Background of the Invention

Field of the Invention

This invention relates to a method for making mineral products. More particularly, it relates to a method for making strong, structural panels of mineral wool and/or mineral aggregate that may vary from very lightweight (less than 8

3 pounds per cubic foot (128 kg/m )) in one embodiment to

₃ densities up to about 20 pounds per cubic foot (320 kg/m ) or more in other embodiments. These panels may be used as acoustical ceiling tiles, thermal insulating panels, sound absorbing panels, pipe and beam insulation and the like products.

Description of the Prior Art

The water felting of dilute aqueous dispersions of mineral wool and lightweight aggregate is known. By such methods, a dispersion of mineral wool, lightweight aggregate, binder and other adjuvants are flowed onto a moving foraminous support wire screen for dewatering, such as that of an Oliver or Fourdrinier mat forming machine, at line speeds of about

10-50 feet (3-15m) per minute. The dispersion dewaters first by gravity and then vacuum suction means; the wet mat is dried over a number of hours in heated convection drying ovens; and the product is cut and optionally top coated, such as with paint, to produce lightweight structural panels such as acoustical ceiling products. Such methods cannot produce low density structural products below about 12 pounds per cubic

3 foot (192 kg/m ) density. A "structural" panel, product by- definition, is capable of supporting its own weight without visible sagging, bending, or collapsing when supported only at the edges of the panel, as in a suspended ceiling grid.

U.S. Patent 3,510,394 discloses flocculating inorganic kaolin clay in dilute dispersions of mineral fiber.

Flocculation to clumps or floes of the clay with starch grains is effected by adding extremely small amounts of flocculant such as polyacrylamide just before the flurry is dewatered, and the wet mat is baked or fired in addition to conventional drying. Dewatering time is increased by this flocculation treatment.

It is an object and advantage of the present invention to provide a method for manufacturing low density, structural, mineral fiber panels without having to dry extremely large amounts of water out of the wet mass over long periods of time.

A further object is to provide low density yet strong mineral panels having densities between about 3-10 pounds per

3 cubic foot (48-160 kg/m ) and a modulus of rupture of at

3 least about 30 pounds per (320 kg/m ) square inch for the core of the panel.

Another object is to provide mineral fiber and/or lightweight mineral aggregate structural panels which have excellent strength and integrity at densities up to about 20

3 pounds per cubic foot (320kg/m ) or more.

A still further object and advantage is the provision of a method for manufacturing lightweight mineral fiber panels wherein the dewatering and drying of the wet mat may be accomplished in a facile, rapid manner such that the mat is dewatered and dried in a few minutes.

The above objects and advantages, and others which will become more apparent from the ensuing description, are accomplished by forming a dilute aqueous dispersion furnish of mineral fiber and/or lightweight mineral aggregate and a binder which is preferably an anionically-stabilized resin latex binder, such as polyvinyl acetate. Almost at the end of mixing, a small but effective amount of a cationic flocculant, such as polyacrylamide, is added and the dispersion is passed to a flooded section of a drainage wire of a foraminous mat forming apparatus. In this system and at the levels added,

the flocculant does not cause clumping of the latex resin particles with each other. Rather, the latex resin particles are dispersed throughout the water and coated upon the mineral materials. Virtually all of the binder resin solids added to the system become coupled with the coated mineral surfaces in the wet felted product, with very low losses of binder resin in the drainage section white water. Thus, the drainage water need not be recycled to avoid substantial losses of binder solids. By varying the proportions of lightweight aggregate in the particular method of felting, water stripping and drying of the panel products may be performed at various densities, ranging from about 3 to about 20 pounds per cubic foot (48-320

3 kg/m ) or more as open, porous structures.

Brief Description of the Drawings

Figure 1 is a schematic diagram of a mineral board manufacturing process in accordance with the present invention.

Figure 2 is a top view cross section of a part of the manufacturing line showing the modified forming box apparatus of Figure 1.

Figure 3 is a side view sectional of the same part of the manufacturing line as Figure 2. Description of the Preferred Embodiments

The fiber material for use in the present invention may be any of the conventional mineral fibers prepared by attenuating a molten stream of basalt, slag, granite or other vitreous mineral constituent. The molten mineral is either drawn linearly through orifices, commonly referred to as textile fiber, or it is recovered tangentially off the face of a spinning cup or rotor, commonly referred to as wool fiber. Ceramic fibers and organic fibers such as polyamide fibers, acrylic fibers, polyester fibers, polyolefin fibers, cellulosic fibers and the like may also be used. Porous bonded mats or batts of fibers may be used as well as individual fibers to

form the low density products of the invention. Expressed in terms of the dry solids content of the final panel product, the fiber constituent is suitably present in an amount up to about

95% by weight, and preferably amounts of about 30-45% are used. For reasons of convenience and economy, mineral wool is the preferred fiber material.

The lightweight mineral aggregate ingredient may be an inorganic lightweight aggregate of exfoliated or expanded volcanic glass origin. Such aggregate includes the well known expanded perlite, exfoliated vermiculite, exfoliated clay and the like products which are available in a variety of mesh sizes. Generally, mesh sizes smaller than 8 mesh are suitable, although this is not critical. Expanded perlite is the preferred aggregate for reasons of availability and economy.

The amount of lightweight aggregate included may range up to about 85% or more on a dry weight basis in the final product.

For the preferred low density products, the lightweight aggregate will generally constitute 30-65% of the product.

Higher density versions of the products, having densities up to

3 about 20 pounds per cubic foot (pcf) (320 kg/m ), or more, may be produced by employing higher density mineral aggregate such as stucco (calcium sulfate hemihydrate) , gypsum, clays, limestone or the like.

The preferred binder used in the present invention may be any commercially available anionically-stabilized resin latex dispersions having polymeric materials containing active acrylic groups, acetate groups, or butadiene-styrene monomer, in various homopolymer, copolymer or mixtures thereof dis¬ persions as functionally active low temperature curing binder. It is generally preferred that the binder be curable at low temperatures (below about 100°C) . For reasons of economy and availability, polyvinyl acetate (PVA) polymer binder is preferred and any of the commercially available PVA polymers

containing an anionic particle charge emulsifier may be used, such as X-LINK latex or RESYN latex resins from National Starch and Chemicals Corporation, or SYNTHEMUL latex emulsions from Reichold Chemicals, Inc. Other anionic type synthetic resin latices such as vinylidene chloride, polyvinyl chloride, nitrile rubber, carboxylated acrylonitrile, polychloroprenes such as neoprene and the like or copolymers thereof may be used singly or in combination. The preferred anionic polyvinyl acetate latex binders are available in various concentrations having a full range of viscosities. These polymers are available in a pH range of about 1-8 although other pH ranges that do not adversely effect the mineral material may be used. They are commercially available in a range of particle sizes of about 0.1 to 2 micrometers and containing an anionic particle charge.

The binder latex solids may be present in the final product on a dry weight basis in an amount ranging from about 2% to about 35% depending upon the amount of mineral fiber, amount of lightweight aggregate, and the degree of stiffness and strength desired for the core of the final panel product. Generally, the amount of binder retained in the core of the final panel product. Generally, the amount of binder retained in the core of the final product will be about 99 weight % on a dry solids basis of the amount of binder added in formulating the furnish. In the method of this invention there is almost no binder loss. Heretofore, the high levels of resin loss in the methods used to make mineral fiber panels precluded the use of latex dispersions like polyvinyl acetates.

It has been found that mineral surfaces such as the mineral fibers and mineral aggregates disclosed herein carry a slight residual negative charge. In the present invention, the remaining essential ingredient is a coupling agent. A preferred material is a cationic flocculant that carries a

residual positive charge. When it comes into contact with the negative charge on the mineral fiber or the mineral aggregate surface, an electrostatic interaction occurs which bonds the flocculant onto the mineral surface. The positive charge on the flocculant acts to couple or deposit the anionic surface of the resin latex binder to the cationic flocculant. In effect, the cationic flocculants of the types called for herein appear to be acting to couple the latex binder to the mineral fibers and/or the mineral aggregate particles without clump formation. A marked advantage of the present invention is the improvement in retention of binder solids in the final product when using an anionically stabilized synthetic polymeric latex binder and the proper amounts of cationic flocculant. With the cationic flocculant attracting and coupling the anionic binder latex onto the mineral surfaces, retention in the final product on a dry solids basis was improved from about 25-40% of the latex added without the cationic flocculant to over 95% retained when using the cationic flocculant in accordance with this invention. Suitable cationic flocculants for use in the present invention have a cationic charge, molecular weights of about 1-12 million, and at least about 5 mole percent cationic monomer.

The flocculant may be added in quite variable amounts and may range from about 0.5% to about 15% by weight based on the binder resin solids, although somewhat more or less may be used without further apparent advantage. Preferably about 2-4% polyacrylamide by weight based upon the weight of the binder resin solids is used. Depending upon the particular cationic flocculant and latex binder used to carry out the method of this invention, the amount of flocculant to achieve complete deposition of the active binder solids on the surface of the mineral materials may vary. Other suitable flocculants may include commercially available cationic polyamine, cationic

guar, cationic cymene resin and cationic polyethoxylate materials having at least about 5 mole percent cationic monomer

In normal practice under the present invention, the cationic flocculant will be diluted to about 1% by weight active ingredients prior to addition to the mineral fiber and/or mineral aggregate dispersion, although other concen¬ trations may be effective. The concentration of flocculant present in the dispersion, however, does markedly affect the level of binder retention. A concentration between about 2% and about 4% based on the weight of the binder solids generally provides excellent retention.

Optionally, one or more woven or random weave (nonwoven) fiber web cover sheets, such as glass fiber scrim, may be applied to the mineral fiber/aggregate core during manufacture. When used, it is preferred to utilize a porous nonwoven scrim fabric, such as that available under the designation of "Battery" type scrim, having a weight of about

2 0.4-2.5 pounds (.2-1 kg) per hundred square feet (9 m ) of scrim. If a cover scrim is utilized, it may be necessary to provide an additional binder application as by spraying or roll coating the scrim with resin latex binder before the scrim is applied to the core in order to provide additional adherence between the core and scrim.

EXAMPLE 1

A dilute dispersion of about 3% by weight solids consistency was formed containing approximately 53% expanded perlite, 35% mineral wool that had not been treated to remove contained shot, and 12% by solids of an anionically stabilized polyvinyl acetate latex. The formulation was mixed to homogeneity over 1-3 minutes and then a 2% cationic polyacrylamide solution was added to provide approximately 1% polyacrylamide based on the total weight of solids of the panel product on a dry weight basis. Upon addition of the polyacryla-

acrylamide solution, the cloudy dispersion of the expanded perlite, mineral wool and polyvinyl acetate became clear, and it was observed that the mineral wool fibers had become coated with the polyvinyl acetate particles.

EXAMPLE 2

The following Example should be read with reference to Figure 1 which shows a schematic diagram of a method in accordance with the present invention.

A dilute mineral fiber furnish was prepared by first charging to water in primary mix tank 10 a quantity of mineral wool, then an anionicaly-stabilized polyvinyl acetate binder latex having a viscosity of 50-200 centipoises (cps) at 25°C, pH of 4.5 and a glass transition temperature (Tg) of 33 C, and finally expanded perlite. This furnish was mixed by a motor-driven impeller 12 for 2-4 minutes to achieve homogeneity. Flows from mix tank 10 were proportioned by valve 14 to provide a furnish of about 3% by weight solids concentration, with the individual ingredients proportioned to each other on a dry solids basis of about 44% mineral wool, 44% expanded perlite, and about 12% polyvinyl acetate latex active solids. A cationic polyacrylamide having a molecular weight between 8 and 12 million, viscosity of about 1000 cps and 30 mole percent cationic monomer was added to secondary mix tank 16 and metered into the furnish via valve 18 at a rate to provide the polyacrylamide proportioned to the other ingredients on a dry solids basis of about 0.4% (and proportioned to the resin latex binder on a dry basis of 2.6% by weight of latex solids) .

A pump 22 transferred the furnish to a modified flow head box 30 above a conventional moving foraminous wire screen of a mat forming machine, hereinafter and commonly referred to as the wire 40. The functions of the modified head box 30 were

to allow the furnish to consolidate and mature to provide for the ionic coupling of the polyvinyl acetate binder solids to the mineral wool and perlite as the furnish passed through the branched feed pipe 28 (shown more particularly in FIGURE 2) an through the convoluting channel course within the modified hea box 30 (shown more particularly in Figure 3) and onto wire 40 as layer of furnish solids mass 41. By providing a perforated roll 32 having multiple passageways through its diameter for fluid flow located within head box 30 and also smoothing rolle

34 above wire 40 just after the mass 41 is deposited upon wire

40, a velocity transition zone to a first flooded section 42 o wire 40 was established to allow for further ionic coupling of the solids in mass 41 as an evenly spread layer of furnish solids in open, highly voided, entangled mass having water in the interstitial spaces of the entangled mass.

A continuous scrim bottom cover sheet 43, such as of nonwoven Battery scrim having a weight of about 0.8-2 pounds

2 (.4-.9 kg) per 100 square feet (9 m ) of scrim, was laid above wire 40 before the mass 41 cascaded out of box 30 onto wire 40. A similar scrim top cover sheet 47 was overlaid at the smoothing roller 36. By feeding the top sheet 47 and bottom sheet 43 as shown in Figure 3, an intimate contacting of the cover sheets with the mass 41 was provided.

The core mass 41 cascading out of head box 30 was deposited upon and then floated through water flooded section

42 of the wire 40 for a few seconds before encountering the vacuum sections 44,46, and 48. In high vacuum section 44, a partial vacuum pressure differential equivalent to about 8-20 inches (.2-.5m) of mercury was applied in brief pulses across the surface of the core 41 in order to begin stripping water from the wet mass without any substantial collapsing of the open, voided structure which had been formed in flooded section

42. A lessened pressure differential equivalent to about 5-70

(.1-1.8m), and preferably about 14 (.4m), inches of water was maintained across the surface of mass 41 in vacuum section 46, and in section 48, the same vacuum pressure differential was augmented with positive pressure dry air flow through enclosure

49 from blower 50. The blower 50 provided dry heated air to assist continued stripping of water and drying of the wet mass

41. The blower was operated to provide air through mass 41 at

3 a volume-velocity of about 50-350 (.02-.16m /s)and preferably

3 about 300 cubic feet per minute (.14m /s) of air per one square foot of mat surface with the air at a temperature of about 37-180°C. The time for a segment of core 41 mass to pass through section 48 was varied considerably, generally averaging 1-2 minutes, to produce a panel of nominal 1/2 inch

(.013m) thickness. The panel had a core of uniform, small-sized voids averaging about l/64th (.0004m) inch

3 diameter, a density of 6.5 pounds per cubic foot (104 kg/m ), and was quite strong although flexible with the two cover sheets in place. Testing the core alone after stripping off the scrim cover sheets gave a modulus of rupture of about 45 pounds per square inch (.3 Pa), while testing with the cover sheets gave 150 pounds per square inch (1 Pa) .

In further evaluations, the amount of perlite was varied between about 26% and about 43% The amount of mineral wool used was also varied in a manner such that the sum of the perlite and mineral wool accounted for 88% by weight of the total solids of the furnish. It was found that increases- in the perlite-to-mineral wool ratio yielded in a linear fashion a progressively lighter, weaker and more flexible core. On a weight basis, the strength of the core remained relatively constant when these values were corrected for the changed density of the different samples. It was also found that about

2% of the perlite processed became broken and settled out onto th.e bottom facing sheet.

SUBSTITUTE SHEET

EXAMPLE 3

The procedure of Example 2 was repeated with propor¬ tioning of the ingredients to each other on a dry weight solids basis of about 52% perlite, about 35% mineral wool, about 12.5% polyvinyl acetate and about 0.45% polyacrylamide. Different cationic polyacrylamide materials were used as follows:

(1) Cationic polyacrylamide augmented with considerable monomeric material having a molecular weight of about 1 million, about 30 mole percent cationic monomer and a viscosity of .1050 centipoises at 25°C;

(2) Cationic polyacrylamide having a molecular weight of 4-6 million, about 15 mole percent monomer, and a viscosity of 1400 centipoises at 25 C;

(3) Cationic polyacrylamide having a molecular weight of 8-12 million, about 35 mole percent monomer, and a viscosity of 100 centipoises at 25 C.

Each of the different cationic polyacrylamides performed satisfactorily with results equivalent to those obtained in Example 2.

In still further evaluations, the amount of polyacryla- amide in the first set of evaluations in this Example was varied from 0.72% to 8.6% based on the dry active solids of the binder. All levels performed satisfactorily. As the amount increased to 3%, the percentage of polyvinyl acetate binder retained also increased. At levels above 3% for the particular polyacrylamide used, the percentage of binder retained declined slightly. Modulus of rupture increased linearly with the amount of binder retained.

EXAMPLE 4

In another evaluation following the procedure of Example , the following furnish was prepared:

SUBSTITUTESHEET

64.78% mineral wool

25.91% calcium sulfate hemihydrate

9.07% anionically stabilized carboxylated styrene- acrylic resin latex binder having a Tg of 100 C

0.16% cationic polyacrylamide of 8-12 million molecular weight and mole 30% cationic monomer, and

9.08% lauryl alkyl sulfate anionic surfactant.

The resulting panels had a density of 16.88 pounds per cubic foot (270 kg/m ) and tested, with the top cover sheet removed, to a modulus of rupture of 95.9 pounds per square inch

(.7 Pa) and modulus of elasticity of 10,131 pounds per square inch (70 Pa) . Further panels were made applying only a bottom layer scrim sheet during manufacture, imparting a textured surface to the uncovered face after removing the panels from the drier 49 after approximately two minutes, and passing the panels for completion of drying in a conventional manner by passing heated dry air over the surfaces of the panel in a convection oven rather than through the interstices within the panel. The physical properties of this panel approximated those of the other panels in this Example tested after removal of the top cover sheet.

EXAMPLE 5

In still further evaluations, a panel was made in accordance with Example 2 except that, in a first series of evaluations, the cationic polyacrylamide was first added only in mix tank 10 and then added only in tank 16. The addition of polyacrylamide to mix tank 10 alone resulted in a 45% loss of strength in the dried panels.

In a second evaluation a cationic polyacrylamide was added from both mix tank 10 and mix tank 16. Specifically, 6.25% of the polyvinyl acetate binder of Example 2 and 0.2% of the cationic polyacrylamide of Example 2 were added to mix tank 10 with the other ingredients in proportions as in Example 2.

After thorough mixing and flocculation in mix tank 10, then

6.25% of anionically stabilized, carboxylated, styrene-acrylic resin latex having a high percentage of styrene, a Tg of

100°C, resin solids average particle size of 1.4-1.7 micrometers, and a pH of 5.0, was added to mix 10. The furnish was passed to the wire 40, with the further addition of 0.2% polyacrylamide now from secondary mix tank 16 metered into this furnish. The resultant panels exhibited significantly higher strength and the ability to withstand sagging from humidified conditions in comparison to the panels of Example 2.

From the foregoing, it is apparent that the present invention provides a method for manufacturing structural mineral products of widely varying densities and uses. Various panel thicknesses from about 1/8 inch through 2 inches

(.003-.05m) may be formed. Very lightweight products having a density ranging from about 3-10 pounds per cubic (48-160

3 K/m ) foot may be formed from a dilute furnish preferably of about 20-65% mineral fiber and about 20-70% expanded lightweight aggregate. Denser products up to about 20 pounds

3 per cubic foot (320 kg/m ) or more may be formed with heavier aggregate such as gypsum. An all mineral fiber or an all lightweight aggregate panel may be formed. Paper and other cellulosic fiber may supplant or replace the mineral or polymeric fibers preferred in the practice of the present invention. Starch or other organic binder may at least partly supplant the preferred binders without departing from the spirit and scope of the present invention. Other ingredients may be present in the furnish such as dyes, pigments, antioxidants water repellents, fire retardants and the like.

Conventional steps for various particular manufactured articles such as cutting, trimming, shaping, adding slots, tabs, and the like for ceiling grid suspension or other mountings; and painting, texturing surface overlaying and the like decorating features may be performed.