WO1993019123A1 - Panneau composite dote d'un liant en latex a particules de grande taille - Google Patents

Panneau composite dote d'un liant en latex a particules de grande taille Download PDF

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Publication number
WO1993019123A1
WO1993019123A1 PCT/US1992/003278 US9203278W WO9319123A1 WO 1993019123 A1 WO1993019123 A1 WO 1993019123A1 US 9203278 W US9203278 W US 9203278W WO 9319123 A1 WO9319123 A1 WO 9319123A1
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Prior art keywords
composite board
percent
fiber
binder
latex
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1992/003278
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English (en)
Inventor
William H. Keskey
John D. Camisa
Kenneth R. Meath
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Dow Chemical Co
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Dow Chemical Co
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Filing date
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Application filed by Dow Chemical Co filed Critical Dow Chemical Co
Publication of WO1993019123A1 publication Critical patent/WO1993019123A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63—Inorganic compounds
    • D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
    • D21H17/68—Water-insoluble compounds, e.g. fillers, pigments siliceous, e.g. clays
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/38—Inorganic fibres or flakes siliceous
    • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/21—Macromolecular organic compounds of natural origin; Derivatives thereof
    • D21H17/24—Polysaccharides
    • D21H17/28—Starch
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/35—Polyalkenes, e.g. polystyrene
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/36—Polyalkenyalcohols; Polyalkenylethers; Polyalkenylesters
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/37—Polymers of unsaturated acids or derivatives thereof, e.g. polyacrylates
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/41—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing ionic groups
    • D21H17/42—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing ionic groups anionic
    • D21H17/43—Carboxyl groups or derivatives thereof
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63—Inorganic compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0045—Polymers chosen for their physico-chemical characteristics
    • C04B2103/0065—Polymers characterised by their glass transition temperature (Tg)
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • This invention relates to composite boards comprising inorganic and organic materials in which the binder system comprises latex.
  • Starch is well known in the art as a binder for composite boards such as ceiling tile.
  • the boards lose dimensional stability.
  • Ceiling tile made with starch acting as the binder sags as a result of the loss of dimensional stability when subjected to adverse environmental conditions.
  • the present invention relates to a composite board which, based on the dry weight of the board, comprises: from 10 to 95 percent inorganic fiber; from 1 to 25 percent latex binder which contains latex copolymer particles having particle size greater than 1800 Angstroms and a T greater than 82°C; and, optionally, up to about 35 percent organic fibers; and, optionally, up to about 60 percent inorganic filler; and, optionally, up to about 25 percent of a second binder.
  • the composite board has a modulus of rupture greater than 75 psi as measured by ASTM 367-78 and whereby upon exposing a 1 1/2 x 6 inch strip of the composite board to 90 percent relative humidity at 94°F for 96 hours the composite board sags less than 2 mm.
  • dimensional stability is a lack of movement of the composite board when exposed to increased temperature and humidity. Dimensional stability can be measured by evaluating sag resistance of the composite board. Sag resistance is determined by exposing a 1
  • the resulting composite board of the composition has the integrity necessary to withstand handling, processing and other forces that are applied to the composite board.
  • the necessary strength can then be determined by preparing a board by the procedure and of the composition as described in Example 1.
  • the resulting cellulosic composite board has a' modulus of rupture
  • the calculated MOR of the resulting composite board will be at least about 310 psi.
  • the most preferred MOR will be at least about320 psi.
  • MOR is calculated from the standard 3 point breaking loading test described in ASTM 367-78 as follows:
  • d thickness of the sample.
  • the glass transition temperature of the copoly er of latex of the present invention is defined functionally such that the T is sufficient when the resulting composite board maintains dimensional stability when exposed to specific environmental conditions and the resulting composite board has a modulus of rupture of at least about 75 psi as measured by ASTM 367-78.
  • the properties of the board are directly correlated to the particle size of the latex and the T of the latex used as the binder in the ceiling board.
  • the preferred T of the latex polymer having a particle size of greater than about 1400 Angstroms preferably greater than 1800 Angstroms, is at least about 82°C. The more preferred range is between 82°C and 120°C. The most preferred range is between 85°C and 120°C.
  • the physical properties of the latex are correlated to the ceiling board properties on a sliding scale, the relationship can be exemplified as follows: if the T of the latex polymer is above 80°C, preferably around 95°C for a conventionally sized latex copolymer, that is a latex having a particle size of less than about 1400 Angstroms preferably less than 1800 Angstroms, then the board resists sag and retains adequate strength when compared to starch and some other latexes. If the same sized latex is prepared to have a T less than about 80°C, then the board decreases in sag resistance. However, if the particle size of the latex is greater than about 1400 Angstroms preferably greater than about 1800 Angstroms and the T g of the polymer is greater than about 80°C, the board strength can be increased without sacrificing sag resistance.
  • the particle sizes of the present invention are greater than about 1400 Angstroms.
  • the more preferred particle sizes of the * present latexes are between 1800 and 3200 Angstroms.
  • the most preferred particle size is within the range of from 1800 to 2500 Angstroms.
  • the latex particle sizes for boards which do not contain cellulosic materials have optimum particle sizes of from 1800 Angstroms to 2200 Angstroms.
  • the latex particle sizes for boards which do contain cellulosic materials have optimum particle sizes of from about 1400, preferably 1800 Angstroms to 2200 Angstroms.
  • the latex copolymer composition of this invention can be prepared by a conventional emulsion polymerization process in aqueous medium with conventional additives.
  • the aqueous phase will contain from 0.5 to 5 weight percent (based on the monomer charge) of conventional nonionic or anionic emulsifiers, for example, potassium, N-dodecyl sulfonate, sodium isooctobenzene sulfonate, sodium laureate and nonyl phenol ethers of polyethylene glycols.
  • emulsion polymerization catalysts can be employed in the foregoing latex polymerization and common examples thereof include peroxides, persulfates and azo compounds such as sodium persulfate, potassium persulfate, ammonium persulfate, hydrogen peroxide, azodiisobutyric diamide as well as catalysts such as redox catalysts which are activated in the water phase for example, by a water-soluble reducing agent.
  • the type and amount of catalyst, as well as the particular polymerization conditions employed, will typically depend on the other monomers which are used and polymerization conditions will be generally selected to favor the polymerization of such other monomers.
  • Such catalysts are employed in a catalytic amount ranging from 0.01 to 5 weight percent based upon the monomer "weight.
  • the polymerization is conducted at a temperature in the range of from -10° to 110°C, preferably from 50° to 90°C.
  • chain transfer agents such as, for example, n-dodecyl mercaptan, bromoform and carbon tetrachloride can also be employed in the normal fashion in polymerization to regulate the molecular weight of the polymer formed therein, and when such chain transfer agents are used, they are employed in amounts ranging from 0.01 to 10, preferably from 0.1 to 5, weight percent based upon the weight of the monomers employed in the polymerization.
  • the amount of chain transfer agent employed depends somewhat on the particular transfer agent employed and the particular monomers being polymerized.
  • crosslinking agents which can be a di- or tri- or tetra-vinyl compound, can also be employed in the normal fashion in polymerization to regulate the T and the molecular weight of the polymer formed therein.
  • a crosslinking agent are a divinylbenzene, allyl methacrylate . or a mono-, di-, tri- or tetra- ethylene glycol diacrylate or dimethacrylate.
  • crosslinking agents are employed in amounts ranging from 0.01 to 4.0, preferably from 0.1 to 1.0, weight percent based upon the weight of the monomers employed in the polymerization. The amount of crosslinking agent employed depends on the monomers being polymerized.
  • the latex composition with a sufficient T can be prepared with a combination of hard monomer and soft monomer.
  • An ⁇ , ⁇ -ethylenically unsaturated carboxylic acid may also be incorporated.
  • hard monomer is meant to include a monomer which homopolymer has a T of at least about 80°C and by the term “soft monomer” is meant a monomer which homopolymer has a T less than about 35°C.
  • Typical hard monomers are those conventionally known in the art, for example styrene and methyl methacrylate.
  • Soft monomers are also conventionally known in the art and can be, for example, butadiene, ethyl acrylate or butyl acrylate.
  • the ⁇ , ⁇ -ethylenically unsaturated carboxylic acids include compositions of the formula:
  • R is H and R 1 is H, C ⁇ -C 4 alkyl, or -CH 2 COOX;
  • R is -COOX and R' is H or -CH 2 COOX; or,
  • R is CH 3 and R' is H
  • X is H or C 1 -C 4 alkyl.
  • Suitable ⁇ , ⁇ -ethylenically unsaturated aliphatic carboxylic acids are monoethylenically unsaturated monocarboxylic, dicarboxylic and tricarboxylic- acids
  • carboxyl groups may be present in the acid or salt -,,- form, -COOM in which M represents hydrogen or a metal, such as for example, sodium or potassium, and are readily interconvertible by well known simple procedures.
  • ⁇ , ⁇ -ethylenically unsaturated aliphatic carboxylic acids are acrylic acid, methacrylic acid, fumaric acid, itaconic acid, maleic acid and aconitic acid.
  • the latex composition will typically include a hard monomer content from 50 to 99 weight percent and the soft monomer content will be in an amount from 1 to 50 weight percent.
  • the carboxylic acid level may be from 0 to 20 weight percent.
  • the hard monomer content from 50 to 99 weight percent and the soft monomer content will be in an amount from 1 to 50 weight percent.
  • the carboxylic acid level may be from 0 to 20 weight percent.
  • the hard monomer content from 50 to 99 weight percent and the soft monomer content will be in an amount from 1 to 50 weight percent.
  • the carboxylic acid level may be from 0 to 20 weight percent.
  • the hard monomer content from 50 to 99 weight percent and the soft monomer content will be in an amount from 1 to 50 weight percent.
  • the carboxylic acid level may be from 0 to 20 weight percent.
  • the hard monomer content from 50 to 99 weight percent and the soft monomer content will be in an amount from 1 to 50 weight percent.
  • the carboxylic acid level may be from 0 to 20 weight percent.
  • a particular copolymer family suitable for the latex of the present invention is a copolymer comprising a monovinylidene monomer and an aliphatic conjugated diene. Normally, an ⁇ , ⁇ -ethylenically unsaturated carboxylic acid termonomer is incorporated into the polymer.
  • R is hydrogen or a lower alkyl such as an alkyl having from 1 to 4 carbon atoms which is attached directly to an aromatic nucleus containing from 6 to 10 carbon atoms, including those wherein the aromatic nucleus is substituted with alkyl or halogen substituents.
  • Typical of these monomers are styrene, ⁇ - methylstyrene, ortho-, meta- and para- ethylstyrene; ortho-, meta- and paraethylstyrene; o,p-dimethylstyrene; o,p-diethylstyrene; isopropylstyrene; o-methyl-p-isopropylstyrene; p-chlorostyrene; p-bromo-styrene; o,p-dichlorostyrene; o,p-dibromostyrene; vinylnaphthalene; diverse vinyl (alkylnaphthalenes) and vinyl (halonaphthalenes) and comonomeric mixtures thereof.
  • Acyclic aliphatic conjugated dienes usefully employed herein include typically those compounds which have from 4 to 9 carbon atoms, for example, 1,3- butadiene, 2-methyl-l,3-butadiene; 2,3-dimethyl- -1,3-butadiene; pentadiene; 2-neopentyl-l,3-butadiene and other hydrocarbon analogs of 2,3-butadienes, such as 2-chloro-l,3-butadiene; 2-cyano-l,3-butadiene, the substituted straight chain conjugated pentadienes, the straight chain and branched chain conjugated hexadienes, other straight and branched chain conjugated dienes having from 4 to 9 carbon atoms, and comonomeric mixtures thereof.
  • 1,3-butadiene hydrocarbon monomers such as those mentioned hereinbefore provide interpolymers having particularly desirable properties and are therefore preferred.
  • the cost, ready availability and the excellent properties of interpolymers produced therefrom makes 1,3-butadiene the most preferred acyclic aliphatic conjugated d jewe.
  • Another family of suitable copolymers is a copolymer of a monovinylidene compound as defined above, and an ester of an ⁇ , ⁇ -ethylenically unsaturated carboxylic acid, as defined below, with a T of less than about 25°C.
  • An ⁇ , ⁇ -ethylenically unsaturated carboxylic acid termonomer can also be incorporated into the polymer.
  • Esters of ⁇ , ⁇ -ethylenically unsaturated carboxylic acid useful herein as soft monomers include typically soft acrylates, for example, those with homopolymers having a of less than about 25°C, such as benzyl acrylate, butyl acrylate, sec-butyl acrylate, cyclohexyl acrylate, dodecyl acrylate, hydroxyethyl acrylate, hydroxypropyl acrylate, ethyl acrylate, 2- ethylbutyl acrylate, 2-ethylhexyl acrylate, heptyl acrylate, hexylacrylate, isobutyl acrylate, isopropyl acrylate, methyl acrylate, propyl acrylate, etc. and soft methacrylates such as butyl methacrylate, and hexyl methacrylate.
  • soft acrylates such as butyl methacrylate, and hexyl
  • Still a third family of copolymers useful in the latex of the present invention comprises a copolymer of two or more esters of ethylenically unsaturated carboxylic acids, one of which has a homopolymer with a T less than about 25°C and the other of which has a homopolymer with a T of greater than about 80°C, as defined above, such as methyl methacrylate and ethyl acrylate.
  • the copolymer can also include a termonomer of an ⁇ , ⁇ -ethylenically unsaturated carboxylic acid.
  • Esters of ⁇ , ⁇ -ethylenically unsaturated carboxylic acids having a homopolymer which T is greater than about 80°C typically include hard methacrylates such as tert-butyl methacrylate, isopropyl methacrylate and methyl methacrylate.
  • hard methacrylates such as tert-butyl methacrylate, isopropyl methacrylate and methyl methacrylate.
  • the cost, availability and known properties of methyl methacrylate make it preferred among the methacrylates.
  • Additional monomers can be added to any of the families of copolymers described above.
  • Additional monomers which can also be added to any of the families of copolymers are termonomers having homopolymers with an intermediate T of greater than about 25°C but less than 80°C such as: 4-biphenyl acrylate, tert-butyl acrylate, vinyl acetate, sec-butyl methacrylate, cyclohexyl methacrylate, ethyl methacrylate, isobutyl methacrylate, propyl methacrylate, isobutyl methacrylate, n-propyl methacrylate and tert-butyl amino ethyl methacrylate.
  • the particle size of the latex copolymer can be controlled by the use of an appropriate amount of seed particles according to the following formula:
  • the composite board of the instant invention can be prepared by any conventional process. Examples are water-felted formed on a Fourdrinier, water-borne (slurried in, water) or cast molded.
  • the inorganic and cellulosic materials of the composite are conventionally known fillers and fibers.
  • mineral wool inorganic fiber
  • perlite perlite
  • clay inorganic fillers
  • cellulose cellulosic _-. material
  • typical amounts of the binder are from 1 to 25 percent by weight;
  • the binder system is not limited exclusively to synthetic latex, but may include other binder components, such as artificial latexes, thermosetting resins and starch. For some applications, mixtures of various synthetic latexes, artificial latexes and starch are desirable.
  • Ceiling tile is usually prepared by dispersing cellulosic material and mixing the dispersion with binder material, inorganic fiber and filler material. Flocculant is added and the resultant furnish is poured into a mold, diluted and drained. Alternatively, the flocculant may be mixed with the other components prior to the addition of the binder. Generally, the order of addition does not matter. The resultant wet mat is then pressed and dried.
  • the latex was then incorporated as the binder into composite boards in the following manner:
  • Printed newsprint was dispersed in water at 2.0 percent solids.
  • a Cowles blade was used with an air stirrer at high rpm to redisperse the cellulose to a Canadian Standard Freeness of 250 to 300 mis.
  • Water (4,400 g); perlite (72.1 g); mineral wool (30.1 g); and the dispersed newsprint (34.9 g) are mixed for three minutes with moderate agitation using a Cowles blade.
  • Latex (12.8 g of polymer) was added and the slurry was mixed for 30 seconds.
  • Flocculant cationic polyacrylamide
  • Flocculation was carried out with less than moderate agitation.
  • the flocculated furnish was poured into a Noble and Wood Sheet mold apparatus and was diluted to approximately 1.0 percent solids.
  • the furnish was dispersed and drained on a retaining wire.
  • the wet mat was pressed to a thickness of 630 mils and dried at 375°°F to 400°F in a forced air oven.
  • the resulting board was approximately 7.5 x 7.5 inches, had a thickness of about 0.7 inches and a density of about 12 lbs/ft 3 .
  • the table above illustrates the high MOR which starch imparts as a binder to ceiling tile but the starch imparts little or no sag resistance.
  • the ceiling tile made with the latex binder having a particle size less than about 1800 Angstroms shows good sag resistance but a relatively low MOR compared to the larger particle sized latexes.
  • the latex binders of the instant invention have both excellent strength (high MOR) and retain sag resistance, with a MOR of at least 300 psi and a sag of 1 mm or less.
  • a styrene/ethyl acrylate/acrylic acid latex having the same monomeric ratios but particle sizes of 900 and 2100 Angstroms and a T g of about 95°C was prepared by conventional polymerization methods.
  • the 900 Angstrom latex was a comparative Example to demonstrate the advantages of the larger particle size latex.
  • the latex was then incorporated as the binder into ceiling tiles in the following manner:
  • the wet mat was pressed to a thickness of 630 mils and dried at 375° to 400°F in a forced air oven.
  • the resulting board was approximately 7.5 x 7.5 inches, had a thickness of about 0.6 inches and a density of approximately 15 lbs/ft 3 .
  • Formulation 1 is for a composite board made with the latex of Example 3, and the data shows the increase in MOR with increasing particle size of the latex copolymer particle.
  • Formulation 2 is for a composite board with a high content of cellulosic fibers.
  • the daca shows an increase in MOR with increasing particle size of the latex copolymer particles.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
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Abstract

L'invention porte sur un panneau composite comprenant des fibres inorganiques, un liant composé de latex, éventuellement une charge inorganique, éventuellement des fibres organiques et éventuellement un deuxième liant. On obtient un module de rupture et une résistance au fléchissement améliorés en utilisant des latex dotés de particules copolymères d'une taille supérieure à 1800 Angströms et d'une température de transition du verre Tg supérieure à 82 °C environ.
PCT/US1992/003278 1992-03-18 1992-04-21 Panneau composite dote d'un liant en latex a particules de grande taille Ceased WO1993019123A1 (fr)

Applications Claiming Priority (2)

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US85346392A 1992-03-18 1992-03-18
US853,463 1992-03-18

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4225383A (en) * 1978-02-02 1980-09-30 The Dow Chemical Company Highly filled sheets and method of preparation thereof
US4711685A (en) * 1982-07-06 1987-12-08 Usg Acoustical Products Company Soft textured reveal edge ceiling board and process for its manufacture
US4863979A (en) * 1986-11-07 1989-09-05 The Dow Chemical Company Latex compositions useful as binders in composite board having dimensional stability and strength
US4963603A (en) * 1989-05-24 1990-10-16 Armstrong World Industries, Inc. Composite fiberboard and process of manufacture

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4225383A (en) * 1978-02-02 1980-09-30 The Dow Chemical Company Highly filled sheets and method of preparation thereof
US4711685A (en) * 1982-07-06 1987-12-08 Usg Acoustical Products Company Soft textured reveal edge ceiling board and process for its manufacture
US4863979A (en) * 1986-11-07 1989-09-05 The Dow Chemical Company Latex compositions useful as binders in composite board having dimensional stability and strength
US4863979B1 (fr) * 1986-11-07 1991-12-24 Dow Chemical Co
US4963603A (en) * 1989-05-24 1990-10-16 Armstrong World Industries, Inc. Composite fiberboard and process of manufacture

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