US4562218A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Formable pulp compositions
Assignee: Armstrong World Industries Inc
•
Filing: 1983-09-16
•
Granted: 1985-12-31
•
Expires: 2003-09-16
Abstract
Abstract The present invention concerns our discovery that aqueous cellulosic slurries comprising primary binder, newsprint, sulfite pulp, and vegetable shell flour can be prepared and formed as desired into various configurations. The materials thus formed are usable for a variety of purposes including furniture, paneling and flooring structures.
Inventors
- 👤 J. Stephen Fornadel
- 👤 Harry F. Long
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 04:35
CPC Classifications
D; D21; D21H; D21H13/00; D21H13/36; D21H13/38; D21H13/40; C; C04; C04B; C04B28/00; C04B28/02; D21C; D21C9/00; D21C9/001; D21C9/002; D21H11/00; D21H11/10; D21H17/00; D21H17/02; D21H17/20; D21H17/33; D21H17/34; D21J; D21J1/00; D21J3/00; D21J7/00; Y; Y10; Y10S; Y10S524/00; Y10S524/907; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31942; Y10T428/31949; Y10T428/31957; Y10T428/3196
Claims Analysis
Total Claims: 58
Claim 1
Independent Claim
60 words
A cellulosic composition useful to prepare articles having a desired configuration, said composition comprising by weight 100 parts of thermoplastic or theromostet primary binder, from about 25 to about 700 parts of newsprint, from about 25 to about 500 parts of sulfite pulp, from about 25 to about 500 parts of vegetable shell flour, and a suitable quantity of water.
Claim 2
Dependent Claim
60 words
A cellulosic composition useful to prepare articles having a desired configuration, said composition comprising by weight 100 parts of thermoplastic or theromostet primary binder, from about 25 to about 700 parts of newsprint, from about 25 to about 500 parts of sulfite pulp, from about 25 to about 500 parts of vegetable shell flour, and a suitable quantity of water.
Claim 3
Dependent Claim
51 words
The invention as set forth in claim 1 hereof wherein said composition comprises from about 50 to about 400 parts of newsprint, from about 50 to about 350 parts of sulfite pulp, and from about 50 to about 350 parts of vegetable shell flour for every 100 parts of primary binder.
Claim 4
Dependent Claim
32 words
The invention as set forth in claim 2 hereof wherein said composition comprises from about 90 to about 310 parts each of the newsprint, the sulfite pulp and the vegetable shell flour.
Claim 5
Dependent Claim
21 words
The invention as set forth in claims 1, 2 or 3 hereof wherein said composition comprises at least one secondary binder.
Claim 6
Dependent Claim
26 words
The invention as set forth in claim 4 hereof wherein said secondary binder is selected from the group consisting of powdered starch, cement, and polyvinyl alcohol.
Claim 7
Dependent Claim
26 words
The invention as set forth in claim 5 hereof wherein said cement is selected from the group consisting of portland cement, fondue cement and medusa cement.
Claim 8
Dependent Claim
18 words
The invention as set forth in claims 1, 2 or 3 hereof wherein said composition comprises reinforcing fibers.
Claim 9
Dependent Claim
16 words
The invention as set forth in claim 7 hereof wherein said reinforcing fibers are glass fibers.
Claim 10
Dependent Claim
27 words
The invention as set forth in claims 1, 2 or 3 hereof wherein said primary binder is a melamine binder, a urea-formaldehyde binder or a latex binder.
Claim 11
Dependent Claim
37 words
The invention as set forth in claim 9 hereof wherein said primary binder is a latex binder selected from the group consisting of polyvinyl chloride binders, polyacrylate binders, SBR binders, chlorinated SBR binders and carboxylated SBR binders.
Claim 12
Dependent Claim
20 words
The invention as set forth in claim 10 hereof wherein said primary binder is a self cross-linking acrylic latex binder.
Claim 13
Dependent Claim
48 words
A cellulosic product having a desired configuration, said product comprising by weight 100 parts of primary binder, from about 25 to about 700 parts of newsprint, from about 25 to about 500 parts of sulfite pulp and from about 25 to about 500 parts of vegetable shell flour.
Claim 14
Dependent Claim
48 words
A cellulosic product having a desired configuration, said product comprising by weight 100 parts of primary binder, from about 25 to about 700 parts of newsprint, from about 25 to about 500 parts of sulfite pulp and from about 25 to about 500 parts of vegetable shell flour.
Claim 15
Dependent Claim
51 words
The invention as set forth in claim 12 hereof wherein said product comprises from about 50 to about 400 parts of newsprint, from about 50 to about 350 parts of sulfite pulp, and from about 50 to about 350 parts of vegetable shell flour for every 100 parts of primary binder.
Claim 16
Dependent Claim
32 words
The invention as set forth in claim 13 hereof wherein said product comprises from about 90 to about 310 parts each of the newsprint, the sulfite pulp and the vegetable shell flour.
Claim 17
Dependent Claim
21 words
The invention as set forth in claims 12, 13 or 14 hereof wherein said product comprises at least one secondary binder.
Claim 18
Dependent Claim
26 words
The invention as set forth in claim 15 hereof wherein said secondary binder is selected from the group consisting of powdered starch, cement, and polyvinyl alcohol.
Claim 19
Dependent Claim
26 words
The invention as set forth in claim 16 hereof wherein said cement is selected from the group consisting of portland cement, fondue cement and medusa cement.
Claim 20
Dependent Claim
18 words
The invention as set forth in claims 12, 13 or 14 hereof wherein said product comprises reinforcing fibers.
Claim 21
Dependent Claim
16 words
The invention as set forth in claim 18 hereof wherein said reinforcing fibers are glass fibers.
Claim 22
Dependent Claim
27 words
The invention as set forth in claims 12, 13 or 14 hereof wherein said primary binder is a melamine binder, a urea-formaldehyde binder or a latex binder.
Claim 23
Dependent Claim
37 words
The invention as set forth in claim 20 hereof wherein said primary binder is a latex binder selected from the group consisting of polyvinyl chloride binders, polyacrylate binders, SBR binders, chlorinated SBR binders and carboxylated SBR binders.
Claim 24
Dependent Claim
20 words
The invention as set forth in claim 21 hereof wherein said primary binder is a self cross-linking acrylic latex binder.
Claim 25
Dependent Claim
23 words
The invention as set forth in claims 12, 13 or 14 hereof wherein said product comprises not less than about 45% cellulosic material.
Claim 26
Dependent Claim
20 words
The invention as set forth in claim 23 hereof wherein said product comprises not less than about 60% cellulosic material.
Claim 27
Dependent Claim
21 words
The invention as set forth in claim 24 hereof wherein said product comprises from about 73 to about 90% cellulosic material.
Claim 28
Dependent Claim
28 words
The invention as set forth in claims 12, 13 or 14 hereof wherein the density of said product is not less than about 10 lbs. per cubic foot.
Claim 29
Dependent Claim
22 words
The invention as set forth in claim 26 hereof wherein said density is not less than about 20 lbs. per cubic foot.
Claim 30
Dependent Claim
22 words
The invention as set forth in claim 27 hereof wherein said density is not less than about 30 lbs. per cubic foot.
Claim 31
Dependent Claim
110 words
A process for preparing cellulosic articles having a desired configuration, said process comprising the steps of preparing an aqueous slurry comprising by weight from about 25 to about 700 parts of newsprint, from about 25 to about 500 parts of sulfite pulp, from about 25 to about 500 parts of vegetable shell flour, and optional components; adjusting the pH as necessary to cause precipitation of a subsequently added thermoplastic or thermoset primary binder onto the solid components of said slurry; dispersing 100 parts of said primary binder in said slurry; disposing said slurry in a desired configuration; removing excess water to form a preshaped article; and drying said preshaped article.
Claim 32
Dependent Claim
110 words
A process for preparing cellulosic articles having a desired configuration, said process comprising the steps of preparing an aqueous slurry comprising by weight from about 25 to about 700 parts of newsprint, from about 25 to about 500 parts of sulfite pulp, from about 25 to about 500 parts of vegetable shell flour, and optional components; adjusting the pH as necessary to cause precipitation of a subsequently added thermoplastic or thermoset primary binder onto the solid components of said slurry; dispersing 100 parts of said primary binder in said slurry; disposing said slurry in a desired configuration; removing excess water to form a preshaped article; and drying said preshaped article.
Claim 33
Dependent Claim
51 words
The invention as set forth in claim 29 hereof wherein said slurry comprises from about 50 to about 400 parts of newsprint, from about 50 to about 350 parts of sulfite pulp, and from about 50 to about 350 parts of vegetable shell flour for every 100 parts of primary binder.
Claim 34
Dependent Claim
32 words
The invention as set forth in claim 30 hereof wherein said slurry comprises from about 90 to about 310 parts each of the newsprint, the sulfite pulp and the vegetable shell flour.
Claim 35
Dependent Claim
21 words
The invention as set forth in claims 29, 30 or 31 hereof wherein said slurry comprises at least one secondary binder.
Claim 36
Dependent Claim
26 words
The invention as set forth in claim 32 hereof wherein said secondary binder is selected from the group consisting of powdered starch, cement and polyvinyl alcohol.
Claim 37
Dependent Claim
26 words
The invention as set forth in claim 33 hereof wherein said cement is selected from the group consisting of portland cement, fondue cement and medusa cement.
Claim 38
Dependent Claim
18 words
The invention as set forth in claims 29, 30 or 31 hereof wherein said slurry comprises reinforcing fibers.
Claim 39
Dependent Claim
16 words
The invention as set forth in claim 35 hereof wherein said reinforcing fibers are glass fibers.
Claim 40
Dependent Claim
27 words
The invention as set forth in claims 29, 30 or 31 hereof wherein said primary binder is a melamine binder, a urea-formaldehyde binder or a latex binder.
Claim 41
Dependent Claim
37 words
The invention as set forth in claim 37 hereof wherein said primary binder is a latex binder selected from the group consisting of polyvinyl chloride binders, polyacrylate binders, SBR binders, chlorinated SBR binders and carboxylated SBR binders.
Claim 42
Dependent Claim
20 words
The invention as set forth in claim 38 hereof wherein said primary binder is a self cross-linking acrylic latex binder.
Claim 43
Dependent Claim
25 words
The invention as set forth in claims 29, 30 or 31 hereof wherein said dried preshaped article comprises not less than about 45% cellulosic material.
Claim 44
Dependent Claim
22 words
The invention as set forth in claim 40 hereof wherein said dried preshaped article comprises not less than about 60% cellulosic material.
Claim 45
Dependent Claim
23 words
The invention as set forth in claim 41 hereof wherein said dried preshaped article comprises from about 73 to about 90% cellulosic material.
Claim 46
Dependent Claim
30 words
The invention as set forth in claims 29, 30 or 31 hereof wherein the density of said dried preshaped article is not less than about 10 lbs. per cubic foot.
Claim 47
Dependent Claim
22 words
The invention as set forth in claim 43 hereof wherein said density is not less than about 20 lbs. per cubic foot.
Claim 48
Dependent Claim
22 words
The invention as set forth in claim 44 hereof wherein said density is not less than about 30 lbs. per cubic foot.
Claim 49
Dependent Claim
37 words
The invention as set forth in claims 29, 30 or 31 hereof comprising the additional steps of pulverizing said preshaped article, placing the pulverized material in a casting having a desired configuration, and molding said pulverized material.
Claim 50
Dependent Claim
19 words
The invention as set forth in claim 46 hereof wherein said preshaped article is chilled before it is pulverized.
Claim 51
Dependent Claim
30 words
The invention as set forth in claim 46 hereof wherein said casting is provided with a wood grain embossing plate which imparts a wood grain appearance to said final product.
Claim 52
Dependent Claim
82 words
A process for preparing cellulosic articles having a desired configuration, said process comprising the steps of preparing a master batch slurry comprising from about 25 to about 700 parts of newsprint, from about 25 to about 500 parts of sulfite pulp and from about 25 to about 500 parts of vegetable shell flour; forming said master batch slurry into a mat; intermixing said mat with optional components and 100 parts of primary binder; and forming the intermixed material into a desired configuration.
Claim 53
Dependent Claim
82 words
A process for preparing cellulosic articles having a desired configuration, said process comprising the steps of preparing a master batch slurry comprising from about 25 to about 700 parts of newsprint, from about 25 to about 500 parts of sulfite pulp and from about 25 to about 500 parts of vegetable shell flour; forming said master batch slurry into a mat; intermixing said mat with optional components and 100 parts of primary binder; and forming the intermixed material into a desired configuration.
Claim 54
Dependent Claim
51 words
The invention as set forth in claim 49 hereof wherein said slurry comprises from about 50 to about 400 parts of newsprint, from about 50 to about 350 parts of sulfite pulp and from about 50 to about 350 parts of vegetable shell flour for every 100 parts of primary binder.
Claim 55
Dependent Claim
32 words
The invention as set forth in claim 50 hereof wherein said slurry comprises from about 90 to about 310 parts each of the newsprint, the sulfite pulp and the vegetable shell flour.
Claim 56
Dependent Claim
35 words
The invention as set forth in claims 49, 50 or 51 hereof wherein said articles are prepared by drying and pulverizing said mat, and intermixing the pulverized material with said optional components and said binder.
Claim 57
Dependent Claim
79 words
The invention as set forth in claim 52 hereof wherein said intermixing is accomplished by preparing a slurry comprising said pulverized material and said optional components; adjusting the pH as necessary to cause precipitation of said primary binder onto the solid components of said slurry when said primary binder is subsequently added; dispersing said primary binder in said slurry; disposing said slurry in a desired configuration; removing excess water to form a preshaped article; and drying said preshaped article.
Claim 58
Dependent Claim
34 words
The invention as set forth in claim 52 hereof wherein said pulverized material, optional components and primary binder are intermixed in a dry state; placed in a casting having a desired configuration; and molded.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-12-30 | 1989-07-01 | 1989-12-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-12-30 | 1993-07-01 | 1993-12-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-12-30 | 1997-07-01 | 1997-12-31 | $7700.00 | Window Closed / Lapsed |