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United States Patent (19) 11 E Patent Number: Re United States Patent (19) 11 E Patent Number: Re. 33,773 Guerro et al. 45 Reissued Date of Patent: Dec. 17, 1991 (54) METHOD OF MANUFACTURING A 52 U.S. C. ................................. 428/288; 427/385.5; SAG-RESISTANT BONDED PARTICULATE 427/393.6; 428/290 MATTER 58) Field of Search .......................... 427/385.5, 393.6; 75) Inventors: Gerald J. Guerro, Trumbell, Conn.; 428/288, 290 Gregory G. Borsinger, Boonton, N.J. (56) References Cited 73) Assignee: American Cyanamid Company, U.S. PATENT DOCUMENTS Stamford, Conn. 4, 158,574 6/1979 Cunnisford et al. ................ 127/32 21 Appl. No.: 570,193 4,524,093 6/1985 Devry .................. 427/389.9 (22 Filed: Aug. 20, 1990 4,756,714 7/1988 Hendrix et al. ..................... 8/115.6 Primary Examiner-Michael Lusignan Related U.S. Patent Documents Attorney, Agent, or Firn-Steven H. Flynn Reissue of: (57) ABSTRACT 64 Patent No.: 4.942,085 A method for the production of improved bonded par Issued: Jul. 17, 1990 ticulate articles, and the articles so produced, are dis Appl. No.: 433,984 closed. Specifically, the manufacture of particulate arti Filed: Nov. 15, 1989 cles having a reduced tendency to undergo humidity U.S. Applications: induced sag is disclosed. These articles have utility in 63 Continuation-in-part of Ser. No. 299,284, Jan. 23, 1989, such application as ceiling tiles. abandoned. 5ll Int. Cl................................................ D04H 1A58 19 Claims, No Drawings Re. 33,773 1. 2 coatings as noxious as those of which we seek to avoid METHOD OF MANUFACTURING A to use. SAG-RESISTANT BONDED PARTICULATE U.S. Pat. No. 4,400,480 relates to a method of prepar MATTER ing water resistant paperboard through use of a cross linking additive for starch-based adhesive compositions, Matter enclosed in heavy brackets II appears in the These compositions are prepared by reacting acetone original patent but forms no part of this reissue specifica and formaldehyde under aqueous alkaline conditions at tion; matter printed in italics indicates the additions made 20-380 C. in a molar ratio of 1 mole acetone: 2-5.5 by reissue. moles of formaldehyde. An effective amount of free O formaldehyde is reduced to about 0.1-2% by weight. CROSS-REFERENCE TO RELATED The resulting reaction product can then be added to a starch-based adhesive or first mixed with dimethylol APPLICATION dihydroxy ethylene urea. Due to its formaldehyde con This application is a reissue application of our original tent, this resin has the same environmental and exposure U.S. Pat. No. 4,942,085 dated July 17, 1990, Ser. No. ls concerns discussed earlier and therefore does not repre 07/433,984, filed Noy, 15, 1989, which is a continuation sent an improvement over the currently practiced art. in-part application of U.S. Ser. No. 07/299,284 filed Jan. U.S. Pat. No. 4,600,439 discloses a coating composi 23, 1989, now abandoned. tion for paper or cardboard, comprising a fluidizing agent and an undepolymerized starch, optionally modi FIELD OF INVENTION fied, a synthetic product, such as polyvinylalcohol, or a This invention relates to a method of manufacturing protein, such as casein or soya proteins. improved bonded particulate articles and to the articles U.S. Pat. No. 3,858,273 discloses a method of improv so produced. More particularly, the present invention ing the wet rigidity of corrugated paperboard through relates to a method of manufacturing improved particu its impregnation with a slow-curing glyoxal-based resin late tiles which possess a reduced tendency to exhibit 25 in the presence of a catalyst and, optionally, an exten humidity-induced sag and to the particulate tiles so der, such as a starch. produced. U.S. Pat. No. 3,288,631 discloses a method for the production of non-woven fiber webs that are stable in BACKGROUND OF THE INVENTION the presence of water comprising a water-soluble bond Maintaining stiffness or rigidity of bonded particulate 30 ing agent having both hydroxyl- and carbonyl-groups tile articles under high humidity conditions has long and a water-soluble resin and metal salt capable of re been a problem in the particulate tile industry. This acting with the aforementioned groups. problem is of particular concern since the articles are The above-mentioned paper coating methods are typically used in ceilings and supported only around inadequate for use in the production of sag resistant tiles their perimeters. Humidity weakens the tile and due to 35 due to their failure to impart adequate moisture resis the perimeter-only support often induces an unaccept tance and/or rigidity to a tile, thereby allowing the tile able sag of the tile. to exhibit an unacceptable degree of humidity-induced The resistance of particulate tiles to moisture has Sag. previously been improved by applying a coating com Unexpectedly, it has now been discovered that a class prised of a melamine-formaldehyde resin. However, use 40 of materials previously used in the manufacture of paper of this resin, due to its formaldehyde content, is of con products is useful in the prevention of humidity-induced cern due to the existence of regulations involving sag in bonded particulate articles, such as ceiling tiles. worker exposure during production of the resin and its application to the particulate tiles. Moreover, the envi SUMMARY OF THE INVENTION ronmental hazards associated with the use of this resin 45 The present invention relates to a method of prevent does not end with the manufacturing process since tiles ing or minimizing humidity-induced sag in bonded par bearing this coating release noxious and undesirable ticulate articles comprising applying to at least one side vapors under conditions such as those encountered in of a particulate substrate a coating composition cun fires. Less noxious materials which exhibit satisfactory prising water, a binder resin comprising the reaction performance with regard to preventing humidity 50 product of glyoxal resin or derivative thereof and a induced sag of the particulate tiles to which they are starch, and a filler material and then curing the coating applied have not heretofore been found. composition on said particulate substrate. U.S. Pat. No. 4,611,445 discloses a ceiling tile resis The present invention further relates to bonded par tant to sag when exposed to a fire comprising mineral ticulate articles which are resistant to humidity-induced wool fibers having distributed therein from about 11% 55 sag which are produced in accordance with the method to about 6% by weight, based on the weight of the claimed herein. fibers, of lithium carbonate or the fused decomposition product thereof. This coating, however, is not useful in DETAILED DESCRIPTION preventing humidity-induced sag. The substrates useful in the practice of the claimed Various methods have been utilized in the corrugated are those such as those present in commercially avail paper art to reduce the degradation of paper strength able particulate tiles. These substrates are generally due to moisture contact. Impregnating paper with cer comprised of processed fiberous materials such as min tain resins, e.g. ureas, melamines, and phenolics, is eral wool as disclosed in U.S. Pat. No. 4,61 1,445. These known, but the use of such resins has only limited utility substrates can be found in commercially available in the manufacturing of particulate tiles because these 65 dropped ceiling tiles currently used in residential con resins cure at normal paper machine temperatures and struction. tiles coated therewith become excessively brittle during The binder resin useful in the production of the coat their processing. Moreover, many of these processes use ing composition and the practice of the present inven Re. 33,773 3 4. tion comprises resin component and a starch compo mixtures. The catalyst is used in an amount ranging nent. The resin component of this invention may be any from about 1 to about 50, and preferably about 12 to suitable slow-curing glyoxal resin or derivative thereof. about 15, percent based on the total weight of the binder Examples include the reaction product of glyoxal, urea, resin. and formaldehyde. This component may be prepared, The coating compositions of this invention are aque for example, by first heating the glyoxal resin and the ous dispersions prepared by mixing water, the binder urea to form a monourein which is then treated with resin components, and the catalyst if employed. The formaldehyde or by reacting glyoxal and formaldehyde order of addition of these materials is not critical. The and then adding the urea. Typical compounds useful as coating composition should contain 20-75 percent by the resin component include, but are not limited to, O weight of solids (i.e. binder resin and filler) and prefera dimethylol dihydroxyethylene urea, partially alkylated bly 30-60 percent on the same basis. dimethylol dihydroxy ethylene urea wherein said alkyl The coating composition is applied to at least one side group contain from 1 to about 8 carbon atoms, alkylated of the particulate substrate in the practice of the present dimethylol dihydroxy ethylene urea wherein said alkyl invention. The coating composition should be applied group contain from 1 to about 8 carbon atoms, and 5 such that subsequent to its curing, it forms a layer hav tetramethylol glycoluril. Preferred are dimethylol dihy ing a dry coating weight of at least about 1 to about 100 droxyethylene urea and tetramethylol glycoluril. grams/ft2 on said substrate. More preferably, the coat The starch component of the binder resin may be ing composition is present in a dry coating weight of at selected from any of the several starches, heretofore least about 5 to about 40 grams/ft2.
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