US4613627A — Process for the manufacture of shaped fibrous pro…

Claim 1

Independent Claim 175 words

A method of manufacturing a shaped fibrous product from an aqueous composition comprising the following ingredients by weight of solids content: fibers: 25-95% binder: 5-75% clay: 0-40% gypsum: 0-15% foaming agent: 0.1-5% said method comprising the successive steps of: (a) preparing an aqueous admixture by admixing the binder and the foaming agent with water, the water being present in the amount of from about 25% to about 70% by weight of the furnish composition; (b) combining said aqueous admixture under agitation with air to form an aqueous foamed binder system, the amount of surfactant in combination with the degree of agitation being sufficient so that said air is present in the amount of from about 30% to about 90% by volume of the aqueous foamed binder system; (c) combining said fibers with said aqueous foamed binder system to form a foamed furnish composition, said foamed composition being a slurry of said fibrous materials in said aqueous foamed binder system; (d) forming a shaped product from said foamed furnish composition; and (e) setting the shaped product.

Claim 2

Independent Claim 175 words

A method of manufacturing a shaped fibrous product from an aqueous composition comprising the following ingredients by weight of solids content: fibers: 25-95% binder: 5-75% clay: 0-40% gypsum: 0-15% foaming agent: 0.1-5% said method comprising the successive steps of: (a) preparing an aqueous admixture by admixing the binder and the foaming agent with water, the water being present in the amount of from about 25% to about 70% by weight of the furnish composition; (b) combining said aqueous admixture under agitation with air to form an aqueous foamed binder system, the amount of surfactant in combination with the degree of agitation being sufficient so that said air is present in the amount of from about 30% to about 90% by volume of the aqueous foamed binder system; (c) combining said fibers with said aqueous foamed binder system to form a foamed furnish composition, said foamed composition being a slurry of said fibrous materials in said aqueous foamed binder system; (d) forming a shaped product from said foamed furnish composition; and (e) setting the shaped product.

Claim 3

Dependent Claim 23 words

The method of claim 1 wherein the foamed composition comprises from about 60% to about 75% gas by volume of the foamed composition.

Claim 4

Dependent Claim 10 words

The method of claim 1 wherein the gas is air.

Claim 5

Dependent Claim 26 words

The method of claim 1 wherein the fibrous material comprises from about 40% to about 70% by weight of the solids content of the foamed composition.

Claim 6

Dependent Claim 24 words

The method of claim 4 wherein the fibrous material comprises fibers having an average diameter of from about 1 micron to about 25 mils.

Claim 7

Dependent Claim 15 words

The method of claim 5 wherein the average diameter not greater than about 5 mils.

Claim 8

Dependent Claim 19 words

The method of claim 5 wherein the average length of the fibers is from at least about 1/64 inch.

Claim 9

Dependent Claim 17 words

The method of claim 7 wherein the average fiber length is no greater than about 2 inches.

Claim 10

Dependent Claim 17 words

The method of claim 5 wherein the fibers have an aspect ratio of at least about 10:1.

Claim 11

Dependent Claim 12 words

The method of claim 1 wherein the fibrous material comprises organic fibers.

Claim 12

Dependent Claim 31 words

The method of claim 10 wherein the organic fibers are selected from the group consisting of cellulose fibers, wood fibers, polyester fibers, polyolefin fibers, polyamide fibers and combinations of the foregoing.

Claim 13

Dependent Claim 12 words

The method of claim 1 wherein the fibrous material comprises mineral fibers.

Claim 14

Dependent Claim 33 words

The method of claim 12 wherein the mineral fibers are selected from the group consisting of mineral wool, rock wool, slag wool, wollastonite, kaolin, glass wool, glass fibers and combinations of the foregoing.

Claim 15

Dependent Claim 26 words

The method of claim 13 wherein the fibers consist essentially of rock wool, slag wool, glass fibers, high aspect ratio wollastonite and mixtures of the foregoing.

Claim 16

Dependent Claim 17 words

The method of claim 1 wherein the fibrous material comprises a mixture of organic and inorganic fibers.

Claim 17

Dependent Claim 12 words

The method of claim 1 wherein the foaming agent is a surfactant.

Claim 18

Dependent Claim 35 words

The method of claim 16 wherein the surfactant is selected from the group consisting of anionic, cationic and amphoteric surfactants and combinations of the same but not including combinations of anionic surfactants with cationic surfactants.

Claim 19

Dependent Claim 14 words

The method of claim 1 wherein the binder system includes a silane coupling agent.

Claim 20

Dependent Claim 19 words

The method of claim 18 wherein the silane coupling agent is present in an amount up to about 0.3%.

Claim 21

Dependent Claim 19 words

The method of claim 18 wherein the silane coupling agent is present in an amount up to about 0.2%.

Claim 22

Dependent Claim 19 words

The method of claim 18 wherein the silane coupling agent is present in an amount up to about 0.1%.

Claim 23

Dependent Claim 12 words

The method of claim 1 wherein the foamed composition includes polyethylene oxide.

Claim 24

Dependent Claim 28 words

The method of claim 22 wherein the polyethylene oxide is present in an amount up to about 0.5% by weight of the solids content of the foamed composition.

Claim 25

Dependent Claim 28 words

The method of claim 22 wherein the polyethylene oxide is present in an amount up to about 0.3% by weight of the solids content of the foamed composition.

Claim 26

Dependent Claim 28 words

The method of claim 22 wherein the polyethylene oxide is present in an amount up to about 0.1% by weight of the solids content of the foamed composition.

Claim 27

Dependent Claim 13 words

The method of claim 1 wherein the binder system includes a thickening agent.

Claim 28

Dependent Claim 26 words

The method of claim 26 wherein the thickening agent is present in sufficient amount to bring the viscosity of the aqueous solution above about 1500 centipoises.

Claim 29

Dependent Claim 24 words

The method of claim 26 wherein the thickening agent is selected from the group consisting of methyl cellulose, hydroxy propyl cellulose and mixtures thereof.

Claim 30

Dependent Claim 31 words

The method of claim 26 wherein the thickening agent is present in the amount of from about 0.1% to about 0.5% by weight of the solids content of the foamed composition.

Claim 31

Dependent Claim 13 words

The method of claim 1 wherein the aqueous solution includes a dispersing agent.

Claim 32

Dependent Claim 12 words

The method of claim 30 wherein the dispersing agent is sodium hexametaphosphate.

Claim 33

Dependent Claim 29 words

The method of claim 30 wherein the dispersing agent is present in the amount of up to about 1% by weight of the solids content of the foamed composition.

Claim 34

Dependent Claim 31 words

The method of claim 1 wherein the foaming agent is present in the amount of from about 0.1% to about 5% by weight of the solids content of the foamed composition.

Claim 35

Dependent Claim 31 words

The method of claim 33 wherein the foaming agent is present in the amount of from about 0.3% to about 3% by weight of the solids content of the foamed composition.

Claim 36

Dependent Claim 31 words

The method of claim 33 wherein the foaming agent is present in the amount of from about 0.3% to about 1.5% by weight of the solids content of the foamed composition.

Claim 37

Dependent Claim 13 words

The method of claim 1 wherein the aqueous solution includes a foam stabilizer.

Claim 38

Dependent Claim 13 words

The method of claim 36 wherein the foam stabilizer is a non-ionic surfactant.

Claim 39

Dependent Claim 18 words

The method of claim 36 wherein the foam stabilizer is present in an amount up to about 1.0%.

Claim 40

Dependent Claim 18 words

The method of claim 36 wherein the foam stabilizer is present in an amount up to about 0.7%.

Claim 41

Dependent Claim 31 words

The method of claim 1 wherein the foamed composition further comprises ingredients selected from the group consisting of dyes, pigments, antioxidants, water repellents, fillers, fire retardants and combinations of the foregoing.

Claim 42

Dependent Claim 12 words

The method of claim 1 wherein the binder is an organic material.

Claim 43

Dependent Claim 24 words

The method of claim 41 wherein the binder is selected from the group consisting of starches, modified starches, latexes and combinations of the foregoing.

Claim 44

Dependent Claim 14 words

The method of claim 42 wherein the modified starch is an oxidized, ethoxylated starch.

Claim 45

Dependent Claim 22 words

The method of claim 42 wherein the latex is selected from the group consisting of polyvinyl acetate, vinyl acetate/acrylic copolymers and styrene-butadiene.

Claim 46

Dependent Claim 30 words

The method of claim 41 wherein the binder is present in the amount of from about 5% to about 50% by weight of the solids content of the foamed composition.

Claim 47

Dependent Claim 30 words

The method of claim 41 wherein the binder is present in the amount of from about 10% to about 35% by weight of the solids content of the foamed composition.

Claim 48

Dependent Claim 20 words

The method of claim 41 wherein the water content of the foamed composition is from about 30% to about 60%.

Claim 49

Dependent Claim 16 words

The method of claim 41 wherein the foamed binder system includes at least one binding filler.

Claim 50

Dependent Claim 24 words

The method of claim 48 wherein the binding filler is selected from the group consisting of clay, gypsum, and mixtures of clay and gypsum.

Claim 51

Dependent Claim 18 words

The method of claim 49 wherein the clay is present in an amount of up to about 40%.

Claim 52

Dependent Claim 18 words

The method of claim 49 wherein the clay is present in an amount of up to about 30%.

Claim 53

Dependent Claim 18 words

The method of claim 49 wherein the clay is present in an amount of up to about 20%.

Claim 54

Dependent Claim 17 words

The method of claim 49 wherein the gypsum is present in an amount up to about 15%.

Claim 55

Dependent Claim 17 words

The method of claim 49 wherein the gypsum is present in an amount up to about 10%.

Claim 56

Dependent Claim 64 words

The method of claim 41 wherein the solids content of the foamed composition comprises from about 25% to about 90% mineral fibers, from about 5% to about 30% of a binder selected from the group consisting of starches and latexes, and combinations of starches and latexes, up to about 40% clay, up to about 15% gypsum, and from about 0.5% to about 2% surfactant.

Claim 57

Dependent Claim 31 words

The method of claim 55 wherein the clay is present in the amount of at least about 10% and the gypsum is present in the amount of at least about 5%.

Claim 58

Dependent Claim 12 words

The method of claim 1 wherein the binder is an inorganic material.

Claim 59

Dependent Claim 23 words

The method of claim 57 wherein the inorganic b:nder is selected from the group consisting of gypsum, silicates, hydraulic cement and Sorel cements.

Claim 60

Dependent Claim 12 words

The method of claim 58 wherein the hydraulic cement is Portland cement.

Claim 61

Dependent Claim 12 words

The method of claim 58 wherein the Sorel cement is magnesium oxychloride.

Claim 62

Dependent Claim 30 words

The method of claim 57 wherein the binder is present in the amount of from about 30% to about 70% by weight of the solids content of the foamed composition.

Claim 63

Dependent Claim 30 words

The method of claim 57 wherein the binder is present in the amount of from about 40% to about 65% by weight of the solids content of the foamed composition.

Claim 64

Dependent Claim 20 words

The method of claim 57 wherein the water content of the foamed composition is from about 30% to about 50%.

Claim 65

Dependent Claim 20 words

The method of claim 57 wherein the water content of the foamed composition is from about 30% to about 40%.

Claim 66

Dependent Claim 39 words

The method of claim 1 wherein the binder includes magnesium oxide, and a phosphate compound or combination of phosphate compounds is present in an amount up to about 1% by weight of the solids content of the foamed composition.

Claim 67

Dependent Claim 37 words

The method of claim 57 wherein the foamed composition comprises from about 25% to about 70% mineral fibers and from about 30% to about 75% of a binder selected from the group consisting of cements and silicates.

Claim 68

Dependent Claim 26 words

The method of claim 66 further including a thickening agent in an amount sufficient to raise the viscosity of the aqueous solution above about 1500 centipoises.

Claim 69

Dependent Claim 20 words

The method of claim 1 wherein the binder comprises at least one organic material and at least one inorganic material.

Claim 70

Dependent Claim 25 words

The method of claim 1 wherein the gypsum, if present, is admixed with the foamed binding system at the same time as the fibrous material.

Claim 71

Independent Claim 190 words

A method of manufacturing an acoustical ceiling board from an aqueous furnish composition comprising the following ingredients by weight of solids content: mineral fibers: 25-90% starch/latex binder: 5-30% clay: 0-40% gypsum: 0-15% surfactant: 0.5-2% said method comprising the successive steps of: (a) preparing an aqueous admixture by admixing the binder and the foaming agent with water, the water being present in the amount of from about 30% to about 60% by weight of the furnish composition; (b) combining said aqueous admixture under agitation with air to form an aqueous foamed binder system, the amount of surfactant in combination with the degree of agitation being sufficient so that said air is present in the amount of from about 60% to about 75% by volume of the aqueous foamed binder system; (c) combining said mineral fibers with said aqueous foamed binder system to form a foamed furnish composition; said foamed composition being a slurry of said fibrous materials in said aqueous foamed binder system; (d) forming a ceiling board from said foamed furnish composition; and (e) drying the ceiling board to a moisture content below about 3% by weight of the board.

Claim 72

Independent Claim 190 words

A method of manufacturing an acoustical ceiling board from an aqueous furnish composition comprising the following ingredients by weight of solids content: mineral fibers: 25-90% starch/latex binder: 5-30% clay: 0-40% gypsum: 0-15% surfactant: 0.5-2% said method comprising the successive steps of: (a) preparing an aqueous admixture by admixing the binder and the foaming agent with water, the water being present in the amount of from about 30% to about 60% by weight of the furnish composition; (b) combining said aqueous admixture under agitation with air to form an aqueous foamed binder system, the amount of surfactant in combination with the degree of agitation being sufficient so that said air is present in the amount of from about 60% to about 75% by volume of the aqueous foamed binder system; (c) combining said mineral fibers with said aqueous foamed binder system to form a foamed furnish composition; said foamed composition being a slurry of said fibrous materials in said aqueous foamed binder system; (d) forming a ceiling board from said foamed furnish composition; and (e) drying the ceiling board to a moisture content below about 3% by weight of the board.

Claim 73

Dependent Claim 18 words

The method of claim 70 wherein the gypsum is present in the amount of at least about 5%.

Claim 74

Dependent Claim 20 words

The method of claim 71 wherein the gypsum and the mineral fibers are simultaneously combined with the foamed binder system.

Claim 75

Dependent Claim 18 words

The method of claim 70 wherein the clay is present in an amount of at least about 10%.

Claim 76

Independent Claim 158 words

A method of manufacturing an acoustical ceiling board from an aqueous furnish composition comprising the following ingredients by weight of solids content: mineral fibers: 25-70% cement binder: 30-75% surfactant: 0.1-1.5% said method comprising the successive steps of: (a) preparing an aqueous admixture by admixing the binder and the foaming agent with water, the water being present in the amount of from about 30% to about 50% by weight of the furnish composition; (b) combining said aqueous admixture under agitation with air to form an aqueous foamed binder system, the amount of srufactant in combination with the degree of agitation being sufficient so that said air is present in the amount of from about 60% to about 75% by volume of the aqueous foamed binder system; (c) combining said mineral fibers with said aqueous foamed binder system to form a foamed furnish composition, said foamed composition being a slurry of said fibrous material in said aqueous foamed binder system.

Claim 77

Independent Claim 158 words

A method of manufacturing an acoustical ceiling board from an aqueous furnish composition comprising the following ingredients by weight of solids content: mineral fibers: 25-70% cement binder: 30-75% surfactant: 0.1-1.5% said method comprising the successive steps of: (a) preparing an aqueous admixture by admixing the binder and the foaming agent with water, the water being present in the amount of from about 30% to about 50% by weight of the furnish composition; (b) combining said aqueous admixture under agitation with air to form an aqueous foamed binder system, the amount of srufactant in combination with the degree of agitation being sufficient so that said air is present in the amount of from about 60% to about 75% by volume of the aqueous foamed binder system; (c) combining said mineral fibers with said aqueous foamed binder system to form a foamed furnish composition, said foamed composition being a slurry of said fibrous material in said aqueous foamed binder system.

Claim 78

Dependent Claim 36 words

The method of claim 74 wherein the ingredients further include a thickening agent in the amount of 0.1-0.5% by weight of solids content and the thickening agent is included in the aqueous admixture of sub-part (a).

Claim 79

Dependent Claim 41 words

The method of claim 75 wherein the thickening agent is present in sufficient amount to bring the viscosity of the aqueous admixture above about 1500 cps on a Brookfield viscometer operated at 25° C. with spindle #4 rotating at 60 rpm.

Claim 80

Dependent Claim 21 words

The method of claim 74 wherein the mineral fibers consist essentially of about 2-6% glass fibers with the remainder being wollastonite.

Claim 81

Dependent Claim 13 words

The method of claim 74 wherein the drying is effected at ambient temperature.

Claim 82

Dependent Claim 12 words

The method of claim 74 wherein the drying includes radio frequency treatment.

Claim 83

Dependent Claim 15 words

The method of claim 79 wherein the radio frequency treatment is between two heating steps.

Claim 84

Dependent Claim 59 words

The method of claim 80 wherein drying is effected by the successive steps of: (a) heating at about 200°-275° F. for about 10-25 minutes; (b) radio frequency treatment for about 1 to 2 minutes at a peak power of about 0.5 to about 1 watt per square centimeter; and (c) heating at about 250°-350° F. for about 1-3 minutes.

Claim 85

Dependent Claim 11 words

A shaped fibrous product made by the method of claim 1.

Claim 86

Dependent Claim 11 words

A shaped fibrous product made by the method of claim 55.

Claim 87

Dependent Claim 11 words

A shaped fibrous product made by the method of claim 56.

Claim 88

Dependent Claim 11 words

A shaped fibrous product made by the method of claim 66.

Claim 89

Dependent Claim 11 words

An acoustical ceiling board made by the method of claim 70.

Claim 90

Dependent Claim 11 words

An acoustical ceiling board made by the method of claim 74.

Claim 91

Dependent Claim 11 words

An acoustical ceiling board made by the method of claim 77.

Claim 92

Dependent Claim 11 words

An acoustical ceiling board made by the method of claim 81.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1989-09-22	1990-03-24	1990-09-23	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1993-09-22	1994-03-24	1994-09-23	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1997-09-22	1998-03-24	1998-09-23	$7700.00	Window Closed / Lapsed

Process for the manufacture of shaped fibrous products and the resultant product

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