Patent ID: 7993570
Filing Date: 2011-08-09
Classification: C04B,Y02W

Abstract:
1. A method of providing a low or medium density FRC product having a density of less than about 1.55 g/cm 3 , comprising the steps of: i) providing a formulation for a low or medium density product; ii) forming a green article from said formulation; iii) curing said green article to form said product; wherein prior to step iii) one or more pore size modifying agents are added to the formulation such that the pore volume of the product is reduced as compared with a conventional product emanating from steps i) to iii), while maintaining a density of no greater than about 1.6 g/cm 3 wherein the reduced pore volume of the product comprises a predetermined pore size distribution, which is obtained by chemical modification by including a predetermined quantity of pore modifying components into the formulation, wherein the pore modifying components include lignocellulosic fibers treated with a water repellant agent and microfine siliceous material, wherein the water repellant agent comprises a hydrophilic group and a hydrophobic group, wherein the lignocellulosic fibers treated with a water repellent agent are incorporated into the formulation at a concentration of about 2 to 4% of total weight of dry solids, wherein the microfine siliceous material is incorporated into the formulation at a concentration of about 2 to 4% of total weight of dry solids, wherein said formulation further comprises reinforcing fibers and the total amount of reinforcing fibers and lignocellulosic fibers treated with a water repellent agent is less than about 7% of total weight of dry solids.