Patent US4175149A successfully refreshed from Google Patents.
US4175149A
Expired / Lapsed
US
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Mineral wool product containing high density skins and method of manufacturing same
Assignee: Masonite Corp
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Filing: 1978-02-27
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Granted: 1979-11-20
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Expires: 1998-02-27
Abstract
Abstract A mineral wool board is manufactured having relatively high density skins by including urea in at least the surface fibers of a consolidated mineral wool fiberboard containing cellulosic fibers and/or starch and then hot-pressing the consolidated board at a temperature of at least 525° F. to form a board having high density surface skins.
Inventors
- 👤 Allan J. Luck
- 👤 John T. Clarke
- 👤 Michael R. Hoffman
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 22:53
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B27; B27N; B27N7/00; B32B29/00; B32B29/02; B32B37/00; B32B37/10; B32B5/26; C; C08; C08L; C08L97/00; C08L97/02; B29; B29K; B29K2311/00; B29K2311/14; B32B2260/00; B32B2262/00; B32B2262/10; B32B2309/00; B32B2309/02; B32B2309/022; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24595; Y10T428/24603; Y10T428/24942; Y10T428/24992; Y10T428/31504; Y10T428/31652; Y10T428/31667; Y10T428/31942; Y10T428/31949; Y10T428/31964; Y10T428/31967
Claims Analysis
Total Claims: 48
Claim 1
Independent Claim
138 words
A mineral wool-containing fiberboard product comprising a base layer including mineral wool fibers and a binder selected from the group consisting of cellulosic fiber, starch, and mixtures thereof, and an integral skin disposed on at least one surface of said base layer, said skin having a density in the range of 40-55 pounds/ft 3 and formed by including said binder in a surface layer in an amount effective to form said skin and contacting said cellulosic fibers or starch in said surface layer with urea in an amount of 5-20% based on the dry weight of said surface layer contacted therewith, and, after consolidation of said base layer, heating said contacted surface layer, under pressure above ambient, at a temperature of at least 525° F., said skin formed during said hot-pressing on the surface layer contacted with urea.
Claim 2
Dependent Claim
138 words
A mineral wool-containing fiberboard product comprising a base layer including mineral wool fibers and a binder selected from the group consisting of cellulosic fiber, starch, and mixtures thereof, and an integral skin disposed on at least one surface of said base layer, said skin having a density in the range of 40-55 pounds/ft 3 and formed by including said binder in a surface layer in an amount effective to form said skin and contacting said cellulosic fibers or starch in said surface layer with urea in an amount of 5-20% based on the dry weight of said surface layer contacted therewith, and, after consolidation of said base layer, heating said contacted surface layer, under pressure above ambient, at a temperature of at least 525° F., said skin formed during said hot-pressing on the surface layer contacted with urea.
Claim 3
Independent Claim
177 words
A method of manufacturing a mineral wool board having a skin on at least one surface thereof comprising: consolidating a fibrous mat containing mineral wool fibers and a binder selected from the group consisting of cellulosic fiber, starch, and mixtures thereof to form a consolidated mineral wool board said cellulosic fiber or starch included in the surface of said consolidated board in an amount effective to form a skin on said surface; including urea in at least a surface layer of said board in an amount of at least 5% based on the dry weight of said surface layer; and hot-pressing said consolidated board containing urea in at least its surface fibers, at a temperature of at least 525° F. to form a mineral wool containing board having a skin on at least one surface thereof, said skin defined by a layer of material on said surface of said board having a density greater than the material on which the skin is formed, said skin formed during said hot-pressing on the surface of said board including urea.
Claim 4
Independent Claim
177 words
A method of manufacturing a mineral wool board having a skin on at least one surface thereof comprising: consolidating a fibrous mat containing mineral wool fibers and a binder selected from the group consisting of cellulosic fiber, starch, and mixtures thereof to form a consolidated mineral wool board said cellulosic fiber or starch included in the surface of said consolidated board in an amount effective to form a skin on said surface; including urea in at least a surface layer of said board in an amount of at least 5% based on the dry weight of said surface layer; and hot-pressing said consolidated board containing urea in at least its surface fibers, at a temperature of at least 525° F. to form a mineral wool containing board having a skin on at least one surface thereof, said skin defined by a layer of material on said surface of said board having a density greater than the material on which the skin is formed, said skin formed during said hot-pressing on the surface of said board including urea.
Claim 5
Dependent Claim
108 words
A method as defined in claim 2 wherein said consolidated board is formed by including urea in the surface fibers as an overlay, said method further comprising depositing a first layer of fibers to form a core of fibers; depositing a second layer of fibers, containing urea therewith, over said core of fibers whereby said second layer of fibers intermingles with said core of fibers such that said second layer of fibers containing urea becomes an integral part of said core of fibers; consolidating said first and second layers to form a consolidated board; and thereafter hot-pressing said consolidated board at a temperature of at least 525° F.
Claim 6
Dependent Claim
31 words
A method as defined in claim 3 wherein said second layer of fibers contains urea in an amount of at least 5% based on the dry weight of said second layer.
Claim 7
Dependent Claim
24 words
A method as defined in claim 2 wherein said urea containing consolidated board is hot-pressed at a temperature in the range of 525°-650° F.
Claim 8
Dependent Claim
26 words
A method as defined in claim 2 wherein said board contains at least 5% cellulosic fibers in a surface layer comprising a thickness of 0.030 inch.
Claim 9
Dependent Claim
40 words
A method as defined in claim 2 wherein said binder is cellulosic fibers and wherein said cellulosic fibers are included in said surface layer in an amount of at least 5% based on the dry weight of said surface layer.
Claim 10
Dependent Claim
37 words
A method as defined in claim 2 wherein said binder is starch and wherein said starch is included in said surface layer in an amount of at least 10% based on the weight of said surface layer.
Claim 11
Independent Claim
104 words
A method of forming a mineral wool-containing board having a relatively dense skin on at least one of its surfaces comprising: applying urea to a surface of a consolidated mineral wool-containing board containing at least 5% by weight cellulosic fibers in said surface, said urea applied in an amount of at least 5 pounds of urea per thousand square feet of surface contacted with said urea to form a urea treated consolidated board; and pressing said urea treated consolidated board at a temperature of at least 525° F., said skin formed during said hot-pressing on the surface of said mineral wool-containing board containing urea.
Claim 12
Independent Claim
104 words
A method of forming a mineral wool-containing board having a relatively dense skin on at least one of its surfaces comprising: applying urea to a surface of a consolidated mineral wool-containing board containing at least 5% by weight cellulosic fibers in said surface, said urea applied in an amount of at least 5 pounds of urea per thousand square feet of surface contacted with said urea to form a urea treated consolidated board; and pressing said urea treated consolidated board at a temperature of at least 525° F., said skin formed during said hot-pressing on the surface of said mineral wool-containing board containing urea.
Claim 13
Dependent Claim
24 words
A method as defined in claim 9 wherein said urea treated consolidated board is pressed at a temperature in the range of 525°-650° F.
Claim 14
Dependent Claim
127 words
In a method of manufacturing a mineral wool-containing fiberboard, including the steps of hot-pressing a mineral wool-containing fiberboard mat, containing at least 5% by weight cellulosic fibers in a surface thereof, to consolidate said mat into a unitary structure to form a consolidated mineral wool fiber-containing board, the improvement comprising impregnating said surface of said consolidated board with urea by applying urea in an amount of at least 5 pounds of urea per thousand square feet of said surface and thereafter hot-pressing said impregnated, consolidated board at a temperature of at least 525° F. for a period of time sufficient to form a hard, dense skin on the surface of said board, said skin formed during said hot-pressing on the surface of said board impregnated with urea.
Claim 15
Dependent Claim
127 words
In a method of manufacturing a mineral wool-containing fiberboard, including the steps of hot-pressing a mineral wool-containing fiberboard mat, containing at least 5% by weight cellulosic fibers in a surface thereof, to consolidate said mat into a unitary structure to form a consolidated mineral wool fiber-containing board, the improvement comprising impregnating said surface of said consolidated board with urea by applying urea in an amount of at least 5 pounds of urea per thousand square feet of said surface and thereafter hot-pressing said impregnated, consolidated board at a temperature of at least 525° F. for a period of time sufficient to form a hard, dense skin on the surface of said board, said skin formed during said hot-pressing on the surface of said board impregnated with urea.
Claim 16
Dependent Claim
21 words
In a method as defined in claim 11 including hot-pressing said impregnated, consolidated board at a pressure not exceeding 200 p.s.i.
Claim 17
Dependent Claim
23 words
In a method as defined in claim 12 including hot-pressing said impregnated, consolidated mat at a pressure in the range of 30-200 p.s.i.
Claim 18
Independent Claim
148 words
A method of forming a hard, dense skin on the surface of a mineral wool fiber-containing board, having at least 5% by weight cellulosic fibers in said surface, and containing a binder, comprising: contacting said surface of said mineral wool fiber-containing mat with urea in an amount of at least 5% based on the dry weight of the surface portion of the mat contacted with said urea; consolidating said mineral wool fiber-containing board to substantially cure the binder therein and to form a consolidated board; and thereafter hot-pressing said consolidated board containing urea in a heated press at a temperature of at least 525° F. to form a board having a skin on said surface of said board having a density greater than the density of material on which the skin is formed, said skin formed during said hot-pressing on the surface of said board contacted with urea.
Claim 19
Independent Claim
148 words
A method of forming a hard, dense skin on the surface of a mineral wool fiber-containing board, having at least 5% by weight cellulosic fibers in said surface, and containing a binder, comprising: contacting said surface of said mineral wool fiber-containing mat with urea in an amount of at least 5% based on the dry weight of the surface portion of the mat contacted with said urea; consolidating said mineral wool fiber-containing board to substantially cure the binder therein and to form a consolidated board; and thereafter hot-pressing said consolidated board containing urea in a heated press at a temperature of at least 525° F. to form a board having a skin on said surface of said board having a density greater than the density of material on which the skin is formed, said skin formed during said hot-pressing on the surface of said board contacted with urea.
Claim 20
Dependent Claim
23 words
A method as defined in claim 14 wherein said urea containing board is hot-pressed at a temperature in the range of 525°-650° F.
Claim 21
Dependent Claim
12 words
A method as defined in claim 14 wherein said binder comprises starch.
Claim 22
Dependent Claim
36 words
A method as defined in claim 14 wherein said surface fibers are contacted with urea in an amount in the range of 5-20% based on the total dry weight of board material contacted by said urea.
Claim 23
Independent Claim
184 words
A method of manufacturing a mineral wool fiber-containing board containing cellulosic fibers said board having a skin on at least one surface thereof comprising: depositing a first layer of fibers containing at least 45% mineral wool fibers, based on the dry weight of said first layer to form a base layer for supporting at least one surface skin thereon; depositing a second layer of fibers over said first layer of fibers, said second layer containing at least 5% cellulosic fibers based on the dry weight of said second layer; including urea in said second layer of fibers in an amount of at least 5% based on the total dry weight of said second layer of fibers; consolidating said first and second layers in a heated press at a temperature less than 500° F. to form a consolidated urea-containing mineral wool board; and thereafter hot-pressing said consolidated urea-containing mineral wool board at a temperature in the range of 525°-650° F. to form at least one skin on said base layer, said skin formed during said hot-pressing on the surface of said second layer of fibers.
Claim 24
Independent Claim
184 words
A method of manufacturing a mineral wool fiber-containing board containing cellulosic fibers said board having a skin on at least one surface thereof comprising: depositing a first layer of fibers containing at least 45% mineral wool fibers, based on the dry weight of said first layer to form a base layer for supporting at least one surface skin thereon; depositing a second layer of fibers over said first layer of fibers, said second layer containing at least 5% cellulosic fibers based on the dry weight of said second layer; including urea in said second layer of fibers in an amount of at least 5% based on the total dry weight of said second layer of fibers; consolidating said first and second layers in a heated press at a temperature less than 500° F. to form a consolidated urea-containing mineral wool board; and thereafter hot-pressing said consolidated urea-containing mineral wool board at a temperature in the range of 525°-650° F. to form at least one skin on said base layer, said skin formed during said hot-pressing on the surface of said second layer of fibers.
Claim 25
Dependent Claim
95 words
A method as defined in claim 18 further including depositing a third layer of fibers containing at least 5% cellulosic fibers based on the dry weight of said third layer over said base layer, prior to consolidation of said first and second layers, to thereby sandwich said base layer between said second and third layers, and including urea in said third layer in an amount of at least 5% based on the total weight of said third layer: and consolidating said three layers and thereafter hot-pressing at a temperature in the range of 525°-650° F.
Claim 26
Dependent Claim
37 words
A method as defined in claim 19 wherein the amount of urea in each of said second and third layers is in the range of 9-17% by dry weight of each of said second and third layers.
Claim 27
Dependent Claim
24 words
A method as defined in claim 2 wherein said surface layer includes a depth of material underlying said surface a depth of 0.030 inch.
Claim 28
Dependent Claim
27 words
The product as defined in claim 1 wherein said base layer is consolidated by heating said base layer to dry the base layer and set the binder.
Claim 29
Dependent Claim
20 words
The product as defined in claim 22 including consolidating said base layer prior to contacting said surface layer with urea.
Claim 30
Dependent Claim
17 words
A method as defined in claim 2 wherein said board contains at least 50% mineral wool fibers.
Claim 31
Independent Claim
109 words
A method of manufacturing a mineral wool board having a skin on at least one surface thereof comprising: consolidating a fibrous mat containing mineral wool fibers to form a consolidated mineral wool base layer; applying a consolidated paper sheet having at least 5% by weight cellulosic fibers over at least one major surface of said base layer; impregnating at least a portion of said paper sheet with urea; hot-pressing said base layer having said impregnated paper sheet thereon at a temperature of at least 525° F. to form a mineral wool board having a skin thereon, said skin formed during said hot-pressing on the paper sheet impregnated with urea.
Claim 32
Independent Claim
109 words
A method of manufacturing a mineral wool board having a skin on at least one surface thereof comprising: consolidating a fibrous mat containing mineral wool fibers to form a consolidated mineral wool base layer; applying a consolidated paper sheet having at least 5% by weight cellulosic fibers over at least one major surface of said base layer; impregnating at least a portion of said paper sheet with urea; hot-pressing said base layer having said impregnated paper sheet thereon at a temperature of at least 525° F. to form a mineral wool board having a skin thereon, said skin formed during said hot-pressing on the paper sheet impregnated with urea.
Claim 33
Dependent Claim
39 words
A method as defined in claim 25 wherein said paper sheet is impregnated with urea in an amount in the range of 5-20% by dry weight of said sheet prior to applying said paper sheet over said base layer.
Claim 34
Dependent Claim
44 words
A method as defined in claim 25 wherein ure is applied to said paper sheet in an amount of at least 5 pounds of urea per thousand square feet of paper sheet surface area after said sheet has been applied over said base layer.
Claim 35
Dependent Claim
20 words
A method as defined in claim 25 wherein said paper sheet is secured to said base layer with a binder.
Claim 36
Dependent Claim
12 words
A method as defined in claim 28 wherein said binder comprises starch.
Claim 37
Dependent Claim
12 words
A method as defined in claim 28 wherein said binder comprises urea.
Claim 38
Dependent Claim
20 words
A method as defined in claim 25 wherein said paper sheet is secured to said base layer during said hot-pressing.
Claim 39
Dependent Claim
26 words
A method as defined in claim 28 wherein said binder is disposed between said base layer and said paper sheet by coating said base layer therewith.
Claim 40
Dependent Claim
18 words
A method as defined in claim 28 wherein said binder is a mixture of urea and lignin sulfonate.
Claim 41
Dependent Claim
34 words
A method as defined in claim 28 wherein said binder is disposed between said base layer and said paper sheet by coating a base layer contacting surface of said paper sheet with said binder.
Claim 42
Dependent Claim
27 words
A method as defined in claim 32 wherein said binder is sprayed over a paper sheet contacting surface of said base layer before applying said paper sheet.
Claim 43
Independent Claim
165 words
A method of manufacturing a cellulosic fiber-containing board having a skin on at least one surface thereof comprising: dry depositing a layer of fibers including mineral wool fibers and a binder selected from the group consisting of cellulosic fibers, starch, and mixtures thereof onto a support member to form a loose mat containing mineral wool fibers, said cellulosic fibers or starch included in the surface of said loose mat in an amount effective to form a skin on said surface; consolidating said mat to bond said mineral wool fibers together to form a completed board; contacting at least a surface of said completed bond with urea in an amount sufficient to form a surface portion having a density greater than the density of the material on which the skin is formed; and hot-pressing said contacted surface at a temperature of at least 525° F. to form a skin, said skin formed during said hot-pressing on the surface of said mineral wool board contacted with urea.
Claim 44
Independent Claim
165 words
A method of manufacturing a cellulosic fiber-containing board having a skin on at least one surface thereof comprising: dry depositing a layer of fibers including mineral wool fibers and a binder selected from the group consisting of cellulosic fibers, starch, and mixtures thereof onto a support member to form a loose mat containing mineral wool fibers, said cellulosic fibers or starch included in the surface of said loose mat in an amount effective to form a skin on said surface; consolidating said mat to bond said mineral wool fibers together to form a completed board; contacting at least a surface of said completed bond with urea in an amount sufficient to form a surface portion having a density greater than the density of the material on which the skin is formed; and hot-pressing said contacted surface at a temperature of at least 525° F. to form a skin, said skin formed during said hot-pressing on the surface of said mineral wool board contacted with urea.
Claim 45
Dependent Claim
20 words
A method as defined in claim 36 further including drying said urea contacted mat prior to hot-pressing said contacted surface.
Claim 46
Independent Claim
166 words
A method of manufacturing a mineral wool fiber containing board having a skin on at least one surface thereof comprising: dry depositing a layer of fibers including mineral wool fibers and a binder selected from the group consisting of cellulosic fiber, starch, and mixtures thereof onto a support member to form a loose mat said cellulosic fibers or starch included in the surface of said loose mat in an amount effective to form a skin on said surface; contacting at least a surface of said mat with urea in an amount sufficient to form a surface portion having a density greater than the density of the material on which the skin is formed; consolidating said urea contacted mat to bond said mineral wool fibers together to form a completed mineral wool board; and hot-pressing said completed board at a temperature of at least 525° F. to form a skin, said skin formed during said hot-pressing on the surface of said mineral wool board contacted with urea.
Claim 47
Independent Claim
166 words
A method of manufacturing a mineral wool fiber containing board having a skin on at least one surface thereof comprising: dry depositing a layer of fibers including mineral wool fibers and a binder selected from the group consisting of cellulosic fiber, starch, and mixtures thereof onto a support member to form a loose mat said cellulosic fibers or starch included in the surface of said loose mat in an amount effective to form a skin on said surface; contacting at least a surface of said mat with urea in an amount sufficient to form a surface portion having a density greater than the density of the material on which the skin is formed; consolidating said urea contacted mat to bond said mineral wool fibers together to form a completed mineral wool board; and hot-pressing said completed board at a temperature of at least 525° F. to form a skin, said skin formed during said hot-pressing on the surface of said mineral wool board contacted with urea.
Claim 48
Dependent Claim
30 words
A method as defined in claim 38 further including contacting a surface on the consolidated board with urea prior to hot-pressing at a temperature of at least 525° l F.
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| 3.5 Years (Year 4) | 1982-11-19 | 1983-05-21 | 1983-11-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-11-19 | 1987-05-21 | 1987-11-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-11-19 | 1991-05-21 | 1991-11-20 | $7700.00 | Window Closed / Lapsed |