U.S. patent application number 13/626139 was filed with the patent office on 2013-10-03 for method for forming a fire resistant cellulose product, and associated apparatus.
The applicant listed for this patent is BLH TECHNOLOGIES, INC.. Invention is credited to Daniel Baroux.
Application Number | 20130255900 13/626139 |
Document ID | / |
Family ID | 44672396 |
Filed Date | 2013-10-03 |
United States Patent
Application |
20130255900 |
Kind Code |
A1 |
Baroux; Daniel |
October 3, 2013 |
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.
Inventors: |
Baroux; Daniel; (Nanaimo,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BLH TECHNOLOGIES, INC. |
Halifax |
NS |
US |
|
|
Family ID: |
44672396 |
Appl. No.: |
13/626139 |
Filed: |
September 25, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
PCT/CA2010/000419 |
Mar 26, 2010 |
|
|
|
13626139 |
|
|
|
|
Current U.S.
Class: |
162/181.2 ;
162/181.1; 162/181.4; 162/181.5 |
Current CPC
Class: |
D21H 21/34 20130101;
D21H 17/63 20130101; D21J 3/00 20130101; D21J 1/00 20130101; D21J
1/16 20130101; D21H 21/14 20130101 |
Class at
Publication: |
162/181.2 ;
162/181.1; 162/181.4; 162/181.5 |
International
Class: |
D21J 1/00 20060101
D21J001/00 |
Claims
1. A method of forming a fire resistant cellulose product, said
method comprising: processing cellulose fibers into a fiber
mixture; forming a slurry from the fiber mixture and a
fire-retarding solution, the fire-retarding solution comprising a
neutral pH liquid including one of an inorganic hydrate, a bromine
compound, magnesium hydroxide, hydromagnesite, antimony trioxide, a
phosphonium salt, ammonium phosphate, diammonium phosphate, and
combinations thereof, the slurry having the fire-retarding solution
substantially uniformly distributed therethrough; and forming the
slurry into a cellulose product.
2. A method according to claim 1, wherein processing cellulose
fibers into the fiber mixture further comprises processing one of
waste paper and waste board, each comprising cellulose fibers, into
the fiber mixture.
3. A method according to claim 1, wherein forming the slurry
further comprises adding water to the fiber mixture.
4. A method according to claim 1, further comprising agitating the
slurry so as to substantially uniformly distribute the
fire-retarding solution therethrough.
5. A method according to claim 1, wherein forming the slurry into
the cellulose product further comprises: dewatering the slurry; and
drying the dewatered slurry to form the cellulose product.
6. A method according to claim 1, wherein forming the slurry into
the cellulose product further comprises compressing the slurry to
form a densified cellulose product.
7. A method according to claim 1, wherein forming the slurry into
the cellulose product further comprises heating the slurry to form
a dried cellulose product.
8. A method according to claim 1, wherein forming the slurry into
the cellulose product further comprises drying the slurry to form a
substantially planar cellulose product having one of a thickness of
between about 0.125 inches and about 2 feet, and a width of between
about 1 inch and about 8 feet.
9. A method according to claim 1, wherein forming the slurry into
the cellulose product further comprises engaging the slurry with
one of a negative die and a positive die, so as to form the
cellulose product having a surface defining a negative impression
of the one of the negative die and the positive die.
10. A method according to claim 1, further comprising recovering
excess fire-retarding solution, in one of a liquid and a vapor
form, upon forming the slurry into the cellulose product.
11. A method according to claim 10, wherein forming the slurry
further comprises adding the recovered excess fire-retarding
solution to the slurry, prior to forming the slurry into the
cellulose product.
12. A method according to claim 1, forming the slurry further
comprises forming the slurry from the fiber mixture and one of an
aqueous fire-retarding solution and a nontoxic liquid
fire-retarding solution.
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,
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.
[0006] In some instances, a paperboard product may have a
fire-retardant product applied thereto, post-formation, to provide
some fire resistance capabilities for the paperboard product. That
is, an exemplary as-formed paperboard product may have a surface
treatment, for example, a liquid fire retardant, applied thereto in
order for the treated product to exhibit at least some fire
resistance. 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.
[0007] Thus, there exists a need for a process and associated
apparatus for evenly and consistently applying a fire retardant,
particularly a liquid fire retardant, to a cellulose product such
as, for example, a paperboard product. In some instances, it may be
desirable to form an integral cellulose product having the
characteristics of an existing product having two or more discrete
components (i.e., drywall), while also providing an enhanced level
of fire resistance. It may also be desirable, in some instances, to
have a paperboard formation process with the capability of
capturing excess fire retardant and recycling the captured excess
in subsequent cellulose product manufacturing cycles, whether the
excess is captured in a liquid form or in other forms, such as
vapors.
BRIEF SUMMARY OF THE DISCLOSURE
[0008] The above and other needs are met by aspects of the present
disclosure, wherein one such aspect relates to a method of 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.
[0009] Another aspect of the present disclosure relates to an
apparatus for forming a fire resistant cellulose product. Such an
apparatus comprises a processing device configured process
cellulose fibers into a fiber mixture, and a mixing device
configured to form a slurry from the fiber mixture and a
fire-retarding solution, such that the fire-retarding solution is
substantially uniformly distributed therethrough. A forming device
is configured to then form the slurry into a cellulose product.
[0010] In particular aspects, the fire-retarding solution may be an
aqueous fire-retarding solution. It may be preferred that the
fire-retarding solution be nontoxic and/or have a neutral pH and/or
be hypoallergenic and/or have any number of otherwise desirable
properties. In some aspects, the fire-retarding solution may
comprise any one of a boron compound, a borate, an inorganic
hydrate, a bromine compound, aluminum hydroxide, magnesium
hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt,
ammonium phosphate, and diammonium phosphate, or various
combinations thereof
[0011] In still further aspects, the processing device may be
configured to process waste paper and/or waste board, each
comprising cellulose fibers, into the fiber mixture. Further, the
mixing device may be configured, for example, to add water to the
cellulose fibers to form the slurry, and/or to agitate the slurry
so as to substantially uniformly distribute the fire-retarding
solution therethrough.
[0012] In further aspects, the forming device may be configured to
dewater the slurry and to dry the dewatered slurry to form the
cellulose product. In doing so, the slurry may be compressed to
form a densified cellulose product and/or heated to form a dried
cellulose product. The forming device may also be configured to dry
the slurry to form a substantially planar cellulose product having
one of a thickness of between about 0.125 inches and about 2 feet,
and a width of between about 1 inch and about 8 feet.
[0013] In some instances, the forming device may be configured to
engage the slurry with one of a negative die and a positive die, so
as to form a cellulose product having a surface defining a negative
impression of the one of the negative die and the positive die.
[0014] In yet other aspects, the apparatus may also comprise a
recovery device configured to recover excess fire-retarding
solution, in one of a liquid and a vapor form, upon the forming
device forming the slurry into the cellulose product. Further, the
recovery device may be configured to direct the recovered excess
fire-retarding solution to the mixing device, for example, in a
closed-loop, fire-retarding solution recycling process.
[0015] Aspects of the present disclosure thus address the
identified needs and provide other advantages as otherwise detailed
herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0016] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0017] FIG. 1 schematically illustrates an apparatus for forming a
fire resistant cellulose product, according to one aspect of the
disclosure; and
[0018] FIG. 2 schematically illustrates a method of forming a fire
resistant cellulose product, according to one aspect of the
disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0019] The present disclosure now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all aspects of the disclosure are shown. Indeed, the
disclosure may be embodied in many different forms and should not
be construed as limited to the aspects set forth herein; rather,
these aspects are provided so that this disclosure will satisfy
applicable legal requirements. Like numbers refer to like elements
throughout.
[0020] Aspects of the present disclosure are generally directed to
apparatuses and methods for forming a fire resistant cellulose
product. As previously discussed, one possible limitation in the
treatment of as-formed cellulose products, such as a paperboard
product, for fire resistance, particularly with a liquid fire
retardant, is achieving an even and consistent treatment of that
cellulose product. That is, the result of some fire resistance
surface-treatment processes may be an uneven or otherwise
inconsistent application of the fire retardant to the cellulose
product. In those cases, such uneven surface treatment may result
in varying levels of fire resistance of the treated cellulose
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.
[0021] As such, one aspect of the present disclosure involves an
apparatus for forming a fire-resistant cellulose product, such an
apparatus being indicated as element 100 in FIG. 1. Such an
apparatus 100 may comprise, for example, a processing device 200
configured to process cellulose fibers into a fiber mixture, a
mixing device 300 configured to form a slurry from the fiber
mixture and a fire-retarding solution, such that the fire-retarding
solution is substantially uniformly distributed therethrough, and a
forming device 400 configured to form the slurry into a cellulose
product.
[0022] The processing device 200 may be configured to process
cellulose fibers from one or more sources 150 into a fiber mixture.
That is, though aspects of the present disclosure contemplate that
the cellulose products may be comprised of recycled cellulose
fibers (i.e., from waste paper, waste board, waste paperboard, or
any other suitable waste source of cellulose fibers), one skilled
in the art will appreciate that raw, original, or otherwise virgin
cellulose fibers may also be used in addition to, in combination
with, or instead of the recycled/waste cellulose fibers. Further,
in some aspects, the cellulose fibers may not necessarily be
required to be free of contaminants, as long as those contaminants
can be processed along with the cellulose fibers to form the fiber
mixture. For example, where the source of cellulose fibers includes
waste pizza boxes, those waste pizza boxes do not necessarily need
to be free of pizza components, such as cheese, in order for those
pizza boxes to be processed by the processing device 200. As such,
a decontamination process may not necessarily be contemplated, but
could be included, should there be a need or desire for a
contaminant-free cellulose product. In addition, the cellulose
fibers do not necessarily need to be dry prior to being processed
by the processing device 200. That is, waste sources of cellulose
fibers may be, in some instances, in the form of bales, wherein the
bales may often be exposed to the elements (i.e., rain or
condensation) prior to being introduced to the processing device
200. In those instances, aspects of the present disclosure are also
configured to process the "wet" source of cellulose fibers into the
fiber mixture. In this regard, the cellulose fibers may be
processed by the processing device 200, regardless of the moisture
level present therein, into the fiber mixture. The extent of the
processing of the cellulose fibers may vary considerably depending,
for example, on the level of refinement (i.e., coarse/fine) desired
of the final cellulose product. The processing device 200 may be
any machine suitable for deconstructing the waste cellulose fibers
in the manner discussed, wherein one such exemplary machine may be
manufactured by Metso Paper, Inc. of Helsinki, Finland.
[0023] Once the fiber mixture is produced in the desired state by
the processing device 200, the fiber mixture may be directed to the
mixing device 300, where the fiber mixture is mixed with a
fire-retarding solution 250 to form a slurry 275, and the slurry
275 is mixed such that the fire-retarding solution is substantially
uniformly distributed therethrough. In some instances, the mixing
device 300 may be configured to add water and/or other appropriate
liquid or chemical to the fiber mixture in forming the slurry.
[0024] In particular aspects, the fire-retarding solution 250 may
be an aqueous fire-retarding solution. It may be preferred that the
fire-retarding solution be nontoxic and/or have a neutral pH and/or
be hypoallergenic and/or have any number of otherwise desirable
properties affecting human/animal and/or environmental safety,
while maintaining the necessary efficacy, as implemented and upon
exposure to heat and/or flame. In some aspects, the fire-retarding
solution 250 may comprise any one of a boron compound, a borate, an
inorganic hydrate, a bromine compound, aluminum hydroxide,
magnesium hydroxide, hydromagnesite, antimony trioxide, a
phosphonium salt, ammonium phosphate, and diammonium phosphate, or
various combinations thereof In this regard, one skilled in the art
will appreciate that various fire-retarding or fire resistant
substances, either currently known or later developed or
discovered, may be applicable to the disclosed processes and
apparatuses herein within the scope of the present disclosure.
[0025] One skilled in the art will further appreciate that the
fire-retarding solution may be formed by adding a solid
fire-retardant product to a liquid (i.e., water) or other chemical
mixed with the fiber mixture such that the solid fire-retardant
product forms a solution with the liquid or other chemical
comprising the slurry with the fiber mixture. In some instances,
the mixing device 300 may be configured to agitate the slurry or
pulp mixture, so as to substantially uniformly distribute the
fire-retarding solution therethrough. The mixing device 300 may be
any machine suitable for forming the slurry 275 from the fiber
mixture and the fire-retarding solution, in the manner discussed,
wherein one such exemplary machine may be manufactured by Metso
Paper, Inc. of Helsinki, Finland.
[0026] The forming device 400 is configured to receive the slurry
275 from the mixing device 300 and to form the slurry into a
cellulose product 600. In some instances, the forming device 400
may be configured to dewater the slurry, before drying the
dewatered slurry to form the cellulose product. Such a dewatering
process may be accomplished, for example, by a suitably modified
Fourdrinier-type machine, or other appropriate process, as will be
appreciated by one skilled in the art. The slurry may also be
dewatered, for instance, using a twin wire forming section and/or
appropriate screening devices. In other instances, whether
dewatered or not, the slurry may be compressed by the forming
device 400 to form a densified cellulose product and/or heated by
the forming device 400 to form a dried cellulose product.
Compression of the slurry may be accomplished, for instance, using
a screw press or other suitable press device. Heat may be applied
to the slurry, for example, via heated air (i.e., heated with
combusted natural gas or other suitable fuel source), or through
any of a variety of heating/drying methods, such as, for example,
microwave or infrared drying techniques, as will be appreciated by
one skilled in the art.
[0027] One skilled in the art will also appreciate that the forming
device 400 may be configured in many different manners. For
example, a suitably-configured screen device may be configured to
receive the slurry, wherein the screen device may include a number
of perforations. Once deposited in the screen device, the slurry
may be engaged by an opposing platen, which may also be perforated.
The perforations may serve to dewater the slurry, while the platen
and/or the screen device may be heated to provide for drying of the
dewatered slurry. Further, pressure may be applied to the screen
device and/or the platen, for example, using a hydraulic or
screw-type pressure device, so as to compress the slurry while the
slurry is dewatered and heated. In some desirable aspects, the
forming device 400 may also be configured to form the slurry into a
substantially planar cellulose product 600 having a thickness of
between about 0.125 inches and about 2 feet, and/or a width of
between about 1 inch and about 8 feet. One skilled in the art will
appreciate, however, that the dimensions of the planar cellulose
product may vary considerably. In still other aspects, the
cellulose product 600 may be formed as a sheet having a desired
length, or as a continuous sheet that is later subdivided into
segments of a desired length. In some instances, the forming device
400 may be configured to engage the slurry with one of a negative
die and a positive die, so as to form a cellulose product having a
surface defining a negative impression of the one of the negative
die and the positive die. That is, for example, the screen device
and/or the platen may be appropriately patterned with a raised
and/or depressed pattern such that the formed cellulose product
will have a corresponding surface defining a negative impression of
the pattern. One skilled in the art will also appreciate that the
capability of manipulating the slurry in this manner indicates that
the final form of the cellulose product need not necessarily be in
planar form, but may take many different shapes, contours, and
sizes in addition to that disclosed herein.
[0028] In other aspects, the apparatus 100 may also comprise a
recovery device 500 configured to recover excess fire-retarding
solution, in one of a liquid and a vapor form, upon the forming
device 400 forming the slurry into the cellulose product. In some
instances, the recovery device 500 may also be configured to engage
the mixing device 300 for accomplishing the recovery of the excess
fire-retarding solution. Further, the recovery device 500 may be
configured to direct the recovered excess fire-retarding solution
to the mixing device 300, for example, in a closed-loop,
fire-retarding solution recycling process. Upon recovery of the
excess portions, including liquids and vapors, by the recovery
device 500, the recovered excess fire-retarding solution may be
strained, filtered, or otherwise purified, and then reintroduced to
the mixing device 300 to form subsequent cellulose products, such
that the fire-retarding solution is substantially or entirely
prevented from leaving the apparatus 100 as a waste product.
[0029] In addition, in some instances, the as-formed cellulose
product may be further processed, for example, to planarize certain
surfaces thereof, or to remove "broke" or otherwise planarize the
edges of the cellulose product. In such instances, the apparatus
100 may also include a collection device (not shown), wherein the
collection device may be configured to capture waste solids from
the post-formation processing of the cellulose product. In those
instances, the captured waste solids may be incorporated into other
products (i.e., blown-in insulation) while providing
fire-resistance properties therefor.
[0030] Many modifications and other aspects of the disclosures set
forth herein will come to mind to one skilled in the art to which
these disclosures pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. For example, one skilled in the art that the apparatuses
disclosed herein readily lead to associated processes and methods
for forming a fire resistant cellulose product, as shown, for
example, in FIG. 2. More particularly, such methods may comprise
processing cellulose fibers into a fiber mixture (block 700), 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 (block 800), and
then forming the slurry into a cellulose product (block 900).
[0031] Further, one skilled in the art will appreciate that, in
some aspects, the slurry, dewatered slurry, and/or cellulose
product may be formed as a general cellulose element that can then
be formed, molded, or otherwise manipulated into various end
products such as, for example, boards, compounded roofing shingles,
compounded roofing shakes, compounded sidewall shingles, compounded
Spanish style "red clay" type roof tiles, electrical outlet
encasements, doors, interior wall planking, exterior sheathing,
cabinetry cores, cupboards, compounded cabinet door faces,
flooring, laminated flooring, veneered compounded flooring, or the
like. However, the exemplary end products presented herein are not
intended to be limiting in any manner with respect to the wide
variety of contemplated end products. Thus, the general cellulose
element concept may be extend to instances where the end product
may be produced in many different manners such as, for example, by
molding, extrusion, pressing, stamping, or by any other suitable
production method.
[0032] Moreover, the general cellulose element concept may be
applicable where the general cellulose element is provided as a
component or other portion of a further end assembly. Particularly,
as shown in such previous examples as laminated flooring and cored
cabinetry, the general cellulose element incorporating the
fire-retarding solution forms a component of the end assembly. One
skilled in the art will thus appreciate that cellulose products in
accordance with aspects of the present disclosure may be produced
such that the fire-retarding solution is dispersed at least
partially, if not consistently and uniformly, throughout. As such,
the components of the end assembly comprising the fire-retarded
cellulose product may likely be wholly resistant to fire and/or
unable to ignite on a more permanent basis (i.e., since the
fire-retarding solution is effectively integrated into the
cellulose product), as compared to simple surface treatments that
may be easily removed, washed away, or subject to degradation over
time.
[0033] Therefore, it is to be understood that the disclosures are
not to be limited to the specific aspects disclosed and that
modifications and other aspects are intended to be included within
the scope of the appended claims Although specific terms are
employed herein, they are used in a generic and descriptive sense
only and not for purposes of limitation.
* * * * *