Process for the manufacture of ceiling tile
First Claim
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1. A process for manufacturing ceiling tiles comprising the steps of:
- preparing a mixture which includes water, starch, boric acid and fire clay,heating said mixture to form a gel,shredding scrap fiber glass prior to its addition to said gel to form shredded fiber glass,adding fibrous material comprising said shredded fiber glass to said gel to form a pulp,wherein said pulp comprises the following components;
space="preserve" listing-type="tabular">______________________________________ COMPONENT PER CENT BY WEIGHT ______________________________________ Water about 80 to about 85 Starch about 2 to about 5 Boric Acid about 0.15 to about 0.35 Fire Clay about 0.7 to about 0.95 Planer Dust about 0 to about 8 Silicone Emulsion about 0 to about 0.1 Scrap Fiber glass about 5 to about 15 ______________________________________ feeding said pulp into trays to form slabs,drying said slabs in an oven to form dried slabs in accordance with a temperature schedule as follows;
a. raise to about 250°
F. in about 1/2 hourb. hold at about 250°
F. for about 2 hoursc. hold at about 275°
F. in about 1/2 hourd. hold at about 375°
F. for about 4 hourse. reduce to about 350°
F. and hold for about 2 hoursf. reduce to about 325°
F. and hold for about 2 hoursg. reduce to about 300°
F. and hold for about 2 hoursh. reduce to about 250°
F. and hold for about 3 hours, andfinishing said dried slabs to form said ceiling tiles.
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Abstract
A process for using shredded scrap or virgin fiber glass in combination with starch, water and other components to make ceiling tiles. The tiles are made by initially preparing a mixture of water, starch, boric acid and fire clay. That initial mixture is then heated to form a gel. Fiber glass is then added to the gel to form a pulp. The pulp is fed into trays to form slabs. The slabs are dried and finished into tiles.
76 Citations
6 Claims
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1. A process for manufacturing ceiling tiles comprising the steps of:
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preparing a mixture which includes water, starch, boric acid and fire clay, heating said mixture to form a gel, shredding scrap fiber glass prior to its addition to said gel to form shredded fiber glass, adding fibrous material comprising said shredded fiber glass to said gel to form a pulp, wherein said pulp comprises the following components;
space="preserve" listing-type="tabular">______________________________________ COMPONENT PER CENT BY WEIGHT ______________________________________ Water about 80 to about 85 Starch about 2 to about 5 Boric Acid about 0.15 to about 0.35 Fire Clay about 0.7 to about 0.95 Planer Dust about 0 to about 8 Silicone Emulsion about 0 to about 0.1 Scrap Fiber glass about 5 to about 15 ______________________________________feeding said pulp into trays to form slabs, drying said slabs in an oven to form dried slabs in accordance with a temperature schedule as follows; a. raise to about 250°
F. in about 1/2 hourb. hold at about 250°
F. for about 2 hoursc. hold at about 275°
F. in about 1/2 hourd. hold at about 375°
F. for about 4 hourse. reduce to about 350°
F. and hold for about 2 hoursf. reduce to about 325°
F. and hold for about 2 hoursg. reduce to about 300°
F. and hold for about 2 hoursh. reduce to about 250°
F. and hold for about 3 hours, andfinishing said dried slabs to form said ceiling tiles. - View Dependent Claims (2, 3, 4, 5, 6)
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Specification
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Current AssigneeKnauf Fiber Glass, GMBH (GEBR Knauf Verwaltungsgesellschaft KG)
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Original AssigneeKnauf Fiber Glass, GMBH (GEBR Knauf Verwaltungsgesellschaft KG)
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InventorsOwen, C. F., Glassley, Mark R., Cunningham, Richard N., Koch, John D.
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Primary Examiner(s)AFTERGUT, KAREN K
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Application NumberUS07/415,588Time in Patent Office1,261 DaysField of Search264/118, 264/119, 264/112, 264/115, 264/120, 264/DIG. 31, 264/145, 264/160, 264/162, 264/163, 264/297.7, 264/297.8, 264/297.9, 264/333, 264/DIG. 69 , 264/DIG. 53, 264/DIG. 32, 264/66, 264/122, 264/319, 162/222, 162/223, 162/225-227, 425/219, 425/220US Class Current264/115CPC Class CodesB28B 1/526 by delivering the materials...B28B 17/02 Conditioning the material p...B28B 5/028 the moulding surfaces being...Y10S 264/31 Processes of making tile an...Y10S 264/53 Processes of using glass fi...
