Building board

• US 4,132,555 A
• Filed: 11/04/1976
• Issued: 01/02/1979
• Est. Priority Date: 01/02/1975
• Status: Expired due to Term

• Current Assignee: Cape Boards & Panels Limited (Altrad Investment Authority SAS)
• Original Assignee: Cape Boards & Panels Limited (Altrad Investment Authority SAS)
• Inventors: Barrable, Victor E.
• Primary Examiner(s): Poer, James
• Application Number:
  US05/738,688
• Time in Patent Office: 789 Days
• Field of Search: 106/99, 106/119, 106/120, 106/90, 106/93, 106/104
• US Class Current: 106/795
• CPC Class Codes: C04B 14/202 Vermiculite
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2111/12 Absence of mineral fibres, e.g. asbestos
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/188 the Ca-silicates being present in the starting mixture
• CPC Class Codes: C04B 40/0064 Processes of the Magnini or Hatscheck type
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A composition suitable for the manufacture of shaped articles comprising (i) a water-settable inorganic binder which is one or more of a calcium silicate binder, Portland cement, aluminous cement, and blast furnace slag cement, and (ii) fibrous reinforcing material, wherein the fibrous reinforcing material is free from asbestoc fibres and includes organic fibres which do not melt below 140° C.

Claims

1. An asbestos-free building board or like product which can be used to provide a fire-resisting structure, made from a composition which comprises water-settable binder, reinforcing fibers including organic fibers and exclusive of asbestos fibers, and vermiculite in amount sufficient to confer fire-resistant properties to the product, said vermiculite being present in amount of about 12% to 50% by weight of the product.

2. A building product as defined in claim 1 wherein said vermiculite is present in amount of 12% by weight of the product.

3. A building product as defined in claim 1 wherein said vermiculite is present in amount of 13% by weight of the product.

4. A building product as defined in claim 1 wherein said vermiculite is present in amount of 50% by weight of the product.

5. A building product as defined in claim 1 wherein said binder is calcium silicate hydrate.

6. A building product as defined in claim 5 wherein said organic fibers are cellulosic fibers.

7. A building product as defined in claim 4 wherein said organic fibers are cellulosic fibers.

8. A bulding product as defined in claim 1 wherein said binder is calcium silicate hydrate having the crystal structure of tobermorite or xonotlite.

9. An asbestos-free building board or like product which can be used to provide a fire-resisting structure, made from a composition which comprises a water-settable binder, reinforcing fibers including at least 5% by weight thereof as organic fibers and exclusive of asbestos fibers, and vermiculite, said binder being present in an amount of 80-89% by weight of binder plus reinforcing fiber, and said vermiculite being present in amount of about 12% to 50% by weight of the product.

10. A building product as defined in claim 9 wherein said binder is calcium silicate hydrate.

11. A building product as defined in claim 10 wherein said organic fibers are cellulosic fibers.

12. The method of making an asbestos-free building board which can be used to provide fire-resisting structures, which comprises the steps of:

(a) forming an aqueous slurry comprising a water-settable binder, reinforcing fibers including at least 5% by weight cellulosic fibers and exclusive of asbestos fibers, vermiculite and water, said binder being present in an amount of 50-99%, by weight, based on the total of binder and reinforcing fiber, and said vermiculite being present in amount of about 12% to 50% by weight of total solids;

(b) dewatering said slurry to form a sheet; and

then

(c) curing said sheet to form the building board.

13. The method according to claim 12 wherein said binder is present in amount of 80-89% by weight based on binder and reinforcing fiber.

14. The method according to claim 13 wherein step (a) comprises first forming the slurry with a water:

solids ratio of 5;

1 to 10;

1 and then diluting the slurry to a water;

solids ratio of about 25;

1, and wherein step (b) is performed on a Magnani machine, a Hatschek machine or a press.

15. The method according to claim 12 wherein step (a) comprises first forming the slurry with a water:

solids ratio of 5;

1 to 10;

1 and then diluting the slurry to a water;

solids ratio of about 25;

1, and wherein step (b) is performed on a Magnani machine, a Hatschek machine or a press.