CA2059627A1 - Moldings based on fibers - Google Patents
Moldings based on fibersInfo
- Publication number
- CA2059627A1 CA2059627A1 CA 2059627 CA2059627A CA2059627A1 CA 2059627 A1 CA2059627 A1 CA 2059627A1 CA 2059627 CA2059627 CA 2059627 CA 2059627 A CA2059627 A CA 2059627A CA 2059627 A1 CA2059627 A1 CA 2059627A1
- Authority
- CA
- Canada
- Prior art keywords
- weight
- fibers
- binder
- polymer
- molding
- 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.)
- Abandoned
Links
- 239000000835 fiber Substances 0.000 title claims abstract description 38
- 238000000465 moulding Methods 0.000 title claims abstract description 32
- 229920000642 polymer Polymers 0.000 claims abstract description 42
- 239000011230 binding agent Substances 0.000 claims abstract description 36
- 239000000178 monomer Substances 0.000 claims abstract description 18
- 238000004519 manufacturing process Methods 0.000 claims abstract description 12
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 claims abstract description 10
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 claims abstract description 10
- 125000004432 carbon atom Chemical group C* 0.000 claims abstract description 7
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims abstract description 6
- GYCMBHHDWRMZGG-UHFFFAOYSA-N Methylacrylonitrile Chemical compound CC(=C)C#N GYCMBHHDWRMZGG-UHFFFAOYSA-N 0.000 claims abstract description 6
- 150000001252 acrylic acid derivatives Chemical class 0.000 claims abstract description 6
- 230000009477 glass transition Effects 0.000 claims abstract description 5
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims abstract description 4
- 150000001298 alcohols Chemical class 0.000 claims abstract description 4
- 150000002734 metacrylic acid derivatives Chemical class 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 30
- 239000006185 dispersion Substances 0.000 claims description 26
- 239000002557 mineral fiber Substances 0.000 claims description 12
- 230000008569 process Effects 0.000 claims description 12
- 239000002002 slurry Substances 0.000 claims description 5
- 239000000725 suspension Substances 0.000 claims description 4
- 239000007900 aqueous suspension Substances 0.000 claims description 2
- 239000000945 filler Substances 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 59
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 24
- 230000009102 absorption Effects 0.000 description 24
- 238000010521 absorption reaction Methods 0.000 description 24
- 239000003795 chemical substances by application Substances 0.000 description 23
- 239000004815 dispersion polymer Substances 0.000 description 20
- 239000003995 emulsifying agent Substances 0.000 description 18
- -1 alkyl radical Chemical class 0.000 description 17
- 239000005871 repellent Substances 0.000 description 17
- 230000002940 repellent Effects 0.000 description 17
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 14
- 229920002522 Wood fibre Polymers 0.000 description 14
- 239000000243 solution Substances 0.000 description 14
- 239000002025 wood fiber Substances 0.000 description 14
- 239000005995 Aluminium silicate Substances 0.000 description 13
- 235000012211 aluminium silicate Nutrition 0.000 description 13
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 13
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 10
- 239000011490 mineral wool Substances 0.000 description 10
- 238000012360 testing method Methods 0.000 description 10
- RPACBEVZENYWOL-XFULWGLBSA-M sodium;(2r)-2-[6-(4-chlorophenoxy)hexyl]oxirane-2-carboxylate Chemical compound [Na+].C=1C=C(Cl)C=CC=1OCCCCCC[C@]1(C(=O)[O-])CO1 RPACBEVZENYWOL-XFULWGLBSA-M 0.000 description 9
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 8
- 239000004743 Polypropylene Substances 0.000 description 8
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 8
- 150000002500 ions Chemical class 0.000 description 8
- 229920001155 polypropylene Polymers 0.000 description 8
- 229920003043 Cellulose fiber Polymers 0.000 description 7
- 238000001035 drying Methods 0.000 description 7
- 238000007046 ethoxylation reaction Methods 0.000 description 7
- 150000002191 fatty alcohols Chemical class 0.000 description 7
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 6
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 6
- 239000000654 additive Substances 0.000 description 6
- 239000000839 emulsion Substances 0.000 description 6
- 238000003756 stirring Methods 0.000 description 6
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 5
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 5
- 239000011094 fiberboard Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 239000011734 sodium Substances 0.000 description 5
- 229910052708 sodium Inorganic materials 0.000 description 5
- 229920002472 Starch Polymers 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 229920001577 copolymer Polymers 0.000 description 4
- 239000003999 initiator Substances 0.000 description 4
- 238000006116 polymerization reaction Methods 0.000 description 4
- 230000001376 precipitating effect Effects 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 235000019698 starch Nutrition 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 239000002023 wood Substances 0.000 description 4
- 210000002268 wool Anatomy 0.000 description 4
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 description 3
- WVDDGKGOMKODPV-UHFFFAOYSA-N Benzyl alcohol Chemical compound OCC1=CC=CC=C1 WVDDGKGOMKODPV-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- BCKXLBQYZLBQEK-KVVVOXFISA-M Sodium oleate Chemical compound [Na+].CCCCCCCC\C=C/CCCCCCCC([O-])=O BCKXLBQYZLBQEK-KVVVOXFISA-M 0.000 description 3
- 239000002585 base Substances 0.000 description 3
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000007720 emulsion polymerization reaction Methods 0.000 description 3
- 239000004816 latex Substances 0.000 description 3
- 229920000126 latex Polymers 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 238000003825 pressing Methods 0.000 description 3
- 239000008107 starch Substances 0.000 description 3
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 2
- KBPLFHHGFOOTCA-UHFFFAOYSA-N 1-Octanol Chemical compound CCCCCCCCO KBPLFHHGFOOTCA-UHFFFAOYSA-N 0.000 description 2
- QHVBLSNVXDSMEB-UHFFFAOYSA-N 2-(diethylamino)ethyl prop-2-enoate Chemical compound CCN(CC)CCOC(=O)C=C QHVBLSNVXDSMEB-UHFFFAOYSA-N 0.000 description 2
- YIWUKEYIRIRTPP-UHFFFAOYSA-N 2-ethylhexan-1-ol Chemical compound CCCCC(CC)CO YIWUKEYIRIRTPP-UHFFFAOYSA-N 0.000 description 2
- OMIGHNLMNHATMP-UHFFFAOYSA-N 2-hydroxyethyl prop-2-enoate Chemical compound OCCOC(=O)C=C OMIGHNLMNHATMP-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 description 2
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 2
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 2
- AMQJEAYHLZJPGS-UHFFFAOYSA-N N-Pentanol Chemical compound CCCCCO AMQJEAYHLZJPGS-UHFFFAOYSA-N 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 230000002411 adverse Effects 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 235000014113 dietary fatty acids Nutrition 0.000 description 2
- 238000004455 differential thermal analysis Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 150000002148 esters Chemical class 0.000 description 2
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 2
- 239000000194 fatty acid Substances 0.000 description 2
- 229930195729 fatty acid Natural products 0.000 description 2
- ZZUFCTLCJUWOSV-UHFFFAOYSA-N furosemide Chemical compound C1=C(Cl)C(S(=O)(=O)N)=CC(C(O)=O)=C1NCC1=CC=CO1 ZZUFCTLCJUWOSV-UHFFFAOYSA-N 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- ZSIAUFGUXNUGDI-UHFFFAOYSA-N hexan-1-ol Chemical compound CCCCCCO ZSIAUFGUXNUGDI-UHFFFAOYSA-N 0.000 description 2
- PHTQWCKDNZKARW-UHFFFAOYSA-N isoamylol Chemical compound CC(C)CCO PHTQWCKDNZKARW-UHFFFAOYSA-N 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- BDERNNFJNOPAEC-UHFFFAOYSA-N n-propyl alcohol Natural products CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 2
- GLDOVTGHNKAZLK-UHFFFAOYSA-N octadecan-1-ol Chemical compound CCCCCCCCCCCCCCCCCCO GLDOVTGHNKAZLK-UHFFFAOYSA-N 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 2
- 229920002239 polyacrylonitrile Polymers 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 150000003254 radicals Chemical class 0.000 description 2
- BTURAGWYSMTVOW-UHFFFAOYSA-M sodium dodecanoate Chemical compound [Na+].CCCCCCCCCCCC([O-])=O BTURAGWYSMTVOW-UHFFFAOYSA-M 0.000 description 2
- 229940082004 sodium laurate Drugs 0.000 description 2
- CHQMHPLRPQMAMX-UHFFFAOYSA-L sodium persulfate Chemical compound [Na+].[Na+].[O-]S(=O)(=O)OOS([O-])(=O)=O CHQMHPLRPQMAMX-UHFFFAOYSA-L 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 2
- QOVCUELHTLHMEN-UHFFFAOYSA-N 1-butyl-4-ethenylbenzene Chemical compound CCCCC1=CC=C(C=C)C=C1 QOVCUELHTLHMEN-UHFFFAOYSA-N 0.000 description 1
- SLBOQBILGNEPEB-UHFFFAOYSA-N 1-chloroprop-2-enylbenzene Chemical compound C=CC(Cl)C1=CC=CC=C1 SLBOQBILGNEPEB-UHFFFAOYSA-N 0.000 description 1
- DMADTXMQLFQQII-UHFFFAOYSA-N 1-decyl-4-ethenylbenzene Chemical compound CCCCCCCCCCC1=CC=C(C=C)C=C1 DMADTXMQLFQQII-UHFFFAOYSA-N 0.000 description 1
- RGYDDAILUUUYRN-UHFFFAOYSA-N 1-prop-2-enoyloxybutyl prop-2-enoate Chemical compound C=CC(=O)OC(CCC)OC(=O)C=C RGYDDAILUUUYRN-UHFFFAOYSA-N 0.000 description 1
- VOBUAPTXJKMNCT-UHFFFAOYSA-N 1-prop-2-enoyloxyhexyl prop-2-enoate Chemical compound CCCCCC(OC(=O)C=C)OC(=O)C=C VOBUAPTXJKMNCT-UHFFFAOYSA-N 0.000 description 1
- JAHNSTQSQJOJLO-UHFFFAOYSA-N 2-(3-fluorophenyl)-1h-imidazole Chemical compound FC1=CC=CC(C=2NC=CN=2)=C1 JAHNSTQSQJOJLO-UHFFFAOYSA-N 0.000 description 1
- GOXQRTZXKQZDDN-UHFFFAOYSA-N 2-Ethylhexyl acrylate Chemical compound CCCCC(CC)COC(=O)C=C GOXQRTZXKQZDDN-UHFFFAOYSA-N 0.000 description 1
- GDTSJMKGXGJFGQ-UHFFFAOYSA-N 3,7-dioxido-2,4,6,8,9-pentaoxa-1,3,5,7-tetraborabicyclo[3.3.1]nonane Chemical compound O1B([O-])OB2OB([O-])OB1O2 GDTSJMKGXGJFGQ-UHFFFAOYSA-N 0.000 description 1
- QZPSOSOOLFHYRR-UHFFFAOYSA-N 3-hydroxypropyl prop-2-enoate Chemical compound OCCCOC(=O)C=C QZPSOSOOLFHYRR-UHFFFAOYSA-N 0.000 description 1
- JLBJTVDPSNHSKJ-UHFFFAOYSA-N 4-Methylstyrene Chemical compound CC1=CC=C(C=C)C=C1 JLBJTVDPSNHSKJ-UHFFFAOYSA-N 0.000 description 1
- NDWUBGAGUCISDV-UHFFFAOYSA-N 4-hydroxybutyl prop-2-enoate Chemical compound OCCCCOC(=O)C=C NDWUBGAGUCISDV-UHFFFAOYSA-N 0.000 description 1
- BHPQYMZQTOCNFJ-UHFFFAOYSA-N Calcium cation Chemical compound [Ca+2] BHPQYMZQTOCNFJ-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 229920002261 Corn starch Polymers 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 206010020751 Hypersensitivity Diseases 0.000 description 1
- JLVVSXFLKOJNIY-UHFFFAOYSA-N Magnesium ion Chemical compound [Mg+2] JLVVSXFLKOJNIY-UHFFFAOYSA-N 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- CNCOEDDPFOAUMB-UHFFFAOYSA-N N-Methylolacrylamide Chemical compound OCNC(=O)C=C CNCOEDDPFOAUMB-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- 239000003568 Sodium, potassium and calcium salts of fatty acids Substances 0.000 description 1
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
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- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 125000000217 alkyl group Chemical group 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- AOJOEFVRHOZDFN-UHFFFAOYSA-N benzyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCC1=CC=CC=C1 AOJOEFVRHOZDFN-UHFFFAOYSA-N 0.000 description 1
- 235000019445 benzyl alcohol Nutrition 0.000 description 1
- 239000003139 biocide Substances 0.000 description 1
- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical compound C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 1
- 150000001642 boronic acid derivatives Chemical class 0.000 description 1
- MKUWVMRNQOOSAT-UHFFFAOYSA-N but-3-en-2-ol Chemical compound CC(O)C=C MKUWVMRNQOOSAT-UHFFFAOYSA-N 0.000 description 1
- 229940043430 calcium compound Drugs 0.000 description 1
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- HPXRVTGHNJAIIH-UHFFFAOYSA-N cyclohexanol Chemical compound OC1CCCCC1 HPXRVTGHNJAIIH-UHFFFAOYSA-N 0.000 description 1
- OIWOHHBRDFKZNC-UHFFFAOYSA-N cyclohexyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OC1CCCCC1 OIWOHHBRDFKZNC-UHFFFAOYSA-N 0.000 description 1
- KBLWLMPSVYBVDK-UHFFFAOYSA-N cyclohexyl prop-2-enoate Chemical compound C=CC(=O)OC1CCCCC1 KBLWLMPSVYBVDK-UHFFFAOYSA-N 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
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- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- USIUVYZYUHIAEV-UHFFFAOYSA-N diphenyl ether Chemical class C=1C=CC=CC=1OC1=CC=CC=C1 USIUVYZYUHIAEV-UHFFFAOYSA-N 0.000 description 1
- LQZZUXJYWNFBMV-UHFFFAOYSA-N dodecan-1-ol Chemical compound CCCCCCCCCCCCO LQZZUXJYWNFBMV-UHFFFAOYSA-N 0.000 description 1
- POULHZVOKOAJMA-UHFFFAOYSA-M dodecanoate Chemical compound CCCCCCCCCCCC([O-])=O POULHZVOKOAJMA-UHFFFAOYSA-M 0.000 description 1
- 125000003438 dodecyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 150000002193 fatty amides Chemical class 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000008394 flocculating agent Substances 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 230000000855 fungicidal effect Effects 0.000 description 1
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- 238000007429 general method Methods 0.000 description 1
- VOZRXNHHFUQHIL-UHFFFAOYSA-N glycidyl methacrylate Chemical compound CC(=C)C(=O)OCC1CO1 VOZRXNHHFUQHIL-UHFFFAOYSA-N 0.000 description 1
- 239000003673 groundwater Substances 0.000 description 1
- 230000036541 health Effects 0.000 description 1
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- 125000004051 hexyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
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- 229940070765 laurate Drugs 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229910001425 magnesium ion Inorganic materials 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- FQPSGWSUVKBHSU-UHFFFAOYSA-N methacrylamide Chemical compound CC(=C)C(N)=O FQPSGWSUVKBHSU-UHFFFAOYSA-N 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 244000005700 microbiome Species 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- GOQYKNQRPGWPLP-UHFFFAOYSA-N n-heptadecyl alcohol Natural products CCCCCCCCCCCCCCCCCO GOQYKNQRPGWPLP-UHFFFAOYSA-N 0.000 description 1
- 230000003472 neutralizing effect Effects 0.000 description 1
- 230000009965 odorless effect Effects 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 229940049964 oleate Drugs 0.000 description 1
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 229920002401 polyacrylamide Polymers 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 229920001592 potato starch Polymers 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 239000003755 preservative agent Substances 0.000 description 1
- 230000002335 preservative effect Effects 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- HJWLCRVIBGQPNF-UHFFFAOYSA-N prop-2-enylbenzene Chemical compound C=CCC1=CC=CC=C1 HJWLCRVIBGQPNF-UHFFFAOYSA-N 0.000 description 1
- 238000007761 roller coating Methods 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 125000002914 sec-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 150000004756 silanes Chemical class 0.000 description 1
- AJPJDKMHJJGVTQ-UHFFFAOYSA-M sodium dihydrogen phosphate Chemical compound [Na+].OP(O)([O-])=O AJPJDKMHJJGVTQ-UHFFFAOYSA-M 0.000 description 1
- RYYKJJJTJZKILX-UHFFFAOYSA-M sodium octadecanoate Chemical compound [Na+].CCCCCCCCCCCCCCCCCC([O-])=O RYYKJJJTJZKILX-UHFFFAOYSA-M 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
- 235000013875 sodium salts of fatty acid Nutrition 0.000 description 1
- 150000003460 sulfonic acids Chemical class 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 238000004065 wastewater treatment Methods 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
-
- 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
-
- 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
- C04B26/06—Acrylates
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L97/00—Compositions of lignin-containing materials
- C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
-
- 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)
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Polymers & Plastics (AREA)
- Health & Medical Sciences (AREA)
- Materials Engineering (AREA)
- Medicinal Chemistry (AREA)
- Ceramic Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Structural Engineering (AREA)
- Paper (AREA)
- Reinforced Plastic Materials (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Nonwoven Fabrics (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
Abstract
- 25 - O.Z. 0050/42166 Abstract of the Disclosure: Moldings based on fibers (component A), containing, as a binder, a polymer (B) having a glass transition temperature above 60°C and consisting of b1) from 70 to 99% by weight, based on B, of one or more vinylaromatic monomers, b2) from 1 to 30% by weight, based on B, of acrylates or methacrylates of alcohols of 1 to 18 carbon atoms, monohydroxyalkyl acrylates or monohydroxy-alkyl methacrylates where the alkyl radical is of 2 to 12 carbon atoms, acrylic acid, methacrylic acid, acrylonitrile and/or methacrylonitrile, where the sum of the amounts of acrylonitrile and methacrylo-nitrile may be not more than 20% by weight, based on B, and b3) from 0 to 5% by weight, based on B, of further copolymerizable monomers, and the production thereof are described.
Description
2~627 O.Z. 0050/42166 Moldinqs based_on fiber~
The present invention relates to moldings based on fibers (component A), containing, as binder (B), a polymer having a glass transition temperature above 60C
and consisting of b1) from 70 to 99% by weight, based on B, of one or more vinylaromatic monomers, b2) fr~m 1 to 30% by weight, based on B, of acrylates or methacrylates of alcohol~ o~ 1 to 18 carbon 1~ atom5, monohydroxyalkyl acrylates or monohydroxy-alkyl methacrylates where th~ alkyl radical is o~ 2 to 12 carbon atoms, acrylic acid, methacrylic acid, acrylonitrile and/or methacrylonitrile, the sum of the amounts of acrylonitrile and methacrylonitrile being from 0 to 20~ by weight, based on B, and b3) from 0 to 5~ by weight, based on B, of further copolymerizable monomers.
Moldings based on mineral fibers are known per se. For example, DE-A 29 24 085, US-A 4 187 142 and US-A 4 189 345 describe a process for the production of fiber boards, in which the additives together with the bindsr, which may be a precipitated binder, are filtered on a Fourdrinier wire (ie. sheet formation) and the fiber boards are then dried at elevated temperature. US-A 4 187 142 and US 4 189 345 describe binderQ of a core-shell latex having a complicated structure. RslativPly large amounts of vinylben~yl chloride are polymerized on the surface of the latex particles, and the vinylbenzyl chloride must be ~eacted with amine before the latex is used. However, these binders, which can only be used with a certain coadditive, lead to moldings having high water absorption.
Ceiling panels are produced in the manner des-cribed above, for example from kaolin, mineral fibers and starches. The serious disadvantage of such panels, which in principle are very rigid, is tha~ they lo~e their 2~5~2~
- 2 - O.Z. 0050/42166 shape, ie. sag under their own weight, in humid, but particularly in humid and warm, rooms, ie. in a tropical climate. The appearance of such sagging ceilings is unattractive and therefore undesirable.
S A further disadvantage is the sensitivity of such sheet-like structures to the degradation of the binder starch by microorganisms, which leads to dark spots and finally has a substantially adverse effect on the mec-hanical strength. Affected ceiling panels may constitute a health risk. Such panels can of course be treated with microcides, for example with formaldehyde depot sub-stances. These ensure protection from attack by gradual-ly releasing formaldehyde. However, to ensure protection over many years, higher doses of preservative must be lS chosen, which may lead to odor annoyances and, in certain circums~ances, to allergic reactions of the inhabitan~s.
EP-A 367 023 discloses fiber boards which contain acrylate copolymers. These can be used as aqueous solution. ~hen these binder systems are employed in practice, it has been found, however, that certain aspects are still unsatisfactory. For example, in the production of mineral fiber boards on the Fourdrinier wire, it has been found that the viscosity of the polymer solutions is too high for conventional operational measures, such as conveying and metering. The viscosity of such polymer solutions which are about 10% strength is about 25 Pa. 5 . Only solution~ having solid contents substantially below 10% by weight can be readily used on virtually all units, but this is uneconomical owing to the large amount of the diluent water. Furthermore, such polymers tend to migrate during drying of the crude boards, ie. tend to result in a 105s of binder in the interior of the mineral fiber boards, which may have an adverse effect on the fur~her processing of the crude boards. The skilled worker know~ that this binder migration can be counteracted by the use of substances having inverse solubility, for example polyvinyl me~hyl , .~ .
2~627 - 3 - O.Z. OOS0/42166 ethers. Howevex, they give rise t~ additional costs and may increase the moisture absorption of the end products.
The same also applies to the acrylate binders of DE-A 29 24 085 and EP-A 123 234.
EP-A 386 579 discloses moldings which are bound with acrylate dispersions. The shaped articles produced with these binders and with those of ÆP-A 367 023 all have satisfactory properties, but their mechanical strength and their water absorption can still be im-proved. An increase in the wa~er resistance can be achieved with a higher dose of agents which impart water repellency, but it is then necessary to accept a decline in the mechanical strength as well as wetting and ad-hesion problems in the shaped articles.
US-A 4 517 240 discloses a proces~ in which a fiber slurry is treated with an acrylate dispersion and a water-soluble acrylylsiloxane during heating. The disadvantage is the necessity of using these silanes.
Apart from the additional costs, process control of the metering is frequently not very s~mple in practice.
Furthermore, only flexible shaped axticles are obtained.
BR-A 1 142 755 describes a butadiene-containing polymer which is used for impregnating cellulose fiber boards. If such a polymer is used as a binder, however, v2ry flexible shaped articles which in addition are not resistant to aging are obtained.
Finally, EP-A 81 230 and JP-A 7 2Z7 343 describe acrylonitrile-rich polymers as adhesion promoters for thermoplastics and for glass fibers. The use of these polymers as binders in fiber boards is not suggested.
It is an object of the presen~ invention to provide moldings based on fibers, which avoid the dis-advantages described above and combine low watex absorp-tion with high rigidity.
We have found that this object is achieved by the moldings defined at the outset and a process for their production. The preferred embodiments are described in 2O~96?J7 - 4 - O.Z. 0050/42166 the subclaLms.
Suitable fibers are mineral fibers, for example rock wool, ba~alt wool, slag wool and glass fibers having fiber lengths of, in general, from 0.2 to 5 cm, in particular from 0.5 to 2.5 cm, and thicknesses of from about 1.7 to 3.3 dtex. Organic fibers are also sui~able.
These include primarily wood fibers, such as comminuted and/or digested wood, such as pinewood. Such wood fibers are usually produced from wood chips, chopped wood or sawdust (for example Ullmann's Encyklopadie der tech-nischen Chemie, 4th Edition, Vol. 12, page 720 et seq.).
Other organic fibers, such as cellulose fibers or fibers of synthetic polymers, such aq polypropylene fibers and/or polyacrylonitrile fibers, may also be added to the wood fibers in minor amounts, in general in amounts o~ 5 to 60, preferably from 15 to 40, in particular from 15 to 30, ~ by weight, ba~ed on wood fiber~. ~hese fiber3 usually have a length of from 0.3 to 1.5 cm and a thicknes~ of from 10 to 30 dtex.
The polymer B iq gen~rally used in amounts of from 5 to 25, preferably from 5 to 15, % by weight, based on the fiber~ A. It is preferably compo3ed of from 75 to 98~ by weight of bl and from 2 to 25% by weight of b2.
Suitable vinylaromatic monomers are those of not more than 20 carbon atoms, such as vinyltoluene, ~- and para-methylstyrene, ~-butylstyrene, 4-n-butylstyrene, 4-n-decylstyrene and preferably s~yrene.
Suitable monomers b2 are esters of acrylic or methacrylic acid with alcohols of 1 to 18 carbon atoms~
preferably alkanols. Examples of alcohols are methanol, e~hanol, n- or isopropanol, n~, sec- and ter~-butanol, n-pentanol, isoamyl alcohol, n-hexanol, cyclohexanol, octanol, 2-ethylhexanol, lauryl alcohol, stearyl alcohol, benzyl alcohol and vinylethanol.
~xamples of esters of acrylic and methacrylic acid are hexyl (meth)acrylate, lauryl (meth)acrylate, cyclohexyl acrylate, phenyle~hyl methacrylate and n-, : :' :~ :
2~5~2~
,, .
The present invention relates to moldings based on fibers (component A), containing, as binder (B), a polymer having a glass transition temperature above 60C
and consisting of b1) from 70 to 99% by weight, based on B, of one or more vinylaromatic monomers, b2) fr~m 1 to 30% by weight, based on B, of acrylates or methacrylates of alcohol~ o~ 1 to 18 carbon 1~ atom5, monohydroxyalkyl acrylates or monohydroxy-alkyl methacrylates where th~ alkyl radical is o~ 2 to 12 carbon atoms, acrylic acid, methacrylic acid, acrylonitrile and/or methacrylonitrile, the sum of the amounts of acrylonitrile and methacrylonitrile being from 0 to 20~ by weight, based on B, and b3) from 0 to 5~ by weight, based on B, of further copolymerizable monomers.
Moldings based on mineral fibers are known per se. For example, DE-A 29 24 085, US-A 4 187 142 and US-A 4 189 345 describe a process for the production of fiber boards, in which the additives together with the bindsr, which may be a precipitated binder, are filtered on a Fourdrinier wire (ie. sheet formation) and the fiber boards are then dried at elevated temperature. US-A 4 187 142 and US 4 189 345 describe binderQ of a core-shell latex having a complicated structure. RslativPly large amounts of vinylben~yl chloride are polymerized on the surface of the latex particles, and the vinylbenzyl chloride must be ~eacted with amine before the latex is used. However, these binders, which can only be used with a certain coadditive, lead to moldings having high water absorption.
Ceiling panels are produced in the manner des-cribed above, for example from kaolin, mineral fibers and starches. The serious disadvantage of such panels, which in principle are very rigid, is tha~ they lo~e their 2~5~2~
- 2 - O.Z. 0050/42166 shape, ie. sag under their own weight, in humid, but particularly in humid and warm, rooms, ie. in a tropical climate. The appearance of such sagging ceilings is unattractive and therefore undesirable.
S A further disadvantage is the sensitivity of such sheet-like structures to the degradation of the binder starch by microorganisms, which leads to dark spots and finally has a substantially adverse effect on the mec-hanical strength. Affected ceiling panels may constitute a health risk. Such panels can of course be treated with microcides, for example with formaldehyde depot sub-stances. These ensure protection from attack by gradual-ly releasing formaldehyde. However, to ensure protection over many years, higher doses of preservative must be lS chosen, which may lead to odor annoyances and, in certain circums~ances, to allergic reactions of the inhabitan~s.
EP-A 367 023 discloses fiber boards which contain acrylate copolymers. These can be used as aqueous solution. ~hen these binder systems are employed in practice, it has been found, however, that certain aspects are still unsatisfactory. For example, in the production of mineral fiber boards on the Fourdrinier wire, it has been found that the viscosity of the polymer solutions is too high for conventional operational measures, such as conveying and metering. The viscosity of such polymer solutions which are about 10% strength is about 25 Pa. 5 . Only solution~ having solid contents substantially below 10% by weight can be readily used on virtually all units, but this is uneconomical owing to the large amount of the diluent water. Furthermore, such polymers tend to migrate during drying of the crude boards, ie. tend to result in a 105s of binder in the interior of the mineral fiber boards, which may have an adverse effect on the fur~her processing of the crude boards. The skilled worker know~ that this binder migration can be counteracted by the use of substances having inverse solubility, for example polyvinyl me~hyl , .~ .
2~627 - 3 - O.Z. OOS0/42166 ethers. Howevex, they give rise t~ additional costs and may increase the moisture absorption of the end products.
The same also applies to the acrylate binders of DE-A 29 24 085 and EP-A 123 234.
EP-A 386 579 discloses moldings which are bound with acrylate dispersions. The shaped articles produced with these binders and with those of ÆP-A 367 023 all have satisfactory properties, but their mechanical strength and their water absorption can still be im-proved. An increase in the wa~er resistance can be achieved with a higher dose of agents which impart water repellency, but it is then necessary to accept a decline in the mechanical strength as well as wetting and ad-hesion problems in the shaped articles.
US-A 4 517 240 discloses a proces~ in which a fiber slurry is treated with an acrylate dispersion and a water-soluble acrylylsiloxane during heating. The disadvantage is the necessity of using these silanes.
Apart from the additional costs, process control of the metering is frequently not very s~mple in practice.
Furthermore, only flexible shaped axticles are obtained.
BR-A 1 142 755 describes a butadiene-containing polymer which is used for impregnating cellulose fiber boards. If such a polymer is used as a binder, however, v2ry flexible shaped articles which in addition are not resistant to aging are obtained.
Finally, EP-A 81 230 and JP-A 7 2Z7 343 describe acrylonitrile-rich polymers as adhesion promoters for thermoplastics and for glass fibers. The use of these polymers as binders in fiber boards is not suggested.
It is an object of the presen~ invention to provide moldings based on fibers, which avoid the dis-advantages described above and combine low watex absorp-tion with high rigidity.
We have found that this object is achieved by the moldings defined at the outset and a process for their production. The preferred embodiments are described in 2O~96?J7 - 4 - O.Z. 0050/42166 the subclaLms.
Suitable fibers are mineral fibers, for example rock wool, ba~alt wool, slag wool and glass fibers having fiber lengths of, in general, from 0.2 to 5 cm, in particular from 0.5 to 2.5 cm, and thicknesses of from about 1.7 to 3.3 dtex. Organic fibers are also sui~able.
These include primarily wood fibers, such as comminuted and/or digested wood, such as pinewood. Such wood fibers are usually produced from wood chips, chopped wood or sawdust (for example Ullmann's Encyklopadie der tech-nischen Chemie, 4th Edition, Vol. 12, page 720 et seq.).
Other organic fibers, such as cellulose fibers or fibers of synthetic polymers, such aq polypropylene fibers and/or polyacrylonitrile fibers, may also be added to the wood fibers in minor amounts, in general in amounts o~ 5 to 60, preferably from 15 to 40, in particular from 15 to 30, ~ by weight, ba~ed on wood fiber~. ~hese fiber3 usually have a length of from 0.3 to 1.5 cm and a thicknes~ of from 10 to 30 dtex.
The polymer B iq gen~rally used in amounts of from 5 to 25, preferably from 5 to 15, % by weight, based on the fiber~ A. It is preferably compo3ed of from 75 to 98~ by weight of bl and from 2 to 25% by weight of b2.
Suitable vinylaromatic monomers are those of not more than 20 carbon atoms, such as vinyltoluene, ~- and para-methylstyrene, ~-butylstyrene, 4-n-butylstyrene, 4-n-decylstyrene and preferably s~yrene.
Suitable monomers b2 are esters of acrylic or methacrylic acid with alcohols of 1 to 18 carbon atoms~
preferably alkanols. Examples of alcohols are methanol, e~hanol, n- or isopropanol, n~, sec- and ter~-butanol, n-pentanol, isoamyl alcohol, n-hexanol, cyclohexanol, octanol, 2-ethylhexanol, lauryl alcohol, stearyl alcohol, benzyl alcohol and vinylethanol.
~xamples of esters of acrylic and methacrylic acid are hexyl (meth)acrylate, lauryl (meth)acrylate, cyclohexyl acrylate, phenyle~hyl methacrylate and n-, : :' :~ :
2~5~2~
,, .
- 5 - O.Z. 0050/42166 sec- and tert-butyl (meth)acrylata, benzyl methacrylate, cyclohexyl methacrylate, methyl methacrylate, ethyl methacrylate and especially 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate and n-butyl acrylate.
S Monohydroxyalkyl acryla~es or methacrylates are, for example, 2-hydroxyethyl acrylate, hydroxypropyl acrylate and hydroxybutyl acrylate.
Suitable substances b3 are acrylamide, methacryl-amide, maleic acid, fumaric acid, itaconic acid, glycidyl methacrylate and monomers which have two double bonds copolymerizable with bl and which are preferably oxygen-containing, such as diallyl phthalate, butanediol di-acrylate, hexanediol diacrylate or divinylbenzene, butadiene or isoprene. Preferably from 0 to 2% by weight o~ the monomers containing 2 double bondæ are used.
Success has been achieved in some cases when not less than 0.1% by weight of b3 is used.
The polymer B i5 preferably prepared by free radical emulsion polymerization in the a~ueous phase.
Batch processes or feed processes in which the initiator and/or the monomers which may be emulsified in water are fed in a little at a time or continuously during the polymerization may be u~ed (cf. for example Encyclopaedia of Polymer Science and Engineering, Vol. 6 (1986), 1 to 52). The aqueous copolymer disparsions formed generally have a copolymer concentration, ie. a solids content, of from 40 to 60, in many cases from 45 to 55, % by weight. From 0.2 to 3% by weight, based on the monomers u~ed, of anionic and/or nonionic emulsifiers, for example sodium dialkylsulfosuccinates, sodium salts of sulfated oils, sodium ~alts of alkylsulfonic acids, sodium, potassium and ammonium alkylsulfates, alkali metal sal~s of sulfonic acids, fatty acids, fatty alcohols, fatty amides and alkylphenols, etho~ylated and/or sulfated derivatives thereof, as well as sodium salts of fatty acids, such as sodium stearate and sodium oleate, and sulfonated alkyl 2~9~27 - - 6 - O.Z. 0050/42166 diphenyl ethers, are generally u~ed as emulsifiers.
The pH of the polymer disper~ions is from 3 to 9, preferably from 4 to 8.5. The polymer dispersions generally have a low viscosity, ie. from about 10 to 2S
mPa.s at 23C, and a shear gradient of 280 s-l. The median particle size is from 100 to 300 ~m, preferably from 100 up to 200 ~m (d50 value, ultracentrifuge, W.
Maechtle, Makromolekulare Chemie 185 (1~84), 1025).
Good results are obtained if the polymer B has a glass transition temperature of from 60 to 150C, prefer-ably from 55 to 110C, in particular from 75 to 110C.
The low residual monomer content of the polymers used according to the invention, which is generally less than 500 ppm, based on the diqpersion, i~ advantageou~
for processing. This means that the concentration of working substance in the air at the workplace is extreme-ly low and that the finishe~ articles are virtually odorless.
The polymer dispersions are stable to shear forces and can be transported without problems and con~eyed by means of suitable pumps. Nevertheless, they have very advantageous precipitation behavior. They coagulate with the circulation or process water en-countered in mineral fiber works without further addi-tives, so that the addition of precipitating agents, eg.aluminum sulfate, can advantageously be dispensed with.
However, in the production of shaped wood articles, it may sometimes be advantageous to promote the coagulation of the polymer dispersions by small doses of, for exam-ple, dilute aqueous aluminum sulfate solutions.
~ he novel moldings may contain nonfibrous fillersC in addition to the compon~nts A and B. These may be fire-dried sand~, finely divided clays, such a~ kaolin or montmorillonite, feldspar, chalk, kiesel~uhr and mica, which are preferably used with the mineral fibers. Their amounts may be from 20 to 80, preferably from 30 to 60, % by weight, based on the fibers u~ed.
' ~
, .
.:
2 ~ 7 - 7 - O.Z. 0050/~2166 The moldings may additionally contain not more than 10, preferably from 1 to 3, ~ by weight, based on fibers, of conventional fireproofing agents, such as aluminum silicate, aluminum hydroxide, borates, such as 5sodium tetraborate, and/or phosphates, such as primary sodium phosphate.
Not more than 5, preferably from l to 2, % by weight, basad on the fibers, of conventional water repellent agents, such as silicones and/or waxes, are 10sometimes added during the production o~ the moldings.
It is also possible to add starch, such as corn starch or potato starch, generally in amounts of from 1 to 5% by weight, based on the fibers.
~no~n flocculants, such as polyacrylamides, may 15also be present in small amounts.
The moldings can be produced by various methods.
An aqueous suspension can be prepared, for exampler from fibers A, if required the filler~ C and further additives with thorough mixing. The polymer B, 20as an aqueous dispersion, is advantageously added at the same time or afterwards. The process is carried out in general at room temperature, ie. at from 15 to 35C. The suspensi~n is then generally flocculated by adding a flocculant. The resulting mixture is introduced into a 25mold and dewatered, which may be effecte~, for example, by suction andtor pressing. The still wet molding is usually dried in the course of from 0.1 to 5 hours at from 100 to 250C. Drying ovens, through-circulation dryers, IR lamps or microwave radiators and/or heatable 30presses may be used.
Other production me~hods are also possible. For example, in the production of sheet-like structures, sheet formation can be carried out on ~ Fourdrinier wire and drying can be effected at elevated temperatures (from 35about 70 to 150C). It is also possible to carry out a molding process after sheet formation before effecting drying at elevated temperatures. Furthermore, all 2~6~7 - 8 - O.Z. 0050/42166 additives can be mixed in the d~y or moist state, and mixing may be effected in a fluidized bed. Thereafter, ths mixture is molded and the molding is dried, prefer-ably at elevated temperatures.
Other production processes which have proved suitable in practice in many cases comprise moistening of the fibers and any further additives by spraying or immersion, followed by squeezing off and subsequent drying at elevated temperatures, and it is possible to adjust the densities of such sheet-like structure~ by pressing to a greater or lesser extent during drying.
Furthermore, it is po~sible first to convert fibers and, if required, precipitatiny agentq and addi-tives into a molding, which is then impragnated with the aqueou~ dispersion of the polymer B. This process is described in EP-A 386 579.
The base moldings are advantageou~ly first impregnated with the agueous disper~ion, all-round impregnation being preferred, and are dried and then coated with the pigmented dispersion for decoration.
In order to obtain coatings having an attrac~ive appearance, it i5 advantageous to carry out the total coating procedure in a plurality of operation~ and to dry the particular layer applied between the individual operations, temperatures of from 100 to 180C generally being used. The process can be particularly advantageously used for the production of sound-in3ulating panels having improved dimensional stability in ~he presence of atmospheric humidity, and the sheet-like base molding~ can, if required, be provided with sound-absorbing structures. The novel materials may be applied by spraying, roller-coating or pouring, the surface of the base molding generally being ground ~eforehand. The amounts applied are in general from 2 to ~5 100 g/m2 (calculated in amount~ M of the anhydrou~ co-polymer present in the co~ting material or impregnating material).
:
S Monohydroxyalkyl acryla~es or methacrylates are, for example, 2-hydroxyethyl acrylate, hydroxypropyl acrylate and hydroxybutyl acrylate.
Suitable substances b3 are acrylamide, methacryl-amide, maleic acid, fumaric acid, itaconic acid, glycidyl methacrylate and monomers which have two double bonds copolymerizable with bl and which are preferably oxygen-containing, such as diallyl phthalate, butanediol di-acrylate, hexanediol diacrylate or divinylbenzene, butadiene or isoprene. Preferably from 0 to 2% by weight o~ the monomers containing 2 double bondæ are used.
Success has been achieved in some cases when not less than 0.1% by weight of b3 is used.
The polymer B i5 preferably prepared by free radical emulsion polymerization in the a~ueous phase.
Batch processes or feed processes in which the initiator and/or the monomers which may be emulsified in water are fed in a little at a time or continuously during the polymerization may be u~ed (cf. for example Encyclopaedia of Polymer Science and Engineering, Vol. 6 (1986), 1 to 52). The aqueous copolymer disparsions formed generally have a copolymer concentration, ie. a solids content, of from 40 to 60, in many cases from 45 to 55, % by weight. From 0.2 to 3% by weight, based on the monomers u~ed, of anionic and/or nonionic emulsifiers, for example sodium dialkylsulfosuccinates, sodium salts of sulfated oils, sodium ~alts of alkylsulfonic acids, sodium, potassium and ammonium alkylsulfates, alkali metal sal~s of sulfonic acids, fatty acids, fatty alcohols, fatty amides and alkylphenols, etho~ylated and/or sulfated derivatives thereof, as well as sodium salts of fatty acids, such as sodium stearate and sodium oleate, and sulfonated alkyl 2~9~27 - - 6 - O.Z. 0050/42166 diphenyl ethers, are generally u~ed as emulsifiers.
The pH of the polymer disper~ions is from 3 to 9, preferably from 4 to 8.5. The polymer dispersions generally have a low viscosity, ie. from about 10 to 2S
mPa.s at 23C, and a shear gradient of 280 s-l. The median particle size is from 100 to 300 ~m, preferably from 100 up to 200 ~m (d50 value, ultracentrifuge, W.
Maechtle, Makromolekulare Chemie 185 (1~84), 1025).
Good results are obtained if the polymer B has a glass transition temperature of from 60 to 150C, prefer-ably from 55 to 110C, in particular from 75 to 110C.
The low residual monomer content of the polymers used according to the invention, which is generally less than 500 ppm, based on the diqpersion, i~ advantageou~
for processing. This means that the concentration of working substance in the air at the workplace is extreme-ly low and that the finishe~ articles are virtually odorless.
The polymer dispersions are stable to shear forces and can be transported without problems and con~eyed by means of suitable pumps. Nevertheless, they have very advantageous precipitation behavior. They coagulate with the circulation or process water en-countered in mineral fiber works without further addi-tives, so that the addition of precipitating agents, eg.aluminum sulfate, can advantageously be dispensed with.
However, in the production of shaped wood articles, it may sometimes be advantageous to promote the coagulation of the polymer dispersions by small doses of, for exam-ple, dilute aqueous aluminum sulfate solutions.
~ he novel moldings may contain nonfibrous fillersC in addition to the compon~nts A and B. These may be fire-dried sand~, finely divided clays, such a~ kaolin or montmorillonite, feldspar, chalk, kiesel~uhr and mica, which are preferably used with the mineral fibers. Their amounts may be from 20 to 80, preferably from 30 to 60, % by weight, based on the fibers u~ed.
' ~
, .
.:
2 ~ 7 - 7 - O.Z. 0050/~2166 The moldings may additionally contain not more than 10, preferably from 1 to 3, ~ by weight, based on fibers, of conventional fireproofing agents, such as aluminum silicate, aluminum hydroxide, borates, such as 5sodium tetraborate, and/or phosphates, such as primary sodium phosphate.
Not more than 5, preferably from l to 2, % by weight, basad on the fibers, of conventional water repellent agents, such as silicones and/or waxes, are 10sometimes added during the production o~ the moldings.
It is also possible to add starch, such as corn starch or potato starch, generally in amounts of from 1 to 5% by weight, based on the fibers.
~no~n flocculants, such as polyacrylamides, may 15also be present in small amounts.
The moldings can be produced by various methods.
An aqueous suspension can be prepared, for exampler from fibers A, if required the filler~ C and further additives with thorough mixing. The polymer B, 20as an aqueous dispersion, is advantageously added at the same time or afterwards. The process is carried out in general at room temperature, ie. at from 15 to 35C. The suspensi~n is then generally flocculated by adding a flocculant. The resulting mixture is introduced into a 25mold and dewatered, which may be effecte~, for example, by suction andtor pressing. The still wet molding is usually dried in the course of from 0.1 to 5 hours at from 100 to 250C. Drying ovens, through-circulation dryers, IR lamps or microwave radiators and/or heatable 30presses may be used.
Other production me~hods are also possible. For example, in the production of sheet-like structures, sheet formation can be carried out on ~ Fourdrinier wire and drying can be effected at elevated temperatures (from 35about 70 to 150C). It is also possible to carry out a molding process after sheet formation before effecting drying at elevated temperatures. Furthermore, all 2~6~7 - 8 - O.Z. 0050/42166 additives can be mixed in the d~y or moist state, and mixing may be effected in a fluidized bed. Thereafter, ths mixture is molded and the molding is dried, prefer-ably at elevated temperatures.
Other production processes which have proved suitable in practice in many cases comprise moistening of the fibers and any further additives by spraying or immersion, followed by squeezing off and subsequent drying at elevated temperatures, and it is possible to adjust the densities of such sheet-like structure~ by pressing to a greater or lesser extent during drying.
Furthermore, it is po~sible first to convert fibers and, if required, precipitatiny agentq and addi-tives into a molding, which is then impragnated with the aqueou~ dispersion of the polymer B. This process is described in EP-A 386 579.
The base moldings are advantageou~ly first impregnated with the agueous disper~ion, all-round impregnation being preferred, and are dried and then coated with the pigmented dispersion for decoration.
In order to obtain coatings having an attrac~ive appearance, it i5 advantageous to carry out the total coating procedure in a plurality of operation~ and to dry the particular layer applied between the individual operations, temperatures of from 100 to 180C generally being used. The process can be particularly advantageously used for the production of sound-in3ulating panels having improved dimensional stability in ~he presence of atmospheric humidity, and the sheet-like base molding~ can, if required, be provided with sound-absorbing structures. The novel materials may be applied by spraying, roller-coating or pouring, the surface of the base molding generally being ground ~eforehand. The amounts applied are in general from 2 to ~5 100 g/m2 (calculated in amount~ M of the anhydrou~ co-polymer present in the co~ting material or impregnating material).
:
_ g _ O.Z. 0050/42166 The novel, generally concrete-free moldings are in particular boards, ie. square elements, usually having a width/length ratio of from 1 : 1 to 1 : 5 and a height/length ratio of from 1 : 10 to 1 : 100.
Exampl~s are mineral fiber boards or wood fiber boards, which may be uæed as ceiling panels or sound-insulating panels. The visible surface of the panels may be provided with known sound-absorbing structures and, in a conventional manner, with decorative coatings~ The sound insulating (ceiling) panels obtained in this manner have very good insulating behavior, are very rigid, even in the moi~t state, and readily release the absorbed moisture again.
Surprisingly, the disadvantages described above are avoided in the novel moldings. Although the polymers B are thermoplastics, as components of the moldings they perform all binding functions o the thermosetting plastics, such as rigidity. Also surprising is the fact that the polymers ensure that the moldings are rigid even in a humid and warm atmosphere and even i~ a limited amount of starch is present in the shaped articles.
Another positive factor is that the polymers can ba readily prepared by emulsion polymerization. Treatment of the moldings with biocides or fungicide~ can be dispensed with since the polymers are not degraded under the conditions of production and use of the boards.
Nevertheless, the disposal of binder residues and also of the moldings produced therewith presents no problems.
The polymers form water-insoluble compounds with poly-valent ions, eg. calcium ions, magnesium ions or Fe(III~
ions, or are precipitated ~y these and thus cannot enter the groundwater. The calcium compounds are very highly adsorbed onto the solid particles in wastewater treatment plants. Polymers which are composed only of carbon hydrogen and oxygen have particular advantages in thi~
re~pect.
In the Example~ which follow, partR and .
2~g27 - - 10 - O.Z. 0050/42166 percentages are by weight, unless stated otherwise.
The investigations of boards produced by way of example were carried out by the following methods:
Density of the mineral fiber boards Test specimens having the dimensions 250 mm x 50 mm are cut out. The thickness is determined with a caliper gage and is used for calculating the volume. The density is calculated in g/cm3, as a mean value of 2 test specimens.
Density of ~he wood fiber boards Circular test specimens with D = 9 mm are punched out by means of a punch. ~he thickness is measured with a caliper gage and is used to calculate the volume, the density is calculated in g/cm3 as the mean value of 3 test specimens.
Water absorption Test specimens having the dimensions 250 mm x 50 mm are stored under water at room temperature under a load for l hour or 2 hours. After removing excess liquid by dabbing off, the weight increase is determined by weighing as the mean value of 2 test specimens in each case, as a percentage of the weight increaseO
Dimensional stability (measure of the rigidity) Test specimens measuring 250 mm x S0 mm are ground by means of a belt grinder until they are 15 mm thick. The side facing the wire during sheet formation is ground.
The test specimens thus obtained are placed flat in an atmosphere of 38C and 95~ relative humidity, horizontal close to the end edges and loaded with a 1 kg weight in the middle, so that the load act~ on the total length of the test specimen. The sag of the test speci-men is measured after the load has been removed and an indication of the long-term behavior of mineral fiber boards is thus obtained.
Bxeaking force The breaking force is detexmined according to DIN
:
.
2 ~ 7 ~ O.Z. 0050/42166 53,455.
The polymer dispersions B used a~ binders in the Examples were prepared by the following general method:
The dispersions were prepared by aqueous free radical emulsion polymerization from the monomers, which were emulsified with the aid of the emulsifiers in half the amount of water used for preparation, using 0.5~ by weight, based on the monomers, of sodium peroxodisulfate as an initiator in the form of a 2.5~ strength by weight solution at 80C. For this purpose, half the water used for preparation was initially taken and 10% by weight of the initiator solution were added while stirring at the polymerization temperature. Thereafter, the monomer emulsion was added continuously to the polymerization vessel with stirring, in the course of 2 hours, and the initiator solution in the course of 2.5 hours. For post-polymeriæation, stirring was carried out for 2 hours at the polymerization temperature and working up was then effec~ed in a known manner. The amount of water used for preparation was such that the stated solids contents were obtained.
The fatty acid salts mentioned a~ emulsifiers in Examples 3 to 8 were prepared in situ by neutralizing the corre~ponding carboxylic acids with sodium hydroxide solution. Nonomer emulsions were prepared by adding the monomers and, if required, water or the other emul-si~iers. In the Examples, furthermore, one third of the water u~ed for preparation was initially taken and two thirds were used for the monomer emulsion. Otherwise, the procedure was as described above~
The glass transition temperatures Tg wexe deter-mined by differential thermal analysis (DTA) according to ASTM D 3418-82 (midpoint temperature~.
Binder: 52.4~ strength aqueous dispersion of a polymer of 98~ by weight of styrene 2~ by weight of acrylic acid 2~5~627 - 12 - O.Z. 0050/42166 Tg: 102C
Emulsifier: 1.25% of sodium C12-C15-alkylsulfonate pH: 3.1 A suspension of 235 g of basalt wool 80 g of kaolin 18 g of aluminum hydroxide 38 g of the abovementioned polymer dispersion 3 g of a commercial about 35% stren~th polysiloxane dispQr~ion for Lmparting water repallency in 6 1 of procesq water is prepared with gentle stirring.
About 3 minutes are requir~d for this purpose. This suspension is flocculated by adding 4.5 g of a 10%
strength aqueous solution of a pol~mer of 70~ by weight of acrylamide ~nd 30~ by weight of diethylaminoethyl acrylate. The fiber slurry thuq obtained is poured into a wire frame having a wire area of 25 cm x 25 cm and is distributed uniformly by means of a wooden spatula. The fiber slurry layer is drained under slightly reduced pres~ure and by careful pressing with a punch (25 cm x 25 cm, pressure not more than 0.1 bar), no more than 0.5 minute being required for this purpose.
~ crude board about 18 mm thick and having an average residual moisture content of 60~ is obtained.
The crude board is dried on siliconized paper in a through-circulation drying oven at 180~C in the course of 2.5 hours.
Properties of the mineral fiber board Density: 0.35 g/cm3 0 Water absorption after 1 h: 6.1%
after 2 h: 6.5%
Dimensional stability: less ~han 1 mm after 290 h.
EX~MPLE 2 Binder: 29.8% strength aqueous dispersion of a polymar of 90% by weight of styrene 10% by weight of methacrylic acid ' .
.:
.
2~9~27 - - 13 - O.Z. 0050/42166 Tg: 107C
Emulsifier: 1.9~ of sodium Clz-C15-alkylsulfonate pH: 3.2 Procedure according to Example 1 The following are used:
245 g of basalt wool 90 g of kaolin 13 g of aluminum hydro~ide 44 g of the abovementioned polymer dispersion Flocculant and water ~epellent agent according to Example 1.
Properties:
Density: 0.32 g/cm3 Water absorption after 1 h: 4.1%
after 2 h: 5.9%
Dimensional ~tability; less than 1 mm after 289 h.
Binder: 49.7% strength aqueous dispersion of a polymer of 90~ by weight of styrene 10% by weight of ethyl acrylate Tg: 93C
Emulsifier: 2.2~ of ~odium laurate pH: 8.2 The following are used:
235 g of slag wool 80 g of kaolin 20 g of aluminum hydroxide 48 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Den~ity: 0.31 g~cm3 Water absorption after 1 h: 4.3%
after 2 h: 5.8%
Dimensional stability: less than 1 mm after 290 h.
- 2~627 - - 14 - O.Z. 0050/42166 Binder: 45.3% strength aqu~ous dispersion of a polymer of 86~ by weight of styrene 10~ by weight of methacrylate 4~ by weight of hydroxyethyl acrylate Tg: 89C
Emulsifier: 2~ of sodium oleate pH: 7.8 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 43 g of the abovementioned polymer dispersion Procedure, flocculant and wa~er repellent agent according to Example 1.
Properties:
Density: 0.35 g/cm3 Water absorption after 1 h: 5.8%
after 2 h: 6.5%
Dimensional stability: less than 1 mm after 270 h.
A suspension of fibers in 6 l of water i8 prepa-red with thorough stirring. About 3 minute is required for this purpose. The next step i~ the addition o~ the binder dispersion, followed by a precipitating agent, eg.
aluminum sulfate. 4.5 g o~ a 10~ strength agueous solution of a polymer of 70% by weight of acrylamide and 30% by weight of diethylaminoethyl acrylate are added as a flocculant, likewise with stirring.
For sheet forma~ion, the fiber slurry is poured into a wire frame having a wire area of 25 cm x 25 cm and the material is uniformly distributed by means of a wooden spatula. The material is then drained under slightly reduced pressure. Moist crude boards, which are generally from 8 to 9 mm thick and contain about 60% of water, are obtained by gentle pressinq (less than 0.1 2 ~ 2 ~
- 15 - O.Z. 0050/42166 bar) with a punch (25 cm x 25 cm) and careful sucking off.
The crude boards are dried in a microwave oven to residual moisture contents of from 10 to 15% and then in a heated pres~ at 220C and at S0 kp/cm2 for 90 s.
Binder: 49.8% strength aqueous dispersion of a polymer of 75~ by weight of styrene 25~ by weight of n-butyl acrylate Tg: 69C
Emulsifier: 1.9% of ssdium oleate pH: 8.0 The following are used:
100 g of wood fibers 8 g of cellulose fibers 17 g of polypropylene fibers 15 g of an 8~ strength emulsion of stearyldiketene (water xepellent agent) l9 g o the abovementioned polymer dispersion 7.5 g of a 10% strength aqueous aluminum sulfate solution 4.5 g of flocculant Properties:
Density: 0.83 g/cm3 Water absorption after 1 h: 5.3%
after 2 h: 7.1%
Breaking force: 9 N/mm2 Binder: 46.7% strength aqueous dispersion of a polymer of 80% by weight of styrene 10% by weight of acrylonitrile 10% by weight of methyl acrylate Tg: 92C
Emulsifier: 3.0% of sodium laurate pH: 8.5 The following are used:
6 l of process water : ` ~
2 ~ ~ 9 6 2 1 - 16 - O.Z~ 0050/42166 100 g of wood fibers 10 g of cellulose fibers 10 g of polypropylene fibers 18 g of the abovementioned polymer dispersion 4.5 g of the flocculan~ as in Example 5 (no water repellent or precipitating agent) Properties:
Density: 0.80 g/cm3 Water absorption after 1 h: 5.5%
after 2 h: 6.3%
Breaking force: 12 N/mm2 Binder: 48.1~ strength aqueous di~persion of a polymer of 80~ by weight of styrene 20% by weight of acrylonitrile Tg: 103C
Emulsifier: 2.5% of sodium oleate pH: 8.5 The following are used:
6 1 of proces~ water 100 g of wood fibers 20 g of polyacrylonitrile fiber~
18 g of the abovementioned polymer dispersion :
4.5 g of the flocculant a~ in Example 5 ~no water repellent or precipita~ing agent) .
Properties:
Density: 0.78 g/cm3 Water absorption after 1 h: 4.4%
after 2 h: 5.4~
Breaking force: 15 N/mm2 Binder: 45.8% strength a~ueous dispersion of a polymer of 80% by weight of styrene 20% by weiyht of methyl acrylate Tg: 84C
, , , . . ~
: : ', , , - 17 - ~Z. O0S0 ~ 6?62 7 Emulsifier: 4.5% of sodium laurate pH: 7.8 The following are used:
6 1 of process water 105 g of wood fibers 15 g of cellulose fibers 15 g of polypropylene fibers 16 g of the abovementioned polymer dispersion 6 g of a 10~ strength aluminum sulfate solution 4.5 g of the flocculant as in Example 5 (no water repellent agent) Properties:
Density: 0.79 g/cm3 Water absorption after 1 h: 5.1%
after 2 h: 5.9%
Breaking force: 14 N/mm2 Binder: 29.7~ strength aqueous dispersion of a polymer of 67.5% by weight of styrene 30% by weight of n-butyl acrylate 2.5% by weight of N-methylolacrylamide Tg: 43~C
Emulsifier: 1.4% of the Na salt of a half-ester of an ethoxylated fatty alcohol with sulfuric acid (degree of ethoxylation: 2) pH: 2.3 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 66 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.33 g/cm3 Water absorp~ion after 1 h: 5.6%
:
2 ~ 7 ~ 18 - O.Z. 0050~42166 after 2 h: 7.2%
DimPnsional ~tability: Fracture within 8 h.
Binder: Polymer dispersion from Comparative Example 1 The following are used:
100 g of wood fibers 8 g of cellulo~e fibers 17 g of polypropylene fibers 15 g of an 8~ strength emulsion of stearyldiXetene ~water repellent agent) 34 g of the abovementioned polymer dispersion 7.5 g of a 10% strength aqueous aluminum sulfate solution 4.5 g of flocculant Procedure according to Example 5.
Properties:
Density: 0.77 g/cm3 Water absorption after 1 h: 46.0 after 2 h: 57.7~
Breaking force: < 1 N/mm2 Binder: 29.1~ strength aqueous dispersion of a polymer of 93.2~ by weight of styrene 5.0% by weight of butadiene 1.8% by weight of the Na salt of methacrylic acid Tg: 9 3C
Emulsifier: 1.5~ of Na salt of a half-ester of an ethox~
ylated fatty alcohol with sulfuric acid (degree of ethoxylation: 2) pH: 8.6 The following are u3ed:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 67 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
~:
- 19 - O.Z. 0050/~2166 Properties:
Density: 0.34 g/cm3 Water absorption after 1 h: 4.0%
after 2 h: 6.9%
Binder: 28.7% strength aqueous dispersion of a polymer of 85.6~ by weight of styrene 12.8% by weight of butadiene 1.6% by weight of the Na salt of methacrylic acid Tg: 84C
Emulsifier: 1.5~ of the Na salt of a half-ester of an ethoxylated fatty alcohol with sulfuric acid (dPgree of ethoxylation: 2) pH: 8.4 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 66 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties-Density: 0.31 g/cm3 5 Water absorption after 1 h: 16.6% after 2 h: 23.2%
Binder: 30% streng~h aqueous dispersion of a polymex of 70% by weight of st.yrene 30~ by weight of acrylonitrile Tg: 87C
Emul~ifier: 1.5% of the Na salt of a half-ester of an et~oxylated fa~ty alcohol with sulfuric acid (degree of ethoxylation: 2) pH: 2.8 The following are u~ed:
220 g of ~lag wool ,, . ' 2 ~ 2 7 - 20 - O.Z. 0050/42166 1~0 g of kaolin 12 g of aluminum hydroxide 65 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.33 g/cm3 Water absorption after 1 h: 27.5%
after 2 hs 42.1~
Dimensional stability: Fracture within 8 h.
COMPARATIVE EXAMPLE S
Binder: As in Comparative Example 4 The following are used:
6 l of process water 100 ~ of wood fibers 10 g of cellulose fibers 10 g of polypropylene fibers 29 g of the abovementioned polymer dispersion 4.5 g of the flocculant as in Example 5 (no water repellent agent or precipitating agent) Procedure otherwise according to Example 5 Properties:
Density: 0.67 g/cm3 Water absorption after 1 h: 148 after 2 h: >> 148~
Breaking force: 0.1 N/mm2 Binder: 29.5% strength aqueous dispersion of a polymer of 40% by weight of styrene 60% by weight of ethyl methacrylate Tg: 78aC
Emulsifiers 1.4~ of the Na salt of a half-ester of ethoxylated fatty alcohol with sulfuric acid (degree of ethoxylation. 2) pH: 2.9 The following are used:
- 2 ~
- - 21 - O.Z. 0050/42166 220 g of slag wool 120 g of kaolin 12 g of aluminum hydro~ide 66 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.29 g/cm3 Water absorption after 1 h: 31.3%
after 2 h: 49.3%
Dimensional stability: Fracture within 8 h.
Binder: As in Comparative Example 6 The following are used:
100 g of wood fibers 8 g of cellulose fibers 17 g of polypropylene fibers 15 g of an 8% strength emulsion of stearyldiketene (water repellent agent) 32 g of the abovementioned polymer dispersion 7.5 g of a 10% strength aqueous aluminum sulfate solution 4.5 g of flocculant Procedure as in Example 5 Properties:
Density: 0.65 g/cm3 Water absorption after 1 h: 93.2%
after 2 h: 154.5%
Breaking force: 0.1 N/mm2 Binder: 30.5~ strength aqueous dispersion of a polymer of 89% by weight of methyl methacryla~e 10% by weight of n-butyl acryla~e 10~ by weight of methacrylic acid Tg: 88C
Emulsifier: 1.4~ of the Na salt of a half-ester of an ethoxylated fatty alcohol with sulfuric acid ` . .
2 ~ ?d 7 - 22 - o. z . 0050/42166 (degree of ethoxylation: 2) p~: 2.1 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 64 g of the abovementioned polymer dispersion ;:
Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.29 g/cm3 Water absorption after l h: 20.9 after 2 h: 84. 6%
DLmensional stability: Fracture within 8 h.
Binder: 30.2~ strength aqueous dispersion of a polymer of 89.5% by weight of methyl methacrylate 10% by weight of n-ethyl methacrylate 0.5% by weight of methacrylic acid Tg: ~7C
Emulsifier: 1.4% of the Na salt of a half-ester of an ethoxylated fatty alcohol with sulfuric acid (degree of ethoxylation: 2) pH: 2.7 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 65 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.29 g/cm3 Water absorption after l h: 37.6%
after 2 h~ 47.8%
Dimensional stability: Fracture after 8 h.
2 ~ 2 ~
- 23 - O.Z. 0050/42166 CO~PARATIVE EXAMæLE 10 Binder: As in Comparative Example 8 The following are used:
100 g of wood fibers 8 g of cellulose ibers 17 g of polypropylene fibers 15 g of an 8% strength emul~ion of stearyldiketene (water repellent agent) 31 g of the abovementioned polymer dispersion 7.5 g of a 10% strength aluminum sulfate solution 4.5 g of flocculant Procedure according to Example 5.
Properties:
Density: 0.71 g/cm3 5 Water absorption after 1 h: 14.5 after 2 h: 17.0~
~ COMPARATIVE EXAMPLE 11 As for Comparative Example 10, but binder as in Comparative Example 9 Properties:
Density: 0.77 g/cm3 Water absorption after 1 h: 12.3%
after 2 h: 16.8%~
Exampl~s are mineral fiber boards or wood fiber boards, which may be uæed as ceiling panels or sound-insulating panels. The visible surface of the panels may be provided with known sound-absorbing structures and, in a conventional manner, with decorative coatings~ The sound insulating (ceiling) panels obtained in this manner have very good insulating behavior, are very rigid, even in the moi~t state, and readily release the absorbed moisture again.
Surprisingly, the disadvantages described above are avoided in the novel moldings. Although the polymers B are thermoplastics, as components of the moldings they perform all binding functions o the thermosetting plastics, such as rigidity. Also surprising is the fact that the polymers ensure that the moldings are rigid even in a humid and warm atmosphere and even i~ a limited amount of starch is present in the shaped articles.
Another positive factor is that the polymers can ba readily prepared by emulsion polymerization. Treatment of the moldings with biocides or fungicide~ can be dispensed with since the polymers are not degraded under the conditions of production and use of the boards.
Nevertheless, the disposal of binder residues and also of the moldings produced therewith presents no problems.
The polymers form water-insoluble compounds with poly-valent ions, eg. calcium ions, magnesium ions or Fe(III~
ions, or are precipitated ~y these and thus cannot enter the groundwater. The calcium compounds are very highly adsorbed onto the solid particles in wastewater treatment plants. Polymers which are composed only of carbon hydrogen and oxygen have particular advantages in thi~
re~pect.
In the Example~ which follow, partR and .
2~g27 - - 10 - O.Z. 0050/42166 percentages are by weight, unless stated otherwise.
The investigations of boards produced by way of example were carried out by the following methods:
Density of the mineral fiber boards Test specimens having the dimensions 250 mm x 50 mm are cut out. The thickness is determined with a caliper gage and is used for calculating the volume. The density is calculated in g/cm3, as a mean value of 2 test specimens.
Density of ~he wood fiber boards Circular test specimens with D = 9 mm are punched out by means of a punch. ~he thickness is measured with a caliper gage and is used to calculate the volume, the density is calculated in g/cm3 as the mean value of 3 test specimens.
Water absorption Test specimens having the dimensions 250 mm x 50 mm are stored under water at room temperature under a load for l hour or 2 hours. After removing excess liquid by dabbing off, the weight increase is determined by weighing as the mean value of 2 test specimens in each case, as a percentage of the weight increaseO
Dimensional stability (measure of the rigidity) Test specimens measuring 250 mm x S0 mm are ground by means of a belt grinder until they are 15 mm thick. The side facing the wire during sheet formation is ground.
The test specimens thus obtained are placed flat in an atmosphere of 38C and 95~ relative humidity, horizontal close to the end edges and loaded with a 1 kg weight in the middle, so that the load act~ on the total length of the test specimen. The sag of the test speci-men is measured after the load has been removed and an indication of the long-term behavior of mineral fiber boards is thus obtained.
Bxeaking force The breaking force is detexmined according to DIN
:
.
2 ~ 7 ~ O.Z. 0050/42166 53,455.
The polymer dispersions B used a~ binders in the Examples were prepared by the following general method:
The dispersions were prepared by aqueous free radical emulsion polymerization from the monomers, which were emulsified with the aid of the emulsifiers in half the amount of water used for preparation, using 0.5~ by weight, based on the monomers, of sodium peroxodisulfate as an initiator in the form of a 2.5~ strength by weight solution at 80C. For this purpose, half the water used for preparation was initially taken and 10% by weight of the initiator solution were added while stirring at the polymerization temperature. Thereafter, the monomer emulsion was added continuously to the polymerization vessel with stirring, in the course of 2 hours, and the initiator solution in the course of 2.5 hours. For post-polymeriæation, stirring was carried out for 2 hours at the polymerization temperature and working up was then effec~ed in a known manner. The amount of water used for preparation was such that the stated solids contents were obtained.
The fatty acid salts mentioned a~ emulsifiers in Examples 3 to 8 were prepared in situ by neutralizing the corre~ponding carboxylic acids with sodium hydroxide solution. Nonomer emulsions were prepared by adding the monomers and, if required, water or the other emul-si~iers. In the Examples, furthermore, one third of the water u~ed for preparation was initially taken and two thirds were used for the monomer emulsion. Otherwise, the procedure was as described above~
The glass transition temperatures Tg wexe deter-mined by differential thermal analysis (DTA) according to ASTM D 3418-82 (midpoint temperature~.
Binder: 52.4~ strength aqueous dispersion of a polymer of 98~ by weight of styrene 2~ by weight of acrylic acid 2~5~627 - 12 - O.Z. 0050/42166 Tg: 102C
Emulsifier: 1.25% of sodium C12-C15-alkylsulfonate pH: 3.1 A suspension of 235 g of basalt wool 80 g of kaolin 18 g of aluminum hydroxide 38 g of the abovementioned polymer dispersion 3 g of a commercial about 35% stren~th polysiloxane dispQr~ion for Lmparting water repallency in 6 1 of procesq water is prepared with gentle stirring.
About 3 minutes are requir~d for this purpose. This suspension is flocculated by adding 4.5 g of a 10%
strength aqueous solution of a pol~mer of 70~ by weight of acrylamide ~nd 30~ by weight of diethylaminoethyl acrylate. The fiber slurry thuq obtained is poured into a wire frame having a wire area of 25 cm x 25 cm and is distributed uniformly by means of a wooden spatula. The fiber slurry layer is drained under slightly reduced pres~ure and by careful pressing with a punch (25 cm x 25 cm, pressure not more than 0.1 bar), no more than 0.5 minute being required for this purpose.
~ crude board about 18 mm thick and having an average residual moisture content of 60~ is obtained.
The crude board is dried on siliconized paper in a through-circulation drying oven at 180~C in the course of 2.5 hours.
Properties of the mineral fiber board Density: 0.35 g/cm3 0 Water absorption after 1 h: 6.1%
after 2 h: 6.5%
Dimensional stability: less ~han 1 mm after 290 h.
EX~MPLE 2 Binder: 29.8% strength aqueous dispersion of a polymar of 90% by weight of styrene 10% by weight of methacrylic acid ' .
.:
.
2~9~27 - - 13 - O.Z. 0050/42166 Tg: 107C
Emulsifier: 1.9~ of sodium Clz-C15-alkylsulfonate pH: 3.2 Procedure according to Example 1 The following are used:
245 g of basalt wool 90 g of kaolin 13 g of aluminum hydro~ide 44 g of the abovementioned polymer dispersion Flocculant and water ~epellent agent according to Example 1.
Properties:
Density: 0.32 g/cm3 Water absorption after 1 h: 4.1%
after 2 h: 5.9%
Dimensional ~tability; less than 1 mm after 289 h.
Binder: 49.7% strength aqueous dispersion of a polymer of 90~ by weight of styrene 10% by weight of ethyl acrylate Tg: 93C
Emulsifier: 2.2~ of ~odium laurate pH: 8.2 The following are used:
235 g of slag wool 80 g of kaolin 20 g of aluminum hydroxide 48 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Den~ity: 0.31 g~cm3 Water absorption after 1 h: 4.3%
after 2 h: 5.8%
Dimensional stability: less than 1 mm after 290 h.
- 2~627 - - 14 - O.Z. 0050/42166 Binder: 45.3% strength aqu~ous dispersion of a polymer of 86~ by weight of styrene 10~ by weight of methacrylate 4~ by weight of hydroxyethyl acrylate Tg: 89C
Emulsifier: 2~ of sodium oleate pH: 7.8 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 43 g of the abovementioned polymer dispersion Procedure, flocculant and wa~er repellent agent according to Example 1.
Properties:
Density: 0.35 g/cm3 Water absorption after 1 h: 5.8%
after 2 h: 6.5%
Dimensional stability: less than 1 mm after 270 h.
A suspension of fibers in 6 l of water i8 prepa-red with thorough stirring. About 3 minute is required for this purpose. The next step i~ the addition o~ the binder dispersion, followed by a precipitating agent, eg.
aluminum sulfate. 4.5 g o~ a 10~ strength agueous solution of a polymer of 70% by weight of acrylamide and 30% by weight of diethylaminoethyl acrylate are added as a flocculant, likewise with stirring.
For sheet forma~ion, the fiber slurry is poured into a wire frame having a wire area of 25 cm x 25 cm and the material is uniformly distributed by means of a wooden spatula. The material is then drained under slightly reduced pressure. Moist crude boards, which are generally from 8 to 9 mm thick and contain about 60% of water, are obtained by gentle pressinq (less than 0.1 2 ~ 2 ~
- 15 - O.Z. 0050/42166 bar) with a punch (25 cm x 25 cm) and careful sucking off.
The crude boards are dried in a microwave oven to residual moisture contents of from 10 to 15% and then in a heated pres~ at 220C and at S0 kp/cm2 for 90 s.
Binder: 49.8% strength aqueous dispersion of a polymer of 75~ by weight of styrene 25~ by weight of n-butyl acrylate Tg: 69C
Emulsifier: 1.9% of ssdium oleate pH: 8.0 The following are used:
100 g of wood fibers 8 g of cellulose fibers 17 g of polypropylene fibers 15 g of an 8~ strength emulsion of stearyldiketene (water xepellent agent) l9 g o the abovementioned polymer dispersion 7.5 g of a 10% strength aqueous aluminum sulfate solution 4.5 g of flocculant Properties:
Density: 0.83 g/cm3 Water absorption after 1 h: 5.3%
after 2 h: 7.1%
Breaking force: 9 N/mm2 Binder: 46.7% strength aqueous dispersion of a polymer of 80% by weight of styrene 10% by weight of acrylonitrile 10% by weight of methyl acrylate Tg: 92C
Emulsifier: 3.0% of sodium laurate pH: 8.5 The following are used:
6 l of process water : ` ~
2 ~ ~ 9 6 2 1 - 16 - O.Z~ 0050/42166 100 g of wood fibers 10 g of cellulose fibers 10 g of polypropylene fibers 18 g of the abovementioned polymer dispersion 4.5 g of the flocculan~ as in Example 5 (no water repellent or precipitating agent) Properties:
Density: 0.80 g/cm3 Water absorption after 1 h: 5.5%
after 2 h: 6.3%
Breaking force: 12 N/mm2 Binder: 48.1~ strength aqueous di~persion of a polymer of 80~ by weight of styrene 20% by weight of acrylonitrile Tg: 103C
Emulsifier: 2.5% of sodium oleate pH: 8.5 The following are used:
6 1 of proces~ water 100 g of wood fibers 20 g of polyacrylonitrile fiber~
18 g of the abovementioned polymer dispersion :
4.5 g of the flocculant a~ in Example 5 ~no water repellent or precipita~ing agent) .
Properties:
Density: 0.78 g/cm3 Water absorption after 1 h: 4.4%
after 2 h: 5.4~
Breaking force: 15 N/mm2 Binder: 45.8% strength a~ueous dispersion of a polymer of 80% by weight of styrene 20% by weiyht of methyl acrylate Tg: 84C
, , , . . ~
: : ', , , - 17 - ~Z. O0S0 ~ 6?62 7 Emulsifier: 4.5% of sodium laurate pH: 7.8 The following are used:
6 1 of process water 105 g of wood fibers 15 g of cellulose fibers 15 g of polypropylene fibers 16 g of the abovementioned polymer dispersion 6 g of a 10~ strength aluminum sulfate solution 4.5 g of the flocculant as in Example 5 (no water repellent agent) Properties:
Density: 0.79 g/cm3 Water absorption after 1 h: 5.1%
after 2 h: 5.9%
Breaking force: 14 N/mm2 Binder: 29.7~ strength aqueous dispersion of a polymer of 67.5% by weight of styrene 30% by weight of n-butyl acrylate 2.5% by weight of N-methylolacrylamide Tg: 43~C
Emulsifier: 1.4% of the Na salt of a half-ester of an ethoxylated fatty alcohol with sulfuric acid (degree of ethoxylation: 2) pH: 2.3 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 66 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.33 g/cm3 Water absorp~ion after 1 h: 5.6%
:
2 ~ 7 ~ 18 - O.Z. 0050~42166 after 2 h: 7.2%
DimPnsional ~tability: Fracture within 8 h.
Binder: Polymer dispersion from Comparative Example 1 The following are used:
100 g of wood fibers 8 g of cellulo~e fibers 17 g of polypropylene fibers 15 g of an 8~ strength emulsion of stearyldiXetene ~water repellent agent) 34 g of the abovementioned polymer dispersion 7.5 g of a 10% strength aqueous aluminum sulfate solution 4.5 g of flocculant Procedure according to Example 5.
Properties:
Density: 0.77 g/cm3 Water absorption after 1 h: 46.0 after 2 h: 57.7~
Breaking force: < 1 N/mm2 Binder: 29.1~ strength aqueous dispersion of a polymer of 93.2~ by weight of styrene 5.0% by weight of butadiene 1.8% by weight of the Na salt of methacrylic acid Tg: 9 3C
Emulsifier: 1.5~ of Na salt of a half-ester of an ethox~
ylated fatty alcohol with sulfuric acid (degree of ethoxylation: 2) pH: 8.6 The following are u3ed:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 67 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
~:
- 19 - O.Z. 0050/~2166 Properties:
Density: 0.34 g/cm3 Water absorption after 1 h: 4.0%
after 2 h: 6.9%
Binder: 28.7% strength aqueous dispersion of a polymer of 85.6~ by weight of styrene 12.8% by weight of butadiene 1.6% by weight of the Na salt of methacrylic acid Tg: 84C
Emulsifier: 1.5~ of the Na salt of a half-ester of an ethoxylated fatty alcohol with sulfuric acid (dPgree of ethoxylation: 2) pH: 8.4 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 66 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties-Density: 0.31 g/cm3 5 Water absorption after 1 h: 16.6% after 2 h: 23.2%
Binder: 30% streng~h aqueous dispersion of a polymex of 70% by weight of st.yrene 30~ by weight of acrylonitrile Tg: 87C
Emul~ifier: 1.5% of the Na salt of a half-ester of an et~oxylated fa~ty alcohol with sulfuric acid (degree of ethoxylation: 2) pH: 2.8 The following are u~ed:
220 g of ~lag wool ,, . ' 2 ~ 2 7 - 20 - O.Z. 0050/42166 1~0 g of kaolin 12 g of aluminum hydroxide 65 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.33 g/cm3 Water absorption after 1 h: 27.5%
after 2 hs 42.1~
Dimensional stability: Fracture within 8 h.
COMPARATIVE EXAMPLE S
Binder: As in Comparative Example 4 The following are used:
6 l of process water 100 ~ of wood fibers 10 g of cellulose fibers 10 g of polypropylene fibers 29 g of the abovementioned polymer dispersion 4.5 g of the flocculant as in Example 5 (no water repellent agent or precipitating agent) Procedure otherwise according to Example 5 Properties:
Density: 0.67 g/cm3 Water absorption after 1 h: 148 after 2 h: >> 148~
Breaking force: 0.1 N/mm2 Binder: 29.5% strength aqueous dispersion of a polymer of 40% by weight of styrene 60% by weight of ethyl methacrylate Tg: 78aC
Emulsifiers 1.4~ of the Na salt of a half-ester of ethoxylated fatty alcohol with sulfuric acid (degree of ethoxylation. 2) pH: 2.9 The following are used:
- 2 ~
- - 21 - O.Z. 0050/42166 220 g of slag wool 120 g of kaolin 12 g of aluminum hydro~ide 66 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.29 g/cm3 Water absorption after 1 h: 31.3%
after 2 h: 49.3%
Dimensional stability: Fracture within 8 h.
Binder: As in Comparative Example 6 The following are used:
100 g of wood fibers 8 g of cellulose fibers 17 g of polypropylene fibers 15 g of an 8% strength emulsion of stearyldiketene (water repellent agent) 32 g of the abovementioned polymer dispersion 7.5 g of a 10% strength aqueous aluminum sulfate solution 4.5 g of flocculant Procedure as in Example 5 Properties:
Density: 0.65 g/cm3 Water absorption after 1 h: 93.2%
after 2 h: 154.5%
Breaking force: 0.1 N/mm2 Binder: 30.5~ strength aqueous dispersion of a polymer of 89% by weight of methyl methacryla~e 10% by weight of n-butyl acryla~e 10~ by weight of methacrylic acid Tg: 88C
Emulsifier: 1.4~ of the Na salt of a half-ester of an ethoxylated fatty alcohol with sulfuric acid ` . .
2 ~ ?d 7 - 22 - o. z . 0050/42166 (degree of ethoxylation: 2) p~: 2.1 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 64 g of the abovementioned polymer dispersion ;:
Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.29 g/cm3 Water absorption after l h: 20.9 after 2 h: 84. 6%
DLmensional stability: Fracture within 8 h.
Binder: 30.2~ strength aqueous dispersion of a polymer of 89.5% by weight of methyl methacrylate 10% by weight of n-ethyl methacrylate 0.5% by weight of methacrylic acid Tg: ~7C
Emulsifier: 1.4% of the Na salt of a half-ester of an ethoxylated fatty alcohol with sulfuric acid (degree of ethoxylation: 2) pH: 2.7 The following are used:
220 g of slag wool 120 g of kaolin 12 g of aluminum hydroxide 65 g of the abovementioned polymer dispersion Procedure, flocculant and water repellent agent according to Example 1.
Properties:
Density: 0.29 g/cm3 Water absorption after l h: 37.6%
after 2 h~ 47.8%
Dimensional stability: Fracture after 8 h.
2 ~ 2 ~
- 23 - O.Z. 0050/42166 CO~PARATIVE EXAMæLE 10 Binder: As in Comparative Example 8 The following are used:
100 g of wood fibers 8 g of cellulose ibers 17 g of polypropylene fibers 15 g of an 8% strength emul~ion of stearyldiketene (water repellent agent) 31 g of the abovementioned polymer dispersion 7.5 g of a 10% strength aluminum sulfate solution 4.5 g of flocculant Procedure according to Example 5.
Properties:
Density: 0.71 g/cm3 5 Water absorption after 1 h: 14.5 after 2 h: 17.0~
~ COMPARATIVE EXAMPLE 11 As for Comparative Example 10, but binder as in Comparative Example 9 Properties:
Density: 0.77 g/cm3 Water absorption after 1 h: 12.3%
after 2 h: 16.8%~
Claims (7)
1. A molding based on fibers (component A), contain-ing, as a binder, a polymer (B) having a glass transition temperature above 60°C and consisting of b1) from 70 to 99% by weight, based on B, of one or more vinylaromatic monomers, b2) from 1 to 30% by weight, based on B, of acrylates or methacrylates of alcohols of 1 to 18 carbon atoms, monohydroxyalkyl acrylates or monohydroxy-alkyl methacrylates where the alkyl radical is of 2 to 12 carbon atoms, acrylic acid, methacrylic acid, acrylonitrile and/or methacrylonitrile, where the sum of the amounts of acrylonitrile and methacrylo-nitrile may be not more than 20% by weight, based on B, and b3) from 0 to 5% by weight, based on B, of further copolymerizable monomers.
2. A molding as claimed in claim 1 in the form of a board.
3. A molding as claimed in claim 1, containing from 5 to 25% by weight, based on A, of the binder B.
4. A molding as claimed in claim 1, wherein mineral fibers are used as component A.
5. A molding as claimed in claim 1, wherein organic fibers are used as component A.
6. A molding as claimed in claim 1, containing from 20 to 80% by weight, based on A, of fillers.
7. A process for the production of moldings as claimed in claim 1, wherein an aqueous suspension con-taining the fibers A is prepared using an aqueous disper-sion of B, this suspension is then flocculated and the resulting fiber slurry is shaped and dried.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE19914102344 DE4102344A1 (en) | 1991-01-26 | 1991-01-26 | FORMKOERPER BASED ON FIBERS |
DEP4102344.7 | 1991-01-26 |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2059627A1 true CA2059627A1 (en) | 1992-07-27 |
Family
ID=6423794
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA 2059627 Abandoned CA2059627A1 (en) | 1991-01-26 | 1992-01-20 | Moldings based on fibers |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0497100A2 (en) |
JP (1) | JPH04370296A (en) |
CA (1) | CA2059627A1 (en) |
DE (1) | DE4102344A1 (en) |
FI (1) | FI920325A (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7794565B2 (en) | 2002-11-06 | 2010-09-14 | Kimberly-Clark Worldwide, Inc. | Method of making low slough tissue products |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE4308499C2 (en) * | 1993-03-17 | 1998-07-02 | Hiendl Heribert | Formwork sheet as permanent formwork for concrete construction |
DE19511130A1 (en) * | 1995-03-27 | 1996-10-02 | Basf Ag | Use of cationically stabilized aqueous polymer dispersions as binders for moldings based on finely divided materials having a negative surface charge |
DE10054162A1 (en) * | 2000-11-02 | 2002-05-16 | Wacker Polymer Systems Gmbh | Process for the production of pressed wood panels |
US6951598B2 (en) * | 2002-11-06 | 2005-10-04 | Kimberly-Clark Worldwide, Inc. | Hydrophobically modified cationic acrylate copolymer/polysiloxane blends and use in tissue |
CN111648163B (en) * | 2020-05-12 | 2022-02-15 | 仙鹤股份有限公司 | Preparation method of high-tightness process packaging base paper |
-
1991
- 1991-01-26 DE DE19914102344 patent/DE4102344A1/en not_active Withdrawn
-
1992
- 1992-01-09 EP EP19920100250 patent/EP0497100A2/en not_active Withdrawn
- 1992-01-20 CA CA 2059627 patent/CA2059627A1/en not_active Abandoned
- 1992-01-24 JP JP1089392A patent/JPH04370296A/en not_active Withdrawn
- 1992-01-24 FI FI920325A patent/FI920325A/en unknown
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7794565B2 (en) | 2002-11-06 | 2010-09-14 | Kimberly-Clark Worldwide, Inc. | Method of making low slough tissue products |
Also Published As
Publication number | Publication date |
---|---|
JPH04370296A (en) | 1992-12-22 |
FI920325A0 (en) | 1992-01-24 |
EP0497100A2 (en) | 1992-08-05 |
FI920325A (en) | 1992-07-27 |
DE4102344A1 (en) | 1992-07-30 |
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