Patent ID: 7815772

Claim:
A process for manufacturing fiber board comprising the steps of: preparing a fiber slurry mixture by adding a material containing cellulose fibers to water and agitating the fiber slurry mixture; transferring the fiber slurry mixture to a spray chamber; heating a bituminous material to a temperature between 300 and 440 degrees F., wherein the bituminous material is in a liquid state; atomizing the liquid bituminous material within the spray chamber by mixing the liquid bituminous material with a pressurized gas, forming a mist comprising droplets of bituminous material having a diameter between 20 microns and 50 microns; solidifying the bituminous material droplets by spraying water into the mist thereby forming bituminous particles which fall into the fiber slurry within the spray chamber; shearing the slurry containing cellulose fibers and bituminous particles; dewatering the slurry containing cellulose fibers and bituminous particles, leaving a wet mat containing fibers and bituminous material; and drying the wet mat thereby forming a fiber board.