Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Composite having voids in a component
Patent
1991-09-17
1993-02-23
Ryan, Patrick J.
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Composite having voids in a component
4283073, 428448, 428702, 428535, 264257, 264 51, 106675, 106698, B32B 900
Patent
active
051888890
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The present invention relates to an inorganic board which is light and has a porous structure and excellent insulating properties, and a method of manufacture thereof.
DESCRIPTION OF THE PRIOR ART
Hitherto, a method of manufacture of a porous cement board which is light and has insulating properties such as a heat insulating property, a soundproof property, and the like has been provided said method comprising molding and heating a mixture consisting of a reinforcing material such as wood chip or flake, pulp, fiber and the like and further expandable plastic beads wherein said plastic beads are expanded and melted by heating to form numerous pores in the resulting mold (Tokkai Sho 54-157125, Tokko Sho 63-1276).
Nevertheless, said prior porous cement board has a large moisture and vapor permeability and it is difficult to obtain a board having a flat and smooth surface and excellent appearance since said prior porous cement has numerous holes in its surface. Further, in the case of the prior wood chip-cement board using wood chip as a reinforcing material, it is necessary to increase the molding pressure to obtain the high density of the product so that the product has sufficient strength, and further in the case of the prior pulp-cement board using pulp fiber as a reinforcing material, the density of the mixture of cement-pulp fiber becomes excessive to suppress the expansion of said expandable plastic beads.
DISCLOSURE OF THE INVENTION
The present invention provides an inorganic board comprising a pair of surface layers consisting of a hardened mixture of 30 to 60% by weight of cement, 30 to 60% by weight of silica-containing material, 0 to 15% by weight of pearlite and 5 to 25% by weight of wood flake and/or wood powder, and a porous core layer consisting of a hardened mixture of 30 to 60% by weight of cement, 30 to 60% by weight of silica-containing material, 0 to 15% by weight of pearlite and 5 to 25% by weight of wood-fiber bundle and further it is desirable to use bulky wood-fiber bundle being branched and/or curved and/or bent.
A desirable method of manufacture of said inorganic board is a dry method having a high production efficiency and said dry method comprises process 1, 2 and 3 wherein cement, 30 to 60% by weight of silica-containing material, 0 to 15% by weight of pearlite, 5 to 25% by weight of flake and/or wood powder, and 30 to 45% by weight of water on a mold panel to form a mat, scattering a mixture B of 30 to 60% by weight of cement, 30 to 60% by weight of silica-containing material, 0 to 15% by weight of pearlite, 5 to 25% by weight of wood-fiber bundle, 0.5 to 5% by weight of expandable plastic beads and 30 to 45% by weight of water on said mat of said mixture A to form a mat, and scattering said mixture A on said mat of said mixture B to form a mat to obtain a mat having a three layer structure, to be pre-hardened. an autoclave to soften, expand and contract said expandable plastic beads and to complete hardning of said mat.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described in detail as follows:
Surface layers
The inorganic board of the present invention has a pair of surface layers which is a hardened mixture of 30 to 60% by weight of cement, 30 to 60% by weight of silica-containing material, 0 to 15% by weight of pearlite and 5 to 25% by weight of flake and/or wood powder.
Said cement may include many kinds of cement such as Portland cement, blast furnace cement, silica cement, fly ash cement, alumina cement, and the like; and said silica-containing material may be an inorganic powder containing silica such as silica sand, silica powder, silica fume, silasballoon and the like.
Said cement and said material silica-containing material react together by silicate-calcium reaction for hardening. To obtain smooth hardening by said silicate-calcium reaction, it is necessary that said mixture A forming the surface layers of said inorganic board include 30 to 60% by weight of cement and 30 to 60% by weight of silica-containing material
REFERENCES:
patent: 599306 (1898-02-01), Johnson
patent: 1583713 (1926-05-01), Rankin
patent: 3705837 (1972-12-01), Breslauer
patent: 4225359 (1980-09-01), Schneider
patent: 4306395 (1981-12-01), Carpenter
patent: 4323527 (1982-04-01), Katzenberger
Nagatomi Wakatsu
Takai Kazuhiko
Edwards N.
Nichiha Corporation
Ryan Patrick J.
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