AU2003271417B2 - Method and apparatus for forming products of fibrous and cellulose material - Google Patents

Description

WO 2004/035899 PCTiAU2003/001376 Method And Apparatus For Forming Products of Fibrous and Cellulose Material Field of the Invention This invention relates to a method and apparatus for producing products comprising an admixture of fibrous and cellulose material. The products may be in the form of a bouffant admixture or a batt that has particular utility as an insulant, or alternatively may be in the form of an absorbent mat that has particular utility for soaking up oil or chemical spills.

Throughout the specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Background Art The following discussion of the background to the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge of the person skilled in the art in any jurisdiction as at the priority date of the application.

The manner of treating and feeding fibrous material such as wool to combine with fluidised cellulose material has been extremely difficult to perfect. This may be attributed to the innate properties of fibrous material, such as its recombinant and absorptive properties, particularly in the case of wool, and the difficulty with dissociating it to a sufficient degree to enable it to fully permeate the cellulose material.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -2- Moreover, where the fibrous material is wool, whilst the insulating qualities of both wool and cellulose have been known for many years and it has been theorised to combine these two materials together to form a wool/cellulose composite which combines the advantageous qualities of each of these materials in the one insulant, in actual fact, it has been near impossible to achieve such a composite in any commercially practical manner.

The main problem in this regard, has been perfecting a suitable treatment of the fibrous material, such aswool, in a manner to facilitate its introduction into the cellulose stream and to enable its effective and even dispersion throughout the resultant composite.

The applicant has developed a method and apparatus that can treat the fibrous material in an efficient and continuous manner to enable it to be fed into a fluidised cellulose stream in a satisfactory manner for effective and even dispersion therethrough so as to form a bouffant admixture of fibrous material and cellulose material suitable for use as an insulant.

Furthermore, the manner of forming a batt from a bouffant admixture of fibrous material and cellulose material has also been difficult to perfect. It is difficult to evenly distribute and set such a bouffant admixture into a batt without compacting the admixture and reducing its bouffanticity.

In a further arrangement the applicant has developed a method and apparatus for forming a batt from a bouffant admixture of fibrous material and cellulose material without substantially reducing its bouffanticity.

Pollution of an environment can be detrimental to flora and fauna inhabiting the environment. To minimise the detriment caused by pollution, it is desirable that the pollutants be removed from the environment. Liquid pollutants, such as oil and chemicals, present a particular difficulty in this regard, as their liquid properties can make them difficult to collect for removal, and they may quickly be dispersed over a wide area of the environment, as, for example, in the case of an oil spill in an ocean.

SUBSTITUTE SHEET (RULE 26) -3-

\O

The applicant has developed an absorbent mat from a bouffant admixture of k fibrous material and cellulose material for absorbing liquid pollution, such as oil or chemicals, and a method and apparatus for forming the absorbent mat.

00 Disclosure of the Invention In accordance with a first aspect of the invention, there is provided an apparatus Sfor forming an admixture of fibrous and cellulose material, the apparatus comprising: N particulate cellulose producing means for processing cellulose material into particulate cellulose material; mixing means for mixing fibrous material with the particulate cellulose material produced by the particulate cellulose producing means; and separating means for separating material into individual fibres or tufts of fibres.

Preferably, the separating means separates the fibrous material and the mixing means comprises: first fluidising means for entraining the separated fibrous material in a first air stream; second fluidising means for entraining a particulate cellulose material in a second air stream; combining means for combining the first air stream with the second air stream to form an admixture of fibrous and cellulose material entrained in a third combined air stream; and removing means for removing the admixture from the third combined air stream.

00

O

O

-4- Preferably, the separating means separates the fibrous material in the admixture of fibrous material and cellulose material.

Preferably, the particulate cellulose material produced by the particulate cellulose producing means is entrained by the second fluidising means in the second air stream.

Preferably, the particulate producing means comprises a shredder.

Alternatively, the particulate producing means comprises a hogger.

Preferably, the apparatus further comprises chemical impregnating means for impregnating the particulate cellulose material with a chemical.

Preferably, the chemical includes a fire retardant.

Preferably, the chemical includes a vermin repellant.

Preferably, the chemical impregnating means comprises: chemical feed means for feeding chemical to the second fluidising means so that the chemical is entrained in the second air stream; and grinding means for grinding the particulate cellulose material and chemical in the second air stream through perforations in a member positioned transverse to the second air stream and thereby impregnate the particulate cellulose material with the chemical.

Preferably, the perforations are circular holes of diameter ranging from 2 mm to mm.

Preferably, the grinding means comprises a grinder.

WO 2004/035899 PCTiAU2003!001376 Preferably, the chemical impregnating means comprises: chemical feed means for feeding chemical to the second fluidising means so that the chemical is entrained in the second air stream; and a hammer mill positioned to operate on particulate cellulose material and chemical in the second air stream and thereby impregnate the particulate cellulose material with the chemical.

Preferably, the fibrous material is a combination of different fibrous materials.

Preferably, the combination of different fibrous materials is a combination of any or all of the following: fibrous bonding material; fibrous filler material; wool fibre; polyester fibre; low melting point polyester fibre.

Preferably, the apparatus further comprises fibre mixing means for mixing the fibrous material prior to feeding to the mixing means.

Preferably, the fibre mixing means comprises: a receptacle for receiving the fibrous material; agitating means for mixing the fibrous material received in the receptacle; and feeding means for feeding the fibrous material from the receptacle to the mixing means.

Preferably, the agitating means comprises a rotating paddle.

Preferably, the feeding means comprises an auger.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCTiAU2003!001376 -6- Preferably, the separating means comprises a first rotating member provided with a first set of projections on an operative surface thereof, the rotating member being operable to separate the fibrous material with the projections.

Preferably, the first rotating member comprises a drum and the first set of projections comprise teeth.

Preferably, the separating means further comprises separating feeding means for feeding fibrous material to the rotating member.

Preferably, the separating feeding means comprises a second rotating member provided with a second set of projections on an operative surface thereof, the second rotating member being operable to feed the fibrous material to the operable surface of the first rotating member by the second set of projections.

Preferably, the second rotating member comprises a roller and the second set of projections comprise teeth.

Preferably, he separating means comprises a conveyer provided with a third set of projections on an operative surface thereof, the conveyor being operable to separate the fibrous material with the third set of projections.

Preferably, the separated fibrous material comprises substantially uniform fibres.

Preferably, fibres of the separated fibrous material are of length ranging from mm to 40 mm.

Preferably, the apparatus further comprises chemical admixture impregnating means for impregnating the admixture with a chemical.

Preferably, the chemical includes a fire retardant.

Preferably, the chemical includes a vermin repellant.

Preferably, the chemical admixture impregnating means comprises: SUBSTITUTE SHEET (RULE 26) -7- O chemical admixture feed means for feeding chemical to the mixing (Ni means; and 00 chemical admixture dispersing means for dispersing chemical in the mixing means and thereby impregnate the admixture with the chemical.

RIn accordance with a second aspect of the invention, there is provided an (admixture of fibrous and cellulose material formed using the apparatus defined in the first aspect of the invention.

Preferably, the apparatus further comprises: shaping means for shaping the admixture into a product shape; and activating means to activate a bonding agent to bond the product shaped admixture to form the product.

Preferably, the bonding agent is low melting point polyester fibre and the activating means comprises an oven to melt the low melting point polyester fibre to bond the admixture to form the product.

Preferably, the shaping means comprises a distributing means for distributing the admixture in a product shaped mould.

Preferably, the distributing means evenly distributes the admixture in the product shaped mould.

Preferably, the distributing means dispenses the admixture in a predetermined pattern in the product shaped mould.

Preferably, the distributing means comprises a rotating paddle.

-8- 0 0 Preferably, the product shaped mould is a tower.

Preferably, the distributing means comprises a pivoting dispensing member for 0 dispensing the admixture in repeating, alternating arcs in the product shaped mould.

Preferably, the shaping means comprises a rotating perforated member through which the admixture is forced.

In accordance with a fourth aspect of the invention, there is provided a product N formed from an admixture of fibrous and cellulose material using the apparatus defined in the third aspect of the invention.

In accordance with another aspect of the invention, there is provided a method for forming an admixture of fibrous and cellulose material, the method comprising: processing cellulose material into particulate cellulose material; mixing fibrous material with the particulate cellulose material; and separating material into individual fibres or tufts of fibres.

Preferably, the fibrous material is separated and the mixing comprises: entraining separated fibrous material in a first air stream; entraining the particulate cellulose material in a second air stream; combining the first air stream with the second air stream to entrain an admixture of fibrous and cellulose material in a third combined air stream; and removing the admixture from the third combined air stream.

-9- 0 Preferably, the separating comprises separating the fibrous material in the admixture of fibrous material and cellulose material.

0 Preferably, the method further comprises processing cellulose material into particulate cellulose material using a shredder.

Preferably, the method further comprises impregnating the particulate cellulose material with a chemical.

OPreferably, the chemical includes a fire retardant.

Preferably, the chemical includes a vermin repellant.

Preferably, the particulate cellulose material is chemically impregnated by: entraining chemical in the second air stream; and grinding the particulate cellulose material and chemical in the second air stream through perforations to impregnate the particulate cellulose material with the chemical.

Preferably, the particulate cellulose material is chemically impregnated by: entraining chemical in the second air stream; and operating on the particulate cellulose material and chemical in the second air stream with a hammer mill to impregnate the particulate cellulose material with the chemical.

Preferably, the fibrous material is a combination of different fibrous materials.

Preferably, the combination of different fibrous materials is a combination of any or all of the following: fibrous bonding material; fibrous filler material; wool fibre; polyester fibre; low melting point polyester fibre.

IND

a Preferably, the method further comprising mixing the fibrous material prior to mixing the fibrous material with particulate cellulose material.

0 Preferably, the fibrous material is separated into substantially uniform fibres.

Preferably, the separated fibres are of length ranging from 30 mm to 40 mm.

Preferably, the method further comprises impregnating the admixture with a N chemical. Preferably, the chemical includes a fire retardant.

SPreferably, the chemical includes a vermin repellant.

Preferably, the particulate cellulose material is chemically impregnated by: dispersing chemical on the admixture.

In accordance with another aspect of the invention, there is provided an admixture of fibrous and cellulose material formed in accordance with the method defined in the fifth aspect of the invention.

Preferably, the method further comprises: shaping the admixture into a product shape; activating a bonding agent to bond the product shaped admixture to form the product.

Preferably, the bonding agent is low melting point polyester fibre and an oven is used to melt the low melting point polyester fibre to bond the admixture to form the product.

Preferably, the shaping comprises distributing the admixture in a product shaped mould.

-11- Preferably, the admixture is evenly distributed in the product shaped mould.

a Preferably, the admixture is dispensed in a predetermined pattern in the product 00 shaped mould.

Preferably, the shaping comprises forcing the admixture through a rotating perforated member.

c In accordance with a still further aspect of the invention, there is provided a O product formed from an admixture of fibrous material and cellulose material in c accordance with the method defined in the previous aspect of the invention.

Brief Description of the Drawings The invention will be better understood in light of the following description of five specific embodiments thereof. The description is made with reference to the following drawings, wherein: Figure 1A is a schematic diagram of a first half of an apparatus for forming a bouffant admixture of fibrous material and cellulose material and for forming a batt from the bouffant admixture so formed; Figure 1B is a schematic diagram of a second half of the apparatus referred to in Figure 1A; Figure 1C is a more detailed fragmentary schematic diagram of the mixing section of the apparatus shown in Figure 1A; Figure 1D is a more detailed fragmentary schematic diagram of the batt forming station of the apparatus shown in Figure 1B; Figure 2 is a schematic diagram of a mixer forming part of the fibre treating and feeding station of the apparatus shown in Figure 1A; WO 2004/035899 PCT/AU20031001376 -12- Figure 3 is a schematic diagram of the fibre treating and feeding station of the apparatus shown in Figure 1A; Figure 4 is a schematic diagram of a fibre pre-opener forming part of the fibre treating and feeding station of the apparatus shown in Figure 1A; Figure 5 is a schematic diagram of a paddle of the batt forming station shown in Figure ID; Figure 6 is a top view schematic diagram of an alternative batt forming station of the apparatus shownin Figure 1B; Figure 7 is a side view schematic diagram of the alternative batt forming station shown in Figure 6; Figure 8A is a schematic diagram of a first quarter of a fourth embodiment of an apparatus for forming a bouffant admixture of fibrous material and cellulose material and for forming a batt from the bouffant admixture so formed; Figure 8B is a schematic diagram of a second quarter of the apparatus referred to in Figure 8A; Figure 8C is a schematic diagram of a third quarter of the apparatus referred to in Figure 8A; Figure 8D is a schematic diagram of a fourth quarter of the apparatus referred to in Figure 8A; Figure 9A is a schematic diagram of a mixer forming part of the fibre/ cellulose treating station of the apparatus shown in Figure 8B; Figure 9B is a cross-section diagram of a mixer forming part of the fibre/cellulose treating station of the apparatus shown in Figure 8C; SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -13- Figure 10 is a schematic diagram of a fibre opening means forming part of the fibre/cellulose treating station of the apparatus shown in Figure 8C; Figure 11 is a schematic diagram of a mixer forming part of a fibre/cellulose treating station of a fifth embodiment of an apparatus for forming a bouffant admixture of fibrous material and cellulose material and for forming a batt from the bouffant admixture so formed; and Figure 12 is a schematic diagram of a fibre opening means forming part of a fibre/cellulose treating station of the fifth embodiment of an apparatus for forming a bouffant admixture of fibrous material and cellulose material and for forming a batt from the bouffant admixture so formed.

Best Modes for Carrying Out the Invention The first embodiment is directed towards an apparatus 11 for forming a bouffant admixture of fibrous material and cellulose material and for forming a batt from the bouffant admixture so formed, as well as the method by which this is done.

As shown in Figures 1A, 1B, 1C and 1D, the apparatus comprises a particulate cellulose production station 13, a chemical feed station 15, a grinding station 17 and a cellulose transfer passageway 19 connected at one end to an outlet of the production station 13 and an inlet of the grinding station 17 at the other end. The chemical feed station 15 has a chemical feed outlet 21 connected to the cellulose transfer passageway 19, between the production station 13 and the grinding station 17.

The apparatus 11 further comprises a fibre treating and feeding station 23, fluidising means 25, a cellulose feeding passageway 27 and a mixing passageway 29. The cellulose feeding passageway 27 is connected in series with the mixing passageway 29 and an outlet of the grinding station 17. A.treated fibre feeding passageway 31 is connected to an outlet of the fibre treating and feeding station 23 at one end, and to the mixing passageway 29, at the other end just prior to an inlet of the fluidising means SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -14- Further still, the apparatus 11 comprises a discharge station 33, dust extraction means 35, and a batt forming station 37. A fibre/cellulose transfer passageway 39 is connected at one end to an outlet of the fluidising means 25, and at the other end connected to an inlet of the discharge station 33. A dust extraction passageway 41 is connected to a dust extraction outlet of the discharge station 33 at one end and to the dust extraction means 35 at the other. The apparatus 11 additionally comprises an admixture feeding passageway 43, connected to an admixture feeding outlet of the discharge station 33 at one end and outletting to the batt forming station 37 at the other end thereof.

The cellulose production station 13 is of standard design including a conveyor belt leading to a shredder 47, whereby cellulose material such as newspaper or cardboard can be placed on the conveyor belt 45 and fed in and shredded to a predetermined cellulose particle size by the shredder 47. In an alternative exemplary embodiment (not shown), a hogger is used instead of the shredder 47 to produce cellulose particles.

Shredded cellulose particles are transferred along the cellulose transfer passageway 19 by action of the fluidising means The fluidising means 25 comprises a fan 49 of sufficient capacity to fluidise the particulate cellulose and treated fibre material in an air stream along the various passageways of the apparatus 11.

The chemical feed station 15 continuously supplies a quantity of fire retarding agent in the form of boric acid and a vermin repelling agent such as borax decahydrate. These chemicals are introduced into the cellulose transfer passageway 19 to intermix with the fluidised cellulose prior to feeding into the grinding station 17.

The grinding station 17 comprises a grinder 18 to forcibly impregnate the particulate cellulose with the chemicals and disperse the fire retarding agent and the vermin repelling agent throughout the fluidised stream, by grinding the particulate cellulose and chemicals through holes in a perforated plate (not SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 shown). The holes in the perforated plate may range in diameter from 2 mm to mm. In an alternative exemplary embodiment (not shown), a hammer mill is used instead of the grinder 18 to forcibly impregnate the particulate cellulose material, as it produces less dust and uses less power.

The chemically impregnated particulate cellulose material is then fed into the mixing passageway 29 from the grinding station 19 via the cellulose feeding passageway 27, where it is admixed with the treated fibre material introduced into the air stream via the treated fibre feeding passageway 31.

Now describing the fibre treating and feeding station 23, which constitutes the main basis for one aspect of the invention in more detail, specific reference is made to Figures 2, 3 and 4 of the drawings.

As shown in these drawings, the fibre treating and feeding station 23 generally comprises a mixing means 51 and a feeding means 53 leading from an outlet of the mixing means 51 to an inlet of a fibre opening and separating means 54. The fibre treating and feeding station 23 is connected to the treated fibre feeding passageway 31, and the fluidising means 25, at an outlet of the fibre opening and separating means 54.

The mixing means 51 comprises a mixing box 67 having a rotating mixing paddle 69. In the embodiment being described, quantities of wool, fibrous filler material and fibrous bonding material are introduced into the mixing box 67 and blended by the mixing paddle 69 to form a wool/fibre/bonding fibre admixture.

The fibrous bonding material comprises a synthetic thermoplastic polymer in the form of low melting point polyester fibre, the fibrous filler material is filler polyester fibre, and the wool is short cross bread wool of a length of 30 to These materials are typically mixed in the following ratios in the mixing box 67: Approximately 50% low melting point polyester fibre; SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -16- Approximately 25% filler polyester fibre; and Approximately 25% wool.

Please note that the type and ratio of fibrous material introduced into the mixing box 67 may vary depending on the purpose the bouffant admixture of fibrous material and cellulose material produced by the apparatus 11 is to be put to, i.e.

whether it is to be used as blow in insulation or for forming batts, blankets, mats, or acoustic panels.

The feeding means 53 comprises an auger 71. The wool/fibre/bonding fibre admixture drops from the outlet of the mixing means 51 and into the auger 71.

The wool/fibre/bonding fibre admixture is then augered by the auger 71 into the fibre opening and separating means 54.

In an alternative exemplary embodiment where a blended admixture of fibrous material is not required to produce the desired product, or a blended admixture of fibrous material has been obtained from another source, quantities of fibrous material are introduced into the fibre opening and separating means 54 directly, rather than via the mixing means 51.

The fibre opening and separating means 54 comprises a hopper 55, a fibre preopening feeding means 57 leading from the hopper 55 to an inlet of a fibre preopening means 59, and a fine opening means 61. A fibre transfer passageway 63 connected to an outlet of the fibre pre-opening means 59 at one end, and to an inlet of the fine opening means 61 at the other end, is also provided.

The fibre opening and separating means 54 further comprises a fibre fluidising means 65 provided in the fibre transfer passageway 63.

The hopper 55 includes a hopper conveyor belt 73 for conveying wool/fibre/bonding fibre admixture entering the hopper 55 to the fibre pre-opening feeding means 57.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -17- The fibre pre-opening feeding means 57 comprises a feed conveyor belt having spikes 77 formed thereon to assist transportation of the wool/fibre/bonding fibre admixture and to separate and partially open the fibres of the admixture. At a position within the fibre pre-opening feeding means 57, adjacent the inlet of the fibre pre-opening means 59, there is provided sweeping brushes 79. The sweeping brushes 79 brush excess wool/fibre/bonding fibre admixture from the feed conveyor belt 75 and back into the hopper 55 to ensure a steady controlled feed of wool/fibre/bonding fibre admixture into the fibre pre-opening means 59.

The fibre pre-opening means 59 comprises a first guiding chute 81 leading to a pair of rollers 83 rotating at different speeds. The rollers 83 are operatively connected and having interlocking angled teeth Wool/fibre/bonding fibre admixture entering the inlet to the fibre pre-opening means 59 is guided by the first guiding chute 81 to pass between the rollers 83.

The fibres of the wool/fibre/bonding fibre admixture are pulled apart by action of the teeth 85 of the rollers 83 to open for increased separation during subsequent action by the fine opening means 61.

After passing between the rollers 83, the wool/fibre/bonding fibre admixture passes through the outlet from the fibre pre-opening means 59 and is transported along the fibre transfer passageway 63 to the fine opening means 61 by the fibre fluidising means The fibre fluidising means 65 comprises a fan 87 of sufficient capacity to fluidise the wool/fibre/bonding fibre admixture in an airstream along the fibre transfer passageway 63.

The fine opening means 61 comprises a second guiding chute 89 leading to a pair of feeder rollers 91 operatively connected with a drum 93 rotating at high speed.

Small teeth (not shown) are provided on the operative surface of the drum 93.

Wool/fibre/bonding fibre admixture entering the inlet to the fine opening means 61 is guided by the second guiding chute 89 to pass between the feeder rollers 91.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -18- The feeder rollers 91 feed the wool/fibre/bonding fibre admixture to the drum 93 which separates the wool/fibre/bonding fibre admixture into treated individual fibres or treated tufts of fibres.

The treated fibres are drawn through the outlet from the fine opening means 61 and are transported along the treated fibre feeding passageway 31 to the mixing passageway 29 by the fluidising means Returning to Figures 1A 1D of the drawings, the admixture of particulate cellulose and treated fibre material is then drawn through the fluidising means and propelled along the treated fibre/cellulose transfer passageway 39 to the discharge station 33. In the embodiment shown, the mixing of particulate cellulose and treated fibre material is maximised by drawing the admixture of particulate cellulose and treated fibre material toward a substantially central location of the fan 49 of the fluidising means The discharge station 33 comprises a filtering means for filtering the combined treated fibre/cellulose admixture from the air stream, prior to exhausting the air from the apparatus 11. The filtered treated fibre/cellulose admixture is retained within a storage hopper 95 from which fine particles of dust are extracted along the dust extraction passageway 41 by the dust extraction means 35, which comprises a cyclone.

The retained treated fibre/cellulose admixture is then drawn through a second fluidising means 97 and propelled along the admixture feeding passageway 43 to the batt forming station 37. The second fluidising means 97 includes a third fan 99.

Now describing in more detail the batt forming station 37, which constitutes the main basis for another aspect of the invention, the batt forming station 37 generally comprises a shaping means 98 feeding to a setting means 100.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -19- The shaping means 98 comprises a second filtering means including a dust bag for filtering the combined treated fibre/cellulose admixture from the air stream, prior to exhausting the air from the apparatus 11.

The shaping means 98 further comprises an admixture guide chute 101 leading to a tower 103, and a distributing means in the form of a rotating paddle 109 provided between the admixture guide chute 101 and the tower 103, as shown in Figure 5 of the drawings.

The setting means 100 comprises an oven conveyor belt 105 feeding to a heating means in the form of a bonding oven 107.

The filtered treated fibre/cellulose admixture falls along the admixture guide chute 101 to the rotating paddle 109. The rotating paddle 109 disperses and evenly distributes the treated fibre/cellulose admixture across the width W of the tower 103. The tower 103 shapes the treated fibre/cellulose admixture into a batt shape.

In the embodiment, the width W of the tower 103 is adjustable to allow batts of variable thickness to be produced. The shaped treated fibre/cellulose admixture falls down the tower 103 and onto the oven conveyor belt 105. The oven conveyor belt 105 conveys the shaped treated fibre/cellulose admixture to the bonding oven 107. The bonding oven 107 melts the bonding fibres to bond the treated fibre/cellulose admixture together to form a batt.

The second embodiment of the invention is directed towards a modification of the apparatus 11 of the first embodiment, and will now be described with reference to Figures 1 to 7 of the drawings. Corresponding numerals are used to denote like elements of the second embodiment.

The apparatus 11 of the second embodiment differs from the first embodiment only in respect of the shaping means 98 of the batt forming station 37. In all other respects, the apparatus 11 of the second embodiment is substantially the same as in the first embodiment, and shall not be described in further detail.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 Referring to Figures 6 and 7, the shaping means 98 of the batt forming station 37 of the second embodiment generally comprises a dispensing means in the form of an admixture dispensing passageway 111 pivotally coupled to the admixture feeding passageway 43 by a pivoting means 113 at one end, and extending above the oven conveyor belt 105 at the other end. By action of the pivoting means 113, which in the second embodiment comprises a motor (not shown) as is well known in the art, the end of the admixture dispensing passageway 111 remote from the admixture feeding passageway 43 pivots in a repeating arc, alternating back and forth across the oven conveyor belt 105.

A dispensing outlet 115 directed toward the oven conveyor belt 105 is provided at the end of the admixture dispensing passageway 111 remote from the admixture feeding passageway 43.

In the second embodiment, the treated fibre/cellulose admixture enters the admixture dispensing passageway 111 from the admixture feeding passageway 43. The treated fibre/cellulose admixture then travels along the admixture dispensing passageway 111 and is dispensed onto the oven conveyor belt 105 via the dispensing outlet 115 in a repeating arc, alternating back and forth. As the dispensing outlet 115 pivots back and forth across the oven belt 105 by action of the pivoting means 113, the treated fibre/cellulose admixture is evenly dispensed across the oven conveyor belt 105 into a batt shape without compacting or reducing its bouffanticity.

The density and dimensions of the dispensed treated fibre/cellulose admixture may be controlled by varying the following parameters: the rate of flow of treated fibre/cellulose admixture; 0 the length of arc traversed by the admixture dispensing passageway 111; the pivot speed of the pivoting means 113; and SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -21the speed of the oven belt 105.

By varying these parameters, fibre/cellulose admixture products may be formed having densities and thicknesses as required for particular applications.

As in the first embodiment, the oven conveyor belt 105 conveys the dispensed fibre/cellulose admixture to the bonding oven 107. The bonding oven 107 melts the bonding fibres to bond the batt shaped treated fibre/cellulose admixture together to form a batt.

A third embodiment of the invention will now be described, with reference again to Figures 1 7 of the drawings. Corresponding numerals are used to denote like elements of the third embodiment.

The third embodiment is directed toward an apparatus 11 for forming an absorbent mat from a bouffant admixture of fibrous material and cellulose material, the method by which this is done, and the absorbent mat so formed.

The apparatus 11 of the third embodiment is substantially the same as in the first embodiment, or alternatively the second embodiment, and shall not be described in further detail.

In the third embodiment, only fibrous bonding material is introduced and processed in the fibre treating and feeding station 23, to result in a bouffant admixture of particulate cellulose and treated bonding fibrous material being propelled along the admixture feeding passageway 43 to the batt forming station 37.

In the batt forming station 37, the bouffant admixture of particulate cellulose and treated bonding fibrous material is formed into an absorbent mat in a similar manner to that that the batt in the first embodiment, or alternatively the second embodiment, is formed.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -22- The resulting absorbent mat consisting of bonded cellulose material may, by adjusting the width of the tower 103 in the case of apparatus 11 according to the first embodiment, or the parameters discussed previously in the case of apparatus according to the second embodiment, be approximately 15 20 mm thick, and may be cut to any length as desired.

This allows mats having a large surface area to be formed, which can then be used to absorb liquid pollutants dispersed over a wide area.

The fourth embodiment of the invention is directed towards a modification of the apparatus 11 of the second embodiment, and will now be described with reference to Figures 8A 10 of the drawings. Corresponding numerals are used to denote like elements of the second embodiment.

The apparatus 11 of the fourth embodiment differs from the apparatus 11 of the second embodiment in that fibrous material is mixed. with particulate cellulose material prior to being treated.

Treatment of the fibre/cellulose admixture is achieved by omitting the fibre treating and feeding station 23, the mixing passageway 29 and the treated fibre feeding passageway 31 from the apparatus 11, and providing a fibre/cellulose treating station 117 fed from the admixture feeding passageway 43. The fibre/cellulose treating station 117 feeds into the admixture dispensing passageway 111 of the apparatus 11.

In all other respects, the apparatus 11 of the fourth embodiment is substantially the same as in the second embodiment, and shall not be described in further detail.

The fibre/cellulose treating station 117 of the fourth embodiment generally comprises a cellulose storage station 119 connected to the outlet of the admixture feeding passageway 43, a fibre feeding station 121 and a fibre opening means 123. An outlet of the cellulose storage station 119 is connected to an inlet of the fibre opening means 123 by a second mixing passageway 125. A fibre feeding SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -23passageway 127 is connected to an outlet of the fibre feeding station 121 at one end, and to the second mixing passageway 125, at the other end just prior to the inlet of the fibre opening means 123. An outlet of the fibre opening means 123 is pivotally coupled to the admixture dispensing passageway 111 by the pivoting means 113.

Fibre fluidising means in the form of a fourth fan 128 is provided at the end of the second mixing passageway 125 proximate the fibre opening means 123 to fluidise and draw towards the fibre opening means 123 material entering the mixing passageway 125 and the fibre feeding passageway 127.

As the fibre treating and feeding station 23, the mixing passageway 29 and the treated fibre feeding passageway 31 are omitted in this embodiment, only chemically impregnated particulate cellulose material is propelled along the admixture feeding passageway 43.

The cellulose storage station 119 comprises a second filtering means including a dust bag 129 for filtering the particulate cellulose material from the air stream, prior to exhausting the air from the apparatus 11.

The cellulose storage station 119 further comprises a cellulose storage chamber 131 leading to feeding means in the form of a second auger 133. Particulate cellulose material drops from the admixture feeding passageway 43 into the storage chamber 131 and falls to the second auger 133. The particulate cellulose material is then augered by the second auger 133 into the second mixing passageway 125.

In the fourth embodiment, the second auger 133 is provided with control means (not shown) to control the rate at which particulate cellulose material is augered into the second mixing passageway 125. This allows precise metering of particulate cellulose material according to the fibre/cellulose admixture product to be produced.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -24- Particulate cellulose material entering the second mixing passageway 125 is fluidised and transported along the second mixing passageway 125 by the fourth fan 128 to the fibre opening means 123.

Now describing the fibre feeding station 121, specific reference is made to Figures 8B, 9A and 9B of the drawings.

As shown in these drawings, the fibre feeding station 121 generally comprises a second mixing means 135 and a second feeding means 137 leading from an outlet 136 of the second mixing means 135 to an inlet of the fibre feeding passageway 127.

The second mixing means 135 comprises a mixing drum 139 having rotating mixing paddles 141. In the fourth embodiment, quantities of wool, fibrous filler material and fibrous bonding material are introduced into the mixing drum 139 via a filling inlet 143 and blended by the mixing paddles 141 to form a wool/fibre/bonding fibre admixture.

The type and ratio of fibrous material introduced into the mixing drum 139 is substantially the same as in the second embodiment, and shall not be described in further detail here.

Controlled suction means (not shown) is provided to draw the wool/fibre/bonding fibre admixture from the outlet 136 of the second mixing means 135 to the feeding means 137.

In an alternative exemplary embodiment where a blended admixture of fibrous material is not required to produce the desired product, or a blended admixture of fibrous material has been obtained from another source, quantities of fibrous material are introduced into the second feeding means 137 directly, rather than via the second mixing means 135.

The second feeding means 137 comprises a hopper 145 and a conveying means 147 leading from the hopper 145 to the inlet of the fibre feeding passageway 127.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU2003/001376 The conveying means 147 comprises a feed conveyor belt 149 having spikes 151 provided thereon to assist transportation of the wool/fibre/bonding fibre admixture, and to separate the wool/fibre/bonding fibre admixture into small pieces of fibre.

Conveyor control means (not shown) is provided on the feed conveyor belt 149 to control the rate at which wool/fibre/bonding fibre admixture is conveyed to the inlet of the fibre feeding passageway 127, allowing precise metering of wool/fibre/bonding fibre admixture according to the fibre/cellulose admixture product to be produced.

At a position of the feeding means 137 adjacent to the inlet of the fibre feeding passageway 127 there is provided a large rotating paddle 153 and a small rotating paddle 155.

The large rotating paddle 153 rotates in a clockwise direction and is provided with small steel teeth (not shown) to sweep excess wool/fibre/bonding fibre admixture from the feed conveyor belt 149 and back into the hopper 145 to ensure a steady, controlled feed of wool/fibre/bonding fibre admixture into the fibre feeding passageway 127.

The small rotating paddle 155 rotates in a clockwise direction and has rubber projections that act to clean the wool/fibre/bonding fibre admixture from the steel teeth of the large rotating paddle 153 and sweep wool/fibre/bonding fibre admixture from the feed conveyor belt 149 into the fibre feeding passageway 127.

Wool/fibre/bonding fibre admixture entering the fibre feeding passageway 127 is fluidised and transported along the fibre feeding passageway 127 to the second mixing passageway 125 by the fourth fan 128.

Wool/fibre/bonding fibre.admixture entering the second mixing passageway 125 mixes with particulate cellulose material in the second mixing passageway 125 to form an untreated fibre/cellulose admixture. The untreated fibre/cellulose admixture is then drawn through the fourth fan 128 to the fibre opening means 123.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU2003/001376 -26- Now describing the fibre opening means 123, specific reference is made to Figures 8C and 10 of the drawings.

The fibre opening means 123 comprises a guiding chute 157 leading to a first and second guider roller 159, 161, rotating at slow speed and guiding to a first and second feeder roller 160, 162 operatively connected with a drum 163 rotating at high speed. A first set of teeth 167 facing in a first direction are provided on the rotating surface of the first feeder roller 160. A second set of teeth 169, facing in a direction opposite to that of the first set of teeth 167, are provided on the rotating surface of the drum 163. The rotating surfaces of the first and second guider roller 159, 161 and the second feeder roller 161 are substantially smooth.

In the fourth embodiment, the first and second feeder rollers 160, 162 rotate at a speed of 60 revolutions per minute, in a clockwise and anticlockwise direction, respectively. The drum 163 rotates at a speed of 3000 revolutions per minute in a clockwise direction.

The clearance between the first feeder rollers 160 and the drum 163 is very small, to the point of almost touching. Untreated fibre/cellulose admixture entering the inlet to the fibre opening means 123 is guided by the guiding chute 157 to pass between the first and second guider rollers 159, 161. The first and second guider rollers 159, 161 guide the untreated fibre/cellulose admixture to pass between the first and second feeder rollers 160, 162.

The first and second feeder rollers 160, 162 feed the untreated fibre/cellulose admixture to the drum 163. As the first set of teeth 167 on the first feeder roller 160 and the second set of teeth 169 on the drum 163 face in opposed directions, as the untreated fibre/cellulose admixture is fed to the drum 163 it is separated by the first and second sets of teeth 167, 169 into treated fibre/cellulose admixture comprising individual fibres of wool/fibre/bonding fibre admixture and particulate cellulose material or tufts of fibres of wool fibre/bonding fibre admixture and particulate cellulose material.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -27- The treated fibre/cellulose admixture is drawn through an outlet from the fibre opening means 123 and transported to the admixture dispensing passageway 111 of the batt forming station 37 by a treated fibre/cellulose fluidising means in the form of a fan 171.

In an alternative exemplary embodiment, the fibre cellulose treating station additionally comprises re-circulating means allowing treated fibre/cellulose admixture to be fed through the fibre opening means 123 multiple times before being transported to the admixture dispensing passageway 111. Such retreatment may be necessary to sufficiently separate the admixture into individual fibres and tufts of fibres depending on the type and ratio of materials in the admixture. The re-circulating means (not shown) comprises a re-circulating passageway leading from the outlet of the fibre opening means 123 to the first and second guider roller 159, 161. A controlled valve (not shown) is provided in the outlet of the fibre opening means 123 to direct treated fibre/cellulose admixture along the re-circulating passageway for re-treatment if insufficiently treated, or the admixture dispensing passageway 111 if sufficiently treated.

The fifth embodiment of the invention is directed toward a modification of the apparatus 11 of the fourth embodiment, and will now be described with reference to Figures 11 and 12 of the drawings. Corresponding numerals are used to denote like elements of the fourth embodiment.

The apparatus 11 of the fifth embodiment differs from the apparatus 11 of the fourth embodiment in that particulate fibrous material is mixed with particulate cellulose material before the resulting mixture is chemically impregnated. The chemically impregnated fibre/cellulose admixture is then treated to produce a chemically impregnated treated fibre/cellulose admixture.

This treatment is achieved by modifying the fibre feeding station 121 and the fibre opening means 123 of the fibre/cellulose treating station 117 of the fourth embodiment. The shaping means 98 of the batt forming station 37 of the fourth embodiment is also modified. These modifications will now be described in detail.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -28- In the fifth embodiment, the fibre/cellulose treating station 117 is fed directly from the cellulose transfer passageway 19. Accordingly, the components of the apparatus 11 between the cellulose transfer passageway 19 and the fibre/cellulose treating station 117 that are present in the fourth embodiment are omitted in the fifth embodiment. The fibre/cellulose treating station 117 feeds into the shaping means 98 of the batt forming station 37 in the fifth embodiment.

The fibre cellulose treating station 117 of the fifth embodiment generally comprises a cellulose storage station 119 connected to the outlet of the cellulose transfer passageway 19, a fibre feeding station 121 and a fibre opening means 123. An outlet of the cellulose storage station 119 is connected to a cellulose inlet 172 of the fibre feeding station 121. A fibre feeding conveyor 173 is connected to an outlet of the fibre feeding station 121 at one end and feeds to an inlet of the fibre opening means 123. An outlet of the fibre opening means 123 feeds to the shaping means 98 of the batt forming station 37.

The cellulose storage station 119 of the fifth embodiment is substantially the same as the cellulose storage station 119 of the fourth embodiment, and shall not be described in further detail.

As the cellulose storage station 119 is connected to the outlet of the cellulose transfer passageway 19, it is fed with particulate cellulose material before the particulate cellulose material is impregnated with chemicals. Such particulate cellulose material is augered by the auger 133 into the cellulose inlet 172 of the fibre feeding station 121.

Now describing the fibre feeding station 121, the fibre feeding station 121 generally comprises a second mixing means 135 and a second feeding means 137 leading from an outlet of the second mixing means 135 to the fibre feeding conveyor 173.

The second mixing means 135 is substantially the same as the second mixing means 135 of the fourth embodiment with the exception that it further comprises the cellulose inlet 172, allowing it to be fed particulate cellulose material from the SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -29cellulose storage station 119, and chemical dispersion means in the form of a nozzle 175 receiving a supply of chemical from a chemical feed means (not shown).

The mixing drum 139 is filled with quantities of wool, fibrous filler material and fibrous bonding material via the filing inlet 143 as described previously, and is filled with particulate cellulose material via the cellulose inlet 172. These materials are then blended by the mixing paddles 141, and impregnated with chemical dispersed from the nozzle 175, to form a chemically impregnated untreated fibre/cellulose admixture. The chemical dispersed comprises a quantity of fire retarding agent in the form of boric acid and a vermin repelling agent such as borax decahydrate.

Mixing fibrous material and particulate cellulose material in the mixing drum 139 removes the need to feed treated fibre/cellulose admixture through the fibre opening means 123 multiple times that may otherwise be necessary to sufficiently separate the admixture into individual fibres and tufts of fibres, depending on the type and ratio of materials in the admixture, as discussed previously.

As both the fibrous material and particulate cellulose material is impregnated with chemical, the resulting admixture is more resistant to fire than in the case where only particulate cellulose material is chemically impregnated. A.further advantage is that the chemically impregnated untreated fibre/cellulose admixture is slightly damp as a consequence of the chemical, causing it to run more smoothly through the apparatus 11 than is otherwise the case.

Controlled suction means (not shown) is provided to draw the chemically impregnated untreated fibre/cellulose admixture from the outlet of the second mixing means 135 to the second feeding means 137.

The second feeding means 137 is substantially the same as the second feeding means 137 of the fourth embodiment with the exception that it further comprises a dispersing chute 177 fed from the conveying means 147 and outletting to the fibre feeding conveyor 173.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 The dispersing chute 177 further comprises vibrating means (not shown) to cause chemically impregnated untreated fibre/cellulose admixture entering the dispersing chute 177 to vibrate and disperse as it drops onto the fibre feeding conveyor 173.

In an alternative exemplary embodiment, the apparatus 11 additionally comprises a further feeding means (not shown) feeding to the filling inlet 143 of the mixing drum 139 for use in the case where the fibrous material is dense as a consequence of, for example, being compressed into a bale. The further feeding means is substantially the same as the second feeding means 137 of the fourth embodiment, and is used to partially separate the compressed fibrous material prior to entry to the mixing drum 139. This is advantage to the mixing process, as it is easier to mix small separated tufts of fibre rather than large clumps of fibre.

The fibre feeding conveyor 173 conveys the chemically impregnated untreated fibre/cellulose admixture to the fibre opening means 123, which is substantially the same at the fibre opening means 123 of the fourth embodiment with the exception that it is oriented to be fed admixture horizontally rather than vertically, and comprises a single guider roller 178 that operates with the fibre feeding conveyor 173 to guide the chemically impregnated untreated fibre/cellulose admixture to pass between the first and second feeder rollers 160, 162.

In the fifth embodiment, the width of the fibre feeding conveyor 173 corresponds to the width of the fibre opening means 123.

Chemically impregnated treated fibre/cellulose admixture is drawn through an outlet from the fibre opening means 123 to the shaping means 98 of the batt forming station 37.

The shaping means 98 of the batt forming station 37 of the fifth embodiment generally comprises a rotating perforated screen 179 through which chemically impregnated treated fibre/cellulose admixture is forced onto the oven conveyor belt 105. The width of the oven conveyor belt 105 corresponds to the width of the fibre opening means 123.

SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -31 In alternative exemplary embodiments, the apparatus 11 of the fourth embodiment, and the apparatus 11 of the fifth embodiment, are used to form an absorbent mat from a bouffant admixture of fibrous material and cellulose material as described in the third embodiment.

It should be appreciated that the scope of the present invention is not limited to the particular embodiments described herein. Moreover, whilst the embodiments has been specifically described with respect to the use of wool fibres, where wool has certain properties making it extremely advantageous to use as a natural fibre, certain synthetic fibres such as polyester may be substituted or used in combination with wool to achieve a similar fibre/cellulose admixture which still has superior insulating qualities compared to previous types of insulant in common use at present. Accordingly, other embodiments of the invention using synthetic fibres in addition to, or as opposed to, wool fibres fall within the scope of the present invention and do not depart from the spirit thereof. Similarly, minor modifications or improvements to the apparatus 11 in accordance with common engineering practice are also considered not to depart from the spirit of the present invention and fall within its scope.

SUBSTITUTE SHEET (RULE 26)

Claims (59)

1. An apparatus for forming an admixture of fibrous and cellulose material, the 00 apparatus comprising: particulate cellulose producing means for processing cellulose material into particulate cellulose material; Smixing means for mixing fibrous material with the particulate Scellulose material produced by the particulate cellulose producing N means; and separating means for separating material into individual fibres or tufts of fibres.

2. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 1, wherein the separating means separates the fibrous material and the mixing means comprises: first fluidising means for entraining the separated fibrous material in a first air stream; second fluidising means for entraining the particulate cellulose material in a second air stream; combining means for combining the first air stream with the second air stream to form an admixture of fibrous and cellulose material entrained in a third combined air stream; and removing means for removing the admixture from the third combined air stream.

3. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 1, wherein the separating means separates the fibrous material in the admixture of fibrous material and cellulose material. N- 33- O 4. An apparatus for forming an admixture of fibrous and cellulose material as Nclaimed in claim 2, wherein the separating means separates the fibrous material in the admixture of fibrous material and cellulose material. 00 O An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 2 or claim 4, wherein the particulate cellulose material produced by the particulate cellulose producing means is entrained by the second fluidising means in the second air stream.

6. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein the particulate producing means comprises a shredder.

7. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims wherein the particulate producing means comprises a hogger.

8. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein the apparatus further comprises chemical impregnating means for impregnating the particulate cellulose material with a chemical.

9. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 8, wherein the chemical includes a fire retardant.

10. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 8 or 9, wherein the chemical includes a vermin repellant.

11. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of claims 8 to 10, wherein the chemical impregnating means comprises: 34 chemical feed means for feeding chemical to the second fluidising means so that the chemical is entrained in the second air stream; and 00 grinding means for grinding the particulate cellulose material and chemical in the second air stream through perforations in a member positioned transverse to the second air stream and thereby impregnate the particulate cellulose material with the chemical.

12. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 11, wherein the perforations are circular holes of diameter ranging from 2 mm to 20 mm.

13. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 11 or 12, wherein the grinding means comprises a grinder.

14. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of claims 8 to 13, wherein the chemical impregnating means comprises: chemical feed means for feeding chemical to the second fluidising means so that the chemical is entrained in the second air stream; and a hammer mill positioned to operate on particulate cellulose material and chemical in the second air stream and thereby impregnate the particulate cellulose material with the chemical. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein the fibrous material is a combination of different fibrous materials.

16. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 15, wherein the combination of different fibrous materials WO 2004/035899 PCT/AU20031001376 is a combination of any or all of the following: fibrous bonding material; fibrous filler material; wool fibre; polyester fibre; low melting point polyester fibre.

17. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein the apparatus further comprises fibre mixing means for mixing the fibrous material prior to feeding to the mixing means.

18. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 17, wherein the fibre mixing means comprises: a receptacle for receiving the fibrous material; agitating means for mixing the fibrous material received in the receptacle; and feeding means for feeding the fibrous material from the receptacle to the mixing means.

19. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 18, wherein the agitating means comprises a rotating paddle. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 18 or 19, wherein the feeding means comprises an auger.

21. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein the separating means comprises a first rotating member provided with a first set of projections on an operative surface thereof, the rotating member being operable to separate the fibrous material with the projections. SUBSTITUTE SHEET (RULE 26) WO 2004/035899 PCT/AU20031001376 -36-

22. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 21, wherein the first rotating member comprises a drum and the first set of projections comprise teeth.

23. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 21 or 22, wherein the separating means further comprises separating feeding means for feeding fibrous mateial to the rotating member.

24. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 23, wherein the separating feeding means comprises a second rotating member provided with a second set of projections on an operative surface thereof, the second rotating member being operable to feed the fibrous material to the operable surface of the first rotating member by the second set of projections. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 24, wherein the second rotating member comprises a roller and the second set of projections comprise teeth.

26. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein the separating means comprises a conveyer provided with a third set of projections on an operative surface thereof, the conveyor being operable to separate the fibrous material with the third set of projections.

27. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein the separated fibrous material comprises substantially uniform fibres.

28. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein fibres of the separated fibrous material are of length ranging from 30 mm to 40 mm. SUBSTITUTE SHEET (RULE 26) 37 O

29. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of the preceding claims, wherein the apparatus further comprises chemical admixture impregnating means for impregnating the o00 admixture with a chemical.

30. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 29, wherein the chemical includes a fire retardant.

31. An apparatus for forming an admixture of fibrous and cellulose material as claimed in claim 29 or 30, wherein the chemical includes a vermin repellant.

32. An apparatus for forming an admixture of fibrous and cellulose material as claimed in any one of claims 29 to 31, wherein the chemical admixture impregnating means comprises: chemical admixture feed means for feeding chemical to the mixing means; and chemical admixture dispersing means for dispersing chemical in the mixing means and thereby impregnate the admixture with the chemical.

33. An admixture of fibrous and cellulose material formed using the apparatus as claimed in any one of the preceding claims.

34. An apparatus for forming a product from an admixture of fibrous and cellulose material, as claimed in any one of the preceding claims, the apparatus further comprising: shaping means for shaping the admixture into a product shape; and activating means to activate a bonding agent to bond the product shaped admixture to form the product. WO 2004/035899 PCT/AU20031001376 -38- An apparatus for forming a product from an admixture of and cellulose material as claimed in claim 34, wherein the bonding agent is low melting point polyester fibre and the activating means comprises an oven to melt the low melting point polyester fibre to bond the admixture to form the product.

36. An apparatus for forming a product from an admixture of fibrous and cellulose material as claimed in claim 34 or 35, wherein the shaping means comprises a distributing means for distributing the admixture in a product shaped mould.

37. An apparatus for forming a product from an admixture of fibrous and cellulose material as claimed in claim 36, wherein the distributing means evenly distributes the admixture in the product shaped mould.

38. An apparatus for forming a product from an admixture of fibrous and cellulose material as claimed in claim 36 or 37, wherein the distributing means dispenses the admixture in a predetermined pattern in the product shaped mould.

39. An apparatus for forming a product from an admixture of fibrous and cellulose material as claimed in and one of claims 36 to 38, wherein the distributing means comprises a rotating paddle.

40. An apparatus for forming a product from an admixture of fibrous and cellulose material as claimed in any one of claims 36 to 39, wherein the product shaped mould is a tower.

41. An apparatus for forming a product from an admixture of fibrous and cellulose material as claimed in any one of claims 36 to 38, wherein the distributing means comprises a pivoting dispensing member for dispensing the admixture in repeating, alternating arcs in the product shaped mould. SUBSTITUTE SHEET (RULE 26) 39 O 0

42. An apparatus for forming a product from an admixture of fibrous and cellulose material having a bonding agent as claimed in claim 34 or wherein the shaping means comprises a rotating perforated member oO through which the admixture is forced.

43. A product formed from an admixture of fibrous and cellulose material using the apparatus as claimed in any one of claims 34 to 42.

44. A method for forming an admixture of fibrous and cellulose material, the method comprising: processing cellulose material into particulate cellulose material; mixing fibrous material with the processed particulate cellulose material; and separating material into individual fibres or tufts of fibres. A method for forming an admixture of fibrous and cellulose material as claimed in claim 44, wherein the fibrous material is separated and the mixing comprises: entraining separated fibrous material in a first air stream; entraining the particulate cellulose material in a second air stream; combining the first air stream with the second air stream to entrain an admixture of fibrous and cellulose material in a third combined air stream; and removing the admixture from the third combined air stream.

46. A method for forming an admixture of fibrous and cellulose material as claimed in claim 44 or 45, wherein the separating comprises separating the fibrous material in the admixture of fibrous material and cellulose material. NO

47. A method for forming an admixture of fibrous and cellulose material as k claimed in any one of claims 44 to 45, wherein the method further comprises processing cellulose material into particulate cellulose material. 00

48. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 44 to 47, wherein the method further comprises impregnating the particulate cellulose material with a chemical. S49. A method for forming an admixture of fibrous and cellulose material as Sclaimed in claim 48, wherein the chemical includes a fire retardant. A method for forming an admixture of fibrous and cellulose material as claimed in claim 48 or 49, wherein the chemical includes a vermin repellant.

51. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 48 to 50, wherein the particulate cellulose material is chemically impregnated by: entraining chemical in the second air stream; and grinding the particulate cellulose material and chemical in the second air stream through perforations to impregnate the particulate cellulose material with the chemical.

52. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 48 to 50, wherein the particulate cellulose material is chemically impregnated by: entraining chemical in the second air stream; and operating on the particulate cellulose material and chemical in the second air stream with a hammer mill to impregnate the particulate cellulose material with the chemical. -41 IND

53. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 44 to 52, wherein the fibrous material is a combination of different fibrous materials. 00 O

54. A method for forming an admixture of fibrous and cellulose material as claimed in claim 53, wherein the combination of different fibrous materials is a combination of any or all of the following: fibrous bonding material; fibrous filler material; wool fibre; polyester fibre; low melting point polyester fibre. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 44 to 54, wherein the method further comprising mixing the fibrous material prior to mixing the fibrous material with particulate cellulose material.

56. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 44 to 55, wherein the fibrous material is separated into substantially uniform fibres.

57. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 44 to 56, wherein separated fibres are of length ranging from 30 mm to 40 mm.

58. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 44 to 57, wherein the method further comprises impregnating the admixture with a chemical.

59. A method for forming an admixture of fibrous and cellulose material as claimed in claim 58, wherein the chemical includes a fire retardant. An method for forming an admixture of fibrous and cellulose material as claimed in claim 58 or 59, wherein the chemical includes a vermin repellant. 42

61. A method for forming an admixture of fibrous and cellulose material as claimed in any one of claims 58 to 60, wherein the particulate cellulose material is chemically impregnated by: 00 dispersing chemical on the admixture.

62. An admixture of fibrous and cellulose material formed using the method as claimed in any one of claims 44 to 61. S63. A method for forming a product from an admixture of fibrous and cellulose (1 material as claimed in any one of claims 44 to 62, the method further comprising: shaping the admixture into a product shape; activating a bonding agent to bond the product shaped admixture to form the product.

64. A method for forming a product from an admixture of fibrous and cellulose material as claimed in claim 63, wherein the bonding agent is low melting point polyester fibre and an oven is used to melt the low melting point polyester fibre to bond the admixture to form the product. A method for forming a product from an admixture of fibrous and cellulose material as claimed in claim 63 or 64, wherein the shaping comprises distributing the admixture in a product shaped mould.

66. A method for forming a product from an admixture of fibrous and cellulose material as claimed in claim 65, wherein the admixture is evenly distributed in the product shaped mould.

67. A method for forming a product from an admixture of fibrous and cellulose material as claimed in claim 65 or 66, wherein the admixture is dispensed in a predetermined pattern in the product shaped mould. WO 2004/035899 PCT/AU20031001376 -43-

68. A method for forming a product from an admixture of fibrous and cellulose material as claimed in claim 63 or 64, wherein the shaping comprises forcing the admixture through a rotating perforated member.

69. A product formed from an admixture of fibrous material and cellulose material using the method as claimed in any one of claims 63 to 68. An apparatus for forming an admixture of fibrous and cellulose material substantially as hereinbefore described with reference to Figures 1A to 4; Figures 1A to 7; Figures 8A to 10; or Figures 10 and 11 of the accompanying drawings.

71. An apparatus for forming a product from an admixture of fibrous and cellulose material substantially as hereinbefore described with reference to Figures 1A to 4; Figures 1A to 7; Figures 8A to 10; or Figures 10 and 11 of the accompanying drawings.

72. A method for forming an admixture of fibrous and cellulose material substantially as hereinbefore described with reference to Figures 1A to 4; Figures 1A to 7; Figures 8A to 10; or Figures 10 and 11 of the accompanying drawings.

73. An method for forming a product from an admixture of fibrous and cellulose material substantially as hereinbefore described with reference to Figures 1A to 4; Figures 1A to 7; Figures 8A to 10; or Figures 10 and 11 of the accompanying drawings. SUBSTITUTE SHEET (RULE 26)