Method of manufacturing paper based honeycomb core wallboard panel

Abstract

The instant invention is directed to a boric and boron based fire resistant wall board panel and method of manufacture. The wall board panels are formed from a pair of sheet members which are parallel in alignment and a honeycomb core sandwiched between the sheet members. The inner surfaces of the sheet members are coated with an adhesive material and the honeycomb core is impressed into the adhesive layers.

What is claimed is: 
     
         1 . A process for forming a fire-resistant honeycomb wallboard structure comprising:
 creating a slurry of paper pulp by use of a hydrapulper;   inducing a forward cyclonic flow to remove heavier materials;   reverse the cyclonic flow to remove lighter materials;   thickening of said treated slurry;   admixing a concentration of boric acid and boron between about 7-25% with said thickened treated slurry;   inducing a forward cyclonic flow to remove heavier materials participated out by said admixing step;   spraying said treated slurry on a moving screen having a width to obtain a uniform thickness;   removing excess water from said treated slurry forming sheet of conditioned paper having a longitudinal length;   applying a plurality of glue bands to one side of said base sheet of conditioned paper, each glue band being relatively short compared to the length of said base sheet of conditioned paper and extending substantially the width of said base sheet of conditioned paper;   arranging an adjacent sheets of conditioned paper in a stacked relationship on top of said base sheet of conditioned paper having glue bands;   applying glue bands on each said adjacent sheet of conditioned paper being spaced apart in a staggered relationship such that the glue bands on each said adjacent sheet of conditioned paper are spaced midway between the glue bands on the previous sheet of conditioned paper;   expanding said stacked sheets of conditioned paper forming a honeycomb structure having individual core cells; and   securing said honeycomb structure between a first and second side sheet of conditioned paper to form a wallboard panel.   
     
     
         2 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 1  wherein the thickness of said wallboard panel is reduced along the longitudinal length. 
     
     
         3 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 1  wherein said step of removing excess water from said treated slurry to form a said conditioned sheet of paper creates a structure having about forty percent (40%) fiber and sixty percent (60%) water. 
     
     
         4 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 1  wherein boric acid and boron are fire retarding additives admixed between two to seven percent (7-25%). 
     
     
         5 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 4  wherein boric acid and boron is borax. 
     
     
         6 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 1  wherein said glue is a one component, solvent free, moisture curing, non-volatile urethane. 
     
     
         7 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 1  wherein said glue is a two component epoxy resin. 
     
     
         8 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 1  including the step of filling a plurality of honeycomb core cells. 
     
     
         9 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 8  wherein a plurality of core cells are filled with plaster. 
     
     
         10 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 9  wherein said filled core cells are marked with indicia to illustrate location. 
     
     
         11 . The process of forming a fire-resistant honeycomb wallboard structure according to  claim 1  including the addition of a phenolic resin to said slurry, whereby said phenolic resin provides waterproofing, insect resistance, and inhibits the growth of fungus and molds.