Methods of Making Fire Retardant Panel Compositions
AssigneeFlexForm Technologies, LLC
InventorsGarry E. Balthes, Darrell R. Eggers, Gregg B. Baumbaugh
Life of this patent
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Abstract
A fire retardant structural board is provided that includes a body of fibrous material, a triglycidyle polyester binder, a sodium borate pentahydride fire retardant, and a sodium borate pentahydride fire retardant. The body of fibrous material has a weight, first and second surfaces, first and second sides, and a thickness. The fibrous material and triglycidyle polyester are dispersed throughout the thickness of the body. The sodium borate pentahydride fire retardant is dispersed between individual fibers of the fibrous material and throughout the thickness of the body. A sodium borate pentahydride fire retardant composition also coats at least the first surface of the body.
Claims18
A method of manufacturing a fire retardant structural board, the method comprising the steps of:
- (a) providing a structural mat constructed of randomly oriented fibrous material having a weight, thickness, and first and second surfaces;
- (b) orienting the structural mat to expose its first surface;
- (c) applying a first application of at least one of polyester, epoxy resin, phenol resin, urethane or polypropylene binder and a fire retardant onto the first surface and into the thickness of the structural mat;
- (d) heating the structural mat to only partially cure the binder applied onto the first surface;
- (e) turning the structural mat over to expose its second surface;
- (f) applying a second application of the binder and the fire retardant onto the second surface and into the thickness of the structural mat;
- (g) heating the second surface of the structural mat to cure the binder applied onto the first and second surfaces and compressing the mat to a desired thickness;
- and
- (h) coating the second surface of the structural mat with a liquid fire retardant composition;
- (i) flash drying the liquid composition wherein the resulting fire retardant structural board having a class A burn rate certification as specified in the NFPA 101 life safety code or its equivalent;
- and
- (j) wherein steps are performed in sequential order:
- (a), (b), (c), (d), (e), (f), (g), (h), and (i).
A method of manufacturing a fire retardant structural board, the method comprising the steps of:
- (a) providing a structural mat constructed of randomly oriented fibrous material having a weight, thickness, and first and second surfaces;
- (b) orienting the structural mat to expose its first surface;
- (c) applying a first application of at least one of polyester, epoxy resin, phenol resin, urethane or polypropylene binder and a fire retardant onto the first surface and into the thickness of the structural mat;
- (d) heating the structural mat to only partially cure the binder applied onto the first surface;
- (e) turning the structural mat over to expose its second surface;
- (f), applying a second application of the binder and the fire retardant onto the second surface and into the thickness of the structural mat;
- (g) heating the second surface of the structural mat to cure the binder applied onto the first and second surfaces and compressing the mat to a desired thickness;
- and
- (h) wherein steps are performed in sequential order:
- (a), (b), (c), (d), (e), (f), and (g).
A method of manufacturing a fire retardant structural board, the method comprising the steps of:
- (a) providing a structural mat constructed of randomly oriented fibrous material having a weight, thickness, and first and second surfaces;
- (b) orienting the structural mat to expose its first surface;
- (c) applying a first application of a binder and a fire retardant onto the first surface and into the thickness of the structural mat;
- (d) heating the structural mat to only partially cure the binder applied onto the first surface;
- (e) turning the structural mat over to expose its second surface;
- (f) applying a second application of the binder and the fire retardant onto the second surface and into the thickness of the structural mat;
- (g) heating the second surface of the structural mat to cure the binder applied onto the first and second surfaces and compressing the mat to a desired thickness;
- and
- (h) wherein steps are performed in sequential order:
- (a), (b), (c), (d), (e), (f), and (g).
Dependencies are inferred from the claim text.