Patent GB-930862-A (GB)
Title: Improvements relating to bonded fibrous glass structures
IPC: E04C2/16
Filed: 1959-10-05
Abstract: 930,862. Fibrous fabrics ; laminates. OWENS-CORNING FIBERGLAS CORPORATION. Oct. 5, 1959 [Oct. 6, 1958], No. 33718/59. Classes 42 (2) and 140. A structure comprises a porous body of interlocking glass fibres and a hardened binder intimately associated with the fibres adjacent to the surface of said body, characterized in that the binder extends below the surface of the body a distance sufficient to form a high-strength region of interlocked binder and fibrous material. Specified binders are gypsum, magnesium oxychloride, magnesium oxysulphate, Portland cement, or thermosetting phenol-aldehyde, urea aldehyde, melamine, polyester or epoxide resins. Specified skin materials are corrugated or other paper, regenerated cellulose, polyvinyl halides, polyethylene, cardboard, inorganic cement, wood, polyester, epoxy, or phenolic resin, scrim fabric, glass cloth or mat, aluminium, stainless steel, wool, or asbestos fibre or paper. As shown (Fig. 1) the product comprises a pair of spaced skins 15, 16 and a plurailty of sections of body material 17 between the skins. Interposed transversely between the body sections 17 and extending longitudinally therewith at right angles to the surfaces of the skins are a series of strips 18 of skin material. Fig. 2 shows an enlarged cross-sectional view of a fragment of the construction of Fig. 1 along the line 2-2 of Fig. 1. A cured binder foam 20 penetrates each of the core sections 17 extending downwardly from top skin 15, upwardly from bottom skin 16 and inwardly from skins 18. Figs. 7, 8 and 10 show apparatus for producing the construction of Fig. 1. A continuous board of body material 25 is fed through spaced parallel rotary saws 26, mounted on shaft 27, which sever the board into a series of body sections 17 which are then forced apart by wedges 30. A series of spools 31 supply strips of reinforcing material coated on one or both sides with foamable binder material. The strips are guided into the separations between the sections 17 of body material by means of manifold 37, after which rolls 41 and 42 urge the body sections together. Skin material 15 and 16 is drawn from supply rolls 48 and 50 and is coated with foamable binder from hoppers 43 and 45. Coated skin 15 passes over rolls 56 and 57 and is applied to the upper surface of the composite assembly of body material. Coated skin 16 passes over rolls 58, 60 and 61 and is applied to the bottom surface of the composite assembly. The transverse dimension of skins 15 and 16 corresponds to the width of the composite assembly. The assembly then passes between spaced dielectrically or otherwise heated platens 62 and 63 whereby the binder is cured and the expanding foam is forced into the porous body sections. In a modification the assembly of sections 17 may be divided by vertical lateral cuts into slices which are then interleaved with coated skin material, the body so formed having both longitudinal and lateral vertical partitions of skin material and being then covered by the skin layers 15, 16. In a further modification a structure as in Fig. 2 may be formed by superposing layers of phenol-aldehyde resin-bonded glass fibre mat coated with foamable binder, cutting the laminate so formed vertically into slices and applying skin material coated with foamable binder to the cut surfaces. A structure is described comprising strips of resinbonded glass fibre mat coated with a gypsum slurry, laid side-by-side with their coated surfaces in contact and coated on their upper and lower faces so formed with the same slurry.