WO1998005492A1 - Dimensionally stable, high density siliceous panel board of reduced thickness - Google Patents

Dimensionally stable, high density siliceous panel board of reduced thickness Download PDF

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Publication number
WO1998005492A1
WO1998005492A1 PCT/US1997/013011 US9713011W WO9805492A1 WO 1998005492 A1 WO1998005492 A1 WO 1998005492A1 US 9713011 W US9713011 W US 9713011W WO 9805492 A1 WO9805492 A1 WO 9805492A1
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WO
WIPO (PCT)
Prior art keywords
panel board
composition
board
inch
thickness
Prior art date
Application number
PCT/US1997/013011
Other languages
French (fr)
Inventor
V. Robert Canfield
James David Kirkham
Original Assignee
Building Materials Corporation Of America
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 Building Materials Corporation Of America filed Critical Building Materials Corporation Of America
Publication of WO1998005492A1 publication Critical patent/WO1998005492A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • 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
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/26—Bituminous materials, e.g. tar, pitch
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2395/00—Bituminous material, e.g. tar, asphalt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • Perlite insulating boards for roofing and siding are known and widely used for their fire resistant properties.
  • the boards employing perlite have been limited to a minimum thickness of 1/2 inch, usually between about 1/2-1.5 inch is conventionally employed.
  • the use of such boards for room dividers and in furniture manufacture are undesirable since they are cumbersome and excessively bulky after application of a fabric covering, particularly coverings having relatively sturdy abrasion resistance.
  • Another object of the invention is to provide a light weight panel board of superior dimensional stability for use in humid environments.
  • Yet another object is to provide a panel board having superior noise damping properties.
  • Still another object is to provide an economical and commercially feasible process for the manufacture of a thin, light weight panel board.
  • a high density panel board having a thickness as low as l/5th inch composed, on a dry basis, of between about 55 and about 75 wt% expanded perlite; between about 2.5 and about 4.5 wt% asphalt having a softening point of at least 180°F.; between about 20 and about 40 wt% cellulosic material, e.g. paper fibers and the like and between about 0.5 and about 3 wt . % starch.
  • the density of the present board is between 12.1 and 20 pcf.
  • starches from corn, potatoes and tapioca are preferred; although other starches can be substituted herein.
  • Suitable cellulosic materials for the present composition include paper fiber, waste newspaper, cotton fiber and the like.
  • One method of producing the present panel board involves forming a homogeneous aqueous composition between about 55 wt . % and about 75 wt . % of perlite particles having a particle diameter of from about 0.1 to about 1.2 mm.
  • the perlite particles are presprayed with a 45 to 65 % aqueous emulsion of the asphalt and the resulting coated particles are then blended with an aqueous pulp slurry of starch and cellulosic fibers containing between about 94 and about 98 wt . % water.
  • the starch/cellulosic pulp slurry may also contain a small amount of asphalt, e.g. less than 0.1 w .
  • % and/or a minor amount, e.g. less than about 20 wt.%, of the total solids, of reject or trim waste panel board After thoroughly blending the above components at a temperature from about 90° to about 110 °F for a period of from about 10 seconds to about 3 minutes, a uniform slurry of 3 to 6 wt.% solids is formed and any excess of water is removed by drainage and/or suction. The resulting slurry is then compressed, e.g. passed on a fabric carrier or wire web, between rollers operated to reduce the water concentration to 60-85 wt.%, preferably less than about 80 wt.% water concentration; thereby forming a wet mat in which the fibers have become intermeshed and coalesced.
  • the partially dewatered mat maintains its sheet integrity without the aid of facers or backers.
  • the wet mat is then finally dried in an oven at 200°-600°F with an initial oven temperature above about 400 °F, preferably above about 500°F, to reduce the water content in the finished product to less than 4 wt.%, preferably less than 2.5 wt . % .
  • the manner of staged water removal, the formation of the self-supportable wet mat before oven drying and the relatively low asphalt content, are the combination of critical factors which permit achievement of high density in instant product and hence the strength and stability required for its commercial use for panels of significantly reduced thickness.
  • the improved strength of the product panel board, using the standard pushpin test, was found to be at least 3 fold over the commercial perlite boards presently in use.
  • the density of the present panel board can be regulated by the controlling material feed rate, the production line speed and the press roller gap.
  • the required density between about 12.1 and 20 pcf, preferably between about 13.5 and about 18.5 pcf, varies inversely with the desired board thickness. In certain cases, it has also been observed that a an equal amount or a small excess of starch with respect to asphalt in the board composition provides good results.
  • Waste newspaper was slurried in water at a concentration of about 2.7% in a hydrapulper. During the mixing, about 1.1% of trim waste and reject board were added, as well as about 0.14% starch and 0.08% asphalt emulsion to produce a liquid of 4% total solids content. After mixing for about 20 minutes, the batch was discharged to a holding tank. From the holding tank the pulp slurry was pumped continuously to a blending tank where dilution water and expanded perlite were added and mixed. As the expanded perlite enters the blending tank, asphalt emulsion was sprayed on the particles to retard its absorption of water. This treatment decreases the formed board's propensity to retain water and thus aids drying of the board. The composition of solids in the resulting slurry was as follows. t. % Expanded Perlite 66.0
  • the blending tank discharged continuously into the headbox of a Fourdrinier paper machine and then out onto a porous woven forming fabric .
  • Water was drained from the slurry through the fabric by gravity, then by vacuum.
  • the resulting continuous web was cut into 16 foot lengths by a serrated cutting blade, and the 16 ft lengths were then fed into a drying oven having 8 drying decks operating at a temperature decreasing from 600° to about 200°F which allows the oven to operate at l/8th the forming machines speed and reducing the length of oven needed to provide 1-2 hours drying time.
  • the panel boards exited the oven at a moisture content of 2 to 4% and were saw cut to size and stacked on pallets for shipment .
  • Panel boards of various thicknesses were tested for strength using the Push/Pull Pin Test. As noted in the following Table, 3/8" inch boards, made by the process of Example 1, were compared with standard, commercially available 1/2 and 3/4 inch perlite boards.
  • n represents the number of boards tested ** The paper pull tests were made with a sheet of bond paper. The paper held to the board is pulled away from the pin in a direction parallel with the board surface. Desirably, the push pin should remain in place after the paper is pulled away. It was found that 70% of all pins remained attached to the 3/8" boards after paper removal; whereas only 5% of the pins were in place in the 1/2" boards and all of the pins were dislodged using the 3/4" boards. Accordingly, it is shown that the present high density panel boards of relatively high starch content are remarkably superior in strength than the thicker, heavier 1/2 and 3/4 inch boards tested.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Paper (AREA)

Abstract

This invention concerns a thin, lightweight panel board of density greater than 12 lb/ft.3 (pcf) composed of 55-75 wt.% siliceous material; 2.5-4.5 wt.% asphalt; 20-40 wt.% cellulosic material and 0.5-3 wt.% starch, which board exhibits superior strength and acoustical dampening at 1/5 to 1 inch thicknesses. The invention also relates to a process required for the production of said board.

Description

DIMENSIONALLY STABLE, HIGH DENSITY SILICEOUS PANEL -BOARD QF REDUCED THICKNESS
This application is based on Provisional Application Serial No. 60/023,147 filed August 5, 1996 by the same inventors of this application V. Robert Canfield and James David Kirkham.
BACKGROUND OF THE INVENTION
Perlite insulating boards for roofing and siding are known and widely used for their fire resistant properties. However, for adequate strength and resistance to breakage or fracture during manufacture, handling, shipping and installation, the boards employing perlite have been limited to a minimum thickness of 1/2 inch, usually between about 1/2-1.5 inch is conventionally employed. On the other hand, the use of such boards for room dividers and in furniture manufacture are undesirable since they are cumbersome and excessively bulky after application of a fabric covering, particularly coverings having relatively sturdy abrasion resistance. Hence, it would be advantageous to provide a thinner, light weight panel board or frame dividing partition having superior strength or having strength at least equal to the 1/2 inch board currently in use. Specific benefits to be realized from boards having reduced thicknesses include easier handling, lower shipping costs and use in the manufacture of movable partitions requiring less floor space. However, such improvement has not been achieved since it has been found that a board thickness below 1/2 inch is not achievable with current manufacturing processes.
The addition of small amounts of binder such as wax, starch and stiffening agents, which have been proposed for preboard slurries in the manufacturing process, have not proved successful. For example, it has been reported that the use of starch in the board composition causes irreversible deformation under humid conditions. This disadvantage would be expected due to the high water absorption properties of starch.
Accordingly, it is an object of this invention to overcome the above difficulties while retaining all of the beneficial properties of perlite panel and insulation boards .
Another object of the invention is to provide a light weight panel board of superior dimensional stability for use in humid environments.
Yet another object is to provide a panel board having superior noise damping properties.
Still another object is to provide an economical and commercially feasible process for the manufacture of a thin, light weight panel board.
These and other objects of the invention will become apparent from the following description and disclosure. THE INVENTION
In accordance with the present invention there is provided a high density panel board having a thickness as low as l/5th inch composed, on a dry basis, of between about 55 and about 75 wt% expanded perlite; between about 2.5 and about 4.5 wt% asphalt having a softening point of at least 180°F.; between about 20 and about 40 wt% cellulosic material, e.g. paper fibers and the like and between about 0.5 and about 3 wt . % starch. The density of the present board is between 12.1 and 20 pcf. A board thickness of 7/16th inch or less, e.g. 5/16th inch, is particularly desirable.
In the above composition, starches from corn, potatoes and tapioca are preferred; although other starches can be substituted herein.
Suitable cellulosic materials for the present composition include paper fiber, waste newspaper, cotton fiber and the like.
One method of producing the present panel board involves forming a homogeneous aqueous composition between about 55 wt . % and about 75 wt . % of perlite particles having a particle diameter of from about 0.1 to about 1.2 mm. The perlite particles are presprayed with a 45 to 65 % aqueous emulsion of the asphalt and the resulting coated particles are then blended with an aqueous pulp slurry of starch and cellulosic fibers containing between about 94 and about 98 wt . % water. Optionally, the starch/cellulosic pulp slurry may also contain a small amount of asphalt, e.g. less than 0.1 w . % and/or a minor amount, e.g. less than about 20 wt.%, of the total solids, of reject or trim waste panel board. After thoroughly blending the above components at a temperature from about 90° to about 110 °F for a period of from about 10 seconds to about 3 minutes, a uniform slurry of 3 to 6 wt.% solids is formed and any excess of water is removed by drainage and/or suction. The resulting slurry is then compressed, e.g. passed on a fabric carrier or wire web, between rollers operated to reduce the water concentration to 60-85 wt.%, preferably less than about 80 wt.% water concentration; thereby forming a wet mat in which the fibers have become intermeshed and coalesced. After compression, the partially dewatered mat maintains its sheet integrity without the aid of facers or backers. The wet mat is then finally dried in an oven at 200°-600°F with an initial oven temperature above about 400 °F, preferably above about 500°F, to reduce the water content in the finished product to less than 4 wt.%, preferably less than 2.5 wt . % .
The manner of staged water removal, the formation of the self-supportable wet mat before oven drying and the relatively low asphalt content, are the combination of critical factors which permit achievement of high density in instant product and hence the strength and stability required for its commercial use for panels of significantly reduced thickness. The improved strength of the product panel board, using the standard pushpin test, was found to be at least 3 fold over the commercial perlite boards presently in use. The density of the present panel board can be regulated by the controlling material feed rate, the production line speed and the press roller gap. The required density between about 12.1 and 20 pcf, preferably between about 13.5 and about 18.5 pcf, varies inversely with the desired board thickness. In certain cases, it has also been observed that a an equal amount or a small excess of starch with respect to asphalt in the board composition provides good results.
EXAMPLE 1
Preparation of Perlite Panel Board
Waste newspaper was slurried in water at a concentration of about 2.7% in a hydrapulper. During the mixing, about 1.1% of trim waste and reject board were added, as well as about 0.14% starch and 0.08% asphalt emulsion to produce a liquid of 4% total solids content. After mixing for about 20 minutes, the batch was discharged to a holding tank. From the holding tank the pulp slurry was pumped continuously to a blending tank where dilution water and expanded perlite were added and mixed. As the expanded perlite enters the blending tank, asphalt emulsion was sprayed on the particles to retard its absorption of water. This treatment decreases the formed board's propensity to retain water and thus aids drying of the board. The composition of solids in the resulting slurry was as follows. t. % Expanded Perlite 66.0
Asphalt 4.0
Paper waste 25.3
Starch 4.7
The blending tank discharged continuously into the headbox of a Fourdrinier paper machine and then out onto a porous woven forming fabric . Water was drained from the slurry through the fabric by gravity, then by vacuum. Press rolls, adjusted to provide sheeting of a predetermined thickness, were employed subsequently to remove an additional quantity of water so that by the end of the press section the board had a moisture content of about 75 to 80%. The resulting continuous web was cut into 16 foot lengths by a serrated cutting blade, and the 16 ft lengths were then fed into a drying oven having 8 drying decks operating at a temperature decreasing from 600° to about 200°F which allows the oven to operate at l/8th the forming machines speed and reducing the length of oven needed to provide 1-2 hours drying time. The panel boards exited the oven at a moisture content of 2 to 4% and were saw cut to size and stacked on pallets for shipment .
EXAMPLE 2
Panel boards of various thicknesses were tested for strength using the Push/Pull Pin Test. As noted in the following Table, 3/8" inch boards, made by the process of Example 1, were compared with standard, commercially available 1/2 and 3/4 inch perlite boards.
TABLE 3/8" 1/2" 3/4"
Tack Pull (lbf) 0.63 0.56 0.35 n* 6 6 6
Tack Push (lbf) 3.99 2.93 1.52 n* 12 12 12
Paper Pull (% Pass)** 70% 5% 0% n* 10 10 10
* n represents the number of boards tested ** The paper pull tests were made with a sheet of bond paper. The paper held to the board is pulled away from the pin in a direction parallel with the board surface. Desirably, the push pin should remain in place after the paper is pulled away. It was found that 70% of all pins remained attached to the 3/8" boards after paper removal; whereas only 5% of the pins were in place in the 1/2" boards and all of the pins were dislodged using the 3/4" boards. Accordingly, it is shown that the present high density panel boards of relatively high starch content are remarkably superior in strength than the thicker, heavier 1/2 and 3/4 inch boards tested.

Claims

WHAT IS CLAIMED IS:
1. A light weight, fracture resistant panel board having a density of from about 12 to 20 pcf which is the composition comprising between about 55 and about 75 wt.% perlite particles; between about 2.5 and about 4.5 wt.% asphalt having a softening point of 180°F or higher; between about 20 and about 40 wt.% cellulose fibers and between about 0.5 and about 3.5 wt.% starch; said panel board having a thickness of not more than 1/2 inch.
2. The panel board of claim 1 wherein the cellulose fibers are paper or cotton fibers.
3. The panel board of claim 1 wherein the amount of starch is equal to or less than the amount of asphalt.
4. The panel board of claim 1 having a thickness of not more than 7/16th inch.
5. The panel board of claim 1 wherein the composition the perlite particles are between about 0.1 and about 1.2 mm in diameter .
6. The panel board of claim 1 wherein the composition additionally contains less than 3.5 wt.% of reject of trim waste panel board of prior manufacture.
7. The panel board of claim 1 wherein the composition contains less than 4 wt.% water, based on total composition.
8. The process of producing the panel board of claim 1 wherein an aqueous slurry of said composition, containing less than 3 wt.% solids is prepared and then concentrated to between about 3 and about 6 wt . % solids by draining followed by suction to form a partially dewatered slurry, the partially dewatered slurry is subjected to compression to form a self-supportable mat containing from about 15 to about 40 wt.% solids and the compressed mat is subjected to drying at from about 200° to about 600°F in an oven with an initial oven temperature above 400°F to form a dry mat containing less than 4 wt.% water.
9. The process of claim 8 wherein the initial oven temperature is above about 500°F.
10. A space dividing partition comprising the panel board of claim 1.
11. The space dividing partition of claim 10 wherein the panel board has a thickness of not more than 7/l6th inch.
12. The space dividing partition of claim 10 wherein the panel board has a density of from about 13.5 to about 18.5 pcf.
13. The space dividing partition of claim 10 wherein said panel board is covered with a fabric.
PCT/US1997/013011 1996-08-05 1997-07-24 Dimensionally stable, high density siliceous panel board of reduced thickness WO1998005492A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US2314796P 1996-08-05 1996-08-05
US60/023,147 1996-08-05

Publications (1)

Publication Number Publication Date
WO1998005492A1 true WO1998005492A1 (en) 1998-02-12

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000046164A1 (en) * 1999-02-02 2000-08-10 Shell Internationale Research Maatschappij B.V. Solid-state composition comprising solid particles and binder
US7879252B1 (en) * 2009-08-07 2011-02-01 Chang Ha Lim Functional cotton spray composition, method for producing the same, and building material using the same

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5264257A (en) * 1991-04-29 1993-11-23 Manville Corporation Glass composite sheathing board

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5264257A (en) * 1991-04-29 1993-11-23 Manville Corporation Glass composite sheathing board

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000046164A1 (en) * 1999-02-02 2000-08-10 Shell Internationale Research Maatschappij B.V. Solid-state composition comprising solid particles and binder
AU756207B2 (en) * 1999-02-02 2003-01-09 Shell Internationale Research Maatschappij B.V. Solid-state composition comprising solid particles and binder
US6749678B1 (en) 1999-02-02 2004-06-15 Shell Oil Company Solid-state composition comprising solid particles and binder
US7879252B1 (en) * 2009-08-07 2011-02-01 Chang Ha Lim Functional cotton spray composition, method for producing the same, and building material using the same

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