US3630822A - Acoustical and fire resistant particleboard - Google Patents

Acoustical and fire resistant particleboard Download PDF

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Publication number
US3630822A
US3630822A US3630822DA US3630822A US 3630822 A US3630822 A US 3630822A US 3630822D A US3630822D A US 3630822DA US 3630822 A US3630822 A US 3630822A
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particles
panel
wood
percent
core
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Andrew E Carmellini
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US PLYWOOD Corp A CORP OF
Georgia Pacific LLC
US Plywood Champion Papers Inc
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US Plywood Champion Papers Inc
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Assigned to U.S. PLYWOOD CORPORATION, A CORP. OF reassignment U.S. PLYWOOD CORPORATION, A CORP. OF ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: CHAMPION INTERNATIONAL CORPORATION A CORP OF NEW YORK
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Assigned to GEORGIA-PACIFIC CORPORATION, A GA CORP. reassignment GEORGIA-PACIFIC CORPORATION, A GA CORP. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: U.S. PLYWOOD CORPORATION
Assigned to U.S. PLYWOOD CORPORATION reassignment U.S. PLYWOOD CORPORATION RELEASED BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: SECURITY PACIFIC BUSINESS CREDIT INC.
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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • 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
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/36—Inorganic materials not provided for in groups C04B14/022 and C04B14/04 - C04B14/34
    • 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
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/12—Condensation polymers of aldehydes or ketones
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/253—Cellulosic [e.g., wood, paper, cork, rayon, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]

Definitions

  • a high-density particleboard of great sound attenuation and resistance to heat and flame comprising wood particles, :1 suitable binder, and a compound having a density of at least 4.
  • ACOUSTICAL AND FIRE RESISTANT PARTICLEBOARD A high-density particleboard of great sound attenuation and resistance to heat and flame, comprising wood particles, a suitable binder, and a compound having a density of at least 4.
  • the present invention is concerned with a high-density particle board which has excellent acoustic properties with respect to sound attenuation and which is also highly resistant to flame and heat.
  • the particleboard comprises wood particles, a suitable binder and particles of a dense compound, having a density of at least 4, for example and preferably a barium compound, such as barium sulfate.
  • the present invention is concerned with a particular type of structural element namely a particleboard structure which is processed and manufactured in a manner to impregnate or fill the interstices between the particles or wood chips with particles of a dense fireproof compound.
  • the fireproofing compound will also function to greatly improve the acoustical properties by significantly reducing the sound transmission coefficient.
  • particleboar is intended to cover any board comprising particles of wood bonded together.
  • the bonding is usually accomplished by the application of heat and pressure in conjunction with natural or synthetic resins or other bonding agent.
  • the wood particles may be in the form of chips, granules, slivers, shavings, flakes and the like.
  • Suitable bonding agents are, for example, phenolformaldehyde resins, ureaformaldehyde resins, resorcinol, various glues and the like. These bonding agents may be used in any concentration such as about 3 to about 40 percent by weight based on the weight of thedry wood particles.
  • a particularly desirable particleboard structural element is one in which a core layer comprises randomly arranged wood particles wherein under usual manufacturing conditions air spaces exist between particles.
  • these air spaces or voids are filled with a high-density substance.
  • the face layers tothe core comprise a relatively thin layer of superimposed unoriented fiat wood shavings arranged substantially parallel to the outerfaces of the finished board.
  • the air spaces or voids between these relatively flat shavings are also filled with particles of the'dense substance.
  • Novoply (trademark of U.S. Plywood Champion Papers Inc.) which is manufactured under US. Pats. Nos. 2,642,371 and 2,686,143.
  • the invention is equally applicable to homogeneous boards of relatively large and thick core particles or relatively thin flake boards.
  • the individual wood particles of which the core material consists have a length of about to 50 mm., a width of about 5 to l0 mm., and a thickness not exceeding several mm. preferably about 1 to 3 Sufficient materials are used in the core to secure a core thickness to slightly less than about inch, inch or H4 inches and 1% inches.
  • the finished product will have the standard commercial thickness of about $6 inch, 56 inch or PA inch and 1% inch (the latter sizes for cores for doors to which expensive veneers or high-pressure laminates are bonded).
  • the binder substance in the core layer of the present invention may amount to a very small percentage, e.g., to about 3.5 to 4 percent by weight of the weight of the wood particles, while the binder substance in the outer or face layers may amount to about 10 to 14 percent by weight of the weight of the wood shavings. It should be noted that preferably the percentage of binder substance in the outer layers is substantially larger than the percentage of the binder substance in the core layer.
  • the flat wood shavings comprising the face plies are relatively large in surface area such as lengths from about Va inch to llz inches and widths from about 54 inch to inches. They are however relatively thin and have a thickness of about 0.5 mm. to 2.0 mm. such as about l.0 mm.
  • the number of the superimposed shavings is at least 2 and not more than 5 at any part of any of the outer layers.
  • These outer layers or plies are relatively thin and have a thickness of about I to 3 mm. such as about l.5 mm.
  • the core layer is substantially thicker than any of the outer or face layers and has a thickness equal to many times the thickness of each of the outer or face layers. Hence the core thickness may vary from nearly )6 inch to over 1% inches. 1
  • the high-density particleboard of the present invention is utilized to produce structural units having high-acoustical attenuation or which produces a very high-sound transmission loss.
  • the particleboard of the present invention is obtained by utilizing particles of a solid material as an inorganic filler.
  • the preferred solid material comprises a barium salt, and particularly barium sulfate which has an overall specific gravity of about 4.5.
  • the solid material particles such as the preferred barium sulfate are homogeneously dispersed among the wood particles.
  • Barium sulfate is particularly important because of its availability and cheapness. For example, it is believed that the cost of lead ranges from 15 to 18 cents per pound while bariurn sulfate ranges from 1 to 2 cents per pound. Barium sulfate is greatly preferred, but other dense materials may be used providing they possess a specific gravity preferably above 4.0 or at the minimum, above 3.0.
  • Other excellent substances are iron carbonate and iron boride.
  • While relatively large particles of heavy solid filler may be embedded throughout the mass of the wood particles, for example, heavy particles which pass through about 100 mesh screen, it is preferred that the heavy particles utilized be relatively fine. For example, a mass of particles wherein at least percent pass through a 250 mesh screen are satisfactory, but a mass of heavy particles wherein at least 90 percent pass through a 325 mesh screen produces better results. When relatively fine particles are used a very high-quality acoustical panel is secured.
  • This solid heavy material which is added to the binder should have a specific gravity between 3.0 to 4.0 and preferably about 4.5.
  • the quantity of heavy substance particles used may vary widely, as for example from about 10 to 150 percent by weight based on the weight of the wood particles. A preferred amount is about 100 percent based on the weight of the wood particles present.
  • a very desirable board of the present invention is one wherein 75 to 125 percent such as about 100 percent by weight of heavy particles are used based on the wood particles in the core, and wherein the size of the heavy particles are such that at least 90 percent pass through a 250 mesh screen.
  • the same amounts of heavy particles may be used in the face plies except that 90 percent of the face ply heavy particles pass through a 325 mesh screen as stated above.
  • a very desirable panel is secured if the amount of heavy particles used in the face plies is about 25 percent to 50 percent by weight based on the wood particles in the face plies.
  • the core and face plies contain heavy particles, having different sizes of particles and different amounts in the core as compared to the face plies, a sharp interface will be secured between the core and face plies which will function to further attenuate sound transmission.
  • the panels are prepared by mixing the wood particles, the bonding agent and the heavy particles as desired.
  • the panels are then cured at a temperature in the range from about 150 F. preferably 275 to 330 F. such as 300 F. for a time period in the range from about 5 minutes to 1 hours such as about minutes.
  • the pressure is in the range from about 100 to 2,000 lbs. per square inch, preferably in the range of about 400 to 1,000 lbs. such as about 800 lbs. per square unit.
  • EXAMPLE A number of /4X4' 8' panels were prepared using relatively small wood chips as a core and wood flakes as the surface plies. These panels were prepared by mixing the bonding agent, the wood particles and the barium sulfate, and then cured at 345 F. and at a pressure of 800 p.s.i. for one hour.
  • Panel A l6% by weight 8. 73% by weight
  • C l00% by weight
  • the densities of these panels were in the range of 0.95 to L00 as compared to 0.67 for a panel containing no barium sulfate.
  • the panels were excellent in that fallout of barium salt form the surfaces was nonexistent.
  • the salt behaved like hardened cement after pressing.
  • a sound attenuating, fire resistant panel comprising wood particles bound together by a bonding agent and characterized by having heavy particles of a density of at least 3 between said wood particles.
  • Panel as defined by claim 1 wherein said panel is characterized by a core layer of randomly arranged wood particles and face plies of relatively flat superimposed wood shavings.
  • Panel as defined by claim 3 wherein the amount of heavy particles present is in the range from about 75 to I25 percent by weight based on the weight of the wood particles.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

A high-density particleboard of great sound attenuation and resistance to heat and flame, comprising wood particles, a suitable binder, and a compound having a density of at least 4.

Description

United States Patent Inventor Andrew E. Carmellini Brookfield, Conn. App]. No. 69,145 Filed Sept. 2, 1970 Patented Dec. 28, 1971 Assignee U. S. Plywood-Champion Papers Inc.
New York, N.Y.
ACOUSTICAL AND FIRE RESISTANT PARTICLEBOARD 9 Claims, No Drawings U.S. Cl 161/168, 161/165, 161/166, 161/403 Int. Cl B32b 5/14, B32b 5/16, B32b 21/02 Field 01 Search 161/ l 65, 166, 168, 403
Primary Examiner-William J. Van Balen Attorneys-James M. l-leilman and Heilman & Heilman ABSTRACT: A high-density particleboard of great sound attenuation and resistance to heat and flame, comprising wood particles, :1 suitable binder, and a compound having a density of at least 4.
ACOUSTICAL AND FIRE RESISTANT PARTICLEBOARD A high-density particleboard of great sound attenuation and resistance to heat and flame, comprising wood particles, a suitable binder, and a compound having a density of at least 4.
The present invention is concerned with a high-density particle board which has excellent acoustic properties with respect to sound attenuation and which is also highly resistant to flame and heat. The particleboard comprises wood particles, a suitable binder and particles of a dense compound, having a density of at least 4, for example and preferably a barium compound, such as barium sulfate.
In the building and construction industry it is very desirable to have a board, panel, or door which is characterized by having a high fire and flame resistance, and which also has excellent sound attenuation. Thus many types of construction have been suggested to attain these characteristics without impairing other qualities such as strength, wearability and pleasing appearance.
Thus the present invention is concerned with a particular type of structural element namely a particleboard structure which is processed and manufactured in a manner to impregnate or fill the interstices between the particles or wood chips with particles of a dense fireproof compound. The fireproofing compound will also function to greatly improve the acoustical properties by significantly reducing the sound transmission coefficient.
The term particleboar is intended to cover any board comprising particles of wood bonded together. The bonding is usually accomplished by the application of heat and pressure in conjunction with natural or synthetic resins or other bonding agent. The wood particles may be in the form of chips, granules, slivers, shavings, flakes and the like.
Suitable bonding agents are, for example, phenolformaldehyde resins, ureaformaldehyde resins, resorcinol, various glues and the like. These bonding agents may be used in any concentration such as about 3 to about 40 percent by weight based on the weight of thedry wood particles.
A particularly desirable particleboard structural element is one in which a core layer comprises randomly arranged wood particles wherein under usual manufacturing conditions air spaces exist between particles. In accordance with the present invention these air spaces or voids are filled with a high-density substance. If desired the face layers tothe core comprise a relatively thin layer of superimposed unoriented fiat wood shavings arranged substantially parallel to the outerfaces of the finished board. The air spaces or voids between these relatively flat shavings are also filled with particles of the'dense substance.
One type of the above nonhomogeneous particle board is Novoply" (trademark of U.S. Plywood Champion Papers Inc.) which is manufactured under US. Pats. Nos. 2,642,371 and 2,686,143. Obviously, the invention is equally applicable to homogeneous boards of relatively large and thick core particles or relatively thin flake boards.
In one embodiment of the present invention the individual wood particles of which the core material consists have a length of about to 50 mm., a width of about 5 to l0 mm., and a thickness not exceeding several mm. preferably about 1 to 3 Sufficient materials are used in the core to secure a core thickness to slightly less than about inch, inch or H4 inches and 1% inches. When the face plies are applied thereto the finished product will have the standard commercial thickness of about $6 inch, 56 inch or PA inch and 1% inch (the latter sizes for cores for doors to which expensive veneers or high-pressure laminates are bonded).
The binder substance in the core layer of the present invention may amount to a very small percentage, e.g., to about 3.5 to 4 percent by weight of the weight of the wood particles, while the binder substance in the outer or face layers may amount to about 10 to 14 percent by weight of the weight of the wood shavings. It should be noted that preferably the percentage of binder substance in the outer layers is substantially larger than the percentage of the binder substance in the core layer.
The flat wood shavings comprising the face plies are relatively large in surface area such as lengths from about Va inch to llz inches and widths from about 54 inch to inches. They are however relatively thin and have a thickness of about 0.5 mm. to 2.0 mm. such as about l.0 mm.
In the preferred embodiment of the present invention the number of the superimposed shavings is at least 2 and not more than 5 at any part of any of the outer layers. These outer layers or plies are relatively thin and have a thickness of about I to 3 mm. such as about l.5 mm. The core layer is substantially thicker than any of the outer or face layers and has a thickness equal to many times the thickness of each of the outer or face layers. Hence the core thickness may vary from nearly )6 inch to over 1% inches. 1
The high-density particleboard of the present invention is utilized to produce structural units having high-acoustical attenuation or which produces a very high-sound transmission loss. The particleboard of the present invention is obtained by utilizing particles of a solid material as an inorganic filler. The preferred solid material comprises a barium salt, and particularly barium sulfate which has an overall specific gravity of about 4.5. The solid material particles such as the preferred barium sulfate are homogeneously dispersed among the wood particles.
Barium sulfate is particularly important because of its availability and cheapness. For example, it is believed that the cost of lead ranges from 15 to 18 cents per pound while bariurn sulfate ranges from 1 to 2 cents per pound. Barium sulfate is greatly preferred, but other dense materials may be used providing they possess a specific gravity preferably above 4.0 or at the minimum, above 3.0.
Compounds of elements which fall into this category possess one or more of the following anionic moieties, the sulfide,
the oxide, the carbide, the iodide, the boride, the selenide, the
chloride, the silicide, the telluride, the carbonate, and/or the sulfate. One or more of the above-mentioned anionic groups of the following elements (listed below), possess a density of 4 or more:
vanadium eropium tantalum gallium tellurium indium thorium iron tin lead tungsten magnesium zinc manganese zirconium molybdenum aluminum neodymium antimony nickel arsenic niobium barium osmium bismuth palladium calcium platinum cadmium rhodium cerium silver chromium sodium copper strontium Of the foregoing, preferred substances are lead sulfide, lead iodide, thoriumboride, lead carbonate, iron sulfide and strontium carbonate. Other excellent substances are iron carbonate and iron boride.
While relatively large particles of heavy solid filler may be embedded throughout the mass of the wood particles, for example, heavy particles which pass through about 100 mesh screen, it is preferred that the heavy particles utilized be relatively fine. For example, a mass of particles wherein at least percent pass through a 250 mesh screen are satisfactory, but a mass of heavy particles wherein at least 90 percent pass through a 325 mesh screen produces better results. When relatively fine particles are used a very high-quality acoustical panel is secured. This solid heavy material which is added to the binder, as mentioned above, should have a specific gravity between 3.0 to 4.0 and preferably about 4.5.
The quantity of heavy substance particles used may vary widely, as for example from about 10 to 150 percent by weight based on the weight of the wood particles. A preferred amount is about 100 percent based on the weight of the wood particles present.
A very desirable board of the present invention is one wherein 75 to 125 percent such as about 100 percent by weight of heavy particles are used based on the wood particles in the core, and wherein the size of the heavy particles are such that at least 90 percent pass through a 250 mesh screen. The same amounts of heavy particles may be used in the face plies except that 90 percent of the face ply heavy particles pass through a 325 mesh screen as stated above.
A very desirable panel is secured if the amount of heavy particles used in the face plies is about 25 percent to 50 percent by weight based on the wood particles in the face plies. Thus while both the core and face plies contain heavy particles, having different sizes of particles and different amounts in the core as compared to the face plies, a sharp interface will be secured between the core and face plies which will function to further attenuate sound transmission.
The panels are prepared by mixing the wood particles, the bonding agent and the heavy particles as desired. The panels are then cured at a temperature in the range from about 150 F. preferably 275 to 330 F. such as 300 F. for a time period in the range from about 5 minutes to 1 hours such as about minutes. The pressure is in the range from about 100 to 2,000 lbs. per square inch, preferably in the range of about 400 to 1,000 lbs. such as about 800 lbs. per square unit.
In order to further illustrate the present invention the following example is given.
EXAMPLE A number of /4X4' 8' panels were prepared using relatively small wood chips as a core and wood flakes as the surface plies. These panels were prepared by mixing the bonding agent, the wood particles and the barium sulfate, and then cured at 345 F. and at a pressure of 800 p.s.i. for one hour.
These panels contained the following amounts of barium sulfate particles:
Panel A. l6% by weight 8. 73% by weight C. l00% by weight The densities of these panels were in the range of 0.95 to L00 as compared to 0.67 for a panel containing no barium sulfate.
Upon testing the STC rating of a conventional panel was 22db. whereas the STC rating of Panel C was 34 to 35db. as compared to a gypsum wall of 32.
Also the panels were excellent in that fallout of barium salt form the surfaces was nonexistent. The salt behaved like hardened cement after pressing.
The embodiment of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A sound attenuating, fire resistant panel comprising wood particles bound together by a bonding agent and characterized by having heavy particles of a density of at least 3 between said wood particles.
2. Panel as defined by claim 1 wherein said particles consist essentially of barium sulfate.
3. Panel as defined by claim 1 wherein said panel is characterized by a core layer of randomly arranged wood particles and face plies of relatively flat superimposed wood shavings.
4. Panel as defined by claim 3 wherein the amount of heavy particles present is in the range from about 75 to I25 percent by weight based on the weight of the wood particles.
5. Panel as defined by claim 4 wherein the heavy particles present in the core are of such a size that at least percent pass through a 250 mesh screen and the heavy particles present in the face plies are of such a size that at least 90 percent gas through a 325 mesh screen.
6. anel as defined by claim 5 wherein the amount of bonding reagent used in the core is about 3.5 to 4 percent by weight based on the wood particles and wherein the amount of bonding agent used in the face plies is about 10 to 14 percent by weight based on the wood particles.
7. Panel as defined by claim 6 wherein the thickness of the core is in the range from about A inch to 1% inches and the thickness of the face plies is in the range from about 0.5 to 2.0
8. Panel as defined by claim 1 wherein said wood particles and said heavy particles are bonded together by curing said bonding agent at a temperature in the range from about 400 to 1,000 p.s.i. for a time period of about 5 to 30 minutes.
9. Panel as defined by claim 5 wherein the amount of heavy particles used in the core is about 75 to percent by weight based on the wood core particles and the amount of heavy particles used in the face plies is about 25 to 50 percent by weight based on the weight of the wood face ply particles.

Claims (8)

  1. 2. Panel as defined by claim 1 wherein said particles consist essentially of barium sulfate.
  2. 3. Panel as defined by claim 1 wherein said panel is characterized by a core layer of randomly arranged wood particles and face plies of relatively flat superimposed wood shavings.
  3. 4. Panel as defined by claim 3 wherein the amount of heavy particles present is in the range from about 75 to 125 percent by weight based on the weight of the wood particles.
  4. 5. Panel as defined by claim 4 wherein the heavy particles present in the core are of such a size that at least 90 percent pass through a 250 mesh screen and the heavy particles present in the face plies are of such a size that at least 90 percent pass through a 325 mesh screen.
  5. 6. Panel as defined by claim 5 wherein the amount of bonding reagent used in the core is about 3.5 to 4 percent by weight based on the wood particles and wherein the amount of bonding agent used in the face plies is about 10 to 14 percent by weight based on the wood particles.
  6. 7. Panel as defined by claim 6 wherein the thickness of the core is in the range from about 1/4 inch to 1 1/4 inches and the thickness of the face plies is in the range from about 0.5 to 2.0 mm.
  7. 8. Panel as defined by claim 1 wherein said wood particles and said heavy particles are bonded together by curing said bonding agent at a temperature in the range from about 400 to 1,000 p.s.i. for a time period of about 5 to 30 minutes.
  8. 9. Panel as defined by claim 5 wherein the amount of heavy particles used in the core is about 75 to 125 percent by weight based on the wood core particles and the amount of heavy particles used in the face plies is about 25 to 50 percent by weight based on the weight of the wood face ply particles.
US3630822D 1970-09-02 1970-09-02 Acoustical and fire resistant particleboard Expired - Lifetime US3630822A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0105154A1 (en) * 1982-08-25 1984-04-11 Fulgurit GmbH & Co. Kommanditgesellschaft Building materials with inorganic binders

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2642371A (en) * 1942-04-25 1953-06-16 Fahrni Fred Composite wooden board
US3383274A (en) * 1965-01-06 1968-05-14 Us Plywood Champ Papers Inc Flameproofing of construction material
US3438847A (en) * 1965-02-26 1969-04-15 Weyerhaeuser Co Process of treating composite boards with borate chemicals produced thereby and product
US3535199A (en) * 1963-04-11 1970-10-20 Reichhold Chemicals Inc Flame-resistant wood-chip panels containing fully hardened urea formaldehyde as flame retardant

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2642371A (en) * 1942-04-25 1953-06-16 Fahrni Fred Composite wooden board
US3535199A (en) * 1963-04-11 1970-10-20 Reichhold Chemicals Inc Flame-resistant wood-chip panels containing fully hardened urea formaldehyde as flame retardant
US3383274A (en) * 1965-01-06 1968-05-14 Us Plywood Champ Papers Inc Flameproofing of construction material
US3438847A (en) * 1965-02-26 1969-04-15 Weyerhaeuser Co Process of treating composite boards with borate chemicals produced thereby and product

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0105154A1 (en) * 1982-08-25 1984-04-11 Fulgurit GmbH & Co. Kommanditgesellschaft Building materials with inorganic binders
US4582755A (en) * 1982-08-25 1986-04-15 Fulgurit Gmbh & Co. Kommanditgesellschaft Construction boards bonded by organic and/or inorganic cementing means

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