US 7,906,176 B2Granted

Methods of manufacturing a fire retardant structural board

AssigneeFlexForm Technologies, LLC

InventorsGarry E. Balthes, Darrell R. Eggers, Gregg B. Baumbaugh

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Abstract

A fire retardant structural board is provided that includes a body of natural fibrous material, a triglycidyle polyester binder, a sodium borate pentahydride fire retardant, and a sodium borate pentahydride fire retardant. The body of natural fibrous material has a weight, first and second surfaces, first and second sides, and a thickness. The natural fibrous material and triglycidyle polyester are dispersed throughout the thickness of the body. The sodium borate pentahydride fire retardant is dispersed between individual natural fibers of the natural 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.

Claims8

Dependent claims

A method of manufacturing a fire retardant structural board, the method comprising the steps of:

(a) providing a structural mat constructed of randomly oriented natural 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 triglycidyl polyester binder and sodium borate pentahydride onto the first surface and into the thickness of the structural mat;
(d) heating the structural mat to only partially cure the binder appliedonto the first surface;
(e) turning the structural mat over to expose its second surface;
(f) applying a second application of triglycidyl polyester binder and sodium borate pentahydride onto the second surface and into the thickness of the structural mat;
(g) heating the second surface of the structural mat to cure the binderapplied onto the second surface and compressing the mat to a desired thickness;
and
(h) coating the second surface of the structural mat with a liquidcomposition that includes sodium borate penta hydride;
(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).

10 more elements

Dependencies are inferred from the claim text.

Facts

Application: 11/650,075Filed 5 Jan 2007 · continuation in part
Priority: 17 Dec 2004
Published: US 2007/0116991 A124 May 2007
Granted: 15 Mar 2011
Term ends: Not estimatedThe source records don’t support an estimate.

Classification66 codes

E04B 1/942
Building elements specially adapted therefor: slab-shaped
B29C 43/003
Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor: characterised by the choice of material
B29C 43/021
Of articles of definite length, i.e. discrete articles: characterised by the shape of the surface
B29C 43/222
Of articles of indefinite length: characterised by the shape of the surface

Family

Application60/637,020Us provisional application · filed 17 Dec 2004
Application11/305,745Parent of this continuation-in-part · filed 16 Dec 2005
US 2007/0116991 A1Pre-grant publication · published 24 May 2007
US 2006/0178064 A1Published application
US 8,012,889 B2Related patent
US 7,906,176 B2This patent

From the US filing history. Foreign family members aren’t listed.