US3652352A - Process for manufacture of hard mineral fiber slabs with coating - Google Patents

Process for manufacture of hard mineral fiber slabs with coating Download PDF

Info

Publication number
US3652352A
US3652352A US879265A US3652352DA US3652352A US 3652352 A US3652352 A US 3652352A US 879265 A US879265 A US 879265A US 3652352D A US3652352D A US 3652352DA US 3652352 A US3652352 A US 3652352A
Authority
US
United States
Prior art keywords
resin
fibers
paper
slabs
spirit solution
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.)
Expired - Lifetime
Application number
US879265A
Other languages
English (en)
Inventor
Frantisek Milsimer
Jiri Zampach
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.)
World Patent Development Corp
Original Assignee
World Patent Development 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 World Patent Development Corp filed Critical World Patent Development Corp
Application granted granted Critical
Publication of US3652352A publication Critical patent/US3652352A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • 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
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31942—Of aldehyde or ketone condensation product
    • Y10T428/31949—Next to cellulosic
    • Y10T428/31964—Paper
    • Y10T428/31967—Phenoplast

Definitions

  • ABSTRACT This disclosure teaches a method of manufacturing hard mineral fiber slabs with a surface finish produced from paper impregnated by a spirit solution of phenolformaldehydrate resin, adding at the same time a spirit solution of stearine and a water-spirit solution of hexamethylenetetramine together with a wetting agent. The paper is pressed onto a carpet made of mineral fibers impregnated by resin.
  • the object of this invention is to manufacture hard slabs from mineral fibers, bound together by synthetic resin, and with surface finishes consisting of papers pressed thereon.
  • the papers are impregnated with a decorative print by a phenolformaldehydrate resin, which resin is prepared from a condensed product of phenol and formaldehydrate in an acid environment in a spirit solution adding at the same time hexamethylenetetramine as a hardening agent and also stearine to inhibit adhesion along with a wetting agent.
  • a phenolformaldehydrate resin which resin is prepared from a condensed product of phenol and formaldehydrate in an acid environment in a spirit solution adding at the same time hexamethylenetetramine as a hardening agent and also stearine to inhibit adhesion along with a wetting agent.
  • binders for mineral fibers used for fabrication of hard slabs were cement, for example asbestos fibers were bound by cement to produce hard slabs.
  • mineral fibers made from blast furnace slag have been treated in a wet process on machines similar to those used in paper making, with the binder being sulfate cellulose.
  • FIG. 1 is a schematic representation of the method of making mineral fiber slabs according to this invention.
  • FIG. 2 is an idealized section taken along line 22 of FIG. 1 to illustrate formation of fibers from molten slag by spinning the slag about wheels of progressively greater angular velocity.
  • FIG. 3 depicts progressively the change in shape of the mineral fibers as they advance from roller to roller in FIG. 2.
  • FIG. 4 shows a blanket of mineral fibers with paper applied to both faces thereof.
  • F 16. 5 indicates pressing of mineral fiber blankets between sheets of polished stainless steel.
  • FIG. 6 demonstrates relationships of strength to density for slabs produced in accordance with this invention.
  • FIG. 7 offers a comparison of slag and glass on a strength to diameter basis.
  • molten slag 11 is tapped from furnace 12 and is delivered to fiber-making equipment generally designated 13 wherein the slag is spun in turn about wheels 14, 16, 17 and 18 (see FIG. 2) which rotate respectively in the directions indicated at progressively higher angular velocities whereby, as shown in FIG. 3, drops of slag 19 are formed progressively by kinetic influences through stages 21 and 22 to become long fibers 23 preferably with thicknesses from 5 to 7 microns.
  • fibers 23 are delivered by air stream 24 into settling chamber 26 which is provided at its bottom with endless belt 27 having vacuum chest 28 therebeneath so that the fibers settle on belt 27 to form a continuous carpet 29 of fibers.
  • carpet 29 is passed between rollers 31 for compaction and impregnation thereof by a water solution of phenolformaldehydrate resin delivered from reservoir 32. Vacuum chest 33 draws the resin into carpet blanket 29. Excess resin is collected and returned to reservoir 32 via line 34. In this manner the carpet is impregnated evenly by to percent resin (on a dry weight basis). Thereafter carpet 29 is. further compressed between rollers 36, has papers 37 applied to it and is cut by shears 38 into convenient lengths. A fiber blanket 29 with papers 37 applied to the top and bottom thereof is shown in FIG. 4. Blankets 29, with papers 37 applied thereto, are shown stacked, with highly polished stainless steel plates 39 interposed therebetween, in a press for further compaction thereof and for thermal setting.
  • This modulus of acidity affords an index of mechanical strength as well as chemical and heat stability of the mineral fibers.
  • Heat resistance is raised by increasing the contents of M 0 and SiO For instance, when 30% M 0 is in the charge, the heat resistance of fibers is 800 C.
  • suitable additives for example brick or ceramic fragments
  • this modulus of acidity can be adjusted.
  • the melting temperature of the mineral should be too high, it can be decreased by using suitable additives. The most satisfactory melting temperature is between 1,300 and 1,400 C. High melting temperature causes increased costs in the fiber manufacture.
  • Mineral fiber carpet 29 impregnated by phenolformaldehydrate resin has paper foil 37 (impregnated by resin) applied thereto.
  • a decorative paper imprinted with wood design can be used as paper 37.
  • a basic paper can be used underneath the decorative paper.
  • the resin in the foil 37 comprises the following:
  • hexamethylenetetramine Due to the fact that the solubility of the hexamethylenetetramine in spirit is limited, a further amount of hexamethylenetetramine is added in the form of a waterspirit solution, and in order that stearine does not precipitate from'the solution, the wetting agent Alfonal K is added.
  • the resin solution impregnates the paper with any print on it in us stirring) the water-spirit soluconventional impregnating equipment, drying it at the same a time at a temperature 'of 110 C. until the solvents are completely evaporated.
  • Hexamethylenetetramine acts as a speedy hardening element, thus preventing formation of surface deformations, while the stearine acts as an antiadhesion agent which diffuses during hot pressing into the surface between the sheet and the papers, forming thus a safety coat: i.e., a film which hinders the paper from sticking to the stainless steel.
  • Mineral fiber carpet 29 covered with papers 37 from both sides is placed between stainless steel sheets 39 about 4 mm. thick.
  • the sides of stainless steel sheets 39 in contact with the foil, should be ground and polished to have a high luster. Their surfaces must be without any defects, in order to obtain perfect surfaces for the pressed slabs.
  • the plurality of stages enables one to change capacity to a large extent.
  • The' most suitable press is one with six to stages.
  • Pressing time is 25 to minutes, and is dependent on the thickness and specific weight of the slab because the fibers act as heat insulation. Heating of the mineral fiber carpet must be thorough so that the binding resin gets hardened across the whole cross section.
  • the paper itself is hardened in 5 minutes at 160 C.
  • the advantages of using the foil and this process of hardening is that when hardening has been completed it is not necessary to cool the stages of the press to take out the pressed slabs at a temperature of 20 C. as must be done when a melamineformaldehydrate resin is used.
  • the present method cuts pressing time in half and saves almost 70 percent of the calories need for heating of the press.
  • Modulus of elasticity Bending strength Tensile strength Specific weight When strained, the material behaves as a brittle one. Up to fracture, the functional dependence of the stress deformation is linear and the deformation limit in tensile strength in 0.1 to 0.2 percent, and in compression 0.1 to 0.5 percent.
  • FIG. 6 A survey of the values of mechanical properties is shown in FIG. 6. From FIG. 6 it can be seen that most of the mechanical properties ascend and that the culminating point is reached with the volume weight of 1,500 kg./m.”. This also well shows that it is essential to consider which mechanical stresses will afiect the slab to be made before the system for theirmanufacture has been finalized. According to FIG. 6 it may be possible to decrease the density of a slab as much as by 30 percent and keep at the same time its mechanical strength. By decreasing the weight the price of the slab is lowered.
  • FIG. 7 shows a comparison between a glass and a slag fiber, as regards their tensile strength. From the graph it can be seen that the strength of slag fibers in comparison with glass fibers is about 50 percent. Due to the fact that one only utilizes 50 percent of the glass fiber strength in glass laminates (which have great tensile strength) one can well presume that by using the slag fiber strength to its full extent one may achieve the same overall effectiveness as glass fiber slabs. For this purpose it will be necessary to use resins with lower moduli of elasticity. Such resins will enable the stress to be evenly spread on individual fibers and thus fully utilize the strength of the fibers.
  • a method for treating a paper to be pressed and comprising impregnating the paper by a solution of phenolformaldehydrate resin along with stearine and hexamythylenetetramine as well as a wetting agent, the wetting agent being a product obtained by condensing fat acids of I coconut oil with diethanolamine.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)
US879265A 1968-11-26 1969-11-24 Process for manufacture of hard mineral fiber slabs with coating Expired - Lifetime US3652352A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CS807268 1968-11-26

Publications (1)

Publication Number Publication Date
US3652352A true US3652352A (en) 1972-03-28

Family

ID=5430835

Family Applications (1)

Application Number Title Priority Date Filing Date
US879265A Expired - Lifetime US3652352A (en) 1968-11-26 1969-11-24 Process for manufacture of hard mineral fiber slabs with coating

Country Status (6)

Country Link
US (1) US3652352A (ja)
JP (1) JPS4820228B1 (ja)
DE (1) DE1959242A1 (ja)
FR (1) FR2024302B1 (ja)
GB (1) GB1294320A (ja)
SE (1) SE373531B (ja)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4105623A (en) * 1976-12-17 1978-08-08 Owens-Corning Fiberglas Corporation Method of making molding compounds and materials made thereby
RU2653157C1 (ru) * 2017-05-18 2018-05-07 Надежда Лаврентьевна Краснова Состав для изготовления полуфабриката прессовочного материала и способ изготовления полуфабриката

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB8400294D0 (en) * 1984-01-06 1984-02-08 Wiggins Teape Group Ltd Fibre reinforced composite plastics material
US4596736A (en) * 1984-06-04 1986-06-24 The Dow Chemical Company Fiber-reinforced resinous sheet

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB954527A (en) * 1962-08-10 1964-04-08 West Virginia Pulp & Paper Co Improved mineral fibre mat formation

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB443449A (en) * 1934-06-07 1936-02-28 Chem Ind Basel Manufacture of compressed sheet material having an opaque decorative surface
GB662810A (en) * 1948-06-26 1951-12-12 Tno Improvements in or relating to low-pressure phenol-aldehyde resins
GB674149A (en) * 1949-06-30 1952-06-18 Herbert John Mallabar Improvements in the manufacture of decorative laminae
FR1243545A (fr) * 1958-10-06 1960-10-14 Owens Corning Fiberglass Corp Produit fibro-cellulaire et son procédé de fabrication

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB954527A (en) * 1962-08-10 1964-04-08 West Virginia Pulp & Paper Co Improved mineral fibre mat formation

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4105623A (en) * 1976-12-17 1978-08-08 Owens-Corning Fiberglas Corporation Method of making molding compounds and materials made thereby
RU2653157C1 (ru) * 2017-05-18 2018-05-07 Надежда Лаврентьевна Краснова Состав для изготовления полуфабриката прессовочного материала и способ изготовления полуфабриката

Also Published As

Publication number Publication date
DE1959242A1 (de) 1970-08-06
JPS4820228B1 (ja) 1973-06-19
SE373531B (sv) 1975-02-10
FR2024302A1 (ja) 1970-08-28
GB1294320A (en) 1972-10-25
FR2024302B1 (ja) 1973-10-19

Similar Documents

Publication Publication Date Title
CH654788A5 (de) Verfahren zur herstellung von geformten verbundgegenstaenden aus faserverstaerkten glasmatrizes bzw. glaskeramikmatrizes.
US2542064A (en) Apparatus for making means to attach friction material to brake shoes and the like
MY103678A (en) A process for the manufacture of autoclaved fiber-reinforced shaped articles,
DE3318785A1 (de) Verfahren zur herstellung von verbundgegenstaenden aus einer mit einem fasergewebe verstaerkten glasmatrix
US3652352A (en) Process for manufacture of hard mineral fiber slabs with coating
US3354031A (en) Cement-asbestos products and improvement in the manufacture thereof
DE3303286C2 (ja)
US2208511A (en) Method of making dense wall panels
US2445415A (en) Insulating board and method of making the same
JPS594455B2 (ja) 耐摩耗性に優れる摩擦材料及びその製造方法
JPS592838A (ja) 耐熱性積層品
US3511731A (en) Composite panel and an improved manufacturing method therefor
US3844877A (en) Carbonaceous fabric laminate
US3269889A (en) Asbestos paper containing carbon and method of making it
JP2522626B2 (ja) 無機面材とその製造方法
US2690100A (en) Method of producing fire-resistant inorganic fiber insulation
JPS59187623A (ja) 炭素繊維成形シ−トの製造法
JP2002235277A (ja) 断熱材及びその製造方法
US1900699A (en) Waterproof insulating body
US2237337A (en) Method of making fibrous product
US3629184A (en) Whisker reinforced binders for laminated composites and adhesives
JPS6350381A (ja) 炭素質摩擦材
EP0206989A1 (de) Asbestfreies Material mit anorganischen Fasern sowie ein Verfahren zur Herstellung des Materials
DE506221C (de) Reibkoerper, insbesondere fuer Bremsen und Kupplungen
JPS5617158A (en) Reinforcing method of ceramic shell mold