Fiber-Wall-Filled Thin Hardboard from Low Cost Waste Paper

The objective of this proposal is the exploration of the feasibility of adapting the fiber-wall-filling technology to improve the properties of wet-process thin hardboard from low-cost waste paper. The patented fiber-wall-filling technology precipitates insoluble inorganic salts within the microporous anatomy of paper fibers. These inorganic depositions comprise the carbonates, silicates, sulfates, borates and phosphates of calcium. Preliminary experimentation has shown up to 30% of precipitated calcium carbonate can be deposited in waste paper fibers to produce a thin hardboard. A series of experiments will explore the effect of fiber-wall-filling on the properties of thin hardboard made from waste paper, with emphasis on fire retardancy. Dimensional stability, water resistance, and mechanical properties will be studied on promising combinations of inorganic substances, loading rate and fiber types. Process conditions and effluents will be monitored. The most promising candidates will be identified for a Phase II study in which larger samples will be prepared for studying the production economics for the most promising niche markets.