Masonite Corporation

William C Sargeant

William L Prior

Compositions and processes for forming inorganic resins, including articles of manufacture incorporating these resins are disclosed. the inorganic resins are characterized by their strength, nonflammability, dimensional stability, resistance to organic and inorganic chemicals, to heat and to abrasion and their adaptability to being formed into noncellular or cellular forms. The resins are formed by reacting a liquid component A containing an aluminum phosphate or a magnesium phosphate and a liquid component B containing a source of magnesium oxide, such as magnesia, and/or wollastonite and an essentially non-reactive phosphate dispersing agent. Various fillers may be incorporated and a blowing agent may be added to form a cellular resin.

Composition and process for forming inorganic resins and resulting

Two distinct resin compositions are provided in two physically separated components--one component impregnates a liquid-penetrable article substrate, such as a paper web, to provide a reactive substrate capable of forming a resin cement in situ upon contact with the other component. A first inorganic resin component, hereinafter referred to as component A, is a liquid comprising an aqueous composition of an aluminum phosphate, or a magnesium phosphate or a mixture thereof. A second component, hereinafter referred to as component B, is a liquid comprising an aqueous vehicle; a phosphate-reactive constituent selected from a magnesium oxide source, reactive wollastonite, or mixtures thereof having a relatively low surface area, e.g. dead-burned magnesium oxide having a surface area of about 0.75 m.sup.2 /gm; and a non-reactive phosphate dispersing agent.

Methods of manufacturing inorganic resin bound articles and product

Compositions and processes for forming inorganic resins, including articles of manufacture incorporating these resins are disclosed. The inorganic resins are characterized by their strength, nonflammability, dimensional stability, resistance to organic and inorganic chemicals, to heat and to abrasion and their adaptability to being formed into non-cellular or cellular forms. The resins are formed by reacting a liquid component A containing a mono aluminum or mono magnesium phosphate and a liquid component B containing a magnesium oxide and/or a wollastonite and a dispersing agent. Various fillers may be incorporated and a blowing agent may be added to form a cellular resin.

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Bolivar, OH, United States of America

William C Sargeant