WO2013006382A1 - Felt for forming fiber cement articles and related methods - Google Patents
Felt for forming fiber cement articles and related methods Download PDFInfo
- Publication number
- WO2013006382A1 WO2013006382A1 PCT/US2012/044682 US2012044682W WO2013006382A1 WO 2013006382 A1 WO2013006382 A1 WO 2013006382A1 US 2012044682 W US2012044682 W US 2012044682W WO 2013006382 A1 WO2013006382 A1 WO 2013006382A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fiber cement
- yarns
- felt
- cement felt
- cmd yarns
- Prior art date
Links
Classifications
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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
- 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
- C04B28/02—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 hydraulic cements other than calcium sulfates
-
- 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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- 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
- B28B1/527—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 rotating drum, e.g. a sieve drum, from which the materials are picked up by a felt
-
- 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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/08—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 structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
-
- 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
- B32B5/24—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 a fibrous or filamentary layer
- B32B5/26—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 a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D1/00—Woven fabrics designed to make specified articles
- D03D1/0094—Belts
-
- 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
- B32B2250/00—Layers arrangement
- B32B2250/02—2 layers
-
- 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
- B32B2250/00—Layers arrangement
- B32B2250/20—All layers being fibrous or filamentary
-
- 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
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
-
- 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
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
- B32B2262/0269—Aromatic polyamide fibres
-
- 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
- B32B2262/04—Cellulosic plastic fibres, e.g. rayon
-
- 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
- B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3065—Including strand which is of specific structural definition
- Y10T442/3073—Strand material is core-spun [not sheath-core bicomponent strand]
Definitions
- the present invention relates generally to fabrics, and more particularly to fabrics employed to form articles of fiber cement.
- Fiber cement is a well-known material employed in many building components, such as siding, roofing and interior structures, and in pipes, particularly for waste water transport.
- Fiber cement typically comprises a mixture of cement (i.e., lime, silica and alumina), clay, a thickener, inorganic fillers such as calcium carbonate, and one or more fibrous materials.
- cement i.e., lime, silica and alumina
- clay i.e., silica and alumina
- inorganic fillers such as calcium carbonate
- fibrous materials i.e., asbestos was commonly included as the fibrous material (see U.S. Patent No. 4,216,043 to Gazzard et al.); because of the well-documented problems asbestos presents, now fiber cement typically includes a natural or synthetic fiber, such as acrylic, aramid, polyvinyl alcohol, polypropylene, cellulose or cotton. Fiber cement is popular for the aforementioned applications because of its combination of strength, rigidity, impact resistance, hydrolytic stability, and
- a fiber cement forming apparatus using the Hatschek process typically includes a porous fabric belt positioned on a series of support rolls. An aqueous fiber cement slurry of the components described above is created and deposited as a thin sheet or web on the porous fabric belt. The slurry is conveyed by the fabric belt over and through a series of rollers to flatten and shape the slurry. As the slurry is conveyed, moisture contained therein drains through openings in the fabric.
- Moisture removal is typically augmented by the application of vacuum to the slurry through the fabric (usually via a suction box located beneath the porous fabric). After passing through a set of press rolls, the fiber cement web can be dried and cut into individual sheets, collected on a collection cylinder for subsequent unrolling and cutting into individual sheets, or collected as a series of overlying layers on a collecting cylinder that ultimately forms a fiber cement tube.
- the porous fabric used to support the slurry as moisture is removed is typically woven from very coarse (between about 2500 and 3000 dtex) polyamide yarns. Most commonly, the yarns are woven in a "plain weave” pattern, although other patterns, such as twills and satins, have also been used. Once they are woven, the yarns are covered on the "sheet side" of the fabric (i.e. , the side of the fabric that contacts the fiber cement slurry) with a batt layer; on some occasions, the "machine side” of the fabric (i.e., the side of the fabric that does not contact the slurry directly) is also covered with a batt layer. The batt layer assists in the retrieval, or "pickup," of the slurry from a vat or other container for processing. Because of the presence of the batt layer(s), the fabric is typically referred to as a fiber cement "felt.”
- Fiber cement felts typically include one or more base fabric layers that are formed into endless belts.
- the base fabric layers can be "flat-woven” and permanently joined after weaving into an endless belt, or the fabric layers can be woven in endless form.
- the longitudinal ends of flat-woven fabrics are generally joined in order to form an endless belt.
- marking in order to improve bonding of overlying layers.
- Such fiber cement product is typically used in roofing sheets, corrugated sheets, pipe and the like.
- Felts that produce marking often employ heavy spunbond CMD yarns in combination with spunbond-multifilament hybrid MD yarns. However, these felts can suffer from contamination and reduced ability to mark over time. It may be desirable to provide a fiber cement product that addresses these shortcomings.
- embodiments of the invention are directed to a fiber cement felt comprising: a base fabric layer including MD and CMD yarns interwoven with each other, wherein the CMD yarns comprise twisted monofilaments; and at least one batt layer overlying the base fabric layer.
- the fiber cement felt may have improved properties over existing fiber cement felts, including easier cleaning, better abrasion resistance of the CMD yarns, improved compaction resistance, higher CMD strength, and better protection of the MD yarns by the CMD yarns.
- embodiments of the invention are directed to a method of forming a fiber cement article, comprising the steps of: (a) providing a fiber cement felt, the fiber cement felt comprising: a base fabric layer including MD and CMD yarns interwoven with each other, wherein the CMD yarns comprise twisted monofilaments; and at least one batt layer overlying the base fabric layer; (b) positioning the fiber cement felt on a series of support rolls of a fiber cement forming machine; (c) depositing a fiber cement slurry on the fiber cement felt; and (d) removing moisture from the slurry to form a fiber cement web.
- Figure 1 is a schematic illustration of a fiber cement forming apparatus of the present invention.
- Figure 2 is a top perspective view of a portion of a base fabric of a fiber cement felt according to embodiments of the present invention, with CMD yarns shown extending in the horizontal direction and MD yarns shown extending in the vertical direction.
- Figure 3 is a schematic section view of a fiber cement felt that includes the base fabric of
- CMD refer, respectively, to a direction aligned with the direction of travel of the fiber cement felt on the fiber cement forming machine, and a direction parallel to the fabric surface and traverse to the direction of travel.
- directional references to the vertical relationship of the yarns in the fabric e.g., above, below, top, bottom, beneath, etc.
- the fiber cement making surface of the fabric is the top of the fabric and the machine side surface of the fabric is the bottom of the fabric.
- spatially relative terms such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
- the forming apparatus 10 which performs a typical Hatschek process, generally includes an endless fiber cement felt 30 positioned in rolling contact with and driven by a number of guide rolls 20. Beginning in the lower right corner of Figure 1, the felt 30 passes above three vats 12, each of which contains a batch of fiber cement slurry 14.
- fiber cement means any cementitious composition including cement, silica, and fiber for reinforcement, including asbestos, polyvinyl alcohol, polypropylene, cotton, wood or other cellulosic material, acrylic, and aramid.
- Each vat 12 is positioned below a deposition cylinder 16 mated with a couch roll 18.
- Each vat 12 also includes agitators 13, which prevent the fiber cement slurry 14 from solidifying therein.
- each deposition cylinder 16 collects fiber cement slurry 14 on the cylinder's surface; as the felt 30 travels over and contacts the cylinder 16, the slurry 14 is transferred from the cylinder 16 to the felt 30.
- the amount of slurry 14 deposited on the fabric 30 by each cylinder 16 is controlled by the corresponding couch roll 18.
- the fiber cement slurry 14 is deposited as a web 21 at a thickness of between about 0.3 mm and 3 mm.
- the felt 30 conveys the slurry web 21 over one guide roll 20, then over one or more suction boxes 26 (two are shown in Figure 1), each of which applies negative pressure to the felt 30, thereby encouraging the removal of moisture from the slurry web 21.
- the felt 30 and the slurry web 21 pass over a second guide roll 20, then between the nip formed by a breast roll 24 and a forming roll 22. After passing through the nip, the slurry web 21 has formed into a semi-solid fiber cement sheet 28 that is collected on the surface of the forming roll 22.
- felts of the present invention can also be used to form fiber cement pipes.
- the fiber cement sheet 28 can be collected in contacting layers on a forming roll; as they dry, the overlying layers form a unitary laminated tube.
- a pipe forming apparatus will include small couch rolls that act in concert with the forming roll to improve interlaminar strength. Also, a second felt may travel over the additional couch rolls to assist in water absorption and finishing.
- the fabric 10 includes MD yarns 41 and CMD yarns 42 interwoven with each other in a plain weave pattern (i.e., an "over l/under 1" pattern). This pattern repeats itself over the expanse of the fabric 40.
- the CMD yarns 42 are monofilament twists. In some embodiments, the
- CMD yarns 42 are monofilament twists with substantially no spunbond material present.
- An exemplary CMD yarn is a monofilament twist with a 0.3x2x3 structure; this nomenclature indicates that the individual monofilaments are (a) 0.3 mm in diameter that are (b) twisted into pairs, the twisted pairs then being (c) twisted into triplets. In other words, each yarn includes three pairs of twisted 0.3 mm monofilaments.
- the monofilaments are formed of polyamide (nylon), and in particular may be polymamide-6 (nylon-6).
- the CMD yarns are typically of a size of 200-800 tex. Other possibilities include monofilament twists of the following constructions: 0.3x2x4; 0.3x3x3; 0.2x3x4; and 0.2x3x5.
- the MD yarns 41 are typically spunbond-multifilament hybrid yarns, but may include other varieties.
- An exemplary MD yarn is one formed from a twist of a spunbond yarn (available from Tonak, a.s., Czech Republic) and a polyamide multifilament yarn (e.g., a 3x4 construction of polyamide multifilament, available from Invista, Wichita, Kansas). Other multifilament constructions may include 3x5, 3x6 or 3x9 arrangements.
- the MD yarns are typically of a size of 1000-5000 tex.
- the felt 30 also includes a top batt layer 52 that overlies the fabric
- the batt layers 52, 54 may be formed of material, such as a synthetic fiber like acrylic aramid, polyester, or polyamide, or a natural fiber such as wool, that assists in taking up fiber cement slurry 14 from the vats 12 to form the fiber cement web 21 in Figure 1.
- Exemplary materials include polyamide, polyester and blends thereof.
- the weight of the batt layers can vary, although it is preferable that the ratio of fabric weight to batt weight is about between about 1.0 and 2.0 with 1.5 being more preferred. Also, in some embodiments, it may be desirable to omit the bottom batt layer.
- a fiber cement felt employing a base fabric such as fabric 30 may have improved properties over existing fiber cement felts, including easier cleaning, better abrasion resistance of the CMD yarns, improved compaction resistance, higher CMD strength, and better protection of the MD yarns by the CMD yarns.
- the CMD yarns may have a lower specific surface than prior CMD yarns, which assists in weight and reduced felt thickness.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Textile Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Woven Fabrics (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP12735391.0A EP2729608B1 (en) | 2011-07-06 | 2012-06-28 | Felt for forming fiber cement articles and related methods |
CN201280032191.9A CN104024501B (en) | 2011-07-06 | 2012-06-28 | For forming felt and the correlation technique of fibre cement product |
RU2014104030/12A RU2549978C1 (en) | 2011-07-06 | 2012-06-28 | Non-woven fabric for articles of fibre cement and methods used |
MX2013015331A MX2013015331A (en) | 2011-07-06 | 2012-06-28 | Felt for forming fiber cement articles and related methods. |
ZA2013/09698A ZA201309698B (en) | 2011-07-06 | 2013-12-20 | Felt for forming fiber cement articles and related methods |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161504794P | 2011-07-06 | 2011-07-06 | |
US61/504,794 | 2011-07-06 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2013006382A1 true WO2013006382A1 (en) | 2013-01-10 |
Family
ID=46513855
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2012/044682 WO2013006382A1 (en) | 2011-07-06 | 2012-06-28 | Felt for forming fiber cement articles and related methods |
Country Status (7)
Country | Link |
---|---|
US (2) | US20130008552A1 (en) |
EP (1) | EP2729608B1 (en) |
CN (1) | CN104024501B (en) |
MX (1) | MX2013015331A (en) |
RU (1) | RU2549978C1 (en) |
WO (1) | WO2013006382A1 (en) |
ZA (1) | ZA201309698B (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2015089022A1 (en) | 2013-12-10 | 2015-06-18 | Huyck Licensco, Inc. | Felt with cellulosic fibers for forming fiber cement articles |
JP6755097B2 (en) * | 2016-01-22 | 2020-09-16 | 日本フイルコン株式会社 | Industrial textiles |
DE202021104492U1 (en) | 2021-08-20 | 2021-10-06 | Heimbach Gmbh | Textile web and use of such |
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2012
- 2012-06-27 US US13/534,353 patent/US20130008552A1/en not_active Abandoned
- 2012-06-28 WO PCT/US2012/044682 patent/WO2013006382A1/en active Application Filing
- 2012-06-28 MX MX2013015331A patent/MX2013015331A/en unknown
- 2012-06-28 EP EP12735391.0A patent/EP2729608B1/en active Active
- 2012-06-28 RU RU2014104030/12A patent/RU2549978C1/en active
- 2012-06-28 CN CN201280032191.9A patent/CN104024501B/en active Active
-
2013
- 2013-12-20 ZA ZA2013/09698A patent/ZA201309698B/en unknown
-
2014
- 2014-09-19 US US14/491,104 patent/US9415564B2/en active Active
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Also Published As
Publication number | Publication date |
---|---|
US20150024128A1 (en) | 2015-01-22 |
CN104024501B (en) | 2016-08-17 |
EP2729608A1 (en) | 2014-05-14 |
US9415564B2 (en) | 2016-08-16 |
US20130008552A1 (en) | 2013-01-10 |
EP2729608B1 (en) | 2016-10-19 |
RU2549978C1 (en) | 2015-05-10 |
ZA201309698B (en) | 2015-05-27 |
CN104024501A (en) | 2014-09-03 |
MX2013015331A (en) | 2014-02-20 |
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