초록 ▼

A wet process for the manufacture of shaped fibrous products such as acoustical ceiling board is disclosed. The ceiling board binder is foamed prior to being combined with the solids. Substantial reductions in water requirements are obtained accompanied by substantial energy savings in the drying op

A wet process for the manufacture of shaped fibrous products such as acoustical ceiling board is disclosed. The ceiling board binder is foamed prior to being combined with the solids. Substantial reductions in water requirements are obtained accompanied by substantial energy savings in the drying operation.

대표청구항 ▼

A method of manufacturing a shaped fibrous product from an aqueous composition comprising the following ingredients by weight of solids content: fibers: 25-95% binder: 5-75% clay: 0-40% gypsum: 0-15% foaming agent: 0.1-5% said method comprising the successive steps of: (a) preparing an aqueous admix

A method of manufacturing a shaped fibrous product from an aqueous composition comprising the following ingredients by weight of solids content: fibers: 25-95% binder: 5-75% clay: 0-40% gypsum: 0-15% foaming agent: 0.1-5% said method comprising the successive steps of: (a) preparing an aqueous admixture by admixing the binder and the foaming agent with water, the water being present in the amount of from about 25% to about 70% by weight of the furnish composition; (b) combining said aqueous admixture under agitation with air to form an aqueous foamed binder system, the amount of surfactant in combination with the degree of agitation being sufficient so that said air is present in the amount of from about 30% to about 90% by volume of the aqueous foamed binder system; (c) combining said fibers with said aqueous foamed binder system to form a foamed furnish composition, said foamed composition being a slurry of said fibrous materials in said aqueous foamed binder system; (d) forming a shaped product from said foamed furnish composition; and (e) setting the shaped product. A method of manufacturing an acoustical ceiling board from an aqueous furnish composition comprising the following ingredients by weight of solids content: mineral fibers: 25-70% cement binder: 30-75% surfactant: 0.1-1.5% said method comprising the successive steps of: (a) preparing an aqueous admixture by admixing the binder and the foaming agent with water, the water being present in the amount of from about 30% to about 50% by weight of the furnish composition; (b) combining said aqueous admixture under agitation with air to form an aqueous foamed binder system, the amount of srufactant in combination with the degree of agitation being sufficient so that said air is present in the amount of from about 60% to about 75% by volume of the aqueous foamed binder system; (c) combining said mineral fibers with said aqueous foamed binder system to form a foamed furnish composition, said foamed composition being a slurry of said fibrous material in said aqueous foamed binder system.