DE1246515B - Process for the production of building and insulating panels - Google Patents

Description

GERMAN WWW PATENT OFFICE

EDITORIAL DEVELOPMENT German class: 80 b -9/07

Number: 1 246 515

File number: U 11374 VI b / 80 b

J 246515 filing date: January 15, 1965

Opened on August 3, 1967

There is already a method for the production of sound-absorbing building panels known, according to which from a mixture of mineral fibers and cellulose, in particular shredded newspaper, is used to produce a pulp and this is processed in the manner of paper production on building boards. As a binder for the fiber mixture is used for starch and betonite. According to another known method, building boards manufactured, with a high proportion of perlite and vermiculite with a low proportion of fiber material is processed with a considerable proportion of binding agent into various moldings. as Asphalt, plastics, starch and sodium silicate solution are used here as binders.

The building and insulating materials obtained by the known method showed an insufficient one internal strength with poor surface quality, making them suitable for interior wall cladding are not suitable in buildings. The known products cannot be considered abrasion or pressure resistant are designated. The products bound with asphalt correspond to their unsightly appearance Color does not meet modern requirements for room linings. Other than that, they're relative difficult to dye and have only a very limited flame or fire resistance.

The invention now relates to a method for the production of building and insulating panels which meet all requirements in terms of mechanical strength, insulation values and appearance. Ge by the inventive process schieht the production of construction and insulating plates on the basis of perlite as a filler of a fibrous slurry, where the binder is a hydrated cellulose having a Schopper-Riegler freeness of less than 100 with expanded perlite to a slurry with a Solids content of 4 to 8%, with 1.6 to 9 parts of perlite, calculated on dry matter, for 1 part of cellulose, and this slurry is allowed to run off on a sieve in a known manner, excess water is pressed off and the fibrous web is dried. Preference is given to 2.33 to 8.5 parts of perlite for 1 part of cellulose binder.

The slurry for making the building and insulating materials of the present invention can be also add a clay as it is generally used in the ceramics industry, namely up to about 2 parts by weight, preferably 0.33 to 2 parts of clay per part of cellulose binder.

In order to increase the flame resistance and fire resistance of the products according to the invention, processes for the production of construction and
Insulating panels

Applicant:

United States Gypsum Company,
Chicago, Jll. (V. St. A.)

Representative:

Dr.-Ing. F. Wuesthoff, Dipl.-Ing. G. Pulse
and Dr. E. Frhr. v. Pechmann, patent attorneys,
Munich 9, Schweigerstr. 2

Named as inventor:

James Robert Roberts, Palatine, Jll. (V. St. A.)
Claimed priority:

V. St. v. America January 16, 1964 (338 057)

the slurry also contains small amounts of boric acid, up to 3 percent by weight, preferably 0.25 to 2 ° / o, add.

In order to increase the water-repellent properties of the building boards, waxes such as microcrystalline Wax, earth wax, paraffin wax, in small amounts up to about 2 percent by weight, preferably 0.25 to 1 percent by weight, can be added.

Amounts of alum can also be added to the slurry to facilitate preprocessing add from about 0.5 to 1.5%. The quantities given here are percentages by weight, based on dry weight.

The cellulose binder used by the process according to the invention is produced by converting cellulose fibers in the form of an aqueous slurry with a concentration of at least 6% in a series of known gelling and grinding stages onto a non-fibrous gelatinous binder with a Schopper-Riegler freeness of less than 100 cm ^{3 is} processed.

The products according to the invention are distinguished by their particular lightness. They have a density of 64 to 400 kg / m ³ , preferably 126 to 320 kg / m 3. They contain 70 to 90% perlite on 30 to 10% cellulose binder. In the case of the clay content, the pearlite content is between 50 and 90%, the content of cellulose binder between 10 and 30%; the clay content can be up to 20%.

The products according to the invention are not only suitable for wall cladding to achieve decorative

709 619/618

Effects and as insulating panels, but in the same way as floor underlays or sub-floors because of their high pressure and abrasion resistance, impact resistance and insensitivity to improper handling. In particular, the products according to the invention with a high pearlite content are suitable as a heat-insulating sub-floor for wooden or plastic floors and in particular Dimensions for sound insulation, for suspended ceilings and non-load-bearing sound-absorbing and sound-absorbing Partitions.

The products according to the invention with a clay content are suitable for particularly fire-resistant building materials. The clay used is generally a non- _{plastic clay with a high Al 2} O ₃ and SiO ₂ content, which is customary in the ceramic industry, such as kaolin, fireclay, brick and binding clays. The composition of the fire-retardant building materials according to the invention then results with about 50 to 80% perlite, 10 to 30% cellulose binder and 20 to 10% clay. When exposed to fire, the clay-containing building materials sinter without burning, splintering or collapsing.

The construction and insulation materials according to the invention can be painted on one or both sides or else cover with papers. In this way, very decorative wall and ceiling coverings can be used Improve the acoustics of rooms.

The pearlite used according to the invention can have a wide variety of grain sizes. For insulating panels and sub-floors are primarily used perlite with a grain size <C 2.38 mm. For wall cladding, where a decorative surface layer is important, a fine perlite is preferred, preferably with> 70% <0.84 mm without oversize with 2.38 mm.

The construction panels according to the invention are produced in the manner of cardboard production. It will First the binder is prepared by, for example, a Kraft paper pulp with water on a solids level of at least 6% is set. This pulp is used in the paper industry generally used to a Schopper-Riegler freeness of less than 100 in various Dutch processed. The so highly hydrated and essentially non-fibrous cellulosic binder is mixed with the required content of perlite and, if necessary, clay and through Addition of fresh water adjusted to a solids content of 4 to 8%.

In the course of these process steps, the other additives such as boric acid, waxes or alum can be added be introduced. After careful mixing, the slurry is then transferred to the Fourdrinier In the case of Fourdrinier machines or on the cylinders, the bulk of the water yields to them the slurry drains. A fiber felt is formed on the screen or cylinder with a layer thickness of about 1.8 to 10 cm. This felt is now between pressure rollers to a thickness of about 1.3 to 2.8 cm compressed and at the same time a substantial part of the water is squeezed off. Then the wet web arrives in an appropriate dryer; the dry web is side trimmed and cut to length, as shown in FIG Paper industry is common. As part of this process, the one or double-sided coating of the building material with pa-

be done. Superficial punching can also be carried out as part of the manufacturing process will.

The method according to the invention will now be explained in more detail using the following examples.

Example 1 to 6

Panels with a thickness of 1.8 to 1.9 cm were produced.

Perlite

Sieve analysis

> 0.84 mm 0%

0.29 to 0.84 mm 7.8%

0.15 to 0.29 mm 36.2%

0.074 to 0.15 mm 28.4%

<0.074 mm 27.6%

Cellulose binder initial concentration 6%

Clay Kentucky-Tennessee Clay Co.

(CTS-I) 57.0% SiO ₂ ,

27.9% Al ₂ O ₃ , loss on ignition 9.8%

Table 1

25 example Perlite Cellulose binders volume 1 90 10 2 85 15th 3 62.5 37.5 30 4 83.3 12.5 4.2 5 70.8 12.5 16.7 6th 62.5 12.5 25th

Plates were made from these raw materials and their modulus of rupture, density and hardness were determined. Hardness is the force in kilograms that is required to press a steel ball with a diameter of 5.6 cm into the surface.
Table 2

example Modulus of rupture Volume weight hardness kg / cm ² kg / m ³ kg 1 4.6 197 105 2 10.2 216 139 3 28.3 221 174 4th 7.1 201 117 5 9.7 210 118 6th 9.0 210 122

In a modification of this, the two surfaces of the products according to the invention from Examples 1 to 6 were ^{coated with manilla paper (weight per unit area 0.351 kg / m 2} ). A polyvinyl acetate adhesive was used as the adhesive. The breaking modulus and hardness of the boards laminated in this way are shown in Table 3.

Table 3

example Modulus of rupture
kg / cm ² hardness
kg 1 35 134 2 43.8 152 3 51.2 172 4th 39.4 136 5 37.8 116 6th 39.1 125

Claims (3)

Example 7 Soundproofing panels are to be produced. A slurry of the following raw materials was used for this purpose: Table 4 Perlite Cellulose Binder (Solid) Clay Wax (Solid) Alum Boric Acid Percentage by Weight kg622251 102072615544136.3136.3136.4 »51003630.0 11.61 water and 7.26 kg waste from unbleached Kraft paper were 30 minutes mixed and ao then passed into four Dutch machines for a throughput of 1 t / h. The binder obtained in this way showed a Schopper-Riegler freeness of less than 100. It reached a mixer at a concentration of about 6% solids, into which 75.551 water and the quantities of the raw products indicated above were introduced: Perlite grain size 70% 0.074-0.84 mm clay binder clay (Kentucky-Tennessee Clay Co.) 57% SiO ,, 27.9% Al2O3, 9.8% loss on ignition 30 The headbox was adjusted to a concentration of about 4% and placed on a Fourdrinier machine. A sheet thickness of about 1.9 cm was obtained for the dry product with a density of 224.28 kg / m 3. Patent claims: 1. Process for the production of building and insulating panels based on perlite as a filler from a fiber sludge, characterized in that a hydrated cellulose with a Schopper-Riegler freeness is used as the binder of less than 100 made with expanded perlite to a slurry with a solids content of 4 to 8%, 1.6 to 9 parts perlite, calculated on dry matter, come to 1 part of cellulose, and one allows this slurry to drain on a sieve in a known manner, excess water presses off and the fiber web dries. 2. The method according to claim 1, characterized in that the binder is a low Amount of clay, preferably 2 parts by weight per part by weight of cellulose binder, is added. 3. The method according to claim 1 or 2, characterized in that the binder up to 2 parts by weight of wax and / or up to 3 parts by weight of boric acid and / or 0.5 to 1.5 parts by weight Alum adds. Considered publications:
German Patent No. 927 260;
U.S. Patent Nos. 3,015,626, 3,095,347.