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    • 专利摘要:
    METHOD FOR FORMING A FIRE RESISTANT CELLULOSE PRODUCT AND ASSOCIATED APPLIANCE. A method for forming a fire resistant cellulose material is described. Such a method comprises processing cellulose fibers into a fiber mixture and then forming a moist mixture from the fiber mixture and a fire retardant solution, wherein the moistened mixture has a substantial solids content of the fire retardant solution, uniform and completely dispersed in it. In some respects, the cohesive mixture can be formed from the wetted mixture and a binding agent, and the cohesive mixture then formed into a formed cellulose product. An associated apparatus is also provided.
    公开号:BR112013017921B1
    申请号:R112013017921-0
    申请日:2011-01-13
    公开日:2020-12-01
    发明作者:Daniel Baroux
    申请人:Blmh Technologies, Inc.；
    IPC主号:
    专利说明:

    [0001] [001] Aspects of the present description refer to methods for forming fire resistant products and, more particularly, a method for forming a fire resistant or otherwise ignition resistant cellulose product and associated apparatus. Description of the state of the art
    [0002] [002] Sometimes it may be desirable that particular products have fire resistance. For example, it may be desirable that the cellulose fiber based slab products used in building construction exhibit a certain degree of fire resistance. In some cases, a cellulose based slab product may have a fire retardant product applied to it, post-forming, to provide some fire resistance capabilities for the cellulose fiber based slab product. That is, an example formed of a cellulose-based slab product may have a surface treatment, for example, a fire retardant liquid, applied to it for the treated product to have at least some fire resistance. In such cases, however, a possible limitation in the treatment of the cellulose based slab product as formed for fire resistance, particularly with a fire retardant liquid, is to achieve a uniform and consistent treatment of that product. More particularly, the result of some fire resistance treatment processes involving the application of a fire retardant liquid to a formed cellulose fiber based board product may be an uneven or otherwise inconsistent coverage of the fire retardant. fire with respect to the product. In these cases, uneven treatment can result in varying levels of fire resistance of the treated cellulose fiber based slab product, which in turn can become a hazard in the event of a fire, where the product is intended to slow down or otherwise provide some resistance. In addition, such treatment processes may not necessarily be efficient in terms of applying the fire retardant to the cellulose fiber based board product, may not include provisions for capturing or recycling excess parts of the fire retardant product, and may not have the ability to prevent or restrict fire retardant losses due to, for example, evaporation processes.
    [0003] [003] Thus, there is a need for an associated process and apparatus to apply a uniform and consistently fire retardant, particularly a fire retardant liquid, to a cellulose product such as, for example, a board based product. cellulose fiber. In some cases, it may be desirable to form an integral cellulose product having increased characteristics and physical properties of an existing product, while also providing an increased level of fire resistance. It may also be desirable, in some cases, to have a cellulose fiber based plaque forming process with the ability to capture excess fire retardant and recycle the excess captured in subsequent cellulose product manufacturing cycles, both if the excess is captured in a liquid form or in other forms, such as vapors. Brief Summary
    [0004] [004] The above and other needs are met by aspects of the present description, where this aspect refers to a method for forming a fire resistant cellulose material. Such a method comprises processing cellulose fibers into a fiber mixture and then forming a moist mixture from the fiber mixture and a fire retardant solution, wherein the wet mixture has a substantial solids content of fire retardant solution. , uniform and completely dispersed in it. In some cases, such a method may further comprise forming a cohesive mixture from the wetted mixture and a binding agent and then forming the cohesive mixture in a formed cellulose product. In additional cases, forming a cohesive mixture can be carried out substantially and simultaneously forming a moist mixture. In still other cases, such a method may include de-wetting the wet mixture to form a dry fire retardant fiber mixture, such that forming a cohesive mixture involves forming a cohesive mixture from the dry fire retardant fiber mixture and a binding agent.
    [0005] [005] Another aspect of the present description relates to an apparatus for forming a fire resistant cellulose material. Such an apparatus comprises a first processing device configured to process cellulose fibers into a fiber blend, and a first mixing device configured to form a wet blend from the fiber blend and a fire retardant solution, wherein the blend The wetted material has a solid, uniform and completely dispersed solid content of the fire retardant solution. In some cases, such an apparatus may additionally comprise a second mixing device configured to form a cohesive mixture from the wetted mixture and a binding agent, and a forming device configured to form the cohesive mixture in a formed cellulose product. In additional cases, the first mixing device and the second mixing device are configured to form substantially and simultaneously a moist mixture and to form a cohesive mixture. In still other cases, a second processing device may be configured to de-wet the wet mixture to form a dry fire retardant fiber blend, wherein the second mixing device is configured to form a cohesive blend from the retardant fiber blend of dry fire and a binding agent.
    [0006] [006] In some cases, the moistened mixture can be maintained for at least a predetermined time, in order to allow the fire retardant solution to be at least partially absorbed by the cellulose fibers in the fiber mixture, before sliding the moistened mixture. or form the cohesive mixture.
    [0007] [007] In some respects, the fire retardant solution may be an aqueous fire retardant solution. It may be preferred that the fire retardant solution is non-toxic and / or has a neutral pH and / or is hypoallergenic and / or has any number of otherwise desirable properties. In some respects, the fire retardant solution can comprise any of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogenated compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diamonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromotoro fluoroethane, dibromomethane carbon tetrachloride, urea-potassium bicarbonate, and combinations thereof.
    [0008] [008] Still in additional aspects, the first processing device can be configured to process raw wood pulp, palm residue, residual fiber, residual paper and board residue, each comprising cellulose fibers, within the fiber mixture. In addition, the first mixing device can be configured, for example, to form the moist mixture by substantially saturating the fiber mixture with the fire retardant solution having a first concentration of solids content and / or forming a paste from the mixture of fibers and the fire retardant solution.
    [0009] [009] In additional aspects, the second processing device can be configured to dehydrate the moist mixture and to dry the dehydrated moist mixture to form the dry fire retardant fiber mixture. In doing so, the moistened mixture can also be heated to facilitate the formation of the dry fire retardant fiber mixture. Additionally, in some cases, moisture may be added to the dry fire retardant fiber mixture such that the dry fire retardant fiber mixture has a moisture content of between about 1% and about 20%, before forming the mixture. cohesive.
    [0010] [010] In still other aspects, the apparatus may also comprise a recovery device configured to recover excess fire retardant solution, in a liquid or vapor form, from the second processing device, the second processing device sliding the moistened mixture to form the dry fire retardant fiber mixture. In addition, the recovery device can be configured to direct the excess fire retardant solution recovered to the first mixing device, to be added to the fiber mixture to form a moist mixture, for example, in a retarding solution recycling process. fire in closed circuit.
    [0011] [011] Also, in other respects, the second processing device can be configured to form a cohesive mixture from the mixture of dry fire retardant fibers and a binding agent comprising one of a resin material and an adhesive material, and the forming device can be configured to compress the cohesive mixture to form a densified cellulose product, extrude the cohesive mixture to form the formed cellulose product, or shape the cohesive mixture to form a formed cellulose product. In doing so, the cohesive mixture can be formed into one of a oriented filament board cellulose product, a medium density fiber board cellulose product, a particle board cellulose product, and a fiber cellulose product. insulating plate.
    [0012] [012] Additionally, by forming the cellulose product, the internal bond strength can be evaluated and compared to an acceptable internal bond strength for the formed cellulose product. If the evaluated internal bond strength is less than the acceptable internal bond strength, the fire retardant solution used to form a moist mixture can be diluted, or an amount of the binder used to form the cohesive mixture can be increased.
    [0013] [013] Aspects of the present description thus cover the identified needs and provide other advantages as otherwise detailed here. Brief Description of Drawings
    [0014] [014] Having described the description in general terms, reference will now be made to the attached drawings, which are not necessarily drawn to scale, and in which: Figure 1 schematically illustrates an apparatus for forming a fire resistant cellulose product, according to an aspect of the description; and Figure 2 schematically illustrates a method of forming a fire resistant cellulose product, according to one aspect of the description. Detailed Description
    [0015] [015] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects of the description are illustrated. In fact, the description can be incorporated in many different ways and should not be interpreted as limited to the aspects defined in this document. Instead, these aspects are provided so that this description meets the applicable legal requirements. Similar numbers refer to similar elements throughout the document.
    [0016] [016] Aspects of the present description are generally directed to apparatus and methods for forming a fire resistant cellulose product. As previously discussed, a possible limitation in the treatment of formed cellulose products, such as a cellulose fiber based slab product, for fire resistance, particularly with a liquid fire retardant, is to achieve a uniform and consistent treatment of such cellulose product. That is, the result of some fire resistance surface treatment processes may be an uneven, non-uniform, or otherwise inconsistent or incomplete application of the fire retardant to the cellulose product. In such cases, such uneven surface treatment can result in varying levels of fire resistance of the treated cellulose product which can, in turn, become a hazard in the event of a fire, in which the product is intended to slow down or otherwise. way to provide some resistance.
    [0017] [017] As such, an aspect of the present description involves an apparatus for forming a fire resistant cellulose product, such apparatus is indicated as element 100 in Figure 1. Such apparatus 100 may comprise, for example, a first processing device 200 configured to process cellulose fibers from a cellulose fiber source 150 into a fiber blend 225, a first mixing device 300 configured to form a wet blend 275 from the fiber blend 225 and a fire retardant solution 250 , such that the moist mixture 275 has a substantial, uniform and completely dispersed solids content of fire retardant solution 250 therein. A second mixing device 400 is configured to form a cohesive mixture 325 from the moistened mixture 275 and a binder 260, and a forming device 800 is configured to form the cohesive mixture 325 in a formed cellulose product 750.
    [0018] [018] The first processing device 200 can be configured to process cellulose fibers from one or more sources 150 in a mixture of fibers 225. That is, although aspects of the present invention contemplate that cellulose products can be composed of recycled cellulose fibers (that is, from palm residue, empty fruit clusters, sugar cane residue, bagasse, residual fiber, residual paper, residual board, residual cardboard, or any other source of waste fiber suitable cellulose), a person skilled in the art will consider that raw, original, or otherwise, virgin cellulose fibers (i.e. raw wood pulp) can also be used in addition to, in combination with, or instead of, the fibers of recycled / residual cellulose. In addition, in some respects, cellulose fibers from all or part of the fiber source 150 may not necessarily need to be free of contaminants, since these contaminants can be processed together with cellulose fibers to form a mixture of fibers. For example, where the cellulose fiber source includes residual pizza boxes, such pizza box waste does not necessarily need to be free of pizza components, such as cheese, for these pizza boxes to be processed by the first processing device. 200. A decontamination process may not necessarily be contemplated (for example, for one or the other or both of the cellulose fibers and the fiber blend), but could be included if there is a need or desire for a contaminant-free cellulose product .
    [0019] [019] In addition, cellulose fibers from all or part of the fiber source 150 do not necessarily need to be dry before being processed by the first processing device 200. That is, residual sources of cellulose fibers may be, in some cases, in the form of bales, where the bales can often be exposed to the environment (ie rain or condensation) before being introduced into the first processing device 200. In other cases, the residual sources of cellulose fibers can be, for example, empty fruit clusters removed from palm trees and which can be stored in the open, in a high humidity environment, or in areas otherwise exposed to the environment. In these cases, aspects of the present invention, such as the first processing device 200, are also configured to process the "wet" source of the cellulose fibers within the fiber blend. In this regard, cellulose fibers can be processed by the first processing device 200, regardless of the moisture level present therein, in a fiber mixture. However, in some cases, such processing can be facilitated by reducing the moisture level at the source 150 through a suitable moisture reducing device 125. For example, in some cases, empty fruit clusters may include a moisture content at the level around 80%, which can make initial handling difficult. In such cases, the moisture content can be reduced in a number of ways, or the empty fruit clusters otherwise moved away, to facilitate material handling, although the moisture content may not necessarily be reduced to 0%. In addition, the extent of processing of cellulose fibers by the first processing device 200 can vary considerably depending, for example, on the desired level of refinement (i.e., coarse / fine) of the final cellulose product 750. For example, cellulose can be separated, deflocculated, chipped, shredded, granulated, fibrated, fiberized, particulate, or otherwise processed by the first processing device 200, either homogeneously or heterogeneously, to form the fiber mixture 225. As such, the first device Processing machine 200 can be any suitable machine for deconstructing cellulose fibers in the manner discussed, wherein such exemplary machine may be a heatable hammer mill manufactured by Siempelkamp of Krefeld, Germany.
    [0020] [020] Since the cellulose fibers are produced or otherwise processed in the desired state for the fiber blend 225 by the first processing device 200, the fiber blend 225 can then be directed to the first mixing device 300, wherein the fiber mixture 225 is mixed with the fire retardant solution 250 to form a wet mixture 275. The first mixing device 300 can be further configured to mix the fiber mixture 225 with the fire retardant solution 250 such that the fire retardant solution 250 is substantially and evenly distributed through the fiber mixture 225. In some cases, the fire retardant solution 250 may have a particular solids content, and the first mixing device 300 may be additionally configured to mix the mixture of fibers with the fire retardant solution 250 such that the moist mixture 275 has the solids content of the fire retardant solution 250 substa tional, uniform and completely dispersed in it. In the formation of the wet mixture 275, the first mixing device 300 can be configured to substantially saturate the fiber mixture 225 with the fire retardant solution 250, wherein the fire retardant solution 250 has a particular first concentration of solids content, and / or the first mixing device 300 can be configured to form a slurry from the fiber mixture 225 and the fire retardant solution 250. In some cases, the first mixing device 300 can also be configured to add water and / or other suitable liquid or chemical, to the fiber mixture 225 and the fire retardant solution 250 to form the paste.
    [0021] [021] In particular aspects, the fire retardant solution 250 can be an aqueous fire retardant solution. It may be preferred that the fire retardant solution is non-toxic and / or has a neutral pH and / or is hypoallergenic and / or has any number of desirable properties that would otherwise affect human / animal and / or environmental safety, while maintaining the necessary effectiveness, as implemented and upon exposure to heat and / or flame. In some respects, the fire retardant solution 250 may include a component which, alone, may not necessarily exhibit one or more of the preferred or desirable previously described properties. However, a person skilled in the art will consider that components other than the fire retardant solution 250 may interact with the observed component in order to neutralize, minimize, or otherwise eliminate, chemically or otherwise, non-preferred or undesirable properties of the observed component such that the general fire retardant solution 250 exhibits one or more of the preferred or desired properties. In some other respects, the fire retardant solution 250 may comprise any of a boron compound, a borate, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a salt of phosphonium, ammonium phosphate, and diamonium phosphate, and various combinations thereof. In this regard, a person skilled in the art will consider that various fire retardant or fire resistant substances, whether currently known or later developed or discovered, may be applicable to the processes and apparatus described in the present document within the scope of this description.
    [0022] [022] A person skilled in the art will additionally consider that the fire retardant solution 250 can be formed by adding a solid fire retardant product to a liquid (ie water) or other chemical mixed with the fiber mixture, such as that the solid fire retardant product forms a solution with the liquid, or another chemical, comprising the paste with the fiber mixture 225. In other cases, the solution formed from the solid fire retardant product and the liquid or other product The chemical can be used to form the wet mixture 275 with the fiber mixture 225. In some respects, the first mixing device 300 can be configured to agitate the slurry or the wet mixture, in order to substantially and evenly distribute the flame retardant solution. fire anyway. In other respects, the first mixing device 300 can be configured to handle the wet mixture 275, such that the solids content of the fire retardant solution is substantial, uniform and completely dispersed through the wet mixture. The first mixing device 300 can be any machine suitable for forming the wet mixture and / or the paste from the fiber mixture and the fire retardant solution, in the various ways discussed, in which one of these exemplary machines can be manufactured by Siempelkamp from Krefeld, Germany.
    [0023] [023] In some respects, since the wet mixture 275 is formed by the first mixing device 300, a second mixing device 400 can be configured to receive the wet mixture 275 and to form a cohesive mixture 325 from the wet mixture 275 and a binder 260 added to it. Such a binder 260 may comprise, for example, a resin material or an adhesive material. In a particular example, the binding agent 260 may comprise diphenyl methylene diisocyanate (MDI). However, a person skilled in the art will find that the binder 260 may vary considerably, as appropriate, and may comprise other suitable materials such as, for example, urea formaldehyde (UF) or phenol formaldehyde (PF). In some cases, the first mixing device 300 can be configured to form a wet mixture 275 before the second mixing device 400 forms cohesive mixture 325. In other cases, the first and second mixing devices 300, 400 can be configured to forming a moist mixture 275 and the cohesive mixture 325 substantially and simultaneously (i.e., adding the fire retardant solution to the substantial fiber mixture and simultaneously with the addition of the binding agent).
    [0024] [024] In some particular respects, a second processing device 500 may be provided to deglaze the moistened mixture 275, to form a dry fire retardant fiber mixture, prior to the formation of the cohesive mixture 325 on the second mixing device 400. In in such cases, the second mixing device 400 can be configured to form the cohesive mixture 325 from the dry fire retardant fiber mixture and a binder 260, as described above. The second processing device 500, such as a dryer, can additionally be provided as needed and, as will be seen by a person skilled in the art, to process the wet mixture 275 to form the dry fire retardant fiber mixture. The second processing device 500 can be configured to apply heat to the moist mixture 275, for example, through heated air (i.e., air heated with combustion natural gas or another suitable fuel source), or through any of a variety heating / drying methods, such as, for example, microwave or infrared drying techniques, as will be considered by one skilled in the art.
    [0025] [025] In cases where the first mixing device 300 is configured to form a paste from the mixture of fibers and the fire retardant solution, the second processing device 500 can be configured to dehydrate the paste, before drying the dehydrated paste to form the dry fire retardant fiber mixture. Such dehydration process can be carried out, for example, by an appropriately modified Fourdrinier machine, or another appropriate process, as will be considered by one skilled in the art. The paste can also be dehydrated, for example, using a twin wire forming section and / or appropriate filtering devices. In addition, as previously described, in order to dry the dehydrated slurry, the second processing device 500 can be configured to apply heat to the moist mixture, for example, through heated air (ie, air heated with combustion natural gas or another source fuel), or through any of a variety of heating / drying methods, such as, for example, microwave or infrared drying techniques, as will be considered by a person skilled in the art. One skilled in the art will also consider that the second processing device 500 can be configured in many different ways. For example, a properly configured filtering device can be configured to receive the paste, where the filtering device can include a number of perforations. Once deposited in the filtering device, the paste can be attached to an opposite press, which can also be perforated. Perforations can serve to dehydrate the paste, while the press and / or the filtering device can be heated to provide drying of the dehydrated paste.
    [0026] [026] In other respects, the apparatus 100 may also comprise a recovery device 600 configured to recover the excess fire retardant solution, in a liquid or vapor state, to the second processing device 500 to de-wet a moist mixture 275 In some cases, the recovery device 600 can also be configured to engage the first mixing device 300 to perform recovery of the excess fire retardant solution. That is, the recovery device 600 can be configured to direct the recovered excess fire retardant solution, removed from the moistened mixture by sliding it through the second processing device 500, to the mixing device 300, for example, in a closed loop fire retardant solution recycling process. Upon recovery of excess parts, including liquids and vapors, by the recovery device 600, the recovered excess fire retardant solution can be sieved, filtered, or otherwise purified and then reintroduced into the first mixing device 300 to form subsequent parts of the moistened mixture 275, such that the fire retardant solution is substantially or entirely prevented from leaving the apparatus 100 as a waste product.
    [0027] [027] In some respects, the second processing device 500 can be configured to de-wet the moist mixture 275 such that the moisture content is substantially 0%. However, upon exposure to the atmosphere, the now dry fire retardant fiber mixture can absorb moisture from atmospheric moisture. As such, the dry fire retardant fiber blend can typically exhibit some moisture content (i.e., about 1% to about 3%). In this regard, some binding agents, such as MDI, may require a particular amount of moisture present to act or otherwise increase their binding properties. Thus, before the second mixing device 400 forms the cohesive mixture, the second mixing device 400 and / or the second processing device 500 can be configured to add moisture to the dry fire retardant fiber mixture. Sufficient moisture can thus be added to the dry fire retardant fiber mixture, as needed or desired, such that the total moisture content in the dry fire retardant fiber mixture is between about 1% and about 20%. In some aspects, the added moisture content can serve to displace at least some solids content of the fire retardant solution from the surfaces of the cellulose fibers, or cells associated with them, in order to facilitate and intensify the interaction between the agent binder and the surfaces of cellulose fibers and / or associated cells.
    [0028] [028] In other respects, a conditioning device 700 can be provided, in which such conditioning device 700 can be configured to receive the wet mixture 275 and to keep the wet mixture 275 for at least a predetermined time, in order to allow that the fire retardant solution is at least partially absorbed by the cellulose fibers in the fiber mixture, before the second mixing device 400 forms the cohesive mixture 325 therefrom, or before the second processing device 500 slows down the moist mixture 275. In some cases, the first mixing device 300 and / or the second mixing device 400 can be configured to serve as the conditioning device 700, as needed or desired. In some aspects, keeping the mixture moist for a predetermined time, for example, for about 1 minute, or 1 hour, or more, can allow more of the solids content of the fire retardant solution to be absorbed by the cellulose fibers , and thus increase their fire retardant properties. In addition, the increased absorption of the solids content of the fire retardant solution by the cellulose fibers can result in less solids remaining on the surfaces of the cellulose fibers and, in turn, can facilitate or increase the interaction between the binding agent and the surfaces of the cellulose fibers.
    [0029] [029] Once the cohesive mixture 325 is formed, a forming device 800 can be implemented to form the cohesive mixture in a formed cellulose product 750. For example, the forming device 800 can be configured to form the cohesive mixture 325 in the formed cellulose product 750 by compressing the cohesive mixture to form a densified cellulose product, extruding the cohesive mixture to form a formed cellulose product, and / or shaping the cohesive mixture to form a formed cellulose product. The formed cellulose product 750 can in some cases be characterized as, for example, a oriented filament plate cellulose product, a medium density fiber board cellulose product, a particle board cellulose product, and / or an insulating plate cellulose product.
    [0030] [030] In some respects, the cellulose product 750 can be formed as a sheet having a desired length, width and thickness, or as a continuous sheet which is then subdivided into segments of a desired length. In some cases, the forming device 800 can be configured to wrap the cohesive mixture with one of a negative mold and a positive mold, so as to form a cellulose product having a surface that defines a negative impression from one of the mold negative and positive mold. That is, for example, several presses can be suitably patterned with a raised or lowered pattern such that the cellulose product formed will have a corresponding surface defining a negative impression of the pattern. One skilled in the art will also consider that the ability to manipulate the cohesive mixture in this manner indicates that the final shape of the cellulose product does not necessarily have to be in the flat shape, but can take any different shapes, contours and sizes than those described in this document.
    [0031] [031] In yet another aspect, it may be advantageous to be able to evaluate the formed cellulose product in order to determine or monitor its characteristics such that the forming process can be changed, as necessary, to provide a specific cellulose product formed as needed or desired. For example, in one case, apparatus 100 may additionally include an evaluation device 900 configured to evaluate an internal bonding resistance of the formed cellulose product. One skilled in the art will consider that such an evaluation device 900 may comprise a tensile strength test device or other suitable device having members capable of being attached to the opposite surfaces of a formed cellulose product test piece 750, wherein the failure of the live specimen provides an indication of the internal bond strength of the formed cellulose product. In such cases, a comparison device 950 can be configured to compare the evaluated internal bond strength to an acceptable internal bond strength for the formed cellulose product, where the acceptable internal bond strength can vary, as needed or desired. If the evaluated internal bond strength is less than the acceptable internal bond strength, a possible resolution may involve, for example, implementing a dilution device 1000 to dilute the fire retardant solution 250 used by the first mixing device 300 to form a mixture moistened to a second concentration of the solids content thereof, the second concentration being less than the first concentration, to increase the internal bond strength of the formed cellulose product 750. The dilution of the fire retardant solution in this way can, in some cases, promoting or otherwise facilitating uniform and complete dispersion of the solids content throughout the moist mixture, the absorption of the solids content by the cellulose fibers, and / or decreasing the solids content on the surfaces of the cellulose fibers. In other respects, if the evaluated internal bond strength is less than the acceptable internal bond strength, another possible resolution may involve, for example, implementing a 1050 binder adjustment device configured to increase an amount of the binder used for forming the cohesive mixture 325. Increasing the amount of the binding agent can thus increase the cohesiveness of the cellulose fibers within the cohesive mixture and thus increase the internal bond strength of the formed cellulose product.
    [0032] [032] In this regard, other factors such as, for example, keeping the mixture moist for a particular time before sliding the moist mixture or forming the cohesive mixture, as well as wetting the dry fire retardant fiber mixture before forming the cohesive mixing can also facilitate the intensification of the internal bond strength of the formed cellulose product. In some cases, any increase in internal bond strength can also be reflected in other characteristics of the formed cellulose product. For example, the increase in internal bond strength (IB) can also be achieved by improving the density, rupture modulus (MOR) and / or elastic modulus (MOE).
    [0033] [033] In a particular example, a formed cellulose product, in the form of a fiber board, was formed from empty fruit cluster fibers, the empty fruit bunches being first loosened in a heated hammer mill, and dry to a moisture content of about 10%. The resulting fiber mixture was then moistened with the fire retardant solution including diamonium phosphate as an active ingredient. The moistened fiber mixture was then maintained for a period of about an hour before being resonated with an isocyanate binder (MDI) and the fibers thus detached again in an unheated hammer mill. The cohesive mixture was then moistened with water before being pressed onto the fiber board comprising a formed cellulose product. The cohesive mixture was characterized as having about 10% of the fire retardant solution and about 18% of the binding agent (MDI). The resulting fiber board exhibited a density of 905 kg / m3, a MOR of 34.3 N / mm2, an EOM of 3341 N / mm2, an IB of 3.03 N / mm2, and a thick swelling (upon exposure to water) of 5.9%. In comparison, a conventional MDF-type general purpose board for use in dry conditions needs to have an IB of 0.55 N / mm2, a MOR of 20 N / mm2, an MOE of 2200 N / mm2 and a thickness swelling of less 12%. As an additional comparison, a Class 4 OSB plate for heavy load support applications in wet conditions needs to have an IB of 0.45 N / mm2, a MOR of between 15 N / mm2 and 28 N / mm2 (average 21.5 N / mm2), an EOM between 1900 N / mm2 and 4800 N / mm2 (average of 3350 N / mm2), and a thickness swelling of less than 12%.
    [0034] [034] In addition, in some cases, the cellulose product formed according to the aspects of the present invention, such as the previously observed empty fruit cluster fiber board product, may also exhibit other desirable and increased properties over those of the conventional fiber board products. For example, such cellulose products may exhibit "zero ignition" and / or "zero flame spread" when treated with the fire retardant solution (ie, instead of merely controlling flame spread, as in the case of a surface treatment of a product with a fire retardant). In another example, the treatment of the fiber mixture with the fire retardant solution can provide a more uniform and complete dispersion and distribution of the fire retardant solution within the formed cellulose product, thus increasing the fire resistance (flame spreading), as well as thermal barrier (thermal resistance / insulation) and / or other characteristics.
    [0035] [035] Many modifications and other aspects of the descriptions set out in this document will come to the mind of a person versed in the technique to which this invention belongs, taking advantage of the teachings presented in the preceding description and the accompanying drawings. For example, for a person skilled in the art the apparatus described here promptly leads to associated processes and methods for forming a fire resistant cellulose product as illustrated, for example, in Figure 2. More particularly, such methods may comprise processing cellulose fibers in a fiber mixture (block 1100), and form a moist mixture from the fiber mixture and a fire retardant solution, in which the paste has the substantial and evenly distributed fire retardant solution (block 1200), forming a cohesive mixture from a moist mixture and a binding agent (block 1300), and then forming the cohesive mixture in a cellulose product (block 1400).
    [0036] [036] In addition, in some cases, the formed cellulose product can be further processed, for example, to flatten certain surfaces of it, or to remove "breaks" or otherwise flatten the edges of the cellulose product. In such cases, apparatus 100 may also include a collection device (not shown), in which the collection device may be configured to capture solid waste from post-formation processing of the cellulose product. In these cases, the captured solid residues can be incorporated into other products (ie, blow insulation) while providing fire resistance properties for them, or recycled through inclusion in the cellulose fibers forming the fiber mixture.
    [0037] [037] In addition, in some cases, the first mixing device 300 may be configured to add and / or receive other substances / materials / chemicals suitable for addition to the fiber mixture. For example, the first mixing device 300 can be configured to receive a mold inhibitor; a water-repellent, waterproof, or otherwise water-resistant substance; and / or an insect deterrent such as glass particles, glass fibers, glass chips, broken glass, or any other suitable forms of glass elements, and / or a borate substance, in order to provide a deterrent of termites. In any case, it may be preferable that any additional substances received in the fiber mixture are suitably processed by the first mixing device 300 so that they are substantial, uniform and completely distributed and dispersed within the fiber mixture.
    [0038] [038] Additionally, one skilled in the art will consider that, in some aspects, the cohesive mixture can generally be prepared, and can then be formed, molded, or otherwise manipulated into various final products such as, for example, slabs, tiles composite, composite side tiles, Spanish style "red clay" composite tiles, electrical outlet enclosures, doors, inner wall boards, outer cladding, built-in cabinets, cupboards, composite cabinet door faces, flooring, laminate flooring, flooring clad composite, or the like. However, the exemplary final products presented here are not intended to be limiting in any way with respect to the wide variety of final products contemplated. Thus, the concept of general cohesive material can be extended to cases where the final product can be produced in many different ways such as, for example, by molding, extrusion, compression, stamping, or by any other suitable production method.
    [0039] [039] In addition, the general cohesive material can be provided as a component or other part of an additional final set, in such previous examples, such as laminate flooring and built-in cabinets. A person skilled in the art will thus consider that cellulose products formed in accordance with aspects of the present description can be produced such that the fire retardant solution is dispersed at least partially, if not consistently, and evenly in them. As such, the components of the final assembly, comprising a fire retardant cellulose product, may be susceptible to being totally fire resistant and / or unable to ignite on a more permanent basis (that is, provided that the fire retardant solution is effectively integrated with the cellulose product) compared to simple surface treatments that can be easily removed, washed or degraded over time.
    [0040] [040] Therefore, it should be understood that the descriptions should not be limited to the specific aspects described and that the modifications and other aspects are intended to be included within the scope of the present invention. Although specific terms are used in this document, they are used only in a descriptive and generic sense and not for the purpose of limitation.
    权利要求:
    Claims (14)
    [0001]
    Method for forming a board product based on fire resistant cellulose fibers, the method including processing cellulose fibers into a mixture of deconstructed fibers, the method being characterized by: form a moist mixture (275) from the mixture of deconstructed fibers (225) and a fire retardant solution (250) by saturating the mixture of deconstructed fibers (225) with the fire retardant solution (250), the retardant solution fire (250) having a first concentration of solids content including handling the wet mixture (275), so that the solids content of the fire retardant solution (250) is uniform and completely dispersed in it, and keeping the mixture moist (275) for at least a predetermined time, in order to allow the fire retardant solution (250) to be at least partially absorbed by the cellulose fibers in the deconstructed fiber mixture (225); slushing the moistened mixture (275) to form a dry fire retardant deconstructed fiber mixture (225) having a moisture content of between 1% and 3%; forming a cohesive mixture (325) from a binding agent (260) and the dry fire retardant deconstructed fiber mixture (225); forming the cohesive mixture (325) into a formed cellulose product (750) by compressing the cohesive mixture (325) to form a densified cellulose product; evaluate an internal bond strength of the formed cellulose product (750) using a tensile strength testing device; comparing the evaluated internal bond strength to an acceptable internal bond strength for the formed cellulose product (750); increasing the amount of binding agent (260) used to form the cohesive mixture (325), if the evaluated internal bond strength is less than the acceptable internal bond strength, or dilute the fire retardant solution (250) used to form the moist mixture (275), such that the fire retardant solution (250) includes a second concentration of the solids content, the second concentration being less than the first concentration of the solids content of solids, if the evaluated internal bond strength is less than the acceptable internal bond strength.
    [0002]
    Method according to claim 1, further characterized by: sliding one of the cellulose fibers and the deconstructed fiber mixture (225) before forming the moist mixture (275); add moisture to the dry fire retardant deconstructed fiber mixture (225), such that the dry fire retardant deconstructed fiber mixture (225) has a moisture content between 1% and 20%, before forming the cohesive mixture (325) , or recovering the excess fire retardant solution (250), in one of a liquid and a vapor form, by sliding the moist mixture (275) to form the dry fire retardant deconstructed fiber mixture (225), and add the recovered excess fire retardant solution (250) to the deconstructed fiber mixture (225) to form the moistened mixture (275).
    [0003]
    Method according to claim 1, characterized in that it processes cellulose fibers and forms a moist mixture (275) further comprising processing cellulose fibers and forming the moist mixture (275) without decontaminating one of the cellulose fibers and the fiber mixture deconstructed (225); or by processing cellulose fibers into a mixture of deconstructed fibers (225) further comprising processing one of raw wood pulp, palm waste, sugar cane waste, waste fiber, waste paper and waste board, each comprising fibers cellulose, in the mixture of deconstructed fibers (225).
    [0004]
    Method according to claim 1, further characterized in that the step of forming a moist mixture (275) additionally comprises: forming a paste from the mixture of deconstructed fibers (225) and the fire retardant solution (250); or form a moist mixture (275) from the mixture of deconstructed fibers (225) and a fire retardant solution (250) comprising one of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, a antimony compound, a borate compound, a halogenated compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, phosphate diamonium, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride, urea-potassium bicarbonate and combinations thereof.
    [0005]
    Method according to claim 1, characterized in that the step of de-wetting the moist mixture (275) to form a dry fire retardant deconstructed fiber mixture (225) further comprises: heat the moistened mixture (275) to form the dry fire retardant deconstructed fiber mixture (225), or dehydrating the moistened mixture (275); and drying the dehydrated moist mixture (275) to form the dry fire retardant deconstructed fiber mixture (225) having a moisture content of between 1% and 3%.
    [0006]
    Method according to claim 1, characterized by: forming a moistened mixture (275) further comprising forming a moistened mixture (275) from the mixture of deconstructed fibers (225) and one among an aqueous fire retardant solution, a non-toxic liquid fire retardant solution and a fire retardant solution neutral pH liquid fire; forming a cohesive mixture (325) further comprising forming a cohesive mixture (325) from the wetted mixture (275) and a binding agent (260) comprising one of a resin material and an adhesive material; forming the cohesive mixture (325) into a formed cellulose product (750) by compressing the cohesive mixture (325) to form a densified cellulose product further comprising extruding the cohesive mixture (325) or shaping the cohesive mixture (325); or wherein forming the cohesive mixture (325) in a formed cellulose product (750) further comprises forming the cohesive mixture (325) in one of an oriented filament plate cellulose product, a density fiber board cellulose product medium, a particle board cellulose product and an insulating board cellulose product.
    [0007]
    Apparatus for forming a board product based on fire resistant cellulose fibers, the apparatus including a first processing device (200) configured to process cellulose fibers into a mixture of deconstructed fibers (225), the apparatus being characterized by: a first mixing device (300) configured to form a moist mixture (275) from the mixture of deconstructed fibers (225) and a fire retardant solution (250) by saturating the mixture of deconstructed fibers (225) with the solution fire retardant (250), the fire retardant solution (250) having a first concentration of solids content including handling the wet mixture (275), so that the solids content of the fire retardant solution (250) is uniform and completely dispersed in it, and keep the mixture moist (275) for at least a predetermined time, in order to allow the fire retardant solution (250) to be at least partially absorbed by the cellulose fibers in the deconstructed fiber mixture (225) ; a second processing device (500) configured to de-wet the wet mixture (275) to form a dry fire retardant deconstructed fiber mixture having a moisture content of between 1% and 3%; a second mixing device (400) configured to form a cohesive mixture (325) from a binder (260) and the dry fire retardant deconstructed fiber mixture; a forming device (700) configured to form the cohesive mixture (325) in the formed cellulose product (750) by compressing the cohesive mixture (325) to form a densified formed cellulose product; a tensile strength test device (900) configured to evaluate an internal bond strength of the formed cellulose product (750); a comparison device (950) configured to compare the rated internal bond strength to an acceptable internal bond strength for the formed cellulose product (750); and a binding agent adjustment device (1050) configured to increase an amount of the binding agent (260), if the assessed internal bond strength is less than the acceptable internal bond strength, or a dilution device (1000) configured to dilute the fire retardant solution (250) used to form the moist mixture (275) such that the fire retardant solution (250) includes a second concentration of the solids content, the second concentration being less than the first concentration of the solids content, if the evaluated internal bond strength is less than the acceptable internal bond strength.
    [0008]
    Apparatus according to claim 7, characterized by: one of the first processing device (200) and the first mixing device (300) to be configured to de-scale one of the cellulose fibers and the deconstructed fiber mixture (225) before the first mixing device (300) forms the mixture moistened (275); the first processing device (200) and the first mixing device (300) are configured to process the cellulose fibers and to form a moist mixture (275), respectively, without decontaminating one of the cellulose fibers and the fiber mixture deconstructed (225); one of the second processing device (500) and the second mixing device (400) being configured to add moisture to the dry fire retardant deconstructed fiber mixture, such that the dry fire retardant deconstructed fiber mixture has a moisture content between 1% and 20%, before the second mixing device forms the cohesive mixture (325), or the first processing device (200) is configured to process one of raw wood pulp, palm waste, sugar cane waste, waste fiber, waste paper and waste board, each comprising cellulose fibers, in the mixture of deconstructed fibers (225).
    [0009]
    Apparatus according to claim 7, additionally characterized by a recovery device (600) configured to recover the excess fire retardant solution, in one of a liquid and a vapor form, to the second processing device (500) to be removed the mixture moistened to form the dry fire retardant deconstructed fiber mixture, and to add the excess fire retardant solution (250) recovered to the deconstructed fiber mixture (225) to form a moistened mixture (275).
    [0010]
    Apparatus according to claim 7, characterized in that the first mixing device (300) is configured to form the moist mixture (275) by forming a paste from the mixture of deconstructed fibers (225) and the fire retardant solution ( 250).
    [0011]
    Apparatus according to claim 7, characterized in that the first mixing device (300) is configured to form the wet mixture (275) from the mixture of deconstructed fibers (225) and a fire retardant solution (250) comprising one of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogenated compound, boric acid, an inorganic hydrate, a bromine compound, aluminum, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diamonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride and bicarbonate tetrachloride of the same.
    [0012]
    Apparatus according to claim 7, characterized in that the second processing device (500) is configured to: heating the moistened mixture (275) to form the dry fire retarded deconstructed fiber mixture; dehydrating the moistened mixture (275), and to dry the dehydrated moistened mixture (275), to form the dry fire retardant deconstructed fiber mixture (225) having a moisture content of between 1% and 3%.
    [0013]
    Apparatus according to claim 7, characterized in that the first mixing device (300) is configured to form a wet mixture (275) from the mixture of deconstructed fibers (225) and one among a fire retardant solution (250) aqueous, a non-toxic liquid fire retardant solution (250) and a neutral pH liquid fire retardant solution (250); or in that the second mixing device (400) is configured to form a cohesive mixture (325) from the wetted mixture (275) and a binding agent (260) comprising one of a resin material and an adhesive material.
    [0014]
    Apparatus according to claim 7, characterized in that the forming device (700) is configured to: forming the cohesive mixture (325) in the formed cellulose product (750) by compressing the cohesive mixture (325) to form a densified cellulose product, by extruding the cohesive mixture (325) or shaping the cohesive mixture (325), or forming the cohesive mixture (325) in one of an oriented filament plate cellulose product, a medium density fiber plate cellulose product, a particle plate cellulose product and an insulating plate cellulose product.
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    PT2663686T|2020-04-29|
    HRP20200576T1|2020-09-18|
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    US20130300015A1|2013-11-14|
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    CA2824699A1|2012-07-19|
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    MY164283A|2017-11-30|
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    法律状态:
    2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-05-07| B06T| Formal requirements before examination|
    2020-03-10| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application according art. 36 industrial patent law|
    2020-07-28| B09A| Decision: intention to grant|
    2020-12-01| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 13/01/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    PCT/CA2011/050013|WO2012094723A1|2011-01-13|2011-01-13|Method for forming a fire resistant cellulose product, and associated apparatus|
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