WO2011113134A1

WO2011113134A1 - Method of forming a fire-resistant product, and associated apparatus

Info

Publication number: WO2011113134A1
Application number: PCT/CA2010/001654
Authority: WO
Inventors: Daniel Baroux; Robert J. Hubbard
Original assignee: Flamehalt Technologies, Inc.
Priority date: 2009-10-22
Filing date: 2010-10-21
Publication date: 2011-09-22
Also published as: CA2683296C; CA2683296A1

Abstract

A method of forming a fire-resistant apparatus is provided. A slurry is formed from cellulose fibers and a liquid mixture including salt particles. The slurry is formed into a cellulose product such that the salt particles are substantially uniformly distributed therethrough. The salt particles are substantially removed from the cellulose product to form a porous cellulose product. The porous cellulose product is interacted with a fire-retarding solution, such that the fire-retarding solution is substantially uniformly distributed therethrough. A liquid portion of the fire-retarding solution is removed from the porous cellulose product, so as to retain fire-retardant solids from the fire-retarding solution therein, to form a fire-resistant cellulose product. An associated apparatus is also provided.

Description

TITLE OF THE INVENTION

METHOD OF FORMING A FIRE-RESISTANT PRODUCT,

AND ASSOCIATED APPARATUS

BACKGROUND OF THE DISCLOSURE

Field of the Disclosure

Aspects of the present disclosure relate to fire-retardant products and, more particularly, to a method of forming a fire-resistant product, including a fire-resistant cellulose product, and associated method.

Description of Related Art

Cellulose sponges are well-known in the art. An exemplary manufacturing process for a synthetic cellulose sponge may be as described in the following steps. In some instances, the cellulose material used to form the sponges is in the form of large, stiff sheets. The sheets are soaked in a vat of water mixed with certain chemical softeners, wherein the cellulose material then becomes soft and jelly-like. The cellulose material is then directed into a mixer and has sodium sulphate crystals, cut hemp fibers, and an optional dye added thereto. The cellulose mixture is then mixed until amalgamated.

From the mixer, the cellulose mixture is directed into a mold, and the mold then heated to heat the cellulose mixture. During this process, the sodium sulphate crystals melt, and drain away through openings in the bottom of the mold. The melting of the sodium sulphate crystals leaves the characteristic pores in the end product, thus forming, in some instances, a sponge or other porous structure. 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, may be made in this manner using relatively coarse crystals, while a fine sponge of the type used for applying makeup may be made in this manner using relatively fine crystals. As the cellulose mixture cools following the heating process, the cellulose mixture solidifies into a porous structure.

The completed porous structure may then be soaked in a vat of bleach or other suitable chemical to remove dirt and impurities, as well as to brighten the appearance (i.e., color) of the porous structure. Next, the porous structure (i.e., sponge) may be cleaned using water or other suitable substance. Additional washings may be performed to alter the texture of the porous structure (i.e., make the sponge more pliable). Once the process is completed, the solidified porous structure is dried, and then cut into appropriate portions, as necessary or desired.

In another exemplary manufacturing process, softened cellulose may be mixed with sodium sulphate crystals, optional cut hemp fibers, and optional dye in a revolving drum. Once blended, the mixture is poured into a mold. As the mixture is heated in the mold, the mixture solidifies, and the sodium sulphate crystals melt and drain away through openings in the bottom of the mold, thus resulting in the porous structure in the finished product. In some instances, the mixture may also include "sponge glue" comprising, for example, moisture- cured polyurethane.

Though such "sponge making" processes appear to be well-known, one common characteristic of the end product is that lack of fire resistance of the cellulose material. That is, there may be many potential applications of a porous cellulose material (i.e., sponge) that may be precluded due to the risk of fire associated with such cellulose products. As such, there exists a need for a method of forming a fire-resistant cellulose product, and a fire- resistant cellulose product produced thereby, wherein such a method is capable of forming a porous cellulose product having fire-resistant characteristics. In some instances, it may also be desirable to control the porosity of the fire-resistant cellulose product. Further, it may be desirable for the fire-resistant cellulose product to be configured so as to be applicable as a component in other fire-resistant products.

SUMMARY OF THE DISCLOSURE

The above and other needs are met by aspects of the present disclosure, wherein one such aspect relates to a method of forming a fire-resistant apparatus. Such a method comprises forming a slurry from cellulose fibers and a liquid mixture including salt particles. The slurry is then formed into a cellulose product, wherein the cellulose product has the salt particles substantially uniformly distributed therethrough. The salt particles are substantially removed from the cellulose product to form a porous cellulose product. The porous cellulose product is interacted with a fire-retarding solution, such that the fire-retarding solution is substantially uniformly distributed therethrough. A liquid portion of the fire-retarding solution is then removed from the porous cellulose product, so as to retain fire-retardant solids from the fire-retarding solution therein, to form a fire-resistant cellulose product. Another aspect of the present disclosure provides a fire-resistant apparatus, comprising a porous cellulose product interacted with a fire-retarding solution, wherein the fire-retarding solution is substantially uniformly distributed therethrough, and a liquid portion of the fire-retarding solution is subsequently removed therefrom, such that fire-retardant solids from the fire-retarding solution are retained within the porous cellulose product to form a fire-resistant cellulose product.

In some aspects, raw wood pulp, palm tree waste, waste fiber, waste paper, and/or waste board, may be processed to provide the cellulose fibers for the slurry. Further, exemplary salt particles may include alkali metal halide salt particles and/or sulphate salt particles, and, in some particular instances, may include sodium sulphate salt particles.

Once the slurry is formed, the slurry may be deposited in a mold and heated to solidify the cellulose fibers and retain the salt particles therein. The solidified cellulose fibers may then be wetted with an aqueous solution, such that the aqueous solution dissolves the salt particles. The dissolved salt particles exit the solidified cellulose fibers with the aqueous solution, and leave empty pores defined by the solidified cellulose fibers, the empty pores formerly having the salt particles therein. Accordingly, an average size of the salt particles may be varied so as to correspondingly vary an average size of the pores defined by the solidified cellulose fibers. Moreover, the average size of the pores defined by the solidified cellulose fibers may be varied so as to correspondingly vary a flexibility of the porous cellulose product.

In some instances, the porous cellulose product is configured to define a plurality of pores having an average pore size of between about 0.5 cm and about 5 cm so as to render the porous cellulose product relatively flexible. In other instances, the relatively-flexible porous cellulose product is configured to define a plurality of pores having an average pore size of between about 2.5 cm and about 4 cm. Further, the porous cellulose product may be configured to define a plurality of pores having an average pore size of less than about 5 mm so as to render the porous cellulose product relatively rigid, in some instances, the relatively- rigid porous cellulose product is configured to define a plurality of pores having an average pore size of between about 0.05 mm and about 3 mm.

In particular aspects, interacting the porous cellulose product with a fire-retarding solution may comprise substantially saturating the porous cellulose product with the fire- retarding solution. Such a fire-retarding solution may be an aqueous fire-retarding solution. In some instances, it may be preferred that the fire-retarding solution be nontoxic and/or have a neutral pH and/or be hypo allergenic and/or have any number of otherwise desirable properties. In some aspects, the fire-retarding solution may comprise any one of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogen compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifiuoromethane, dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride, urea-potassium bicarbonate, or various combinations thereof.

In still further aspects, one of the slurry, the porous cellulose product, and the fire- resistant cellulose product may be interacted with one of a mold inhibitor, a water resistance treatment, and an insect deterrent. In one instance, the insect deterrent may comprise one of glass particles and a borate substance, for providing a termite deterrent.

In still other aspects, the fire-resistant cellulose product may be engaged with a grille member having an intumescent material layer disposed thereon. The grille member and/or the fire-resistant cellulose product may be engaged with a fire-resistant cellulose frame member, wherein the fire-resistant cellulose frame member may comprise the cellulose fibers interacted with the fire- retarding solution, and wherein the fire-resistant cellulose frame member may be configured to support the grille member having the fire-resistant cellulose product engaged therewith.

Aspects of the present disclosure thus address the identified needs and provide other advantages as otherwise detailed herein.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIGS. 1-4 schematically illustrate a method for forming a fire-resistant cellulose product, according to one aspect of the disclosure; and

FIGS. 5A and 5B schematically illustrate an exemplary fire-resistant cellulose product, and a fire-resistant product incorporating a fire-resistant cellulose product, according to one aspect of the disclosure. DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects of the disclosure are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

Aspects of the present disclosure are directed to methods of forming a fire-resistant cellulose product, one exemplary method and associated arrangement for producing such a fire-resistant cellulose product being generally indicated by the numeral 100 in FIG. 1 . In one aspect, such a fire-resistant cellulose product may comprise, for instance, a porous cellulose structure comprised of cellulose fibers. In order to form such a porous cellulose structure, one exemplary method first comprises forming a slurry 125 from cellulose fibers and a liquid mixture 200 including salt particles 250.

The cellulose fibers may be obtained from one or more sources 150, and some aspects of the present disclosure contemplate that the source 150 of the cellulose fibers may comprise recycled cellulose fibers (i.e., from raw wood pulp, palm tree waste, waste paper, waste board, waste paperboard, or any other suitable waste source of cellulose fibers, already used to form a product and suitable for recycling), though one skilled in the art will appreciate that raw, original, or otherwise virgin cellulose fibers may also be used in addition to, in combination with, or instead of the recycled/waste cellulose fibers. For example, sawmill waste and/or empty fruit baskets/bunches from palm trees or other palm tree waste may be suitable sources 150 of previously unprocessed cellulose fibers for refining, as necessary, to obtain the cellulose fibers for the slurry 125. Further, in some aspects, the sources 150 may not necessarily be required to be free of contaminants, as long as those contaminants can be processed / refined by the processing device 175, along with the cellulose material, to refine the cellulose fibers into a form suitable for the slurry 125. As such, a decontamination process may not necessarily be contemplated, but could be included, should there be a need or desire for a contaminant-free cellulose fibers for inclusion in the cellulose end product. The extent of the processing/refining of the cellulose materials may vary considerably depending, for example, on the level of refinement (i.e., coarse / fine) desired of the cellulose fibers for the slurry 125 and/or the nature of the final cellulose product. In addition, the cellulose fibers do not necessarily need to be dry prior to being processed by the processing device 175. That is, waste sources of cellulose fibers may be, in some instances, in the form of bales, wherein the bales may often be exposed to the elements (i.e., rain or condensation) prior to being processed. In those instances, aspects of the present disclosure contemplate the "wet" source of cellulose fibers being processed for inclusion in the slurry 125. That is, the cellulose fibers may be processed, regardless of the moisture level present therein, and any moisture content present upon processing may be taken into account, for example, in subsequent preparation of the slurry 125 (i.e., the amount of water or other liquid used) for forming the cellulose end product.

The liquid mixture 200 combined with the cellulose fibers to form the slurry 125 may be, for example, any appropriate liquid that does not dissolve the salt particles 250, or otherwise negligibly dissolves the salt particles 250. For example, in some instances, the liquid mixture 200 may comprise water, and the salt particles 250 may comprise a water- insoluble salt. In some aspects, the salt particles 250 may comprise one of alkali metal halide salt particles and/or sulphate salt particles. In one particular aspect, the salt particles 250 may comprise sodium sulphate salt particles. In some aspects, the slurry 125 may preferably have the salt particles 250 substantially uniformly distributed therethrough. One skilled in the art, however, will appreciate that any suitable salt may be implemented and, in some instances, non-salt substances that may exhibit similar behavior and characteristics, as disclosed herein.

Once formed, the slurry 125 may be subsequently formed into a cellulose product

300, wherein the cellulose product 300 formed from the slurry 125 may also have the salt particles 250 substantially uniformly distributed therethrough. For example, the slurry 125 may first be "dewatered" or otherwise subjected to a process to remove at least a portion of the liquid mixture 200 from the slurry 125, while leaving the salt particles 250 distributed therethrough. In some aspects, the slurry 125 may then be deposited in a mold 350, and the slurry 125 in the mold 350 subsequently heated or otherwise dried, in order to solidify the cellulose fibers and retain the salt particles therein. In other aspects, the slurry, once prepared, may then be formed into the cellulose product 300, for example, using a conventional paper making process, implementing paper making machinery available, for instance, from Siempelkamp of Dusseldorf, Germany or Metso Paper, Inc. of Helsinki, Finland. More particularly, the slurry may be dewatered, for example, by a suitable

Fourdrinier-type machine, using a twin wire forming section and/or appropriate screening devices, or by another appropriate paper making process, as will be appreciated by one skilled in the art. The dewatered slurry may then be dried, pressed, or otherwise processed to form the cellulose product 300, To form the cellulose product 300, heat may also be applied to the slurry 125, for example, via heated air (i.e., heated with combusted natural gas or other suitable fuel source), or through any of a variety of heating/drying methods, such as, for example, microwave or infrared drying techniques, as will be appreciated by one skilled in the art.

Once the cellulose product 300 is formed, the salt particles 250 may be substantially removed therefrom, for example, by treating the cellulose product 300 to dissolve or otherwise deconstruct the salt particles 250 as shown, for example, in FIG. 2. For instance, the solidified cellulose fibers of the cellulose product 300 may be wetted with a liquid solution 325 configured to dissolve the salt particles 250 such that the salt particles may be "washed out" from the cellulose product 300. In one aspect, the liquid solution 325 is an aqueous solution, whereby the aqueous solution dissolves the salt particles, such that the dissolved salt particles exit the solidified cellulose fibers with the aqueous solution. One skilled in the art will appreciate, however, that the liquid solution 325 may be non-aqueous, depending, for instance, on the particular salt particles 250 implemented in the process. Accordingly, as a result, a porous cellulose product 400 is formed, having empty pores 425 defined by the solidified cellulose fibers, wherein the empty pores 425 formerly had the salt particles 250 disposed therein, in some aspects, the salt particles 250 are completely removed or otherwise eliminated from the cellulose product 300.

In one aspect of the present disclosure, the average size of the salt particles 250 may be varied so as to correspondingly vary an average size of the pores 425 defined by the solidified cellulose fibers. Further, in some aspects, the average size of the pores 425 defined by the solidified cellulose fibers may be varied so as to correspondingly vary a flexibility of the porous cellulose product 400. That is, the average size of the pores 425 defined by the solidified cellulose fibers may be directly related to the relative degree of flexibility / rigidity exhibited thereby. More particularly, in some instances, the porous cellulose product 400 is configured to define a plurality of pores 425 having an average pore size of between about 0.5 cm and about 5 cm. Such relatively large pores may, in some instances, render the porous cellulose product 400 relatively flexible (i.e., as a sponge). In some instances, the relatively- flexible porous cellulose product 400 may be configured to define a plurality of pores 425 having an average pore size of between about 2.5 cm and about 4 cm. In other instances, the porous cellulose product 400 is configured to define a plurality of pores 425 having an average pore size of less than about 5 mm, so as to render the porous cellulose product 400 relatively rigid (i.e., as a board, but with some degree of flexibi lity/bendabi 1 ity ) . In some instances, the relatively-rigid porous cellulose product 400 is configured to define a plurality of pores 425 having an average pore size of between about 0.05 mm and about 3 mm. In some aspects, the degree of flexibility/rigidity exhibited by the porous cellulose product 400 may also be dependent upon the thickness thereof in the referenced direction in proportion to the average pore size. For instance, with a sufficiently small pore size, a "board" product having a thickness of about 2 cm may be essentially "rigid," as will be appreciated by one skilled in the art.

Upon substantial removal of the salt particles 250 from the cellulose product 300, the resulting porous cellulose product 400 may be interacted with a fire-retarding solution 450, such that the fire-retarding solution 450 is substantially uniformly distributed therethrough, as shown, for example, in FIG. 3. For instance, in aspects involving a liquid fire-retarding solution 450, the porous cellulose product 400 may be substantially saturated with the fire- retarding solution 450 (i.e., by immersing the porous cellulose product 400 in a vat 475 containing the fire-retarding solution 450) such that the fire-retarding solution 450 interacts with substantially all of the pores 425 to form interacted pores 525.

In particular aspects, the fire-retarding solution 450 may comprise a fire-retarding substance, and may be an aqueous fire-retarding solution. It may be preferred that the fire- retarding solution 450 be nontoxic and/or have a neutral pi I and/or be hypoallergenic and/or have any number of otherwise desirable properties affecting human / animal and/or environmental safety, while maintaining the necessary efficacy, as implemented and upon exposure to heat and/or flame. In some aspects, the fire-retarding solution 450 / fire-retarding substance may be selected from relatively small molecular weight compounds containing phosphorus, antimony, and/or a halogen; and/or may comprise any one of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogen compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride, urea-potassium bicarbonate, and various combinations thereof, and/or other known fire-retarding substances. In this regard, one skilled in the art will appreciate that various fire-retarding or fire-resistant or ignition- resistant substances, either currently known or later developed or discovered, may be applicable to the disclosed processes and systems herein within the scope of the present disclosure.

One skilled in the art will further appreciate that the fire-retarding solution may be formed by adding a solid fire-retardant product to a liquid (i.e., water) or other chemical, such that the solid fire-retardant product forms a solution with the liquid or other chemical. One skilled in the art will also appreciate that, in some instances, the fire-retarding solution 450 may comprise the liquid solution 325 used to substantially remove the salt particles 250 from the cellulose product 300. That is, in some instances, the fire-retarding solution 450 may be configured to dissolve or otherwise assimilate or remove the salt particles 250 upon interaction with the cellulose product 300.

As shown, for example, in FIG. 4, once interacted with the porous cellulose product 400, at least a liquid portion 500 of the fire-retarding solution 450 is then removed from the porous cellulose product 400, so as to retain fire-retardant solids from the fire-retarding solution 450 therein (for example, within the pores 425, thereby forming treated pores 475), and thus form a fire-resistant cellulose product 550. Such removal of the liquid portion 550 may be accomplished, for example, by a dewatering process, using an appropriate dewatering device, as will be appreciated by one skilled in the art. In other instances, the liquid portion may be removed by drying, by pressing, or by another appropriate process. For instance, heat may also be applied to remove the liquid portion, for example, via heated air (i.e., heated with combusted natural gas or other suitable fuel source), or through any of a variety of heating/drying methods, such as, for example, microwave or infrared drying techniques, as will be appreciated by one skilled in the art. One skilled in the art will further appreciate that any or all of the excess fire-retarding solution 450A (or liquid portion thereof) removed from the porous cellulose product 400, in one of a liquid and a vapor form, may be recovered and/or recycled, wherein, for instance, the recovered excess fire-retarding solution may be directed to interact with a subsequent porous cellulose product 400 in a closed-loop, fire- retarding solution recycling process (see, e.g., optional recycled excess fire-retarding solution 450A in FIGS. 1 -3).

In further aspects, the fire-resistant cellulose product 550 may be applied as a component in other fire-resistant products as shown, for example, in FIGS. 5A and 5B. For example, in one aspect, the fire-resistant cellulose product 550 may be engaged with a grille member 700 having an intumescent material layer (not shown) disposed thereon. Such intumescent compounds may, for example, comprise a mixture of ammonium polyphosphate and pentaerythritol, though one skilled in the art will appreciate that other appropriate compounds and/or mixtures may exhibit intumescent properties as disclosed herein. Further, such intumescent compounds may be configured to expand upon exposure to heat and/or flame. Accordingly, when applied to a grille member 700 defining one or more vent channels 750, exposure of the grille member 700 to heat and/or flame may actuate the intumescent material and cause the intumescent material to expand, thereby extending across and sealing the vent channels 750.

One such fire-resistant product, comprising the fire-resistant cellulose product 550 engaged with a grille member 700, may be, for example, a ventilated eave soffit configured to extend from the top of an exterior building wall to the outer edge of the roof overhang. When so constructed, the soffit may be screwed or nailed to lookouts or lookout rafters forming the roof structure, The soffit exposure profile (i.e., distance from the wall to the roof fascia) can vary from about a few inches to about a few feet, or more, depending on the construction of the building. In such a configuration, the soffit may be configured to ventilate non-livable attic space. Accordingly, when implemented as an eave soffit, the grille member 700 and the porous fire-resistant cellulose product 550 may each be configured to direct an air flow therethrough. That is, such an eave soffit may be configured to permit air to flow from the exterior of the building, through the grille member 700 and the porous fire-resistant cellulose product 550, and into the attic of the building (or in the reverse direction). However, in the event of a fire, the flames/heat associated therewith may extend or travel up the exterior surface of the building toward the eave soffit, in some instances, into proximity with the grille member. In such an instance, the air flow characteristics may direct the flames/heat through the grille member 700. Accordingly, passage of the heat/flames through the grille member 700 may increase the risk of igniting the lookout rafters or other structures within the attic area of the building, commensurately increasing the risk of loss of the entire building structure from the fire.

In such instances, the tumescent material applied to the grille member 700 may be actuated by the heat/flames to begin the expansion process for sealing the vent channels 750. Sealing of the vent channels 750 would thus disrupt the air flow through the grille member 700, and reduce the risk of the heat/fire passing through the grille member 700 to ignite the lookout rafters or other structures within the attic space of the building. However, the response of the intumescent material to heat and/or flame may not necessarily be instantaneous. As such, the engagement of the porous fire-resistant cellulose product 550 with the grille member 700 (in one instance, on the surface of the grille member 700 directed toward the attic space), in some instances, may serve to normally permit air flow

therethrough to ventilate the attic, but in the event of a fire may block the passage of the flame/heat, until the tumescent material deposited on the grille member 700 can be actuated to seal the vent channels 750 and block the heat/fire from being directed therethrough. As such, prevention of the heat/fire from entering the attic space of the building may be a significant factor in determining whether or not the building survives the fire.

In further aspects, since the eave soffit may typically be attached to the lookout rafters supporting the attic structure of the building, it may sometimes be advantageous for the eave soffit structure to include its own support framework 800. That is, it may be useful for the grille member 700 and/or the porous fire-resistant cellulose product 550 to include a support framework 800 configured to support all or portions thereof in the event of a fire, such that the fire-resistant properties are not lost, for example, if the fire melts or otherwise damages the grille member 700. In such instances, the support framework 800 may be configured to support the remaining porous fire-resistant cellulose product 550 to prevent the fire/heat from entering the attic space. In one aspect, such a support framework 800 may be formed as or otherwise comprise a fire-resistant cellulose frame member including cellulose fibers interacted with the fire-retarding solution. More particularly, such a fire-resistant cellulose frame member 800 may be formed, for example, from the relatively rigid "board" (i.e., having a relatively small average pore size) form of the fire-resistant cellulose product 550, as otherwise disclosed herein. In other instances, the fire-resistant cellulose frame member 800 may be comprised, for example, of a particle board, a medium density fiber (MDF) board, and/or an oriented strand board (OSB), each of which may be comprised of cellulose fibers similar to or substantially the same as the cellulose fibers comprising the fire-resistant cellulose product and/or the same or substantially similar fire-retarding solution 450. In some desirable aspects, the fire-resistant cellulose frame member 800 is treated with and incorporates a fire-retarding solution, whether or not the fire-retarding solution is the same as incorporated into the fire-resistant cellulose product 550. That is, the fire-resistant cellulose frame member 800 may not necessarily be treated with the fire-retarding solution, though such treatment may be preferable. One skilled in the art will appreciate, however, that though the fire-resistant cellulose frame member 850 is referred to herein as being comprised of a cellulose material, any other suitable material exhibiting the desired properties disclosed herein may also be desirable and capable of being implemented within the scope of the present disclosure.

Many modifications and other aspects of the disclosures set forth herein will come to mind to one skilled in the art to which these disclosures pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, in some instances, other appropriate substances/materials/chemicals may be added to one of the slurry 125, the porous cellulose product 400, and the fire-resistant cellulose product 550. For example, a mold inhibitor 600 may be added to one of the slurry, the porous cellulose product, and the fire-resistant cellulose product. In other instances, a water repellant, waterproofing, or otherwise water resistant substance 625 may be added to one of the slurry, the porous cellulose product, and the fire-resistant cellulose product such that the end product exhibits water-resistive properties. In yet other instances, an insect-deterrent 650 may be added to one of the slurry, the porous cellulose product, and the fire-resistant cellulose product. Such an insect deterrent may comprise, for example, glass particles, glass fibers, glass slivers, glass shards, or any other suitable forms of glass elements, and/or a borate substance, so as to provide a termite deterrent.

In another example, a cellulose end product formed in accordance with aspects of the present disclosure may also exhibit other desirable and enhanced properties over those of untreated cellulose products. For example, such cellulose end products may exhibit "zero ignition" and/or "zero flame spread." In another example, treatment of the cellulose end product with a substantially uniform and thorough dispersion and distribution of the fire- retarding solution within the product, may also enhance fire resistance (flame spread), as well as thermal barrier (thermal resistance / insulation) characteristics.

In yet a further aspect, the fire-resistant cellulose product 400 may be incorporated into other end products such as, for example, a wallboard comprising the fire-resistant cellulose product 400 having a sheet member (not shown) applied to at least one major surface thereof. In particular instances, the fire-resistant cellulose product 400 may have a sheet member applied to opposing major surfaces thereof. The sheet member may be, for example, comprised of paper, plywood, particle board, MDF, OSB, or other suitable material, whether or not treated with a fire retardant substance as disclosed herein.

In other instances, the fire-resistant cellulose product 400 may be implemented as an insulation product, for example, as a wrap for wires and pipes. In those instances, the fire- resistant cellulose product 400 may have an adhesive applied to a surface thereof to facilitate installation about the wires or pipes.

If formed as a sheet (i.e., in discrete lengths or in an extended length which may be rolled), the fire-resistant cellulose product 400 may be used, for example, as a liner for a vehicle engine compartment or for the hull of a water-borne vessel.

In some aspects, if the fire-resistant cellulose product 400 is intended to be relatively flexible, suitable additives, such as, for example, a resin, glue, or other suitable adhesive may be incorporated therein to promote cohesion of the cellulose fibers and to facilitate stiffening or rigidity of the end product.

Therefore, it is to be understood that the disclosures are not to be limited to the specific aspects disclosed and that modifications and other aspects are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

WHAT IS CLAIMED IS:

1. A method of forming a fire-resistant apparatus, said method comprising: forming a slurry from cellulose fibers and a liquid mixture including salt particles; forming the slurry into a cellulose product, the cellulose product having the salt

particles substantially uniformly distributed therethrough;

substantially removing the salt particles from the cellulose product to form a porous cellulose product;

interacting the porous cellulose product with a fire-retarding solution, such that the fire-retarding solution is substantially uniformly distributed therethrough; and removing a liquid portion of the fire-retarding solution from the porous cellulose product, so as to retain fire-retardant solids from the fire-retarding solution therein, to form a fire-resistant cellulose product.

2. A method according to Claim 1, wherein forming a slurry comprises forming a slurry from cellulose fibers and a liquid mixture including salt particles comprising one of alkali metal halide salt particles and sulphate salt particles.

3. A method according to Claim 1 , wherein forming a slurry comprises forming a slurry from cellulose fibers and a liquid mixture including sodium sulphate salt particles.

4. A method according to Claim 1 , wherein forming the slurry into a cellulose product comprises depositing the slurry in a mold and heating the slurry in the mold to solidify the cellulose fibers and retain the salt particles therein.

5. A method according to Claim 4, wherein substantially removing the salt particles comprises wetting the solidified cellulose fibers with an aqueous solution, such that the aqueous solution dissolves the salt particles, and such that the dissolved salt particles exit the solidified cellulose fibers with the aqueous solution, so as to leave empty pores defined by the solidified cellulose fibers, the empty pores formerly having the salt particles therein.

6. A method according to Claim 5, further comprising varying an average size of the salt particles so as to correspondingly vary an average size of the pores defined by the solidified cellulose fibers.

7. A method according to Claim 6, further comprising varying the average size of the pores defined by the solidified cellulose fibers so as to correspondingly vary a flexibility of the porous cellulose product,

8. A method according to Claim 1 , wherein interacting the porous cellulose product with a fire-retarding solution comprises substantially saturating the porous cellulose product with the fire-retarding solution.

9. A method according to Claim 1 , further comprising processing one of raw wood pulp, palm tree waste, waste fiber, waste paper, and waste board, to provide the cellulose fibers for the slurry.

10. A method according to Claim 1 , wherein interacting the porous cellulose product with a fire-retarding solution further comprises interacting the porous cellulose product with a fire-retarding solution comprising one of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogen compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride, urea-potassium bicarbonate, and combinations thereof,

1 1 . A method according to Claim 1 , wherein interacting the porous cellulose product with a fire-retarding solution further comprises interacting the porous cellulose product with a fire-retarding solution comprising one of an aqueous fire-retarding solution, a nontoxic liquid fire-retarding solution, and a neutral pH liquid fire-retarding solution.

12. A method according to Claim 1 , further comprising interacting one of the slurry, the porous cellulose product, and the fire-resistant cellulose product with one of a mold inhibitor, a water resistance treatment, and an insect deterrent.

13. A method according to Claim 1, further comprising interacting one of the slurry, the porous cellulose product, and the fire-resistant cellulose product with an insect deterrent, comprising one of glass particles and a borate substance, so as to provide a termite deterrent.

14. A method according to Claim 1, further comprising engaging the fire-resistant cellulose product with a grille member having an intumescent material layer disposed thereon.

15. A method according to Claim 14, further comprising engaging one of the grille member and the fire-resistant cellulose product with a fire-resistant cellulose frame member, the fire-resistant cellulose frame member comprising the cellulose fibers interacted with the fire-retarding solution, and being configured to support the one of the grille member and the fire-resistant cellulose product engaged therewith.

16. A fire-resistant apparatus, comprising:

a porous cellulose product interacted with a fire-retarding solution, such that the fire- retarding solution is substantially uniformly distributed therethrough, and having a liquid portion of the fire-retarding solution subsequently removed therefrom, such that fire-retardant solids from the fire-retarding solution are retained therein to form a fire-resistant cellulose product.

17. An apparatus according to Claim 16, wherein the porous cellulose product is configured to define a plurality of pores having an average pore size of between about 0.5 cm and about 5 cm so as to render the porous cellulose product relatively flexible.

18. An apparatus according to Claim 16, wherein the porous cellulose product is configured to define a plurality of pores having an average pore size of between about 2.5 cm and about 4 cm so as to render the porous cellulose product relatively flexible.

19. An apparatus according to Claim 16, wherein the porous cellulose product is configured to define a plurality of pores having an average pore size of less than about 5 mm so as to render the porous cellulose product relatively rigid.

20. An apparatus according to Claim 16, wherein the porous cellulose product is configured to define a plurality of pores having an average pore size of between about 0.05 mm and about 3 mm so as to render the porous cellulose product relatively rigid.

21. An apparatus according to Claim 16, wherein the porous cellulose product comprises cellulose fibers processed from one of raw wood pulp, palm tree waste, waste fiber, waste paper, and waste board.

22. An apparatus according to Claim 16, wherein the fire-retarding solution comprises one of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogen compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydro magnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoiOmethane, dibromotetrafiuoiOethane, dibromodifluoromethane, carbon tetrachloride, urea-potassium bicarbonate, and combinations thereof.

23. An apparatus according to Claim 16, wherein the fire-retarding solution comprises one of an aqueous fire-retarding solution, a nontoxic liquid fire-retarding solution, and a neutral pH liquid fire-retarding solution.

24. An apparatus according to Claim 16, wherein one of the slurry, the porous cellulose product, and the fire-resistant cellulose product is further interacted with one of a mold inhibitor, a water resistance treatment, and an insect deterrent.

25. An apparatus according to Claim 16, wherein one of the slurry, the porous cellulose product, and the fire-resistant cellulose product is further interacted with an insect deterrent, comprising one of glass particles and a borate substance, so as to provide a termite deterrent.

26. An apparatus according to Claim 16, further comprising a grille member having an intumescent material layer disposed thereon, the grille member being engaged with the fire-resistant cellulose product.

27. An apparatus according to Claim 26, further comprising a fire-resistant cellulose frame member engaged with one of the grille member and the fire-resistant cellulose product, the fire-resistant cellulose frame member comprising the cellulose fibers interacted with the fire-retarding solution, and being configured to support the one of the grille member and the fire-resistant cellulose product engaged therewith.