Moulded product

• US 4,497,662 A
• Filed: 02/22/1983
• Issued: 02/05/1985
• Est. Priority Date: 02/22/1983
• Status: Expired due to Fees

• Current Assignee: Birdwood Fleet Douglas Ross
• Original Assignee: Douglas Ross Fleet
• Inventors: Newton, Colin, Winchester, Stanley W., Chisholm, Donald M.
• Primary Examiner(s): Woo, Jay H.
• Assistant Examiner(s): McGurk, Mike
• Application Number:
  US06/468,075
• Time in Patent Office: 714 Days
• Field of Search: 264/86, 264/299, 264/69, 264/125, 264/126, 264/122, 264/128, 264/DIG. 7, 264/DIG. 59, 264/336, 264/109, 264/119, 264/319, 264/330, 264/333, 425/404, 425/84, 425/412, 106/92, 106/93, 106/99, 428/283, 428/326
• US Class Current: 106/649
• CPC Class Codes: B28B 1/00 Producing shaped prefabricated articles from the material using presses B28B3/00; shaping on moving conveyors B28B5/00; producing tubular articles B28B21/00 ; producing articles with embedded elements B28B23/00
• CPC Class Codes: B28B 1/52 specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cementby wrapping on to mandrels B28B1/42
• CPC Class Codes: B28B 1/525 containing organic fibres, e.g. wood fibres B28B1/526, B28B1/527 take precedence
• CPC Class Codes: B28B 7/36 Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded articlelubricating surfaces of moulds, cores or mandrels B28B7/38
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 22/062 of the alkali or alkaline-earth metals
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/04 Portland cements
• 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: C04B 40/02 Selection of the hardening environment
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A process of moulding a product (and a product thus formed) wherein particulate ligno-cellulose such as shredded paper, flour, Portland cement, a small amount of caustic soda, and water are mixed together, placed in a mould, and subjected to both pressure and heat until set, and the moulded product is then removed from the mould.

Claims

1. A process for moulding an article, comprising:

(a) forming a mixture of between 32 and 48 parts by weight of shredded paper, between 24 and 36 parts by weight of plain wheaten flour, between 0.7 and 1.3 parts by weight of caustic soda, between 32 and 48 parts by weight of Portland cement, and a quantity of water equal to between 30% and 70% of the total weight of the other said components,

(b) placing a lining of sheet material into a female mould, and pouring said mixture into said female mould,

(c) placing perforate sheet material over the surface of a vented male mould, and urging the male mould into the female mould and imparting a pressure to said mixture,

(d) heating said female mould to a temperature of between 66°

C. and 150°

C. until set, and

(e) removing said article from the mould.

2. A process according to claim 1 comprising curing said article by heating after removal from the mold.

3. A process according to claim 2 wherein said curing temperature lies between 32°

C. and 50°

C.

4. An article made by the process of claim 1.

5. A process for moulding an article in a mould comprising:

(a) forming a mixture of between 32 and 48 parts by weight of particulate ligno-cellulose, between 24 and 36 parts by weight of flour, between 0.7 and 1.3 parts by weight of caustic soda, between 32 and 48 parts by weight of Portland cement, and a quantity of water equal to between 30% and 70% of the total weight of the other said components,

(b) placing said mixture in a mould, subjecting it to sufficient pressure for water to escape from said mixture, and heating the mixture to a temperature of between 150°

F. and 300°

F. (66°

C. and 150°

C.) until set, and

(c) removing the set article from the mould.

6. A process according to claim 5 comprising curing said article by heating after said removal from the mould.

7. A process according to claim 6 wherein said curing temperature lies between 32°

C. and 50°

C.

8. An article made by the process of claim 5.