US4433020A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Sheet-like material, heat-insulating material derived therefrom and methods of manufacturing same
Assignee: Kuraray Co Ltd
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Filing: 1982-10-21
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Granted: 1984-02-21
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Expires: 2002-10-21
Abstract
Abstract A sheet-like material having excellent fire resistance and bending workability comprises 80 to 97% by weight of a non-flammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin. The fibrous substance is orientated at an angle of 3 DEG to 80 DEG . The material has an intermediate layer containing at least 2% by weight of the binder and at least 25% of the average quantity of the binder in the material. A heat insulating material comprising such sheet-like materials is also disclosed. The sheet-like material, and the heat insulating material are manufactured by a wet sheet forming process in which a slurry containing the fibrous substance and the binder is fed to a carrier net or sheet at an angle of 5 DEG to 60 DEG thereto, whereby the fibers are orientated. Alternatively, the slurry is fed to the carrier net or sheet at an angle of 20 DEG to 45 DEG , while a fluid is blown into the slurry to create turbulence therein.
Inventors
- 👤 Hiroshi Narukawa
- 👤 Rentaro Tada
- 👤 Yasuhira Takeuchi
- 👤 Osamu Ohara
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 18:05
CPC Classifications
B; B32; B32B; B32B15/00; B32B15/04; B32B15/08; E; E04; E04B; E04B1/00; E04B1/62; E04B1/74; E04B1/76; E04B1/78; B32B2315/00; B32B2315/08; B32B2315/085; B32B2323/00; B32B2323/04; B32B2323/10; B32B2325/00; B32B2331/00; B32B2331/04; B32B2367/00; B32B2377/00; Y; Y10; Y10S; Y10S428/00; Y10S428/902; Y10S428/92; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24124; Y10T428/249921; Y10T428/249924; Y10T428/24994; Y10T428/25; Y10T428/30; Y10T428/31504; Y10T428/31652
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
70 words
A sheet-like material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3° to 80°, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material.
Claim 2
Dependent Claim
70 words
A sheet-like material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3° to 80°, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material.
Claim 3
Dependent Claim
34 words
A sheet-like material as set forth in claim 1, wherein said fibrous substance is selected from the group consisting of asbestos, rock wool, glass fibers, ceramic fibers, aluminous fibers, carbon fibers, and mixtures thereof.
Claim 4
Dependent Claim
23 words
A sheet-like material as set forth in claim 1, wherein said thermoplastic resin has a glass transition temperature of -50° to 30° C.
Claim 5
Dependent Claim
17 words
A sheet-like material as set forth in claim 1, wherein said resin is a self-crosslinking type resin.
Claim 6
Dependent Claim
31 words
a sheet-like material as set forth in claim 1, wherein said binder contains a crosslinking agent for said resin in the quantity of 0.1 to 30% by weight of said resin.
Claim 7
Dependent Claim
19 words
A sheet-like material as set forth in claim 1, which contains 3 to 15% by weight of said binder.
Claim 8
Dependent Claim
22 words
A sheet-like material as set forth in claim 1, wherein said fibrous substance is orientated at an angle of 5° to 30°.
Claim 9
Dependent Claim
22 words
A sheet-like material as set forth in claim 7, wherein said fibrous substance is orientated at an angle of 10° to 30°.
Claim 10
Dependent Claim
29 words
A sheet-like material as set forth in claim 1, which has a thickness of 0.5 to 25 mm, and an apparent density of 0.08 to 0.4 g/cm 3 .
Claim 11
Dependent Claim
22 words
A sheet-like material as set forth in claim 1, wherein said fibrous substance is orientated at an angle of 31° to 80°.
Claim 12
Dependent Claim
22 words
A sheet-like material as set forth in claim 10, wherein said fibrous substance is orientated at an angle of 40° to 70°.
Claim 13
Dependent Claim
29 words
A sheet-like material as set forth in claim 1, which has a thickness of 0.5 to 50 mm, and an apparent density of 0.04 to 0.2 g/cm 3 .
Claim 14
Dependent Claim
42 words
A sheet-like material as set forth in claim 1, wherein said binder additionally contains, for 100 parts by weight thereof, 5 to 50 parts by weight of an antimony compound and 10 to 100 parts by weight of an aromatic bromine compound.
Claim 15
Dependent Claim
32 words
A sheet-like material as set forth in claim 13, wherein said antimony compound is selected from the group consisting of antimony trioxide, antimony pentachloride, antimony trichloride and antimony trisulfide, and mixtures thereof.
Claim 16
Dependent Claim
53 words
A sheet-like material as set forth in claim 13, wherein said bromine compound is selected from the group consisting of tetrabromobenzene, pentabromomethylbenzene, hexabromobenzene, hexabromodiphenyl ether, decabromodiphenyl ether and tetrabromobisphenol A, and a mixture thereof, and has a decomposition temperature of above 280° C., and a bromine content of at least 50% by weight.
Claim 17
Dependent Claim
25 words
A sheet-like material as set forth in claim 13, wherein said antimony compound and said bromine compound have a weight ratio of 1:1 to 1:10.
Claim 18
Dependent Claim
77 words
A heat insulating material comprising a sheet-like material containing 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3° to 80°, said sheet-like material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said sheet-like material.
Claim 19
Dependent Claim
77 words
A heat insulating material comprising a sheet-like material containing 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3° to 80°, said sheet-like material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said sheet-like material.
Claim 20
Dependent Claim
20 words
A heat insulating material as set forth in claim 17, which contains 3 to 15% by weight of said binder.
Claim 21
Dependent Claim
23 words
A heat insulating material as set forth in claim 17, wherein said fibrous substance is orientated at an angle of 5° to 30°.
Claim 22
Dependent Claim
23 words
A heat insulating material as set forth in claim 17, wherein said fibrous substance is orientated at an angle of 10° to 30°.
Claim 23
Dependent Claim
33 words
A heat insulating material as set forth in claim 17, wherein said sheet-like material has a thickness of 0.5 to 25 mm, and an apparent density of 0.08 to 0.4 g/cm 3 .
Claim 24
Dependent Claim
23 words
A heat insulating material as set forth in claim 17, wherein said fibrous substance is orientated at an angle of 31° to 80°.
Claim 25
Dependent Claim
23 words
A heat insulating material as set forth in claim 17, wherein said fibrous substance is orientated at an angle of 40° to 70°.
Claim 26
Dependent Claim
33 words
A heat insulating material as set forth in claim 17, wherein said sheet-like material has a thickness of 0.5 to 25 mm, and an apparent density of 0.08 to 0.4 g/cm 3 .
Claim 27
Dependent Claim
52 words
A heat insulating material as set forth in claim 17, wherein said sheet-like material further contains a flame retarder which consists of 5 to 50 parts by weight of an antimony compound, and 10 to 100 parts by weight of an aromatic bromine compound for 100 parts by weight of said binder.
Claim 28
Independent Claim
166 words
A method of manufacturing a sheet-like material having excellent fire resistance and bending workability, said material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3° to 30°, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material, said method comprising: dissolving in water a binder consisting essentially of a water-soluble thermoplastic resin or a thermoplastic resin in the form of an emulsion or latex, and a crosslinking agent for said resin or a high polymer coagulant; dispersing a non-inflammable fibrous substance therein to prepare a slurry; feeding said slurry to a traveling or rotating carrier net or porous carrier sheet at an angle of 5° to 60° to form a wet mat thereon; dehydrating said mat; and drying said mat.
Claim 29
Independent Claim
166 words
A method of manufacturing a sheet-like material having excellent fire resistance and bending workability, said material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3° to 30°, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material, said method comprising: dissolving in water a binder consisting essentially of a water-soluble thermoplastic resin or a thermoplastic resin in the form of an emulsion or latex, and a crosslinking agent for said resin or a high polymer coagulant; dispersing a non-inflammable fibrous substance therein to prepare a slurry; feeding said slurry to a traveling or rotating carrier net or porous carrier sheet at an angle of 5° to 60° to form a wet mat thereon; dehydrating said mat; and drying said mat.
Claim 30
Dependent Claim
27 words
A method as set forth in claim 26, wherein said slurry is fed to said carrier net or sheet at an angle of 20° to 45° thereto.
Claim 31
Dependent Claim
25 words
A method as set forth in claim 26, further including adding a flame retardant to said slurry immediately prior to the formation of said mat.
Claim 32
Dependent Claim
19 words
A method as set forth in claim 26 further including adding a foam stabilizing surfactant when preparing said slurry.
Claim 33
Independent Claim
179 words
A method of manufacturing a sheet-like material having excellent fire resistance and bending workability, said material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 31° to 80°, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material, said method comprising: dissolving in water a binder consisting essentially of a water-soluble thermoplastic resin or a thermoplastic resin in the form of an emulsion or latex, as well as a crosslinking agent for said resin or a high polymer coagulant; dispersing a non-inflammable fibrous substance therein to prepare a slurry; feeding said slurry to a traveling or rotating carrier net or porous carrier sheet, while blowing a liquid or gas into said slurry to create turbulence therein, to form a wet mat on said carrier net or sheet; dehydrating said mat; and drying said mat.
Claim 34
Independent Claim
179 words
A method of manufacturing a sheet-like material having excellent fire resistance and bending workability, said material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 31° to 80°, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material, said method comprising: dissolving in water a binder consisting essentially of a water-soluble thermoplastic resin or a thermoplastic resin in the form of an emulsion or latex, as well as a crosslinking agent for said resin or a high polymer coagulant; dispersing a non-inflammable fibrous substance therein to prepare a slurry; feeding said slurry to a traveling or rotating carrier net or porous carrier sheet, while blowing a liquid or gas into said slurry to create turbulence therein, to form a wet mat on said carrier net or sheet; dehydrating said mat; and drying said mat.
Claim 35
Dependent Claim
27 words
A method as set forth in claim 30, wherein said slurry is fed to said carrier net or sheet at an angle of 20° to 45° thereto.
Claim 36
Dependent Claim
25 words
A method as set forth in claim 30, further including adding a flame retarder to said slurry immediately prior to the formation of said mat.
Claim 37
Dependent Claim
19 words
A method as set forth in claim 30, further including adding a foam stabilizing surfactant when preparing said slurry.
References Cited (Backward Citations)
JPS56112594A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-02-20 | 1987-08-22 | 1988-02-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-02-20 | 1991-08-22 | 1992-02-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-02-20 | 1995-08-22 | 1996-02-21 | $7700.00 | Window Closed / Lapsed |