Paper pulping process and composition

Abstract

This is a method and composition for a paper pulp product used to create formable or moldable products from the paper pulp that cures with significant rigidity, stability and strength. The composition includes a mixture of raw paper, Portland Type 1, Class C fly ash, hydrated lime, perlite polyvinyl alcohol and water. Calcium lignosulfonate may be added to increase product strength and sodium citrate may be added to increase the working time of the pulp prior to curing. The pulp composition is particularly suitable to molding and can be used to manufacture picture frames, tile, small items of furniture and the like. The resulting product is highly suitable to art paper, arts and crafts but is also suitable for outdoor use as it is water and weather resistant. The process is extremely easy and results in a product that is highly adaptable for numerous uses.

What is claimed is: 
     
         1 . A process for creating a paper pulp composition, comprising the steps of:
 combining paper, and water to create a wet mix; combining Portland Type 1, fly ash, and hydrated lime to create a dry mix;   combining the wet mix and the dry mix together to create a slurry;   adding polyvinyl alcohol to the slurry;   mixing the slurry in a mixer to create a substantially uniform pulp; and   curing the pulp until dry.   
     
     
         2 . The process of  claim 1  adding a stabilizer to the slurry prior to mixing. 
     
     
         3 . The process of  claim 2  wherein the stabilizer is calcium lignosulfonate. 
     
     
         4 . The process of  claim 1  adding perlite to the dry mix. 
     
     
         5 . The process of  claim 1  adding sodium citrate to the dry mix. 
     
     
         6 . The process of  claim 1  adding perlite and sodium citrate to the dry mix. 
     
     
         7 . The process of  claims 1  further comprising the step of placing the pulp mixture into a mold prior to the step of curing. 
     
     
         8 . The process of  claim 1  further comprising the step of forming the pulp mixture prior to the step of curing. 
     
     
         9 . The process of  claim 8  wherein the pulp mixture is formed into dimensional pieces prior to the step of curing. 
     
     
         10 . The process of  claim 1  adding the step of tinting the slurry during the mixing step, by adding to the mixture a tinting agent selected from the group comprising: paint, varnish, bleach, natural coloring agents, and highlighting materials. 
     
     
         11 . A paper pulp composition comprising: from between approximately 18% and approximately 25% raw paper, from between approximately 20% and approximately 30% Portland Type 1, from between approximately 12% and approximately 20% fly ash, from between approximately 3% and approximately 6% hydrated lime, from between approximately 2% and approximately 4% perlite, from between approximately 0.5% and approximately 5% polyvinyl alcohol, and from between approximately 30% and approximately 60% water. 
     
     
         12 . The composition of  claim 11  further comprising from between approximately 0.1% and approximately 1% calcium lignosulfate. 
     
     
         13 . The composition of  claim 11  further comprising from between approximately 0.01% and approximately 0.03% sodium citrate. 
     
     
         14 . The composition of  claim 11  further comprising from between approximately 0.01% and approximately 0.03% sodium citrate and from between approximately 0.1% and approximately 1% calcium lignosulfate. 
     
     
         15 . A paper pulp composition comprising: approximately 21% raw paper, approximately 22.4% Portland Type 1, approximately 15% Class C fly ash, approximately 4.5% hydrated lime, approximately 3% perlite, approximately 1% polyvinyl alcohol, approximately 0.34% calcium lignosulfate, approximately 0.02% sodium citrate and from between approximately 32% and approximately 34% water.