Document X74LDB4ZBNY53Y3RvDXMXVaKy

-- TWIJ s* "5 2.326,516 Patented Aof. 10,1943 2,326,5161J UNITED STATES PATENT OFFICE U1U1I COMTRESSED AND SCNSIFIZD PBODGCT AND TBS METHOD Or MAXING TBS SAME George X Brava. MutOU, N. JJebiu-ManvlDe Corporation. Ntv a corporation af Nav Talk Ka Onatet. Application Jam Serial No. Uilli 4 Claim. (CL !*--114) Ibis invention relates to a eompraaed and thus caused a substantially complete reaction denalfled fibrous product and the satbotf of between the lime and tha finely divided silica, matinf tha asm*, and particularly to such a yinally, tha product is dried ot a temperature product la which calcium aliicate binder is above the boiling point ot water to remove free lonnad In contact with tha flbras bound tharaby water. and In the presence of a relatively small propor tion of valor. It is an object of the Invention to provide a Particularly desirable result* have been ob tained when the finely divided silica is dlatemaceous earth. Sueh silica not only esusea a quick strong yet non-brittle sheet or Week contalalat reaction with the Ume during the beating at an alerse proportion Sf fihfel US PMteMn? In IS elevated temperature, but also makes possible seneral the fibrous nature vhlle belas substan the production of o lightweight article suitable tially Impermeable to air. Another object Is to tor use aa a ship panel or a thermal insulating make a flbreboard that Is fireproof, relatively wall board. It further permit* tha ns* of the ifilKfidhilve. sirens but light weight. durable binder in sueh relatively small proportions with wnen exfiftldfl' tfl Ml Action ol weather or to IS respect to the weicht of the fibres a* to preserve soaking in water lor a suostanual period of time, non-brittleness and appreciable flexibility in the ana HU IllllWeff low thermal conductivity. finished article. Other objects and advanUyes will appear from Par the fibrous component I bare used to ad- the more detailed description that follows. VABiAge aaphlbole asbestos fibres which include The invention comprises the herein described SO amasTgnSLSbWmig. eiBUUUmj. auuiuilUl tnZ~ novel features of the product and the method of --UvaailU Sifll. It U desirable that the fibrous making It and. more particularly, a sheet la compdnrntl 'IBM in tha manufacture ot the compressed and hardened condition Including a product of my invention bave a water of crystal large proportion of fibres and a binder therefor, lization or composition not la excess of i% since said binder Including the reaction product of a S3 the thermal conductivity of tbe finished products wet mixture of hydrated lime and finely divided Increases very rapidly If the fibres have a water silica of very low density. The invention com of crystallization In excess of the quantity Indi prises sueh a sheet In which the fibres Include a cated. Products constituted largely of amoalle substantial proportion of aaphlbole asbestos fibres, which have a water, of crystallization of fibres. The Invention comprises also the method :u about 4.7%. have been found to give very de- of making sudfi A product IB WfilSft there "Is au-ablc results la the finished product and are. fOrglWU lqUtBUI tnlxlure of the selected noreT. therefore, preferred. The feature ot low thermal nyaratea time artfi'JfillT BlVIflefsiiica such as conductivity Is a very desirable feature in my ciawmaceoua earth, shaping and strongly coriw finished product and should not exceed I (meas- pressing the mixture against a muring member Zi ured In I. t u.'s. Inches per hour per square to ferfiBVf Uli Biajor portion oi tne water pres- foot per *P.) on a product having a density in 'Iflt ih'd' tnen autoclaving tne tnaoed ana com the order of 40 lbs. per cu. ft when measured pressed material at an elevated temperature to at a mean temperature of 100* P. Amoslie fibre* el'Jit practically coftiPUU HleUon'of" the JlSie have a water of crystallization of leas than 3% with the silica, the stllea being used preferably 40 and when made Into a sheet, according to the In amount In slight excess of the stoichiometric method herein described, the resulting product proportions. has a thermal conductivity of less than 1. It u. In making the articles of the present Inven therefore, recommended that amosite fibres be tion. there is used a method which comprises used either entirely or m large proportions in the forming an aeneous mixture with the selected 40 preparation of the product ol my invention. The fibres. hydrated lime and finely divided silica, amoj;ir fibre cootent may be modified to some shaping and strsr.giy compressing the mixture, degree by replacing small prcportlona of the to expel therefrom a large portion of the wa amotite fibres with chrysatile fibres or with wood ter present and form a denslfied mixture, and scmenlngs. I: is. he*ever, desirable that live then subjecting the shaped and compressed SO amosite fibres should not be replaced with more material to an elevated temperature while min than about 10 to 25 r. ot the modifying material imizing she, evaporation of water. This latter based on the total weight of the finished product. step Is preferably accomplished by placing The Physical characteristics of the finished prod shaped product In an autoclave la the presence uct whieh Include fibrous materials other than of steam at superatmcsphtrle pressure. There la S3 amosite fibres may, however, be leas desirable i:h to* --tm' s? r!.326.M6 Patented Auf. 10. 1943 2^26,516 UNITED STATES PATENT OFFICE tUUII COMPBKSSSD AND DSNSmSO FBODECT and ran xriod or majdno tbi Omw B. Brava. MaavUe. N. 3. itolffior to JikM-lbMlII. Ctnmtlo, New York. N. Y, a wwwiun .1 Ni* Tift No Drewto*. AppUaatien Janaary 10. 1040. Serial No. >1U1> 4 ClatoM. (CL IOC--1101 TtiU Invention relator to eomprmeed tad denuded flbrou* product tad tha method of marine tha uaa. and particularly to eh a product la which caielua tUlcato Under la tbua cauaod a ruhttantlally eemplata reaction between tho lima and tha finely divided tillca. finally, the product la dried at a temperature above the ^`""f potot at water to remove free formed la cantact with tha fibrae bound tbanbr aad la tba pracaace el a relatively ouB proper* Pirtieularty detirebto reeulta have bam ob- tloa of wmtor. rhm tha finely dtvldad tillca to diatoaa- It la aa object of the Javaatlea to proaldo a ifth. Such tiltoa not only eaueaa a quick tttoao rat neo-bflttia cheat or block rtmtolnlai reaettoa with the Umo durtnc tho htattoa at aa a larce proportion of fibre* and prooorvac la 10 olovatod tomparature. but alao mabaa poatihia Ctnaral the flbroua natura while bataa ruhatoa- tha praduettaa of a Ushtwelshi article rultable uauy Impermeable to air. Another object la to tor uao on a titlp panel or a thermal incuiatlns make a fibrtboard that la fireproof, raiatieelr wall board. It further permit* tba tw of tho Inoxpaanv*. atroat but llaht wolfUL durable btodar to cuch relatively snail proportion* with whan expeeed to the actiea of weather or to U romoot to tho weiohl of tho fibre* u to preserve Maklac la water for a aubetantlal parted of thee, nen-brittioneee aad appiactobto ftoxibilitr in tho aad haa relatively low thermal coaductlvttr. ftatohod artist*. Other obiaeta and advanucaa *10 appear from Far the fihrouc component I have used to ad- the more detailed deacrtptioa that follow*. vaataeo omphiboto iiboimo flbrea which ineiudo Tha laventtan coaprtaaa tha hereto Jiicnbid aoMtita. antaophyUlto. croddoUta. actmollte end novel featurea of tha product aad tha method of trealttc fibre*. It to detirebto that the flbroua maklac It and. more particularly, a cheat la cotopeama ueed la tha manufacture of the eompreaaad aad hardmed eoedlttoo toetodbic a product of ay tovmttm have a orator of eryitai- larce proportloa of fibtea aad a binder therefor, Itterkw or eooipntinrm not to eacoee of m.tme* laid binder indudlac tha reaction produat of a tba thensal conductivity of tba finiibed producte wet minute of hydratod lime aad fiaaly dlvtoad toaooMi very rapidly if the florae have a water tuica of very low deamty. Tha lavaauea oom- of ctyetaUtoetlon to taaao of the quantity indi prime tuch a abaat to which the flbrea tochido a cated. Frodueta oonetinited lercely of eaooaua tubeteaUal proportion of amphtbato aabaatm libra. whiah have a watm.ef cmtallltation of flbrea Tha tarnation mminrlma alao tha method about 4.1%, have bam found to sive very do- of maklac mb a pradoct to whiah there la tirehla reeulta to tba flnlilwd preduet aad ere. loraad aa Xtoto mixtao of tha mlaatad flfarea therefore, preferred. The feature of low thermal hydimtad ttao aad fiaaly divided slim conductivity la a very rteelrtble feature to my dlatomaeaeoi earth, maatad aad atram flnlthod product end ihouid not exceed 1 imtet pmmac tba austine acatoet a fiitartac ri ured to B. L u.**. tochw per hour par tquaro to remove the major portion of tho water foot par 'F.) oa a produst bavina a dentity ta aol aad than autaetavtoc the titapad aad com* the order of 40 Ibd. par eu. ft when oiaaeurad Prearad material at aa atovetad tomparature to at a atoan tonmaraturo of 100* P. Amotite fibm eauao practically remplala reaction of the now hove a water of oryemUtootion of tom than 0% with tho tillca. the (thee betod uaod preforably 40 and when mode into o rtioet. aecordtoa to the to amount la tileht ezeea of tha iinlrhlnmatrla method herein diwrtbod. tho twulttoc product proportiona had a thermal conductivity of tern than 1. It u. la marine tha ertidaa of tha praaeat Invert- therefore. rennmmrnOiO that atnotito fibre* be Urn. there to uaad a method which eoaprtoee uted eiihar mtirety or to larce proportion* in the formlnc an aguaoua mtnure with the aeieeted 40 prepiratlm of the produat of my invention. Tho fibre*, hydimtad Uaa aad finely divided rUica. ameetto fibte canmot may be ondllim to ooom thaptoc tad strongly compieatind tha aiiaaire. decree by renleiinc email ptemrttone of the to axpal therefrom a larce portion of the wa ter preamt tad form a denailtod mixture, aad atootito fibrae with ehryeetlto fibre* or with wood ecreentoca n to. however, dootroble that Uie then aubjectinc Uw shaped aad rnmnr--d M leictite fibrae eheuld net be replace* with more matartol to aa olovatod tampareturo while mto- than about to to % of the modUytos material - hpltinc tho avapoiBtiaa of wmtor. Thia laitar baaed m the total wtight of tho fintohod product. to preferably manaipllihad by plactod tho Tho phnlaol ehorastoctotica of tho flatohod prod I product to aa autoclave to tho uct whim Include flbratia, matortoto other than me el Mioeoetmeeobiele weaeeMO* ^ao I# SS amotite fibres mnv however be !* AMlrnble 1,310 than thorn produett containing only amesitt flbrw. nd therefore, U u pnfinM that only amoalta fibres or a substantial proportion turn* o( mould bo used. In any srent. at laaat 30% ot tho fibrous content la tht flaiahod aruela mould bo empnibel# fibre*. In ordor to obtain tho daairad proportion la tho finished boadtd fibrous product I hart usod to advantage a larto proporuoa or fibres at leant equal approximately to tho weight of tho lino and tiUea used. For Instance. I taao urod M partn by watght of amoalta Abra to 100 porta by weight or tho Aalahod bonded article in dried coa- its. Inasmuch u the lime and the mica art originally prosit in apprammato stoichiometric proportions. Uu Umo and the silica win ce sub stantially completely reacted. It is preferable. 1 however, that the silica bo present in slight ex* cm in order that aa the itme will be substantially eompletatr reacted. The occurrence of ihu reaction ta the pmeaee of waior results m the com bination of some of tho water with the fibre* presumably aa water at hydration, and the inti mate aiaoclatlon of tha resulting silicate hydrated with the Abra* make* possible additional hardentng of the Under by drying. dltlea. Alto. I hao uaed Abroua components la Tho reaction described Is effected quite >an- tho proportion sf 39 to SO paru by weight to 100 1 factortty la aa autoclave heated by live steam at porta or the Aalahod dried article. auparatmeiharle premure as. for sxampie. at a The method or manufacture la Uluatrotod la sauce pressure ot lflO to 130* per square inch. creator detail by tho following more specific os* Ia tho autoclaving stop I allow tha steam a enter ample: slowly rrom an inlet so that tho prtssura it not There la 1armed o mixture Including S0% o( .1 built up suddenly to the maximum desired Thus. amoalta flbrea. 3S% hydrated time oad 23% el I have ratted tho prasura on Ui gauge from 0 comminuted dlotomaeooue earth and voter in tho to 130a at tho rate of about no per hour to mini, amount to permit the auspeailoa or tho *Ud la* moo epl'ttlag or swelling of the sheet during the eradicate in a fluid enmpeettlon. The quantity of itwm cuittf operation. water la about 1300% oT tho total weight or tho ; The stooa cured product Is then ruble-tcd m teud incfodlonta ta tht aUhtum. thorough drying. pstfcraMy at a temperature well Tho misrare is then aottotod to form a ilurrr. abov* tho boiling petal or water to cause the re tho alurry la charged to tho bod of a praea hoeing moval of substantially all tree crater inn any a Altering body such aa a flrmly supported vim calcium silicate that our exist in gelauanua at aereea anchored to a drain to that the thirty u., other form Intimately eoeeciated with a brga ex Aova tear tha aereea and forma a layer of aub* tern at water oo distinguished from water of hy itanually uniform Uttekara om aO parts there dration that la mailed only at very hitfc tem of. The amount or slurry uaed la selected to atm peratures. Thus. I have dried the product at r. tho dulrsd Anal thietcaose or tne cempramod temperature of about 334* r. (or about as hours. meet which le approximately J to ut Inches. -- After drytng. the product may be shaped to the Strong compression Is than aspiled aa by brtne- exact sttt desired. One face of the sheets is mg doom tha ram or a hydraulic pna upoa the made Us tha pm Is generally a practically plane mixture oa the Altering bed. Tho pressure ea surface. tho ram may bo varied within limits from about A shoot so mode has been found to we`rh ae- 300 to 1300 lbe. nor square inch altboush t baee ,, praelmauly 40 to the cu. foot, hes a spcciAc found that a pressure ia the order ot 300 lbe. gteie thermal conductivity <measured in a. t. u.-.*. a eery desirable product tram tha standpetal at tnehi per hour per square foot per *F.) at only proper balance hetwuoa etroagth sad tlghtaem about A3, to bo Artproof. Aemble to on sppre- of tho material i risblo ewtll strong <having a modulus of rap Dunne tho streets tompratlca described. a ed tore la tho order of about ltOO iba/sq. m.) and largo proportion ot the water ta tho slurry to Impermooblo to air to such degree that the beard foreod therefrom and tho misuse Is camnraood Is adapted tor um m structural panels, as. for to term a donstflod and thoswughly tonsolldotsd sample, ter walls or buildings, or bulk hoods of mass inrliming a very paallprqpartlen of water la shin. compartsoo with tho amount oelgtaaDy 3resit so It has toe found that produets In which am- Thus the oomprtmod produet erdiaaniy eontame ptdhott Abra art used entirely or in the propor- about 40 to TO parti of water to 100 parts o/eoUd tloog tnrtlcated above, tho products which arr eemprerad aa that tha density or the finished Tha naotlca or the lime and tho itm which will bo dmenbed ta the not step occurs there ta product la within tho limits of 33 to 43 pounds prr cu. ft, tha modulus o( rapture exceeds 1500 fore la the prisms of o small sreportion at pounds per square inch, id the thermal con- water tad a bead at strung raidurn silicate la formed me though the prupcttii at the cal cium sflieato le retoUvtor low in eompartai M the ueoportli of such bead Us articles of some- M ductiylty to leas Uu l when measured at mean laainsiitiiiaa or 14P* F. In using tha term "mean temperature." t rofer to the temperature at r point halt way batwoen the epposiu mils rr what similar quantitative composition made here taam at the psiuet. tofore. It has bai found that vtua tho mate rials are cesgraol under about 300a prente tho dvnalUea of tho flniahod produett vary be tween 33 to 430 per ea. ft. Tho Aalahod produett which weigh ebons 400 per cu. ft. five very de sirable results la that they pesetas low heat concucttvtty and a high modulus at rapture. Tho shaped oad compressed material la re moved from the pras to aar suitable manner sad a TO During tha autetlavlne step deneiihed above. I eonflao Um ahoou ia such a manner aa to cause voiding together at pcetuona where permanent crmcktng would otherwise develop aa steam e.*- eapi tram Um sheet*. In Uib manner the deiijlufisul of cracks and attcudit weakening of Um structoto are minimtacd. that the sheet! beInc steam cured may bo sucked one upon another with Impermeable material as (or example, two nr subleetod to an eimtod temperaturo to cause subtuaually oomplete rooottoa between the Umo and tho silica, tha* Is. to cause om of the reactive throe sheet* o( ubestoe-cement board or melt thiebnoM. eaeh laid over the up at the stack. At the bottom, the stack may rest upon tho steel togredlMUa which it not preeit ia cacw to bo combined practically aad entirely u calcium fill- Tl floor at a conventional handtruck. Obviously, if tho stack la very toll intermediate racing mem-  'Ji. S`ltr 4' COAliNG UR PLAr-nc 120 3,339, did 3 boa but ba used to petal* itna of the fleatine sBtotdclku.m. aueh u uu itna. to the interior of uu ttb* * amotlta fibers, and said article hartnc a dry oenatty below 49 iba. per cubic foot and a thermal eonducunty of lea* Ai another boom of mialmtanc eraeklnc.there than 1 when measured at a mean temperature of may bo used a small proportion of a skdaunis- 100' F. Inc atm admixed into tba composition of tho 2. An article of manufacture eonalatinc of a shwts aad allowed to mi or harden botoro Uw hoot taautounc sheet harm* a tush modulus at shoou art subject to autoelavtat- Tor uu* par* pom thtr* may b* used a email proponton of rupture and esmpnatac amoaita flben and a binder, the binder tnctudia* the product of the hydreuUe cement u. for example. 10 to 30% of in subttanuailr complete reaction under the influ Portland esmsnt or a eaJcium aluaunete cement ence of steam of aa aqueous mixture of hrerateO cased on the weiebt of tha flaished arttei*. Tho lime and finely divided dlatestaceous sartn. md cement la thoroughly muted vtta the outer raw amonte fibre* coosmutm* at least is% of the material*, the eompoauioa thaa formed Into dry wetcht of tho cruel*. and said article hartnc ihaett aa described. with eemm la the abeet al- ia a dry density of leu thaa 4* lb*, par cubic toot lowed to act tubataaUaily fully, or to a ton* and a thermal coaducurity of lea* than l when extant, tbea the abeet autoclaved la tho manner measured at a mean umparatur* of 100' F. described. 3. An article of manufacture eonalatinc of a For tom* purvoaaa, aa oxido of any of the other heat inawlatinc afloat havtnc a hten modulus of alkaUno earth* aay be aubatltotad for tho lime, to rupture and eampnaBc 3* 40 parts by wmcht Whan tueh oxide la *o tUcbtly soluble aa oot to of asbaatoo flben and 40-40 parts of o binder, the react suaeieatly rapidly with tha tlllca then binder indudinc tha product of tho auhatontmiy there may be uaod a promotor to aoealerata tha eoaplato reaction under tho influence of steam raaettoB Thu*, finely dtetdod macnoala aay be of aa aqueoua mixture of hydrated lime and finely tubaUtutad la equl*molecular proportion far the divided diatomacenua varth. said fibrous portion Uae with the addition to tha macnoala of about lnclinline as leeo* M% aaMaua fibre*. and said 1 mol of sodium earOoauto for each 10 aola of artieia havtnc a dry deadly of 3W4* Iba. per eubte Thu appUcntfon la a continuation la part of tool aad a thermal whoa aeaourad at a caadueuvtty of lets mean temperature of thaa 100* r.1 my eopondlac application, Aortal No. OIJN filed so 4. A Itiled Uant-wetcht beat Inaulatlnc ma July lfi, UJd. taauod ao Fauna No. 2.341.m terial wtueb eomprtaae aosodta asbaetos fibers It will bo understood that tho datailo (Iren are and a Madar bondtac tba fibre* law * sheet, the for tha pupae* of Wusirattofl not reetneUon. and Madar meludinc the produet of tho substantially that ranauona wlUUn tha aptrtt of tha larontton an intended to ba inrhidod u tba eeopo of the complete reaction under the influence of steam of aa mucous mixture of substantially scoictuo- appended clausa. metrlo proportions of hydrated Ua* and finely I claim: divided Mica, the amodta flbrae bavins * water L An article of manufacture eonalaMnc of a of cryataluattea of leas than i par cent, end con. neat uuulattnc thaat hartnc a hlch modulua of sUtutlas 3#%-40% of the dry weiyhl of the fin rupture* end cemprtalac eaheetne flben and a 40 ished material, said material havtnc a density binder, tha Madar tha product of a sub la the order of to pound* par eubte foot a modu stantially complete reaction under tho influence of 1team of an acuaona mixture of hydrated Uma and finely dinded nhsa. tho flbrae cooaUtaUac lua of rupture of at lead 1400 lb*, par must* men aad a thermal conductivity of lem thaa 1 when measured at a mean temperature of 100* F. at leaat half of the dry watsht of tha arttaio and a 0*0410* S. BROWN