpanded vermiculite ore bonded with a suitable binder.
  • a composite board comprising the particle board of claim 1 and having on at least one side of said particle board a layer of compressed exfoliated vermiculite integral therewith.
  • a composite board comprising the particle board of claim 1 and having on at least one side of said particle board a layer of unexpanded vermiculite ore integral therewith.
  • a composite board comprising a particle board of claim 1 and having on at least one side of said particle board, two layers, the first layer being unexpanded vermiculite ore integral with said board, and the second layer being exfoliated vermiculite integral with said first layer.
  • a method of making a composite board comprising the steps of spreading a mixture of exfoliated vermiculite and synthetic resin on the bottom half of pressing means in which the board is to be prepared, spreading on such layer a mattress of wood chips and unexpanded vermiculite ore mixed with a synthetic resin binder, spreading on the mattress of wood chips and unexpanded vermiculite ore a further layer of exfoliated vermiculite and synthetic resin, and subjecting the three layers to heat and pressure thereby to form a composite board with two integral layers of exfoliated vermiculite.
  • a particle board consisting of a mixture of wood ROBERT F. BURNETT, Primary Examiner gagi-iglfiadgd unexpanded perlite ore bonded with a suit- WILLIAM L VAN BALEN, A S Si stant Examiner References Cited U s,c1 X,R. UNITED STATES PATENTS 5 161-162, 168, 171, 208, 261; 264--113 2,390,732 12/1945 Page 161-163 3,109,767 11/1963 Polovtsefi et a1 161-163

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
US562195A 1966-07-01 1966-07-01 Wood particle board containing vermiculite and method of making same Expired - Lifetime US3459629A (en)

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DE (1) DE1659083A1 (fr)
FR (1) FR1530046A (fr)
GB (1) GB1158460A (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4111730A (en) * 1972-03-21 1978-09-05 Balatinecz John J Producing recycle composition paper flake board
WO1980001576A1 (fr) * 1979-02-05 1980-08-07 Hollingsworth & Vose Co Materiau en feuilles contenant de la vermiculite exfoliee
USRE34020E (en) * 1980-07-11 1992-08-04 Imperial Chemical Industries Plc Fibrous composite materials and the production and use thereof
US20030010258A1 (en) * 2000-11-10 2003-01-16 Yoshiaki Fukuda Composition for building material and building material
FR2897083A1 (fr) * 2006-02-08 2007-08-10 Cooperative Ouvriere De Menuis Structure de type panneau, d'isolation accoustique et/ou thermique
FR2897883A1 (fr) * 2006-02-08 2007-08-31 Cooperative Ouvriere De Menuis Structure de type panneau, d'isolation acoustique et/ou thermique
US20100105494A1 (en) * 2008-10-28 2010-04-29 Chien-Tu Lu billiard panel and a billiard table coupled with the billiard panel
CN112500119A (zh) * 2020-12-16 2021-03-16 江苏必得科技股份有限公司 一种应用于轨道交通的吸声材料及其制备方法

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DK146936C (da) * 1976-04-22 1984-07-30 Kaj Skotte Moeller Fremgangsmaade til fremstilling af spaanplader indeholdende ekspanderet vermiculit som brandhaemmende middel
BE849114A (fr) * 1976-12-07 1977-04-01 Eugene Pierre Smits Procede pour la realisation d'elements en beton ignifuges, elements et constructions appliquant ces elements
GB1583308A (en) * 1978-04-20 1981-01-21 Crosby & Co Ltd Heat resistant composition
FR2478726A1 (fr) * 1980-03-19 1981-09-25 Sohier J Porte insonore, thermiquement isolante et incrochetable
YU42515B (en) * 1980-07-02 1988-10-31 Brest Process for the manufacture of compressed, fire resistant,thermo insulating, three layered construction plates
IT1263383B (it) * 1993-06-28 1996-08-05 Orv Spa Pannello particolarmente per pareti divisorie tagliafuoco e procedimento per la sua realizzazione

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2390732A (en) * 1944-07-03 1945-12-11 Shaw Walker Co Fire-resisting cabinet
US3109767A (en) * 1960-10-24 1963-11-05 Polovtseff Boris Composite board and method of making same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2390732A (en) * 1944-07-03 1945-12-11 Shaw Walker Co Fire-resisting cabinet
US3109767A (en) * 1960-10-24 1963-11-05 Polovtseff Boris Composite board and method of making same

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4111730A (en) * 1972-03-21 1978-09-05 Balatinecz John J Producing recycle composition paper flake board
WO1980001576A1 (fr) * 1979-02-05 1980-08-07 Hollingsworth & Vose Co Materiau en feuilles contenant de la vermiculite exfoliee
DE3025341C2 (fr) * 1979-02-05 1991-05-02 Hollingsworth & Vose Co., East Walpole, Mass., Us
USRE34020E (en) * 1980-07-11 1992-08-04 Imperial Chemical Industries Plc Fibrous composite materials and the production and use thereof
US20030010258A1 (en) * 2000-11-10 2003-01-16 Yoshiaki Fukuda Composition for building material and building material
US20080060316A1 (en) * 2000-11-10 2008-03-13 Mitsubishi Shoji Construction Materials Corporation Construction material composition, construction material, coating composition and waste construction material soil conversion method
FR2897083A1 (fr) * 2006-02-08 2007-08-10 Cooperative Ouvriere De Menuis Structure de type panneau, d'isolation accoustique et/ou thermique
FR2897883A1 (fr) * 2006-02-08 2007-08-31 Cooperative Ouvriere De Menuis Structure de type panneau, d'isolation acoustique et/ou thermique
US20100105494A1 (en) * 2008-10-28 2010-04-29 Chien-Tu Lu billiard panel and a billiard table coupled with the billiard panel
CN112500119A (zh) * 2020-12-16 2021-03-16 江苏必得科技股份有限公司 一种应用于轨道交通的吸声材料及其制备方法

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DE1659083A1 (de) 1971-10-28
GB1158460A (en) 1969-07-16
FR1530046A (fr) 1968-06-21

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