Method for forming a fire resistant cellulose product, and associated apparatus

Abstract

A method is provided for forming a fire resistant cellulose product. Such a method comprises processing cellulose fibers into a fiber mixture, and forming a slurry from the fiber mixture and a fire-retarding solution, wherein the slurry has the fire-retarding solution substantially uniformly distributed therethrough. The slurry is then formed into a cellulose product. An associated apparatus is also provided.

That which is claimed: 
     
         1 . A method of forming a fire resistant cellulose product, said method comprising:
 processing cellulose fibers into a fiber mixture;   forming a slurry from the fiber mixture and a fire-retarding solution, the fire-retarding solution comprising a neutral pH liquid including one of an inorganic hydrate, a bromine compound, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diammonium phosphate, and combinations thereof, the slurry having the fire-retarding solution substantially uniformly distributed therethrough; and   forming the slurry into a cellulose product.   
     
     
         2 . A method according to  claim 1 , wherein processing cellulose fibers into the fiber mixture further comprises processing one of waste paper and waste board, each comprising cellulose fibers, into the fiber mixture. 
     
     
         3 . A method according to  claim 1 , wherein forming the slurry further comprises adding water to the fiber mixture. 
     
     
         4 . A method according to  claim 1 , further comprising agitating the slurry so as to substantially uniformly distribute the fire-retarding solution therethrough. 
     
     
         5 . A method according to  claim 1 , wherein forming the slurry into the cellulose product further comprises:
 dewatering the slurry; and   drying the dewatered slurry to form the cellulose product.   
     
     
         6 . A method according to  claim 1 , wherein forming the slurry into the cellulose product further comprises compressing the slurry to form a densified cellulose product. 
     
     
         7 . A method according to  claim 1 , wherein forming the slurry into the cellulose product further comprises heating the slurry to form a dried cellulose product. 
     
     
         8 . A method according to  claim 1 , wherein forming the slurry into the cellulose product further comprises drying the slurry to form a substantially planar cellulose product having one of a thickness of between about 0.125 inches and about 2 feet, and a width of between about 1 inch and about 8 feet. 
     
     
         9 . A method according to  claim 1 , wherein forming the slurry into the cellulose product further comprises engaging the slurry with one of a negative die and a positive die, so as to form the cellulose product having a surface defining a negative impression of the one of the negative die and the positive die. 
     
     
         10 . A method according to  claim 1 , further comprising recovering excess fire-retarding solution, in one of a liquid and a vapor form, upon forming the slurry into the cellulose product. 
     
     
         11 . A method according to  claim 10 , wherein forming the slurry further comprises adding the recovered excess fire-retarding solution to the slurry, prior to forming the slurry into the cellulose product. 
     
     
         12 . A method according to  claim 1 , forming the slurry further comprises forming the slurry from the fiber mixture and one of an aqueous fire-retarding solution and a nontoxic liquid fire-retarding solution.