Title of Invention

A METHOD OF MANUFACTURING NATURAL FIBER THERMOSET COMPOSITE FIREPROOF SHEET / BOARD.

Abstract

A method of manufacturing Natural Fiber and Thermosel Composite fireproof Sheet/board Comprising the steps of a) reacting phenol , monochloro Phenol with formaldehyde ii the molar ratio 0.1 to 5.0:0.01 to 4.0:0.1 to 7.0 ii presence of acid catalyst or Phenol, Monochloro Phenol and Formaldehyde in the molar ratio 0.1 to 5.0:0.01 to 4.0 0.1 : 7.0 in presence of Alkaline catalyst ; to obtaii modified mouldable Phenolic resin ; b) dissolving the said resin of step (a) in methenol with crosslinking agent ; c) forming a slurry by mixing filler and additives in the resin solution of step (b) ; d) impregnating jute cloth of any form in the said slurry of step (c) ; e) drying the impregnated jute cloth oven at temperature of 100°C to 400°C ; f) cutting the dried jute of any form impregnated in slurry : the required size ; g) layering the jute of any form impregnated with slurry in multilayered fashion in the required thickness and pressinc in the hydraulic press at a pressure 1 to 3 tons per square inches for a period of 5 to 3 0 minutes, at a temperature of 100°C to 200° C ; h) trimming the multilayered pressed material in required size to form the Natural Fiber Thermoset Composite sheet/boards

Full Text

FORM 2 THE PATENTS ACT, 1970 (39 of 1970) COMPLETE SPECIFICATION (See Section 10) A METHOD OF MANUFACTURING NATURAL FIBER THERMOSET COMPOSITE FIREPROOF SHEET / BOARD- A B COMPOSITES PVT. LTD. of B-6 MANISH APARTMENT, MATHURADAS ROAD, KANDIVLI (WEST), MUMBAI - 400 067, MAHARASHTRA, India, INDIAN Company The following specification particularly describes the nature of the invention and the manner in which it is to be performed : - ORIGINAL 729/MUM/2003 21/07/03 GRANTED 9-12-2003 A METHOD OF MANUFACTURING NATURAL FIBER THERMOSET COMPOSITE FIREPROOF SHEET/BOARD This invention relates to a method of manufacturing Natural Fibre Thermoset Composite fireproof Sheet / Board . More particularly this invention relates to a method of manufacturing board/sheet mainly from Jute of any form , Non woven fabric and felt. In prior Art the press fiber sheets /boards are well known. According to Indian Patent specification no.60341 pressed Fibre sheets/boards is made of felt mass of fiber of jute , or jute mixed with other fibers impregnated with adhesive or bonding agents selected from a solution containing Glue , Potassium ,Bi¬carbonate , Formaldehyde and Oxalic acid or Latex , Casein in alkali solution , vulcanizing agents with or without dextrine or tamarind seed powder size ; and consolidated into a sheet by heat and pressure . It is observed that the board produced by this process are not of tough quality for various industrial applications and are not fireproof. The main object of the present invention is to provide a method to produce moulded Natural Fiber Thermoset Composite fireproof sheet/board. Another object of the invention to provide a moulded substance which replaces wood , Asbestos , metal , plastics for making eco - friendly , bio - friendly , pollution free environment. The moulded substance is made from natural fibres of organic and inorganic origin as reinforcement alongwith one or more thermoset resins such as Phenol Formaldehyde, urea Formaldehyde, polyster , epoxy , Palyamide resin. With the extensive research we have found out that jute of any form when impregnated in a slurry of resin and additives and dried pressed product in multilayered as per size required and thickness , it gives the following enhanced physical properties which is cheaper than wood, plastic , Asbestos, metals, fireproof and low maintenance . Cross Breaking Tensile Density Bending for Sheet Up To 3mm Drop Impact 900 Gm. Load Flexibility Water Absorption a) Cold Water b) Boiling Water Fire Proof 70 to 80 Mpa 20 - 25 Mpa Min 1.5 +- 0.2 12 Kg. Min 130 mm. 3 75 mm dia Mandrel 1.5 % 3 % Fire Proof - On a Fire of temperature 850°C to 900°C if kept for 5 Min & no Flame is observed. The above properties of invented sheet/board made of jute is far superior to that of sheet / board of Indian Patent specification no. 60341 . Accordingly there is provided a method for the manufacturing Natural Fiber Thermoset Composite Sheet/Board comprising the steps of :- a) reacting phenol , monochloro Phenol with formaldehyde in the molar ratio 0.1 to 5.0:0.01 to 4.0:0.1 to 7.0 in" presence of acid catalyst or Phenol, Monochloro Phenol and Formaldehyde in the molar ratio 0.1 to 5.0:0.01 to 4.0: 0.1 : 7.0 in presence of Alkaline catalyst ; to obtain modified mouldable Phenolic resin ; b) dissolving the said resin of step (a) in methenol with crosslinking agent ; c) forming a slurry by mixing filler and additives in the resin solution of step (b) ; d) impregnating jute cloth of any form in the said slurry of step (c) ; e) drying the impregnated jute cloth oven at temperature of 100°C to 400°C ; f) cutting the dried jute of any form impregnated in slurry in the required size ; g) layering the jute of any form impregnated with slurry in multilayered fashion in the required thickness and pressing in the hydraulic press at a pressure 1 to 3 tons per square inches for a period of 5 to 3 0 minutes, at a temperature of 100°C to 200° C ; h) trimming the multilayered pressed material in required size to form the Natural Fiber Thermoset Composite sheet/boards. Example 1 : Monochloro Phenol resin is produced by condensation reaction with Phenol , Monochloro Phenol and Formaldehyde in presence of acid catalyst in the molar ratio 0.1 : 0.01 : 0.1 as indicated in block 1 , The said resin is dissolved in methanol with suitable hardner as indicated block 2. The said resin solution mixed with filler and other additives to form a slurry as shown in block 3. The jute cloth is impregnated in the slurry as shown in block 4. The said impregnated jute cloth is dried in an oven at temperature 100°to 4 00°C to make the cloth dried as shown in block 5. The said impregnated dried cut pieces of jute cloth is multilayer accordingly to required thickness and pressed in the hydrulic press at a pressure 1 to 3 tons per square inches for a period of 5 to 3 0 minutes, at temperature 100°C to 200°C as shown in block 7. The pressed sheets / boards are trimmed to obtain the required size board of sheets. Example 2 : Monochloro Phenol resin is produced by condensation reaction with Phenol , Monochloro Phenol and Formaldehyde in presence of acid catalyst in the molar ratio 5.0 : 4.0 : 7.0 as indicated in block 1 , The said resin is dissolved in methanol with suitable hardner / crosslinking agent as indicated in block 2. The said resin solution mixed with filler and other additives to form a slurry as shown in block 3. The jute cloth is impregnated in the slurry as shown in block 4. The said impregnated jute cloth is dried in an oven at temperature 100°to 400°C to make the cloth dried as shown in block 5. The said impregnated dried cut pieces of jute cloth is multilayer accordingly to required thickness and pressed in the hydrulic press at a pressure 1 to 3 tons per square inches for a period of 5 to 30 minutes, at temperature 100° C to 200°C as shown in block 7. The pressed sheets/boards are trimmed to obtain the required size of board of sheets. 1) Jute of any form of 100 - 700 Grms per square meter. 2) Filler : Aliminium Trihydrade 5 - 10% , Coconut 5 - 10% , Marble 3 - 6% , Mica 4 - 8% , Talc 4 - 8% , Zinc stearate 0.5 - 2% , Rubber 0.5 - 2% , & CPW 5 - 10% , Total 25 - 45% in weight. 3) Resin : Phenolic Resin 25 - 45% by weight. 4) Additives : - Ammonium Hydrogen phosphate - 2 to 3 % , Zinc Borate - 2 to 3 % , Antimony Tri-Oxide - 2 to 4 %, Phosphate - 2 to 4 % and Borate - 2 to 4% also Aluminium Trihydrate 5 - 50 %. Size and Thickness of the Board. 4' * 8' and 5 ' * 10' . Thickness 1.5 to 25 mm. Advantages The Product Obtained By This Process:- It is; Long lasting Non Thermal / Electric Conductive Fire Proof Water Resistant Acid & Alkali Resistant Low Maintenance Cost Termite Resistant Anti - Abrasive Value for Money Wide Range of uses Eco Friendly WE CLAIM:- 1) A method of manufacturing Natural Fiber and Thermoset Composite fireproof Sheet/board Comprising the steps of :- a) reacting phenol , monochloro Phenol with formaldehyde in the molar ratio 0.1 to 5.0:0.01 to 4.0:0.1 to 7.0 in. presence of acid catalyst or Phenol, Monochloro Phenol and Formaldehyde in the molar ratio 0.1 to 5.0:0.01 to 4.0: 0.1 : 7.0 in presence of Alkaline catalyst ; to obtain modified mouldable Phenolic resin ; b) dissolving the said resin of step (a) in methenol with crosslinking agent ; c) forming a slurry by mixing filler and additives in the, resin solution of step (b) ; d) impregnating jute cloth of any form in the said slurry of step (c) ; e) drying the impregnated jute cloth oven at temperature of 100°C to 400°C ; f) cutting the dried jute of any form impregnated in slurry in the required size ; g) layering the jute of any form impregnated with slurry in multilayered fashion in the required thickness and pressing in the hydraulic press at a pressure 1 to 3 tons per square inches for a period of 5 to 3 0 minutes, at a temperature of 100°C to 200° C ; h) trimming the multilayered pressed material in required size to form the Natural Fiber Thermoset Composite sheet/boards. 2) A method of manufacturing Natural Fiber Thermosat composite fireproof Sheet/board as claimed in claim (1) wherein the fillers are Aluminium Trihydrade 5 - 10% , Coconut 5 - 10% , Marble 3-6%, Mica 4-8%, Talc 4-8%, Zinc Stearate0.5 - 20% , Rubber 0.5 - 2% , Chlorinated Paraffin Walks (CPW) 5 - 10%. 3) A method of manufacturing Natural Fiber Thermoset Composite Fireproof sheet/board as claimed in claim 1 , wherein the additives are Ammonium Hydrogen phosphate - 2 to 3 % , Zinc Borate - 2 to 3 % , Antimony Tri-Oxide - 2 to 4 %, Phosphate - 2 to 4 % and Borate - 2 to 4% and Aluminium Trihydrate 5 - 50 %. 4) A method of manufacturing Natural Fiber Thermoset composite Fireproof Sheet/board as claimed in claim 1 , wherein the jute of any form is of 100 - 700 GMS. per square meters. 5) A method of manufacturing Natural Fiber Thermoset composite Fireproof Sheet/board as claimed in claim 1 , wherein the acid catalyst is selected from mineral acid , organic acid, alkali catalyst form and hydroxide. 6) A method of manufacturing Natural Fiber Thermoset Composite fireproof sheet/board as claimed in claim 1 , and substantially as herein described with the reference to the Examples 1 & 2 . Dated this 21st day of July, 2003. HIRAL CHANDRAKANT JOSHI AGENT FOR A B COMPOSITES PVT. LTD.

Documents:

729-mum-2003-abstract(09-12-2003).pdf

729-mum-2003-abstract-(9-12-2003).doc

729-mum-2003-cancelled pages(09-12-2003).pdf

729-mum-2003-claims(granted)-(09-12-2003).pdf

729-mum-2003-claims(granted)-(9-12-2003).doc

729-mum-2003-correspondence(09-12-2003).pdf

729-mum-2003-correspondence(ipo)-(09-11-2004).pdf

729-mum-2003-drawing(09-12-2003).pdf

729-mum-2003-form 1(21-07-2003).pdf

729-mum-2003-form 19(22-07-2003).pdf

729-mum-2003-form 2(granted)-(09-12-2003).pdf

729-mum-2003-form 2(granted)-(9-12-2003).doc

729-mum-2003-form 3(11-07-2003).pdf

729-mum-2003-power of attoreny(11-07-2003).pdf

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