Lightweight insulating boards and process for manufacturing same

• US 4,840,672 A
• Filed: 03/12/1987
• Issued: 06/20/1989
• Est. Priority Date: 03/14/1986
• Status: Expired due to Fees

• Current Assignee: Redco NV
• Original Assignee: Redco NV
• Inventors: Baes, Emile
• Primary Examiner(s): Bleutge, John C.
• Assistant Examiner(s): NOT, DEFINED
• Application Number:
  US07/025,195
• Time in Patent Office: 831 Days
• Field of Search: 524/4, 524/2, 524/5, 524/295, 106/93, 106/86, 106/99, 523/218
• US Class Current: 106/716
• CPC Class Codes: C04B 14/12 Expanded clay
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 18/16 from building or ceramic industry
• 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 20/10 Coating or impregnating roofing granules E04D7/005
• CPC Class Codes: C04B 28/10 Lime cements or magnesium oxide cements
• CPC Class Codes: C04B 38/08 by adding porous substances
• 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 7/02 Portland cement
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Lightweight insulating boards in accordance with the present invention comprise Portland cement, fibers and fillers including:

(a) 50-75% by weight of cement,

(b) 0-5% by weight of cellulose fibers,

(c) 0.5-4% by weight of alkali-resistant fiber material,

(d) 5-20% by weight of mica,

(e) 5-20% by weight of light filler and

(f) 8-25% by weight of hydrated lime.

They are shaped into boards from a suspension and are set at least 15 days, and preferably 28 days. The insulating boards of the present invention meet all of the requirements set for such materials regarding flexural strength, incombustibility, and the like.

Claims

1. Lightweight insulating board comprising:

(a) 50-70% by weight of cement,

(b) 0-5% by weight of cellulose fibers,

(c) 0.5-4% by weight of non-cellulose, alkali-resistant fiber material,

(d) 5-20% by weight of mica,

(e) 5-20% by weight of light filler and

(f) 8-25% by weight of hydrated lime.

2. Insulating board according to claim 1 comprising:

(a) 55-65% by weight of cement,

(b) 2-4% by weight of cellulose fibers,

(c) 0.8-1.5% by weight of non-cellulose, alkali-resistant fiber material,

(d) 10-15% by weight of mica,

(e) 8-18% by weight of light filler, and

(f) 10-18% by weight of hydrated lime.

3. Insulating board according to claim 1 wherein said non-cellulose, alkali-resistant fiber material comprises 0.8 to 2.0% by weight of polyvinylalcohol (PVA), polyacrylonitrile (PAN) or polyamides, or from 1 to 4% by weight of glass fibers coated so as to be alkali-resistant or mixtures thereof, based on the total weight of the insulating board.

4. Insulating board according to claim 2 wherein said alkali-resistant fiber material comprises 0.8 to 2.0% by weight of polyvinylalcohol (PVA), polyacrylonitrile (PAN) or polyamides, or from 1 to 4% by weight of glass fibers coated so as to be alkali-resistant, or mixtures thereof, based on the total weight of the insulating board.

5. Insulating board according to claim 1 wherein said light fillers comprise expanded perlites, puffed clay, synthetic spherical xonotlite aggregates or ground foam concrete, or mixtures thereof.

6. Insulating board according to claim 2 wherein said light fillers comprise expanded erlites, puffed clay, synthetic spherical xonotlite aggregates or ground foam concrete, or mixtures thereof.

7. Insulating board according to claim 3 wherein in said light fillers comprise expanded perlites, puffed clay, synthetic spherical xonotlite aggregates or ground foam concrete, or mixtures thereof.

8. A process for producing a lightweight insulating board comprising:

compounding in an excess of water;

50-75% by weight of cement, 0-5% by weight of cellulose fibers, 0.5-4% by weight non-cellulose, alkali-resistant fiber material, 5-20% by weight of mica, 5-20% by weight of light filler and 8-25% by weight of hydrated lime to produce a suspension;

separating superfluous water from the suspension while shaping into a board; and

setting the board in a humid atmosphere for at least 15 days.

9. The process according to claim 8, wherein said non-cellulose, alkali-resistant fiber material is from 0 8 to 2.0% by weight of polyvinylalcohol (PVA), polyacrylonitrile (PAN) or polyamides, or from 1 to 4% by weight of glass fibers coated such as to be alkali-resistant, or mixtures thereof, based on the total weight of the insulating board.

10. The process according to claim 8, wherein said light fillers comprise expanded perlites, puffed clay, synthetic spherical xonotlite aggregates or ground foam concrete, or mixtures thereof.

11. The process according to claim 9, wherein said light fillers comprise expanded perlites, puffed clay, synthetic spherical xonotlite aggregates or ground foam concrete, or mixtures thereof.