Perlite boards and method for making same

• US 4,313,997 A
• Filed: 07/14/1980
• Issued: 02/02/1982
• Est. Priority Date: 07/14/1980
• Status: Expired due to Term

• Current Assignee: Grefco, Inc. (American Greetings Corporation)
• Original Assignee: Grefco, Inc. (American Greetings Corporation)
• Inventors: Nath, Narikottile G., Ruff, David L.
• Primary Examiner(s): Van Balen, William J.
• Application Number:
  US06/168,483
• Time in Patent Office: 568 Days
• Field of Search: 428/403, 428/407, 428/489, 428/404, 428/220, 428/405, 106/84, 106/DIG. 2, 264/123, 156/62.2, 427/220, 427/221
• US Class Current: 428/220
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 24/36 Bituminous materials, e.g. tar, pitch C04B24/243 takes precedence
• CPC Class Codes: C04B 24/42 Organo-silicon compounds
• CPC Class Codes: C04B 26/06 Acrylates
• CPC Class Codes: C04B 40/00 Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02
• CPC Class Codes: Y10S 106/02 Perlite
• CPC Class Codes: Y10T 428/2991 Coated
• CPC Class Codes: Y10T 428/2993 Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]
• CPC Class Codes: Y10T 428/2995 Silane, siloxane or silicone coating
• CPC Class Codes: Y10T 428/2998 including synthetic resin or polymer

Abstract

Perlite board made from expanded perlite and a binder having the property of permanent tackiness in the dry state. The board may be made by expanding the perlite, adding a tacky resin emulsion to the perlite, drying the mixture and forming it into a board-like product.

Claims

1. A perlite board having a thickness greater than about 1 inch said perlite board comprising particles of expanded perlite and a binder having the property of permanent tackiness in the dry state.

2. The board of claim 1 wherein said perlite comprises from about 65% to about 95% by weight of the final composition and said binder, expressed as a solid, comprises from about 5% to about 35% by weight of the final composition.

3. The board of claim 1 further including a reinforcing fiber material.

4. The board of claim 3 further including a waterproofing material.

5. The board of claim 1 wherein he binder is organic.

6. The board of claim 5 wherein the binder is a polyacrylic resin compound.

7. The board of claim 1 wherein the binder is inorganic.

12. The perlite board of claim 1 wherein said board is flexible and resilient.

8. A perlite board consisting essentially of 65 to 95% by weight expanded perlite, 5 to 35% by weight organic binder, said binder having the property of permanent tackiness in the dry state, reinforcing fibers in an amount up to about 15% by weight, asphalt in an amount up to 10% by weight, silicone in an amount up to 2% by weight, said board having a density in the range of from about 7 to 15 pounds per cubic foot.

13. The perlite board of claim 8 wherein said board is flexible and resilient.

9. A process for making expanded perlite board of a thickness greater than about 1 inch comprising the steps of:

expanding said perlite;

adding a tacky resin emulsion having the property of permanent tackiness in the dry state to said perlite to form a mixture;

drying said mixture; and

fabricating said dried mixture into boards.

10. A process according to claim 9 including the step of mixing fiber with said expanded perlite.

11. A process according to claim 9 including the steps of mixing a dilute asphalt emulsion with the expanded perlite;

and drying the resulting mixture of the asphalt emulsion and the perlite prior to the step of adding said tacky resin emulsion.

14. The process of claim 9 wherein said boards are flexible and resilient.