Masonite Corporation

Arthur D. Little, Inc.

William L Prior

Richard S Lindstrom

William C Sargeant

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.

Essentially nonflammable, moldable, strong laminates formed of alternating layers of cured magnesium oxycement and a fibrous web, e.g., paper formed of cellulosic, glass or synthetic resin fibers or mixtures thereof. The magnesium oxycement may contain a suitable filter, the surfaces of the laminate may be modified and composites may be formed with a wide variety of core materials. The laminates are made by coating the fibrous webs with a reactive slurry of a magnesium salt solution and magnesium oxide. The fibrous web materials used are impermeable to the extent that no appreciable amount of the magnesium salt solution is absorbed and no appreciable amount of the magnesium oxide is filtered out onto the surface or into the intertices of the web.

Magnesium oxycement/fibrous web composites

Process and composition for forming cellular inorganic plastic cements of magnesium oxychlorides and magnesium oxysulfates. A water slurry containing a magnesium salt, magnesium oxide and a water-soluble phosphate is formed and to it are added an anionic water-repellent surfactant and a blowing agent capable of providing a gaseous component in the strongly alkaline environment either through decomposition or reaction or through vaporization. Inorganic filler material may be added to impart strength, the maximum flexural strength being attained when at least about one-half of the filler comprises microfibers. The resulting cellular product is nonflammable and exhibits essentially zero flame spread, zero smoke density and zero fuel contribution. The cellular products are further characterized as being formed of substantially uniformly sized cells and having densities over a wide range.

Cellular inorganic resin cements, and process and compositions for

Magnesium oxide cements are formulated to contain microfiber fillers multidirectionally oriented throughout. Secondary reinforcing fillers may also be incorporated into these inorganic cements. The use of the microfiber fillers significantly increases the modulus of rupture and tensile and impact strengths of the magnesium oxide cements thus making them available for a wide range of uses including many now presently served by reinforced synthetic organic resins.

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Newark, OH, United States of America

William L Prior