Patent ID: 8697586
Filing Date: 2014-04-15
Classification: B29C,B29K,B32B,B60R,C08J,C09D,D04H,D06N,E04B,Y10T

Abstract:
1. A fire retardant structural board for use in office structures and vehicle manufacturing, the structural board comprising of: an unrolled nonwoven structural mat of randomly-oriented natural fibers forming the body of the structural board; wherein the structural mat having a weight, first and second outer surfaces, first and second ends, first and second sides and a thickness; wherein the thickness of the structural mat is composed of the randomly-oriented natural fibers; wherein the nonwoven structural mat has a gram weight range of about 300 gsm to about 5,000 gsm; a polyester resin binder dispersed between individual natural fibers, inside and throughout the thickness of the structural mat; and wherein the nonwoven structural mat combined with the polyester resin binder form the characteristics of the structural board suitable for office structures and vehicle manufacturing; a powder borate fire retardant agent dispersed between individual natural fibers inside and throughout the thickness of the structural mat; wherein the mat is cured and calendared as part of forming the structural board wherein the calendaring determined the board's thickness and wherein the board is no longer a mat; a liquid based surface treatment of a fire retardant composition applied to at least the first outer surface of the cured mat to coat the first outer surface; wherein the fire retardant composition is applied separate to the powder borate fire retardant agent; wherein the fire retardant composition comprises a surfactant that breaks down surface tension post cure to support absorption of liquid into the natural fibers; and tetraborate pentahydride and a phosphate with about 30 percent solids; and wherein the fire retardant composition and fire retardant agent result in the board's flame spread and smoke developed index pursuant ASTM E-84 testing meet a Class A rating.