Method for forming a fire resistant cellulose product, and associated apparatus

Abstract

A method is provided for forming a fire resistant cellulose product. Such a method comprises processing cellulose fibers into a fiber mixture, and forming a slurry from the fiber mixture and a fire-retarding solution, wherein the slurry has the fire-retarding solution substantially uniformly distributed therethrough. The slurry is then formed into a cellulose product. An associated apparatus is also provided.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application is a continuation of international application number PCT / CA2010 / 000419, filed Mar. 26, 2010, which is incorporated herein by reference in its entirety and for all purposes.BACKGROUND OF THE DISCLOSURE[0002]1. Field of the Disclosure[0003]Aspects of the present disclosure relate to methods for forming fire resistant products, and, more particularly, to a method for forming a fire resistant cellulose product, and associated apparatuses.[0004]2. Description of Related Art[0005]It may sometimes be desirable for particular products to exhibit resistance to fire. For example, it may be desirable for paperboard products used in building construction to exhibit a certain degree of fire resistance. In the case of drywall, which generally comprises a gypsum core with paperboard facing sheets, it is the gypsum core, and not the paperboard facing sheets, which is relied upon to provide some fire resistance capabilities. However, sinc...

AI Technical Summary

Benefits of technology

The present patent is about a method and apparatus for making a fire-retarded cellulose product. The method involves processing cellulose fibers into a fiber mixture, blending them with a fire-retarding solution, and forming a slurry with the solution unevenly distributed throughout. The slurry is then formed into a cellulose product. The apparatus includes a processing device, a mixing device, and a forming device. The fire-retarding solution can be an aqueous solution and may have desirable properties such as being nontoxic, neutral pH, and hypoallergenic. The processing device can use waste paper and payroll board, and the slurry can be dewatered and dried to form a cellulose product with a desirable thickness and width. The forming device can engage the slurry with negative or positive dies to create a cellulose product with the desired surface appearance. The recovered excess fire-retarding solution can be directed back to the mixing device for recycling in a closed-loop process. The technical effects of the patent include providing a safer and effective method for producing fire-retarded cellulose products.

Problems solved by technology

However, since drywall is comprised of two different materials, it may be difficult and / or relatively expensive to produce.

Further, the fire resistance capabilities of drywall may not necessarily be enough to make a significant difference in the overall construction of the building.

In such instances, however, one possible limitation in the treatment of the as-formed paperboard product for fire resistance, particularly with a liquid fire retardant, is achieving an even and consistent treatment of that product.

More particularly, the result of some fire resistance treatment processes involving application of a liquid fire-retardant to an as-formed paperboard product may be an uneven or otherwise inconsistent coverage of the fire retardant with respect to the product.

In those cases, the uneven treatment may result in varying levels of fire resistance of the treated paperboard product which may, in turn, become a hazard in the event of a fire which the product is intended to retard or otherwise provide some resistance.

Further, such treatment processes may not necessarily be efficient in terms of applying the fire retardant to the paperboard product, may not include provisions for capturing or recycling excess portions of the fire retardant product, and may not have the capability for preventing or restricting losses of the fire retardant due, for instance, to evaporative processes.

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