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US4247364A
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Method of making a smooth, dimensionally stable, mica-filled, glass fiber sheet
Assignee: Armstrong World Industries Inc
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Filing: 1979-07-02
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Granted: 1981-01-27
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Expires: 1999-07-02
Abstract
Abstract A mica-filled glass fiber sheet which is smooth, of relatively low porosity, and dimensionally stable is described as is its method of manufacture. The sheet is prepared from a low-consistency aqueous slurry wherein the solids consist essentially of glass fibers, organic fibers, mica, and binder. Based on 100 parts by weight glass fibers, 3 to 15 parts by weight organic fibers, 30 to 100 parts by weight mica flakes, and 5 to 20 parts by weight organic binder are added to the water in preparing the furnish. In forming the sheet, this slurry or furnish is deposited onto a moving screen, the excess water is removed, and the wet laid sheet is dried and the binder set. In a subsequent operation, the sheet is saturated with a resin solution or latex.
Inventors
- 👤 Charles R. Culp
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 16:13
CPC Classifications
D; D21; D21H; D21H5/00; D21H5/12; D21H13/00; D21H13/36; D21H13/38; D21H13/40; D21H13/44; Y; Y10; Y10T; Y10T428/00; Y10T428/25; Y10T428/251; Y10T428/29; Y10T428/2911; Y10T442/00; Y10T442/60; Y10T442/697
Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
111 words
A method of making a smooth, dimensionally stable mica-filled, glass fiber sheet having low porosity comprising: (a) preparing without prepulping an aqueous slurry having a pH below about 4.0 consisting essentially of glass fibers and, based on 100 parts by weight glass fibers, from 3 to 15 parts by weight organic fibers, 30 to 100 parts by weight mica flakes, and 5 to 20 parts by weight binder; (b) diluting the slurry to a consistency between about 0.01% and 0.05% by weight solids; and (c) depositing said slurry onto a moving screen, removing the excess of water to form a water laid sheet, and drying the sheet to set the binder.
Claim 2
Independent Claim
111 words
A method of making a smooth, dimensionally stable mica-filled, glass fiber sheet having low porosity comprising: (a) preparing without prepulping an aqueous slurry having a pH below about 4.0 consisting essentially of glass fibers and, based on 100 parts by weight glass fibers, from 3 to 15 parts by weight organic fibers, 30 to 100 parts by weight mica flakes, and 5 to 20 parts by weight binder; (b) diluting the slurry to a consistency between about 0.01% and 0.05% by weight solids; and (c) depositing said slurry onto a moving screen, removing the excess of water to form a water laid sheet, and drying the sheet to set the binder.
Claim 3
Dependent Claim
68 words
The method in accordance with claim 1 in which the glass fibers have diameters in the range of 3-15 microns, an average length of 1/4 to 1/2 inch and are of a low alkali content, the mica flakes having size ranging from 20 to 100 mesh, and the organic fibers are of an average length between about 1/4 and 1/2 inch and deniers between about 1 and 6.
Claim 4
Dependent Claim
28 words
The method of claim 2 in which the organic fibers are polyester fibers and in which the binder is poly(vinyl alcohol) fibers which dissolve during the drying step.
Claim 5
Dependent Claim
29 words
The method in accordance with claim 2 in which the sheet is post saturated with from about 30% to 100% dry weight pick-up of an organic resin and cured.
Claim 6
Dependent Claim
30 words
The method in accordance with claim 4 in which the organic resin is melamine modified styrene-butadiene latex having a melamine to styrene-butadiene weight ratio of from about 1:6 to 1:10.
Claim 7
Dependent Claim
89 words
A mica filled glass fiber web of low porosity consisting essentially of 100 parts by weight of low alkali content glass fibers having diameters in the range of 3-15 microns and an average length of 1/4 to 1/2 inch; from 3-15 parts by weight synthetic organic fibers of an average length of 1/4 to 1/2 inch and deniers between about 1 and 6; 30 to 100 parts by weight mica flakes of a size range between about 20 and 100 mesh; and 5 to 20 parts by weight binder.
Claim 8
Dependent Claim
89 words
A mica filled glass fiber web of low porosity consisting essentially of 100 parts by weight of low alkali content glass fibers having diameters in the range of 3-15 microns and an average length of 1/4 to 1/2 inch; from 3-15 parts by weight synthetic organic fibers of an average length of 1/4 to 1/2 inch and deniers between about 1 and 6; 30 to 100 parts by weight mica flakes of a size range between about 20 and 100 mesh; and 5 to 20 parts by weight binder.
Claim 9
Dependent Claim
24 words
The web in accordance with claim 6 in which the synthetic organic fibers are polyester fibers and in which the binder is poly(vinyl alcohol).
Claim 10
Dependent Claim
31 words
The web in accordance with claim 6 or 7 wherein the web has been post saturated and cured with from about 30% to 100% dry weight pick-up of an organic resin.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1984-01-27 | 1984-07-28 | 1985-01-27 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-01-27 | 1988-07-28 | 1989-01-27 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-01-27 | 1992-07-28 | 1993-01-27 | $7700.00 | Window Closed / Lapsed |