CA2637828A1 - Industrial hemp low-density fiberboard - Google Patents
Industrial hemp low-density fiberboard Download PDFInfo
- Publication number
- CA2637828A1 CA2637828A1 CA 2637828 CA2637828A CA2637828A1 CA 2637828 A1 CA2637828 A1 CA 2637828A1 CA 2637828 CA2637828 CA 2637828 CA 2637828 A CA2637828 A CA 2637828A CA 2637828 A1 CA2637828 A1 CA 2637828A1
- Authority
- CA
- Canada
- Prior art keywords
- low
- density fiberboard
- fiber
- panel
- industrial hemp
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
- D21J1/00—Fibreboard
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
Abstract
Disclosed is primarily the composition of, and secondarily a method for forming, a low--density fiberboard panel primarily utilizing the fiber derived from the agricultural product industrial hemp.
Uses for the panel include, but are not limited to, ceiling tile, insulation board, automotive interior finishes, and construction product core stock.
The panel is formed primarily from the agricultural product industrial hemp.
However sisal, flax, switchgrass, and other, agricultural products may be integrated within the product as supplemental agricultural fiber or filler as disclosed herein.
The low-density fiberboard originates as dry industrial hemp fibers which are then bound together by pulping, creating an aqueous slurry, then the slurry is directed to a forming box, tray, or die, removing the liquid, where felting of the material is forced by the utilization of heat, forced air, pressing, rolling, and other dewatering techniques to form the panel to the desired size and attributes.
Uses for the panel include, but are not limited to, ceiling tile, insulation board, automotive interior finishes, and construction product core stock.
The panel is formed primarily from the agricultural product industrial hemp.
However sisal, flax, switchgrass, and other, agricultural products may be integrated within the product as supplemental agricultural fiber or filler as disclosed herein.
The low-density fiberboard originates as dry industrial hemp fibers which are then bound together by pulping, creating an aqueous slurry, then the slurry is directed to a forming box, tray, or die, removing the liquid, where felting of the material is forced by the utilization of heat, forced air, pressing, rolling, and other dewatering techniques to form the panel to the desired size and attributes.
Description
Description The presented invention primarily relates to the usage of industrial hemp as the primary fiber in the making of a low-density fiberboard, as described herein, utilizing inherent natural binders and manipulating the natural characteristics of the fiber to bind the material together, and secondarily relates to the process of forming low-density fiberboards using industrial hemp as the primary fiber.
Backsround Fibrous low-density fiberboards are used for a variety of different purposes and are comprised from an array of different materials, fibers, binders, and fillers.
Presently, fibers used in ceiling tile and other low-density fiberboard may include a variety of wood products, mineral fibers, fiberglass and cellulosic material, and utilize various polymers as binding agents.
Synthetic polymeric materials such as styrene-acrylate lattices and polyethylene terepthalate mono-filament fibers have been used to bind mineral fiber-based articles together in currently available ceiling tile and other low-density boards in an effort to overcome the deficiencies of organic binders.
For example, one current method provides for disposing a surface charge of styrene-acrylate lattices onto cellulosic components of a mineral fiber panel during the wet formation process with subsequent drying serving to coalesce the latex and bind the fibers and particulates. A Further example includes attaching polymeric fibers and melted fiber particulates onto fiberglass by directing a stream of mono-filament high weight polymeric fibers into a hot stream of newly formed fiberglass, collecting the polymer treated fibers and then heat-forming into an article.
Backsround Fibrous low-density fiberboards are used for a variety of different purposes and are comprised from an array of different materials, fibers, binders, and fillers.
Presently, fibers used in ceiling tile and other low-density fiberboard may include a variety of wood products, mineral fibers, fiberglass and cellulosic material, and utilize various polymers as binding agents.
Synthetic polymeric materials such as styrene-acrylate lattices and polyethylene terepthalate mono-filament fibers have been used to bind mineral fiber-based articles together in currently available ceiling tile and other low-density boards in an effort to overcome the deficiencies of organic binders.
For example, one current method provides for disposing a surface charge of styrene-acrylate lattices onto cellulosic components of a mineral fiber panel during the wet formation process with subsequent drying serving to coalesce the latex and bind the fibers and particulates. A Further example includes attaching polymeric fibers and melted fiber particulates onto fiberglass by directing a stream of mono-filament high weight polymeric fibers into a hot stream of newly formed fiberglass, collecting the polymer treated fibers and then heat-forming into an article.
Another major category of fibrous panels includes panels made from fiberglass bound with a phenolic resin. Fiberglass is a relatively long continuous fiber compared to rock or slag mineral wools. An expensive scrim coat and paint are required to hide the yellow color, while also allowing acoustical permeation. Further, the phenolic resins traditionally employed to bind fiberglass batts have associated environmental problems.
The resins deposit on process equipment, requiring frequent shut-downs and cleaning or the equipment. Formaldehyde gas is evolved as the resin cures.
Current standard fibrous panel production utilizes combinations of fibers, fillers, bulking agents, binders, water surfactants and other additives. In these examples, for the most part, these panels are comprised of non-renewable and/or slowly renewable feedstock. As well, they introduce many environmental issues that emanate from the manufacturing through to the handling of the product.
Many fibrous low-density fiberboards are formed from mineral fiber and/or fiberglass.
The above examples of fiberboard contribute considerable negative environmental attributes including ongoing effluent from their processes and the introduction of non-decomposable materials into the product stream.
For the purposes of this invention, industrial hemp (Cannabis Sativa L) agricultural fiber is the majority composite fiber. It has been identified for this use because it is a resilient, lightweight, durable, highly cellulosic material that utilizes primarily natural or inherent binding agents, felts extremely well, and is a rapidly renewable resource with little or no environmental concerns.
The use of industrial hemp is well documented for many applications, however using sized fibers, as described herein, the creation of a low-density fiberboard of the appropriate and necessary dimensions and attributes creates a novel product.
Inherent cellulosic binders combined with the forced felting of the fibrous components when processed, as described herein, provide the structural rigidity and adhesion for the industrial hemp fiber low-density fiberboard.
The resins deposit on process equipment, requiring frequent shut-downs and cleaning or the equipment. Formaldehyde gas is evolved as the resin cures.
Current standard fibrous panel production utilizes combinations of fibers, fillers, bulking agents, binders, water surfactants and other additives. In these examples, for the most part, these panels are comprised of non-renewable and/or slowly renewable feedstock. As well, they introduce many environmental issues that emanate from the manufacturing through to the handling of the product.
Many fibrous low-density fiberboards are formed from mineral fiber and/or fiberglass.
The above examples of fiberboard contribute considerable negative environmental attributes including ongoing effluent from their processes and the introduction of non-decomposable materials into the product stream.
For the purposes of this invention, industrial hemp (Cannabis Sativa L) agricultural fiber is the majority composite fiber. It has been identified for this use because it is a resilient, lightweight, durable, highly cellulosic material that utilizes primarily natural or inherent binding agents, felts extremely well, and is a rapidly renewable resource with little or no environmental concerns.
The use of industrial hemp is well documented for many applications, however using sized fibers, as described herein, the creation of a low-density fiberboard of the appropriate and necessary dimensions and attributes creates a novel product.
Inherent cellulosic binders combined with the forced felting of the fibrous components when processed, as described herein, provide the structural rigidity and adhesion for the industrial hemp fiber low-density fiberboard.
It is presented that a flexible low-density fiberboard comprised primarily from environmentally friendly rapidly renewable material that can be molded and embossed, that meets certain criteria of acoustical absorbency, that can be colorized through the product, that possesses a smooth paint-able, emboss-able, laminate-ready surface, is highly desirable as a building and construction product.
Additionally, a panel that has a low sensitivity to moisture and requires no coating or back-coating systems to prevent the panel from sagging in a humid environment would also be desirable.
Furthermore, a panel as presented with the above attributes and developed for integration into current construction infrastructure and processes would be extremely desirable.
The presented invention provides primarily a composition and secondarily a method for forming a low-density fiberboard panel from an agricultural fiber.
Construction industry use is perceived as filler board, ceiling tile panel and acoustical board.
However uses have also been identified that include automotive mats, door skins, and construction product core material.
This original concept low-density fiberboard panel is to be formed from natural fibers that are mixed with water, agitated to pulp, and brought to an aqueous state.
The compound is then delivered to a forming box, deckle box, or other containment device where it is bound together by the prompting of the fiber to felt, and combined with natural inherent cellulosic binders, attains a semi-rigid state by the employment of heat, suction and airflow until the compound achieves the desired panel formation.
A second methodology may be employed in panel formation is that the panel may be pulped with water, then formed by the application of heat in the process of air-forming on wire belt as may be best explained through an understanding of Fourdrinier mechanizations.
Additionally, a panel that has a low sensitivity to moisture and requires no coating or back-coating systems to prevent the panel from sagging in a humid environment would also be desirable.
Furthermore, a panel as presented with the above attributes and developed for integration into current construction infrastructure and processes would be extremely desirable.
The presented invention provides primarily a composition and secondarily a method for forming a low-density fiberboard panel from an agricultural fiber.
Construction industry use is perceived as filler board, ceiling tile panel and acoustical board.
However uses have also been identified that include automotive mats, door skins, and construction product core material.
This original concept low-density fiberboard panel is to be formed from natural fibers that are mixed with water, agitated to pulp, and brought to an aqueous state.
The compound is then delivered to a forming box, deckle box, or other containment device where it is bound together by the prompting of the fiber to felt, and combined with natural inherent cellulosic binders, attains a semi-rigid state by the employment of heat, suction and airflow until the compound achieves the desired panel formation.
A second methodology may be employed in panel formation is that the panel may be pulped with water, then formed by the application of heat in the process of air-forming on wire belt as may be best explained through an understanding of Fourdrinier mechanizations.
In greater detail, this low-density fiberboard panel is primarily comprised of industrial hemp fibers. Additionally, the panel may also include other cellulosic material, coloring, and perlite and also may be coated or laminated with an organic coating or a scrim. The panel typically has a density of between about 3 lb./ft3 to about 201b./ft3 and an NRC
value of at least 0.45.
The primary method of forming this subject low-density fiberboard includes introduction and blending of water to a prepared agricultural fiber base component. The agricultural fiber base component is in the form of super-short fiber, and/or pulverized fiber, and/or powdered fiber, and/or fiber dust. By a process of agitating the mixture, the aqueous pulp slurry is prepared to an appropriate level of latency.
The slurry is applied to a forming mechanism, which may be either in the `deckle box', `die', or `Fourdrinier' methodology, where the slurry is formed to a desired thickness;
after which it is subjected to a process of press-rolling, heat-drying and vacuum mechanisms to achieve the appropriate properties required for use as a low-density fiberboard.
Detailed Description The presented invention provides both a composition and method for forming a low-density fiberboard.
The principal fiber component of this low-density fiberboard is agricultural fiber found in industrial hemp (Cannabis Sativa L). This low-density fiberboard is to have a thickness of one-half (0.5cm) centimeter to two-and-one-half (2.5cm) centimeters (0.5cm-2.5cm).
Thicker boards are also possible.
Generally, the dimensions of this low-density fiberboard is to be determined by the end-use as well as the technological capabilities of the manufacturing mechanization.
value of at least 0.45.
The primary method of forming this subject low-density fiberboard includes introduction and blending of water to a prepared agricultural fiber base component. The agricultural fiber base component is in the form of super-short fiber, and/or pulverized fiber, and/or powdered fiber, and/or fiber dust. By a process of agitating the mixture, the aqueous pulp slurry is prepared to an appropriate level of latency.
The slurry is applied to a forming mechanism, which may be either in the `deckle box', `die', or `Fourdrinier' methodology, where the slurry is formed to a desired thickness;
after which it is subjected to a process of press-rolling, heat-drying and vacuum mechanisms to achieve the appropriate properties required for use as a low-density fiberboard.
Detailed Description The presented invention provides both a composition and method for forming a low-density fiberboard.
The principal fiber component of this low-density fiberboard is agricultural fiber found in industrial hemp (Cannabis Sativa L). This low-density fiberboard is to have a thickness of one-half (0.5cm) centimeter to two-and-one-half (2.5cm) centimeters (0.5cm-2.5cm).
Thicker boards are also possible.
Generally, the dimensions of this low-density fiberboard is to be determined by the end-use as well as the technological capabilities of the manufacturing mechanization.
Composition fiber is to be generally sized between `0' and `5000' microns.
This will determine the `freeness' of the pulp to be used in the slurry described below.
Generally, the lower the `freeness' of the source fiber the stronger and smoother the board produced, while a higher `freeness' will produce a weaker board with a more dimpled surface and higher acoustical qualities.
Industrial hemp fiber, as described above, is mixed with water to create a pulp slurry and agitated for a period of time to reduce the latency of the fibers. Generally a pulp consistency of 1% - 5% can be employed, dependent upon the fiber quality and end-usage. Typical consistency of 2% is desirous for limiting surface inconsistencies and strong inter-felting of the component fiber. This provides a smooth finish and a higher tensile strength for the low-density fiberboard.
In the primary concept of forming the low-density fiberboard, the board will be formed within `dies', or `deckle boxes', subsequent to pulping. Once delivered to the `die' or `deckle box', the slurry is dewatered, conveyed to an area where it is heated and pressed until it achieves the desired attributes as it proceeds through the mechanization process.
A further embodiment may include a method where the fibers are dispersed and co-mingled in water, as above, and subsequently deposited and de-watered on a continuous wire conveyor with appropriate edge boundaries to contain the spread of the slurry. In a similar fashion to the primary concept, the material is then heated and pressed to the desired specifications.
In either embodiment, the low-density fiberboard may require further cold or hot compressing to maintain a consistent flat formation.
To provide fire-retardancy or reduce flame spread, the low-density fiberboard may contain agents that provide such assurance. These agents may include natural resins, colemanite or boric acid.
This will determine the `freeness' of the pulp to be used in the slurry described below.
Generally, the lower the `freeness' of the source fiber the stronger and smoother the board produced, while a higher `freeness' will produce a weaker board with a more dimpled surface and higher acoustical qualities.
Industrial hemp fiber, as described above, is mixed with water to create a pulp slurry and agitated for a period of time to reduce the latency of the fibers. Generally a pulp consistency of 1% - 5% can be employed, dependent upon the fiber quality and end-usage. Typical consistency of 2% is desirous for limiting surface inconsistencies and strong inter-felting of the component fiber. This provides a smooth finish and a higher tensile strength for the low-density fiberboard.
In the primary concept of forming the low-density fiberboard, the board will be formed within `dies', or `deckle boxes', subsequent to pulping. Once delivered to the `die' or `deckle box', the slurry is dewatered, conveyed to an area where it is heated and pressed until it achieves the desired attributes as it proceeds through the mechanization process.
A further embodiment may include a method where the fibers are dispersed and co-mingled in water, as above, and subsequently deposited and de-watered on a continuous wire conveyor with appropriate edge boundaries to contain the spread of the slurry. In a similar fashion to the primary concept, the material is then heated and pressed to the desired specifications.
In either embodiment, the low-density fiberboard may require further cold or hot compressing to maintain a consistent flat formation.
To provide fire-retardancy or reduce flame spread, the low-density fiberboard may contain agents that provide such assurance. These agents may include natural resins, colemanite or boric acid.
To provide coloration either on the surface of the low-density fiberboard or throughout the board material, pigments or dyes may be used. Additives may also be added to assist the panel in resisting color degradation.
To provide assurance of the performance of the panel in severe conditions, a water repellant may be employed.
The resulting panel after the step of consolidation is depicted in Figure 03.
In the consolidation step, the bonded material may be subjected to hot and cold pressing sequence. This serves to consolidate the material further. While smoothing and compressing the panel, an additional porous skin or scrim may be adhered to the panel, if desired.
Further forming and aesthetic design of the low-density fiberboard may be further enhanced through further processing or by the application of heat and/or pressure to the panel. This may include, but is not limited to, embossing any of the surfaces, laminating similar or other materials to any of the surfaces, or adhering other components to any of the surfaces.
To provide assurance of the performance of the panel in severe conditions, a water repellant may be employed.
The resulting panel after the step of consolidation is depicted in Figure 03.
In the consolidation step, the bonded material may be subjected to hot and cold pressing sequence. This serves to consolidate the material further. While smoothing and compressing the panel, an additional porous skin or scrim may be adhered to the panel, if desired.
Further forming and aesthetic design of the low-density fiberboard may be further enhanced through further processing or by the application of heat and/or pressure to the panel. This may include, but is not limited to, embossing any of the surfaces, laminating similar or other materials to any of the surfaces, or adhering other components to any of the surfaces.
Claims (16)
1. This low-density fiberboard is comprised of agricultural fibers, primarily industrial hemp, and secondarily materials from other groups of agricultural fiber, and combinations thereof.
2. The low-density fiberboard of Claim 1, wherein composition fiber is generally sized between '0' and '5000' microns.
3. The low-density fiberboard of Claim 1, wherein the fiber is mixed with water to create a pulp slurry and agitated for a period of time to reduce the latency of the fibers.
4. The low-density fiberboard of Claim 1, wherein the agricultural fiber forms a fiber board bound together by inherent components of the fiber and the forced felting of the fiber.
5. The low-density fiberboard of Claim 1, wherein the panel has an NRC value of at least about 0.45.
6. The low-density fiberboard of Claim 1, if required, may contain other natural cellulosic material, and additives.
7. The low-density fiberboard of Claim 1, wherein any additional cellulosic material is selected from a group consisting of newsprint, sisal, flax, switchgrass, and combinations thereof.
8. The low-density fiberboard of Claim 7, wherein the additional multi-component cellulosic fiber material comprises less than about 20% by weight of the panel.
9. The low-density fiberboard of Claim 1, wherein the industrial hemp agricultural fiber comprises from about 80% to 98% by weight of the panel.
10. The low-density fiberboard of Claim 1, further having a density of between about 3 lb/ft3 to about 20 lb/ft.3.
11. The low-density fiberboard of Claim 1, wherein the panel may have an embossed surface.
12. A method of forming an low-density fiberboard comprising the steps of pulping industrial hemp agricultural fiber to a desired slurry state then directing the slurry to a forming mechanism where it is dewatered and dried and formed to achieve appropriate thickness and strength and other desirous attributes.
13. The method of Claim 12, wherein sequential heating and cooling may allow for additional consolidation of the formed low-density fiberboard.
14. The method of claim 12, further comprising pressing the formed fibrous batt.
15. The method of claim 12, wherein the formed low-density fiberboard may be form cured.
16. A method of forming a low-density fiberboard as described in Claim 1, comprising the steps of:
-Providing industrial hemp fibers to be pulped in water;
-Dispersing and mixing the industrial hemp fibers in the aqueous mix to form wet fibrous formable slurry;
-Adding other agricultural fibers, if necessary,;
-Adding appropriate additives to provide coloration, water resistance, and fire retardancy elements, as needed.
-Dewatering and drying the wet fibrous batt to form a dewatered board, determined to be a low-density fiberboard.
-Finish the dewatered board to a state of readiness utilizing combinations of heat, air flow, and pressing.
- If required, further develop the finished board by laminations, colorizing, embossing, or other surface finishing techniques.
-Providing industrial hemp fibers to be pulped in water;
-Dispersing and mixing the industrial hemp fibers in the aqueous mix to form wet fibrous formable slurry;
-Adding other agricultural fibers, if necessary,;
-Adding appropriate additives to provide coloration, water resistance, and fire retardancy elements, as needed.
-Dewatering and drying the wet fibrous batt to form a dewatered board, determined to be a low-density fiberboard.
-Finish the dewatered board to a state of readiness utilizing combinations of heat, air flow, and pressing.
- If required, further develop the finished board by laminations, colorizing, embossing, or other surface finishing techniques.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2637828 CA2637828A1 (en) | 2008-08-11 | 2008-08-11 | Industrial hemp low-density fiberboard |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2637828 CA2637828A1 (en) | 2008-08-11 | 2008-08-11 | Industrial hemp low-density fiberboard |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2637828A1 true CA2637828A1 (en) | 2010-02-11 |
Family
ID=41668157
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2637828 Abandoned CA2637828A1 (en) | 2008-08-11 | 2008-08-11 | Industrial hemp low-density fiberboard |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2637828A1 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102179855A (en) * | 2011-04-07 | 2011-09-14 | 西南林业大学 | High-strength structural artificial board and manufacturing method thereof |
| CN102179856A (en) * | 2011-04-07 | 2011-09-14 | 云南工业大麻股份有限公司 | High-intensity shaving board and manufacturing method thereof |
| CN102179857A (en) * | 2011-04-07 | 2011-09-14 | 云南工业大麻股份有限公司 | High-strength fiberboard and manufacturing method thereof |
| CN102218758A (en) * | 2011-04-07 | 2011-10-19 | 西南林业大学 | High-strength light plate material and manufacture method thereof |
-
2008
- 2008-08-11 CA CA 2637828 patent/CA2637828A1/en not_active Abandoned
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102179855A (en) * | 2011-04-07 | 2011-09-14 | 西南林业大学 | High-strength structural artificial board and manufacturing method thereof |
| CN102179856A (en) * | 2011-04-07 | 2011-09-14 | 云南工业大麻股份有限公司 | High-intensity shaving board and manufacturing method thereof |
| CN102179857A (en) * | 2011-04-07 | 2011-09-14 | 云南工业大麻股份有限公司 | High-strength fiberboard and manufacturing method thereof |
| CN102218758A (en) * | 2011-04-07 | 2011-10-19 | 西南林业大学 | High-strength light plate material and manufacture method thereof |
| CN102179855B (en) * | 2011-04-07 | 2013-02-13 | 西南林业大学 | High-strength structural artificial board and manufacturing method thereof |
| CN102218758B (en) * | 2011-04-07 | 2013-02-13 | 西南林业大学 | High-strength light plate material and manufacture method thereof |
| CN102179857B (en) * | 2011-04-07 | 2013-02-13 | 云南工业大麻股份有限公司 | High-strength fiberboard and manufacturing method thereof |
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