Paper making and fiber liberation – Processes and products – Plural fiber containing
Reexamination Certificate
1997-08-05
2001-02-27
Silverman, Stanley S. (Department: 1731)
Paper making and fiber liberation
Processes and products
Plural fiber containing
C162S152000, C162S155000, C162S164100, C162S166000, C162S168200, C162S179000
Reexamination Certificate
active
06193842
ABSTRACT:
The present invention relates to a process for preparing insulant boards based on mineral and paper fiber by slurrying mineral fiber, binder and customary additives in water, forming the insulant board by applying the slurry to a wire, and drying and consolidating the insulant board.
Such boards, provided with decorative surfaces, are predominantly used as sound insulation in suspended ceilings or wall panels. However, they also find utility in building fire protection, especially as door linings and linings for beams and supports in steel structures and for air and electric cabling ducts.
The boards in question are produced in a wet process. In this process, a highly aqueous slurry of mineral wool, paper fiber, starch and clay is prepared and passed to a wire to drain off some of the water under suction. The resulting wire cake is then passed into an oven, where the rest of the water evaporates at elevated temperature. At the same time, the starch gel dries hard and forms a firm bond between the crossing mineral and paper fibers.
The aqueous slurry is admixed with nonionic surfactants to achieve faster drainage of the machine wire and also in order that the resulting foam may reduce the density. However, this addition of surfactant has the disadvantage that, after drying, a highly hydrophilic component remains in the boards. These disadvantages show themselves specifically as follows:
After the dried crude boards have been sanded, they are coated with waterborne emulsion paints. Since the substrate is highly porous a lot of paint is absorbed into the substrate, and therefore works paint.
Furthermore, the prior art surfactants tend to adsorb atmospheric humidity. This may cause the binder used to soften. The binding force is reduced as a result, and the framed boards may then begin to sag under their own weight.
It is an object of the present invention to dewater the mixture to be dried as completely as possible ahead of the drying process and not leave any hydrophilic surfactant in the board.
This object is achieved according to the invention by the use of the below-recited surface-active compounds.
The preferred surface-active compounds are betaines which conform to the general formula
where
R
1
is an alkyl radical of a fatty acid having 6 to 21 carbon atoms,
R
2
and R
3
are independently of each other alkyl radicals having 1 to 4 carbon atoms,
x is 2 or 3,
y is 1, 2 or 3, and
z is 0 or 1.
Particular preference is given to adding a betaine in which
R
1
=the alkyl radical of a fatty acid mixture obtained from hydrogenated coconut fat,
R
2
and R
3
each=a methyl radical,
x=3,
y=2, and
z=1.
A further feature of the invention is the use of amine oxides of the general formula
where
R
1
is an alkyl radical of a fatty acid having 6 to 18 carbon atoms,
R
2
and R
3
are independently of each other alkyl radicals having 1 to 4 carbon atoms,
x is 2 or 3, and
z is 0 or 1.
It is advantageous to use amine oxide in which
R
1
=the alkyl radical of a fatty acid mixture obtained from hydrogenated coconut fat,
R
2
and R
3
each=a methyl radical,
x=3, and
z=1.
Further surfactants added are quaternary ammonium compounds which conform to the following general formula:
where
R
4
is an alkyl or alkenyl radical having 8 to 22 carbon atoms,
R
5
is an alkyl or hydroxyalkyl radical having 1 to 5 carbon atoms,
R
6
is R
4
or R
5,
R
7
is R
5
or optionally a substituted benzyl radical, and
x is an anion.
A particularly preferred representative of this group is stearyltrimethylammonium chloride, bromide or methosulfate; examples of further compounds which can be used are stearyldimethylhydroxypropylammonium halides, cetyltrimethyl-ammonium chloride, bromide or methosulfate, lauryl-dimethylammonium chloride and bromide and lauryldimethylammonium hydroxypropyl and hydroxyethyl salts or else cocoyltrimethylamnonium halides.
Of particular effectiveness are ester quats of the formula
where
R
8
CO is an aliphatic, optionally hydroxyl-substituted acyl radical having 12 to 22 carbon atoms and 0 or 1 double bond,
R
9
is a methyl group or a polyethylene glycol ether chain having 1 to 5 ethylene oxide units,
x and z are each 0 or together from 1 to 20, and
Y is halogen, alkylsulfate or alkylphosphate.
Particular preference is given to an ester quat of the formula
where
R is the alkyl radical of a fatty acid mixture obtained from hydrogenated coconut fat, and
x+y=15.
The preparation of the abovementioned surface-active compounds is described in a wide range of patent literature, which need not be cited here in detail.
The surface-active compounds used have been found to give very rapid drainage, so that the filter residues to be dried contain distinctly less water. As a result, energy is saved and higher production speeds are achieved. The dried boards have distinctly hydrophobic properties at their surface.
It is advantageous to add hydrophobicizing silicone resins to the mineral and paper fiber slurry. The use of these known silicone resins in conjunction with the surface-active compounds used according to the invention provides even more uniform and better hydrophobicization.
The examples which follow illustrate the process of the invention.
The first step is to prepare a mixture which does not include an added surfactant. 3 l of water, 120 g of rockwool, 10 g of starch, 30 g of clay and 0.4% by weight of a 50% hydrophobicizing methylsilicone resin emulsion, based on the abovementioned solids, are thoroughly mixed.
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Fortuna Jose S.
Frommer & Lawrence & Haug LLP
Silverman Stanley S.
TH Goldschmidt AG
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