Wet-End Manufacturing Process for Bitumen-Impregnated Fiberboard
AssigneeW. R. Meadows, Inc.
InventorTariq Mahmood Malik
Life of this patent
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Abstract
A process for manufacturing fiberboard by preparing a fiber slurry mixture including containing cellulose fibers and water then atomizing a liquid bituminous material, such as asphalt. The liquid bituminous material is atomized by mixing it with a pressurized gas, such as compressed air, forming a mist comprising droplets of bituminous material having a diameter between 20 microns and 50 microns. A water spray solidifies the bituminous material droplets thereby forming bituminous particles which fall into the fiber slurry within the spray chamber. From there the slurry is sheared, dewatered, and dried, forming a finished fiberboard.
Claims30
A bitumen-impregnated fiberboard comprising:
- a core comprising
- at least 10% weight bituminous material, alternatively at least 15% weight bituminous material, alternatively, at least 25% weight bituminous material, alternatively, at least 35% weight bituminous material,
- about 55.5% weight to about 62% weight cellulose fibers,
- about 3% weight to about 7.5% weight filler materials,
- about 0.001 % weight to about 2% weight dye;
- and
- an outer coating disposed on both major sides of the fiberboard.
A bitumen-impregnated fiberboard comprising:
- a core comprising
- at least 15% weight bituminous material,
- cellulose fibers,
- one or more filler materials,
- about 0.001% weight to about 2% weight dye;
- and
- an outer coating disposed on both major sides of the fiberboard.
A bitumen-impregnated fiberboard or expansion joint comprising:
- from about 10% to about 40% by weight asphalt, wherein the asphalt has a particle size in the range of approximately 20 to 50 microns;
- cellulose fibers;
- one or more filler materials;
- a dye;
- and
- optionally, an outer coating disposed on both major sides of the fiberboard or expansion joint.
A bitumen-impregnated fiberboard or expansion joint comprising:
- from about 10% to about 40% by weight bituminous material, wherein the bituminous material has a particle size in the range of approximately 20 to 50 microns;
- cellulose fibers;
- one or more filler materials;
- a dye;
- and
- optionally, an outer coating disposed on both major sides of the fiberboard or expansion joint.
A bitumen-impregnated fiberboard or expansion joint made by the process comprising the steps of:
- preparing a fiber slurry mixture by adding a fibrous material to water and agitating the fiber slurry mixture;
- transferring the fiber slurry mixture to a spray chamber;
- heating a bituminous material to a temperature between 300° Fahrenheit and 400° Fahrenheit, wherein the bituminous material is in a liquid state;
- atomizing the liquid bituminous material within the spray chamber by mixing the liquid bituminous material with a pressurized gas, forming a mist comprising droplets of bituminous material having a diameter between approximately 20 microns to 50 microns;
- solidifying the bituminous material droplets within the spray chamber to form bituminous particles that mix with the fiber slurry in the spray chamber;
- adding a dye to the slurry;
- dewatering the slurry containing fibers and bituminous particles, leaving a wet mat containing fibers and bituminous particles;
- and
- drying the wet mat thereby forming the fiberboard or expansion joint.
A bitumen-impregnated fiberboard or expansion joint comprising:
- from about 10% to about 40% by weight bituminous material, wherein the bituminous material has a particle size of less than approximately 20 microns;
- cellulose fibers;
- one or more filler materials;
- a dye;
- and
- optionally, an outer coating disposed on both major sides of the fiberboard or expansion joint.
Dependencies are inferred from the claim text.