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US20180066401A1 - Construction board - Google Patents

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Publication number
US20180066401A1
US20180066401A1 US15/557,751 US201615557751A US2018066401A1 US 20180066401 A1 US20180066401 A1 US 20180066401A1 US 201615557751 A US201615557751 A US 201615557751A US 2018066401 A1 US2018066401 A1 US 2018066401A1
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Prior art keywords
fiberboard
graphite
composition
silicate
rubber
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Abandoned
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US15/557,751
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English (en)
Inventor
Doug Bilbija
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2423465 Ontario Inc
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2423465 Ontario Inc
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Priority to US15/557,751 priority Critical patent/US20180066401A1/en
Assigned to 2423465 ONTARIO INC. reassignment 2423465 ONTARIO INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BILBIJA, DOUG
Publication of US20180066401A1 publication Critical patent/US20180066401A1/en
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/08—Impregnated or coated fibreboard
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F9/00—Complete machines for making continuous webs of paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/16—Special fibreboard
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/16—Special fibreboard
    • D21J1/20—Insulating board

Definitions

  • the present disclosure relates to construction boards, in particular fiberboards.
  • Fiberboard structural and decorative—is a fibrous-felted, homogeneous panel made from ligno-cellulosic fibers—usually wood—which has a density of less than 31 lb/ft3 (497 kg/m3), but more than 10 lb/ft3 (160 kg/m3). Fiberboard is characterized by an integral bond which is produced by interfelting the fibers, but which has not been consolidated under heat and pressure as a separate stage in manufacture. Other materials may be added to fiberboard during manufacture to improve certain properties of the produced panel such as well known waxes to provide moisture resistance and well known plant derived starches for fiber bonding to impart degrees of strength.
  • the present invention relates to a wood fiberboard comprising wood fibers bound together with a binder polymer resin that imparts additional strength, moisture resistance and incorporating a thermal fire suppressing expandable flake inorganic graphite and sodium silicate component to render the fiberboard to be non-combustible.
  • the invention here described discloses a method of substantially improving the fire resistance properties of a Fiberboard (Cellulosic fiber) homogenous panel by the admixture during the manufacturing process of certain known intumescent and binding materials in such a way that a significant and unexpected improvement in the properties of the fiberboard composition may be achieved.
  • the unexpected improvements rival thermal resistance and fire protection properties that are only generally achieved by well known inorganic construction boards such as Dens glass, gypsum and concrete wallboards (Drywall)
  • fiberboard and “construction board” may be used interchangeably.
  • FIG. 1 is a block diagram illustrating a manufacturing system for producing a construction board product according to one embodiment of the present application
  • FIG. 2 is a block diagram illustrating a continuation of the manufacturing system for producing the construction board product according to the one embodiment of the present application;
  • FIG. 3 is a graph illustrating the mean furnace temperature during a full wall burn test of a sample construction board having 30% of graphite by weight according to an embodiment of the present application;
  • FIG. 4 is a graph illustrating the mean furnace temperature during a full wall burn test of a sample construction board having 15% of graphite by weight according to an embodiment of the present application;
  • FIG. 5 is a graph illustrating the unexposed face maximum temperature during a full wall burn test of a sample of construction board of the present application
  • FIG. 6 is a graph illustrating the unexposed face average temperature during a full wall burn test of a sample of construction board of the present application
  • FIG. 7 is a graph illustrating the furnace pressure during a full wall burn test of a sample of construction board of the present application.
  • FIG. 8 is a graph illustrating the surface temperature of a conventional fiberboard subjected to a heat test
  • FIG. 9 is a graph illustrating the surface temperature of a fiberboard having a to silicate coating subjected to a heat test
  • FIG. 10 is a graph illustrating the surface temperature of a fiberboard comprising graphite according an embodiment of the present application subjected to a heat test.
  • FIG. 11 is a graph illustrating the surface temperature of a fiberboard comprising graphite according an embodiment of the present application subjected to a heat test.
  • a fiberboard composition comprising a plurality of ligno-cellulosic fibers and an inorganic expandable graphite in an amount suitable for providing fire resistance.
  • the ligno-cellulosic fibers may be wood-based, cardboard, or any other organic ligno-cellulosic fiber known to one skilled in the art.
  • the inorganic expandable graphite forming part of the fiberboard composition provides fire-resistance properties.
  • the inorganic expandable graphite may not expand at temperatures less than about 240° C. In some embodiments, the inorganice expandable graphite may not expand at temperatures less than about 220° C.
  • a suitable inorganic expandable graphite is produced by Asbury Carbons and sold under the product ID Expandable Graphic Grade 1722HT (previously product number RD18702 HT).
  • the fiberboard comprises between 15% to 30% of graphite by weight.
  • the content of graphite in the fiberboard may be larger, for example up to 60% of graphite by weight.
  • the graphite in the fiberboard improves the fire resistance properties of the fiberboard.
  • the fiberboards of the present application meet and exceed fire-resistance ratings according to Canadian and International standards. Due to the fire-resistance properties of the fiberboard, it may be used in various industries and applications, for example in interior home and building construction as well as for exterior sheathing of structures.
  • the fiberboard composition may further comprise a waterborne polymer binder resin in an amount suitable for providing water resistance.
  • a waterborne polymer binder resin may be selected from the group consisting of: latex, natural rubber, gutta-percha, styrene-butadiene rubber, styrene-isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, organic polysulphides, butyl rubber, halogenated butyl rubber, chlorinated polyethelene, chlorosulfanated polyethylene, ethylene-propoylene rubber, butadiene acrylonitrile copolymers, polyvinyl acetate, vinyl-acrylic, styrene-acrylic, and all acrylic polymers, or other waterborne polymer binder resins known to one skilled in the art.
  • the use of the polymer binder resin instead of a starch binder provides a fiberboard with increased strength properties. Due to the increased strength of the fiberboard product of the present application, the fiberboard products may be used in various industries for multiple applications, including roofing systems, exterior siding, and sound proofing.
  • the fiberboard composition may further comprise a silicate for enhancing fire resistance.
  • This silicate may be around 10% water-based and may be selected from the group consisting of sodium silicate and potassium silicate.
  • polymeric binders were found to be effective in providing the required strength and water resistance that included a wide range of latexes well known to the art that include dispersions of natural rubber, gutta-percha, styrene-butadiene rubber, styrene-isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, organic polysulphides, butyl rubber, halogenated butyl rubber, chlorinated polyethelene, chlorosulfanated polyethylene, ethylene-propoylene rubber, butadiene acrylonitrile copolymers, polyvinyl acetate, vinyl-acrylic, styrene-acrylic, all acrylic polymers and the like.
  • the preferred binder was found to be included in the class of elastomeric styrenated acrylic in which the proportion of styrene to methyl acrylic acid between 10/90 and 20/80 and the glass transition temperature of +5° C. or higher as produced by Ona Polymers of Garland, Tex. USA.
  • the ability to increase strength and water resistance was achieved by direct in line addition of approx: 2-3 gals per minute into the pulp slurry during the manufacture of the fiberboard as it was being formed just ahead of the forming line presses.
  • the wood fiber used in the present method is acquired through conventional methods of processing recycled wood.
  • recycled wood products may be cut up into wood chips and processed using conventional processes to remove any foreign materials and other impurities.
  • Such a conventional process may include use of a belt and magnet conveyor to remove any metallic foreign materials from the wood chips.
  • the wood chips may be treated using conventional processes for cleaning and treating the wood chips.
  • the system 100 includes a machine chest 102 , a constant level box 104 and a head box 108 .
  • the machine chest 102 contains a mixture of the processed and/or treated wood fiber and water (for example, also referred to herein as wood pulp slurry).
  • wood pulp slurry a mixture of the processed and/or treated wood fiber and water
  • graphite is added into the machine chest 102 at a substantially constant rate. This allows the graphite to evenly mix with the wood fiber pulp and water mixture prior to the graphite wood fiber mixture entering the head box 108 .
  • the graphite may be introduced into the machine chest 102 at a constant rate of ten (10) pounds of graphite per minute.
  • the graphite may be added into the machine chest 102 manually or by some automated system or component (not shown). In alternative embodiments, the graphite may be introduced at a different location during the manufacturing process, such as at the head box 108 or prior to the machine chest 102 .
  • the graphite wood fiber mixture previously combined in the machine chest 102 is moved via the constant level box 104 using a pump 106 into the head box 108 .
  • the constant level box 104 recirculates any overflow back to the machine chest 102 .
  • a coloring agent is added to the graphite wood fiber mixture using a coloration device 103 such that the finished product will have a particular color.
  • water is circulated into the head box 108 by a dilution device 105 to provide a high water content mixture.
  • the graphite wood fiber mixture is then evenly distributed onto the formation table 110 , which has a flat wire mesh surface.
  • the graphite wood fiber mixture is approximately comprised of 99% water and 1% of combined wood fiber and graphite.
  • the graphite wood fiber mixture is moved along the formation table 110 towards a plurality of rollers 118 .
  • water in the graphite wood fiber mixture is filtered out of the mixture through the wire mesh on the formation table 110 and into the water canal 116 .
  • water may be further removed from the graphite wood fiber mixture using a low vacuum 112 and a high vacuum 114 along the formation table 110 .
  • the graphite wood fiber mixture is approximately comprised of 70% water and 30% of combined wood fiber and graphite.
  • the graphite wood fiber mixture is then passed through a plurality of rollers 118 which flatten the mixture to a predetermined thickness.
  • An overhead vacuum system 111 removes moisture and water from the graphite wood fiber mixture while it is being passed along the formation table and while it is being flattened. As well, during the flattening step, further water is removed from the graphite wood fiber mixture, the water falling into the water canal 116 . After flattening, the mixture is now formed into a semi-rigid board on the formation table 110 .
  • An optional coating may be applied to the semi-rigid board at this stage from coating shower system 126 .
  • the semi-rigid pre-fiberboard is cut into predetermined sized pieces by the cross-cutter 120 and then is sent to a dryer system 200 for drying and hardening.
  • the semi-rigid pre-fiberboard is approximately comprised of 48% water and 52% of combined wood fiber and graphite. Any excess graphite wood fiber mixture falls into a pulper 122 and is stored in a reserve chest 123 .
  • FIG. 2 illustrates the dryer system 200 as part of the overall manufacturing system of the fiberboard shown in FIG. 1 , according to the one embodiment of the invention.
  • the semi-rigid board continues onto one or more conveyors 202 into one or more dryers 204 .
  • the dryers 204 operate to remove the majority of the remaining water that is in the semi-rigid fiberboard.
  • the dryers 204 remove a significant amount of water such that the dried fiberboard leaving the dryers 204 is approximately comprised of 5% water and 95% of combined wood fiber and graphite.
  • the dried fiberboard exits the dryers 204 onto one or more conveyors 205 and may be cut into predetermined sized pieces by one or more saws 206 .
  • the fiberboard may be cut in any size of board.
  • the fiberboard proceeds onto a conveyor 208 to receive final treatments.
  • the surface of the fiberboard may be smoothed by a calender 210
  • the surface of the fiberboard may receive a polymer coating applied by a coating device 212
  • the surface of the fiberboard may be laminated by a lamination device 214 .
  • the finished fiberboard product may be stored.
  • the finished fiberboard may be cut into boards having generally the dimensions 4 feet ⁇ 8 feet ⁇ 1 ⁇ 2 feet.
  • the fiberboard may be cut into any size and the thickness of the finished fiberboard may vary depending on the intended end use application.
  • Table 1.1 illustrates a comparison between conventional fiberboards having starch as a binder and fiberboards of the present application which utilize polymer as a binder.
  • the example fiberboards 173 G, 174 I and 174 H each utilized starch as a binder.
  • Starch is a highly combustible material.
  • Fiberboards 173 G, 174 I and 174 H have generally the same percentages of wood fiber, water and weight of the starch binder.
  • the characteristics of fiberboards 173 G, 174 I and 174 H differ in the percentage of wax used, with 173 G having 0%, 174 I has 1.09% and 174 H having 3.70%.
  • the use of wax in the fiberboards decreases to the water absorption percentage after 2 hours and after 4 hours, with the highest amount of wax 3.70% in fiberboard 174 H providing the lowest water absorption rates.
  • Fiberboards 170 A and 174 J of the present application utilize the above-described polymer as a binder.
  • the fiberboards 170 A and 174 J have generally the same percentages of solids of the polymer binder, wood fiber, crosslink-WB31B and water, and generally the same weight of the polymer binder.
  • the characteristics of the fiberboards 170 A and 174 J differ in the percentage of wax used, with 170 A having 0% and 174 J having 1.24%.
  • Fiberboard 174 J of the present application differs from fiberboard 170 A in that it contains 1.24% of wax.
  • the introduction of the wax does not provide a significant decrease in water absorption percentages, as the 4 hour water absorption percentage of the fiberboard 174 JA of the present application is 33.21% and the 4 hour water absorption percentage of the fiberboard 170 A (without wax) of the present application is 34.96%.
  • Conventional fiberboards 173 G, 174 I and 174 H are made with a starch binder and include a wax component in order to reduce percentages of water absorption.
  • starch and wax in fiberboards are highly flammable.
  • the fiberboards are manufactured without starch and without wax, making them less flammable than conventional fiberboards.
  • the fiberboards of the present application manufactured with a polymer binding, which results in decreased water absorption percentages than the conventional starch binder based fiberboards.
  • the surface treatment of the face of the boards is realized by subjecting the finished board as it came out of the dryers 204 to a surface coat of sodium silicates (case trials were done with both sodium and potassium silicates and sodium due to its relatively inexpensive cost was chosen as the preferred method.)
  • the surface treatment was optimized using a spray coat of a 10% water based solution(higher and lower concentrations in the range of 5% to 100% were trialed but the optimum was 10%) of inorganic sodium silicate which quickly penetrated the surface of the fiberboard and then was sent into a calender press roller 210 to provide a suitable smooth profile for paint application.
  • the surface treatment is performed by a coating device 212 after the fiberboard is sent into the calender press roller 210 , as shown in FIG.
  • the application of the sodium silicate was enhanced by the addition of a high heat (450F-500F) pressure compression roller that not only provided for a smooth surface but in doing so set the sodium silicate due to the high temperature flash drying of the water carrier that resulted in a smooth glass like appearance that provided an additional fire resistance quality that is well known in this particular chemistry of silicates otherwise known as waterglass.
  • a high heat (450F-500F) pressure compression roller that not only provided for a smooth surface but in doing so set the sodium silicate due to the high temperature flash drying of the water carrier that resulted in a smooth glass like appearance that provided an additional fire resistance quality that is well known in this particular chemistry of silicates otherwise known as waterglass.
  • FIG. 3 is a graph of the mean furnace temperature during the CAN ULC S101-14 full wall test of fiberboard from the second batch having a graphite content of 30% by weight.
  • the x-axis of FIG. 3 represents the temperature of the furnace in Fahrenheit and the y-axis represents the length of time in minutes the fiberboard burns until it reaches a failure state.
  • a failure state of the fiberboard is when the fiberboard reaches a thermal loss value that exceeds ASTM fireproofing standards.
  • two thermal losses occur after 35 minutes and after 40 minutes.
  • Conventional fiberboards subjected to a similar full wall burn test would reach a thermal loss within 5 minutes. Accordingly, the fiberboard of the present application provides superior fireproofing qualities compared to conventional fiberboard. This improved fireproofing characteristic of the fiberboard of the present application is in part a result of the graphite added to the fiberboard during manufacturing.
  • FIG. 4 is a graph of the CAN ULC S101-14 mean furnace temperature during the full wall test of fiberboard from the first batch having a graphite content of 15% by weight. As shown, a thermal loss occurs on the graph between 25 and 30 minutes. Accordingly, when comparing the full wall burn test results of the first batch of fiberboard having 15% graphite by weight with the second batch of fiberboard having 30% graphite by weight, it is shown that the increased amount of graphite in the fiberboard resulted in an increase in time before a thermal loss event occurs, thereby improving the fireproofing characteristics of the fiberboard.
  • FIG. 5 is a graph illustrating the unexposed face maximum temperature during a CAN ULC S101-14 full wall burn test of a sample of construction board of the present application
  • FIG. 6 is a graph illustrating the unexposed face average temperature during a CAN ULC S101-14 full wall burn test of a sample of construction board of the present application
  • FIG. 7 is a graph illustrating the furnace pressure during a CAN ULC S101-14 full wall burn test of a sample of construction board of the present application.
  • the fiberboard (Cellulosic fiber) of the present application is rendered non-combustible due to the inclusion in its composition of a new high temperature activated expandable graphite.
  • the fiberboard (Cellulosic fiber) of the present application has improved strength characteristics and water resistance properties due to the inclusion of polymer binders in its composition.
  • the fiberboard (Cellulosic fiber) of the present application has a sodium silicate (waterglass) surface treatment and compressed profile that results in a smooth and paint ready surface with inherent fire resistant properties.
  • Thermal testing was conducted on sample fiberboards to illustrate the effects that the silicate and graphite, alone and in combination, have on the thermal resistant properties of the fiberboard of the present application.
  • a thermal test was conducted on a standard conventional fiberboard. For each of the thermal tests, the furnace temperature was maintained at an approximate temperature of 1500° F.
  • the furnace temperature was maintained at an approximate temperature of 1500° F.
  • the unexposed surface temperature of the board is shown to surpass the furnace temperature is an indication of a thermal loss event, which may considered as a failure point of the fiberboard that is being subjected to heat.
  • FIG. 8 illustrates the results of such the thermal test on a conventional fiberboard. As shown, the unexposed surface temperature of a conventional fiberboard rapidly rises to just over 1400° F. and reaches a failure state in less than approximately 2 minutes.
  • FIG. 9 illustrates the results of the thermal test on a fiberboard having a silicate coating.
  • a silicate coating provides fire-resistant properties to a fiberboard.
  • the unexposed surface temperature rises to approximately only 400° F. after 30 minutes of exposure, despite the furnace temperature being approximately 1500° F.
  • the fiberboard having the silicate coating reaches a failure state at approximately between 35 and 40 minutes. Accordingly, the silicate coating on the fiberboard provides improved thermal resistance when compared with the heat test results of the conventional fiberboard of FIG. 8 which reached a failure state within 2 minutes under the same furnace temperature conditions.
  • FIG. 10 illustrates the results of the thermal test on a fiberboard comprising a predetermined percentage of graphite, according to the present application.
  • the introduction of graphite during the fiberboard manufacturing process, as provided in the present application improves the fire resistant properties of the fiberboard.
  • the unexposed surface temperature rises to approximately only 400° F. after about 35 minutes of exposure, despite the furnace temperature being approximately 1500° F.
  • the fiberboard comprising the graphite reaches a failure state at approximately between 40 and 50 minutes. Accordingly, the fiberboard comprising graphite provides improved thermal resistance when compared with the heat test results of the conventional fiberboard of FIG. 8 which reached a failure state within 2 minutes under the same furnace temperature conditions.
  • FIG. 11 illustrates the results of the thermal test on a fiberboard comprising a predetermined percentage of graphite and having a silicate coating, according to the present application.
  • the unexposed surface temperature rises to approximately only 400° F. after about 45 minutes of exposure, despite the furnace temperature being approximately 1500° F.
  • the fiberboard comprising the graphite and having the silicate coating reaches a failure state at approximately 50 to 55 minutes. Accordingly, the combination of the fiberboard comprising graphite and having a silicate coating provides the greatest level of thermal resistance relative to the examples provided in FIGS. 9 (fiberboard having silicate coating only) and 10 (e.g. fiberboard comprised of graphite only).
  • the combination of the fiberboard comprising graphite and having a silicate coating provides significant improvement of thermal resistance (e.g. failure after 50 minutes of heat exposure) when compared with the heat test results of the conventional fiberboard of FIG. 8 which reached a failure state within 2 minutes under the same furnace temperature conditions.
  • Tables 2.1 and 2.2 show results of thermal conductivity tests performed in accordance with the ASTM C518 standard.
  • Tables 2.1 the thermal conductivity of the gypsum boards is shown.
  • the thermal conductivity properties of sample fiberboards of the present application are shown (for example, the fiberboard has the proprietary name “Starboard”).
  • the RSI value for thermal resistance is 0.29 Cm 2 /W and the heat flow rate in the measured area is 5.53W.
  • the other tested fiberboard # 8 of the present application as tested had a similar RSI and heat flow rate as fiberboard # 7 .
  • the fiberboard produced according to the present application has improved heat resistance properties (e.g. RSI, heat flow rate) over gypsum boards.
  • Tables 3.1. 3.2 and 3.3 show results of water absorptiveness tests performed on the gypsum board samples (Table 3.1) and the fiberboard samples of the present application (Table 3.2 and 3.3), in accordance with the ASTM D3285 Standard Test Method for Water Absorptiveness of Nonbibulous Paper and Paperboard (also known as the “Cobb Test”).
  • Table 3.1 the results of the Cobb Test for the gypsum board samples is shown, where the average absorption of the gypsum board over a 4 hour period was 773.64 g/m 2 and the average surface absorption was 3.24%.
  • the fiberboard produced according to the present application has reduced absorption properties and characteristics (absorption and surface absorption percentage) over gypsum boards.
  • Table 4 shows results of an absorption by water immersion test performed on the fiberboard samples of the present application, according to the ASTM C209 Standard (Standard Test Methods for Cellulosic Fiber Insulating Board—Section 14). As shown in Table 4, after a 2 hour test duration, the average absorption percentage is 6.81%.
  • Table 5 shows the measured results of a tensile strength test performed according to the ASTM C208 Standard (Section 13). As shown in Table 5, the tensile strength perpendicular to the surface of the fiberboard was measured, with an average net strength of: 620.67 psf, 281.53 kg and 29.72 Kpa.
  • Tables 6.1 and 6.2 show the measured results of transverse strength tests performed on the fiberboard of the present application, according to the ASTM C209 standard (Section 10).
  • Table 6.1 the average transverse strength perpendicular to the board panel length of the “M” samples was 28.501 bf and the average transverse strength perpendicular to the board panel length of the “T” samples was similar with 27.831 bf.
  • the transverse strength was measured again, and as shown in table 6.2, the average transverse strength of the “M” samples was 25.17 lbf and the average transverse strength of the “T” samples was similar with 24.70 lbf.
  • a gypsum board has a standard specification (according to ASTM 1.1.1) of transverse strength perpendicular to the board panel length of 23.5 lbf. Accordingly, the fiberboard of the present application has an increased transverse strength compared to gypsum board.

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