CA2683296C - Fire retardant-impregnated cellulose board, process of manufacture thereof and uses thereof - Google Patents

Fire retardant-impregnated cellulose board, process of manufacture thereof and uses thereof Download PDF

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Publication number
CA2683296C
CA2683296C CA2683296A CA2683296A CA2683296C CA 2683296 C CA2683296 C CA 2683296C CA 2683296 A CA2683296 A CA 2683296A CA 2683296 A CA2683296 A CA 2683296A CA 2683296 C CA2683296 C CA 2683296C
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Prior art keywords
board
salt
impregnated
fire retardant
sponge
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Application number
CA2683296A
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French (fr)
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CA2683296A1 (en
Inventor
Daniel Baroux
Robert J. Hubbard
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BLMH TECHNOLOGIES Inc
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BLMH TECHNOLOGIES Inc
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Priority to CA2683296A priority Critical patent/CA2683296C/en
Priority to PCT/CA2010/001654 priority patent/WO2011113134A1/en
Publication of CA2683296A1 publication Critical patent/CA2683296A1/en
Application granted granted Critical
Publication of CA2683296C publication Critical patent/CA2683296C/en
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Classifications

    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21JFIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00Fibreboard
    • D21J1/08Impregnated or coated fibreboard
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21JFIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00Fibreboard
    • D21J1/16Special fibreboard
    • D21J1/20Insulating board

Abstract

A board comprising dried, fire retardant-impregnated cellulose material. The board may be essentially rigid or a sponge depending on the size of the voids in the board. The boards are preferably made from particulate cellulose material using a void- creating salt and an aqueous fire retardant. The boards are of value in the production, for example, of wallboard and insulation wrapping.

Description

FIRE RETARDANT-IMPREGNATED CELLULOSE BOARD, PROCESS OF MANUFACTURE THEREOF AND USES THEREOF

FIELD OF THE INVENTION

This invention relates to fire retardant-impregnated cellulose materials, particularly in the form of sponges, boards and blocks, to methods of manufacture and uses thereof.

BACKGROUND OF THE INVENTION

Cellulose sponges are well-known in the art - see, for example, USP 1,142,619 -G. Pum et al (1915) and USP 6,281,258 B1 - Hausdorf J. et al (August 28, 2001) and references cited therein.
A typical manufacturing process for a synthetic cellulose sponge is described by the following steps 1. The cellulose used for sponges arrives at the sponge factory in large, stiff sheets.
Workers take the sheets and soak them in a vat of water mixed with certain chemical softeners. The cellulose becomes soft and jelly-like. Then workers load the cellulose into a revolving mixer, which is a large rotating metal drum. Workers add sodium sulphate crystals, cut hemp fibers, and dye, and close the mixer. The mixer is set to rotate, and it churns the ingredients so that they are thoroughly amalgamated.
2. From the mixer, workers pour the material into a large rectangular mold that may be 2 ft (61 cm) high, 2 ft (61 cm) wide, and 6 ft (1.8 m) long. The mold is heated, and the cellulose mixture cooks. As it cooks, the sodium sulphate crystals melt, and drain away through openings in the bottom of the mold. It is their melting that leaves the characteristic pores in the finished sponge. The size of the pores is determined by the size of the sodium sulphate crystals. A rough sponge used for washing a car, for instance, is made with coarse crystals, while a fine sponge of the type used for applying makeup is made with very fine crystals. As the celluolose mix cooks, then cools, it becomes a hard, porous block.
3. The sponge block is then soaked in a vat of bleach. This removes dirt and impurities, and also brightens the color. Next the sponge is cleaned in water. Additional washings alter the texture, making the sponge more pliable. The sponge is left to dry, to prepare it for cutting.
4. Some manufacturers make the sponge and cut and package it themselves.
Others produce the raw blocks of sponge, and then sell them to a company known as a converter. The converter cuts the sponges according to its customers needs, and takes care of the packaging and distribution. Whether at the first manufacturing facility or at the converter, workers cut the sponges on an automatic cutter. They load each big rectangle of sponge into a machine that slices it into the desired size.
Because the sponge block is rectangular, it can be cut into many smaller rectangles with little or no waste.
5. Many household sponges have a textured plastic scouring pad attached to one side.
This is attached in a process called laminating, after the sponge is cut. The scouring pad, which is cut to the same size as the sponge, is affixed to the sponge in a laminating.

Alternatively, softened cellulose is mixed with sodium sulphate crystals, cut hemp fibers, and dye in a large, revolving metal drum. Once blended, the material is poured into a large rectangulor mold, which may be 2 ft (61 cm) high, 2 ft (61 cm) wide, and
6 h (182.9 cm) long. As the mold cooks, the sodium sulphate crystals melt, and drain away through openings in the bottom of the mold. It is their melting that leaves the characteristic pores in the finished sponge machine that uses a specialized sponge glue made of moisture-cured polyurethane. Next, the sponges move to a packaging area where they are sealed in plastic.
The packaged sponges are boxed, and the boxes sent to a warehouse for further distribution.
SUMMARY OF THE INVENTION

The invention, in one aspect, provides a board comprising dried, fire retardant-impregnated cellulose material.

In preferred embodiments, the boards are essentially rigid, and preferably comprises voids of an average particle size of less than 5mm and more preferably selected from 0.05mm to 3mm.
In alternative embodiments, the boards are constituted as cellulose sponges comprising voids of an average particle size selected from 0.5cm to 5.0cm, preferably 2.5cm to 4.0cm.
The invention, in a further aspect, provides a method of making a board comprising a dried, fire retardant-impregnated cellulose material comprising (a) mixing a particulate cellulose material in a salt-containing aqueous solution;
(b) forming a salt-impregnated cellulose board from said particulate cellulose material;
(c) washing said salt-impregnated cellulose board with an aqueous solution to remove said impregnated salt to provide a reduced salt-containing board;
(d) treating said reduced salt-containing board with a fire retardant-containing aqueous solution to provide a fire retardant-impregnated board; and (e) drying said fire retardant-impregnated board to provide said dried, fire retardant-impregnated cellulose board.
Preferably, the salt is essentially eliminated.
We have found, surprisingly, that the average particle size of the salt of use in the practise of the invention has an effect on the size of the voids produced resulting from the removal of the salt crystals and also the physical property of degree of flexibility and rigidity in the resultant dried, fire retardant-impregnated cellulose board.
For example, we have found that salt having an average particle size of less than 0.5cm and preferably selected from 0.05mm to 3mm produces an essentially rigid board, having some degree of bendable dependent on its thickness.
In contrast, an average particle size of at least 2.5cm, preferably 2.5cm to 5.0em, and more preferably 2.5cm to 4.0 cm, provides an extremely flexible sponge.
Any suitable salt may be used to provide the desired void-size. Preferred examples are selected from alkali metal halides and sulphates, particularly sodium sulphate.
Suitable fire retardants may be selected from compounds of small molecular weights containing phosphorus, antimony, or halogens. The most effective commercially available fire retardant systems are based on halogen- containing compounds. However, due to concerns over the environmental effects of such halogenated compounds, there is an international demand to control the use of such halogenated additives.
Some of the most common halogenated agents are methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane and carbon tetrachloride. These halogenated fire retarding materials are usually available commercially in the form of gases or liquids. Unlike chlorine and bromine, fluorine reduces the toxicity of the material and imparts stability to the compound. However, chlorine and bromine have a higher degree of fire extinguishing effectiveness and, accordingly, a combination of fluorine and either chlorine or bromine is usually chosen to obtain an effective fire-retarding compounds.
Other commercially available fire retardant materials that do not include halogens include boric acid and borate based compounds, monoammonium phosphonate, and urea-potassium bicarbonate.
Intumescent compounds which limit the heat and mass transfer by creating an insulating charred layer on the surface of the burning cellulose are also considered fire retardant materials. A typical intumescent additive is a mixture of ammonium polyphosphate and pentaerythritol.
In a further embodiment of the invention, steps (c) and (d) are combined.
In a further aspect, the invention provides a method of making a dried, fire retardant-impregnated cellulose board comprising (a) mixing a particulate cellulose material with an aqueous solution of a fire retardant;

(b) forming a fire retardant-impregnated cellulose board; and (c) removing water from said fire retardant-impregnated cellulose board to provide said dried, fire retardant-impregnated cellulose board.
Preferred embodiments of the boards according to the invention are essentially rigid, particularly if of a thickness greater than 2cm.
Further preferred embodiments are constituted as flexible sponge materials produced using salt having an average particle size of at least 0.5cm and preferably, at least 2.5cm to 5.0cm and more preferably 2.5cm to 4.0cm.

In a further aspect, the invention provides a dried, fire retardant impregnated cellulose board when made by a process as hereinabove defined.
In yet a further aspect, the invention provides a wallboard comprising a dried, fire retardant-impregnated cellulose board, as hereinabove defined, sandwiched between a first member and a second member.
The member may be formed, for example, of paper, plywood or like suitable material, optionally impregnated and/or coated with a fire retardant.
The boards produced according to the invention may be manufactured having any suitable thickness, for example, having a thickness selected from 3mm to 2.5cm and of a desired width, typically, 1.5cm to 1.5m. The smaller widths can be utilized as a wrap around wires and pipes for fire protection and manufactured as rolls, optionally bearing an adhesive on one surface.
The selected, suitable boards, according to the invention, may be used as wall structures in buildings, such as, for example, residences and commercial establishments having a thickness selected, for example, from 1cm to 80 cm. Such boards would preferably be sandwiched, for example, with paper, cardboard, plyboard or like material sheets. When the board has an average void size to provide a somewhat flexible sponge, suitable additives, such as a resin or glue, may be used to provide adequate stiffening.
The larger void cellulose "matting" can be used in rolls and sheets as well for various applications. For example the lining of an engine compartment or the hull on a fiber glass boat.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be better understood, preferred embodiments will now be described, by way of example only, with reference to the accompanying drawings wherein Fig. I is a diagrammatic cross section of a sheet of wall board according to the invention; and Fig. 2 is a diagrammatic side view of a board according to the invention in the form of a wrapping roll.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Fig. 1 shows generally as 10, a wallboard having a cellulose sponge core 12 sandwiched between paper sheets 14 and 16. Sponge 12, impregnated with boric acid fire retardant 18, has an average void size of 2cm. Wallboard 10 is a typical sized 2.4m x 1.2m x 1.2 cm sheet, used in home construction.
Fig. I also represents a more rigid ammonium polyphosphate/pentaerythritol fire retardant-impregnated cellulose core 20 having an average void size of 0.lmm.
Fig. 1 also represents a more flexible fire retardant-impregnated cellulose sponge core 22 having an average void size of 3.5cm.
Fig. 2 shows generally as 24 a urea/potassium bicarbonate fire retardant-impregnated cellulose board in the form of a coil or tape for use as insulation wrapping for pipes, wires and the like. Coil 24 has an average void size of about 4.0cm.
Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is to be understood that the invention is not restricted to those particular embodiments. Rather, the invention includes all embodiments which are functional or mechanical equivalence of the specific embodiments and features that have been described and illustrated.

Claims (16)

THE EMBODIMENTS OF THE INVENTION TO WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A board comprising a dried, fire retardant-impregnated cellulose material, the material being in a sponge form, disposed between first and second covering members, wherein each of the first and second covering members is a paper sheet, cardboard or plywood, and wherein the sponge material and the first and second covering members cooperate to form a flexible board product or a rigid board product.
2. A board as claimed in claim 1, wherein the sponge material defines voids having an average void size of 0.5 cm to 5.0 cm.
3. A board as claimed in claim 1, wherein the sponge material defines voids having an average void size of 2.5 cm to 4.0 cm.
4. A board as claimed in claim 1, wherein the sponge material defines voids having an average void size of less than 5 mm.
5. A board as claimed in claim 1, wherein the sponge material defines voids having an average void size of 0.05 mm to 3 mm.
6. A method of making a board comprising a dried, fire retardant-impregnated cellulose material, disposed between first and second covering members, said method comprising (a) mixing a particulate cellulose material in a salt-containing aqueous solution;
(b) forming a salt-impregnated cellulose board having impregnated salt therein from said mixing of the particulate cellulose material and the salt-containing aqueous solution; (c) washing said salt-impregnated cellulose board with an aqueous solution to remove said impregnated salt therefrom and provide a reduced salt-containing board; (d) treating said reduced salt-containing board with a fire retardant-containing aqueous solution to provide a fire retardant-impregnated board; (e) drying said fire retardant-impregnated board to provide said dried, fire retardant-impregnated cellulose board, the dried, fire retardant-impregnated cellulose board being in a sponge form; and (f) engaging the sponge board between first and second covering members, wherein each of the first and second covering members is a paper sheet, cardboard or plywood, and wherein the sponge material and the first and second covering members cooperate to form a flexible board product or a rigid board product.
7. A method as claimed in claim 6, wherein said impregnated salt has on average particle size of 0.5 cm to 5 cm, and engaging the sponge board between the first and second covering members forms the flexible board product.
8. A method as claimed in claim 7, wherein forming a salt-impregnated cellulose board comprises forming a salt-impregnated cellulose board having impregnated salt with an average particle size of 2.5 cm to 4.0 cm.
9. A method as claimed in claim 6, wherein said impregnated salt has an average particle size of less than 5 mm, and engaging the sponge board between the first and second covering members forms the rigid board product.
10. A method as claimed in claim 9, wherein forming a salt-impregnated cellulose board comprises forming a salt-impregnated cellulose board having impregnated salt with an average particle size of 0.05 mm to 3 mm.
11. A method as claimed in claim 6, wherein mixing a particulate cellulose material in a salt-containing aqueous solution comprises mixing a particulate cellulose material in an aqueous solution containing salt selected from an alkali metal sulphate and an alkali metal halide.
12. A method as claimed in claim 6, wherein step (c) and step (d) are combined.
13. A method as claimed in claim 6, comprising impregnating each of the first and second covering boards with a fire retardant selected from compounds including phosphorus, antimony or a halogen.
14. A method as claimed in claim 6, wherein treating said reduced salt-containing board with a fire retardant-containing aqueous solution comprises treating said reduced salt-containing board with an aqueous solution containing a fire retardant selected from compounds including phosphorus, antimony or a halogen.
15. A board as claimed in claim 1, wherein the sponge material is impregnated with a fire retardant selected from compounds including phosphorus, antimony or a halogen.
16. A board as claimed in claim 1, wherein each of the first and second covering members is impregnated with a fire retardant selected from compounds including phosphorus, antimony or a halogen.
CA2683296A 2009-10-22 2009-10-22 Fire retardant-impregnated cellulose board, process of manufacture thereof and uses thereof Active CA2683296C (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CA2683296A CA2683296C (en) 2009-10-22 2009-10-22 Fire retardant-impregnated cellulose board, process of manufacture thereof and uses thereof
PCT/CA2010/001654 WO2011113134A1 (en) 2009-10-22 2010-10-21 Method of forming a fire-resistant product, and associated apparatus

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA2683296A CA2683296C (en) 2009-10-22 2009-10-22 Fire retardant-impregnated cellulose board, process of manufacture thereof and uses thereof

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CA2683296A1 CA2683296A1 (en) 2011-04-22
CA2683296C true CA2683296C (en) 2018-11-06

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Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011047465A1 (en) * 2009-10-20 2011-04-28 Flamehalt Fire Retardants, Inc. System for forming a fire resistant wall structure, and associated method

Family Cites Families (3)

* Cited by examiner, † Cited by third party
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US4755225A (en) * 1985-08-26 1988-07-05 Pruitt Norman W Cellulosic-based particulate insulation and method of manufacturing same
US20020150758A1 (en) * 1998-12-15 2002-10-17 Prieto Juan J. Fire resistant cellulose insulation and method of production from sugar cane bagasse
US7354503B2 (en) * 2003-06-20 2008-04-08 Sierra Pine Ltd. Fire retardant composite panel product and a method and system for fabricating same

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CA2683296A1 (en) 2011-04-22

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