AU2016102484A4 - Panel and method of producing a panel - Google Patents
Panel and method of producing a panel Download PDFInfo
- Publication number
- AU2016102484A4 AU2016102484A4 AU2016102484A AU2016102484A AU2016102484A4 AU 2016102484 A4 AU2016102484 A4 AU 2016102484A4 AU 2016102484 A AU2016102484 A AU 2016102484A AU 2016102484 A AU2016102484 A AU 2016102484A AU 2016102484 A4 AU2016102484 A4 AU 2016102484A4
- Authority
- AU
- Australia
- Prior art keywords
- panel
- rice straw
- rice
- phenolic resin
- bonded
- 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.)
- Active
Links
- 238000000034 method Methods 0.000 title claims description 24
- 235000007164 Oryza sativa Nutrition 0.000 claims abstract description 50
- 235000009566 rice Nutrition 0.000 claims abstract description 50
- 239000010902 straw Substances 0.000 claims abstract description 39
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000005011 phenolic resin Substances 0.000 claims abstract description 16
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 16
- 241000209094 Oryza Species 0.000 claims description 55
- 240000007594 Oryza sativa Species 0.000 abstract description 2
- 239000004566 building material Substances 0.000 abstract description 2
- 239000004035 construction material Substances 0.000 abstract description 2
- 238000000465 moulding Methods 0.000 abstract description 2
- 238000004519 manufacturing process Methods 0.000 description 9
- 238000001125 extrusion Methods 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 235000013339 cereals Nutrition 0.000 description 5
- 238000003306 harvesting Methods 0.000 description 5
- 241000196324 Embryophyta Species 0.000 description 4
- 230000006835 compression Effects 0.000 description 4
- 238000007906 compression Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000003973 irrigation Methods 0.000 description 3
- 230000002262 irrigation Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000002699 waste material Substances 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 235000013305 food Nutrition 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 239000002689 soil Substances 0.000 description 2
- 241000283690 Bos taurus Species 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 241001465754 Metazoa Species 0.000 description 1
- 244000184734 Pyrus japonica Species 0.000 description 1
- 241000282887 Suidae Species 0.000 description 1
- 239000002551 biofuel Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000000805 composite resin Substances 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 239000004459 forage Substances 0.000 description 1
- 239000010903 husk Substances 0.000 description 1
- 239000003621 irrigation water Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000010908 plant waste Substances 0.000 description 1
- 244000144977 poultry Species 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000001932 seasonal effect Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Classifications
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
Landscapes
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Forests & Forestry (AREA)
- Panels For Use In Building Construction (AREA)
Abstract
A panel is formed from rice straw compressed with a phenolic resin under conditions of
elevated temperature and pressure to thereby press or extrude the panel. The panel
disclosed is relatively light weight, mechanically strong, resistant to moisture, vermin
5 attack and damage and has a low level of flammability. The panel may be suitable as a
building and construction material for walls, floors, ceilings, tiles, architraves,
mouldings and/or cornices associated with structures such as houses, sheds, garages,
factories, commercial buildings and/or fences, although without limitation thereto.
10
2817034v1
Description
TITLE PANEL AND METHOD OF PRODUCING A PANEL TECHNICAL FIELD THIS INVENTION relates to a panel, such as a building panel. More particularly, this invention relates to a panel comprising rice straw bonded by a phenolic resin and a method for producing same. BACKGROUND Rice as a food source is the second largest crop grown around the world with annual production of approximately 471 million metric tonnes according to the USDA. For each tonne of grain harvested there is approximately the same amount of residual material left behind in the field and has to be removed prior to planting the next crop. One of the most common methods of removal is by burning the residual material, however this process progressively becoming unacceptable in many countries due to the effect on atmospheric pollution. Where rice growers seek to incorporate rice residues into the soil there is the potential of causing methane emissions that contribute to climate change. The consequence of reduced or eliminated burning of rice straw is that large amounts of the waste material needs to be applied to other uses. The other end uses include bedding and fodder for animals such as pigs, cattle or poultry and to a lesser extent biofuel production. SUMMARY The invention is directed to a new and economically valuable use of rice straw in a panel which may be used in a variety of applications in building and construction. A first aspect of the invention provides a panel comprising compressed rice straw bonded with a phenolic resin. A second aspect of the invention provides a method of producing a panel, said method including the step of compressing rice straw bonded with a phenolic resin to thereby produce the panel. A third aspect of the invention provides a panel produced by the method of the second aspect. A fourth aspect of the invention provides a structure comprising the building panel of the first or third aspects or produced according to the method of the second aspect.
2817034v1
Suitably, the rice straw is bonded with the phenolic resin at about 2-20%, 5-15%
or preferably about 10% by dry weight. Typically, bonding occurs for sufficient time
and at a suitable elevated temperature and pressure to ensure or facilitate completion of
the bonding reaction.
In one embodiment, compression is performed by a forming press. Suitably, the
forming press comprises one or more heating elements to provide an elevated
temperature suitable for bonding the rice straw and the phenolic resin.
In another embodiment, compression is achieved by extrusion. In one particular
embodiment, extrusion is by a screw press-equipped block press with an appropriately
shaped extruding dye for the profile required.
Unless the context requires otherwise, the terms "comprise", "comprises" and
"comprising", or similar terms are intended to mean a non-exclusive inclusion, such that
a recited list of elements or features does not include those stated or listed elements
solely, but may include other elements or features that are not listed or stated.
The indefinite articles 'a' and 'an' are used here to refer to or encompass
singular or plural elements or features and should not be taken as meaning or defining
"one" or a "single" element or feature.
DETAILED DESCRIPTION The invention provides a panel that comprises a rice straw, a by-product of rice
growing. The rice straw is compressed with a phenolic resin under conditions of
elevated temperature and pressure to thereby press or extrude a panel formed of the
cured, bonded rice straw. The panel disclosed herein is relatively light weight, mechanically strong, resistant to moisture, vermin attack and damage and has a low
level of flammability. The panel disclosed herein may also provide significant
environmental benefits by utilizing rice straw that would be burned or otherwise wasted
or discarded. The panel may be suitable as a building and construction material for
walls, floors, ceilings, tiles, architraves, mouldings and/or cornices associated with
structures such as houses, sheds, garages, factories, commercial buildings and/or fences,
although without limitation thereto.
In one aspect, the invention provides a panel comprising compressed rice straw
bonded with a phenolic resin.
2817034v1
In another aspect, the invention provides a method of producing a panel, said
method including the step of compressing rice straw bonded with a phenolic resin to
thereby produce the panel.
Yet another aspect of the invention provides a panel produced by the method of
the aforementioned aspect.
A further aspect of the invention provides a structure comprising the panel
disclosed herein.
It will be appreciated that the panel disclosed herein comprises rice straw
bonded with a phenolic resin.
As generally used herein "rice straw" refers to any vegetative part or portion of a
rice plant, inclusive of stems, leaves, leaf shoots, husks or any other part or portion of
the plant that is not a rice grain. Typically, the vegetative part or portion of the rice plant
is at least partly dehydrated or has reduced moisture content relative to the starting
vegetative plant material. Suitably, the rice plant is of the genus Oryza, preferably of the
species Oryza sativa inclusive of all varieties and cultivars such as the japonica and
indica varieties.
Suitably, the rice straw is obtained after rice grain harvesting. Rice fields are
selected for the straw to be utilised for panel production based on an absence of
significant weed contamination and/or uniformity of the field surface to thereby reduce
soil contamination of the harvested rice straw.
Typically, rice plants are mown or otherwise cut to reduce rice plant moisture
levels to less than 12% for harvest. Preferably, rice straw harvesting is performed using
a precision chop forage harvester that cuts the rice straw into lengths of about 5-20 mm
or preferably about 10-12 mm. However, it will be appreciated that the preferred lengths
of about 10-12 mm can be achieved by any harvesting procedure known in the art.
Suitably, the harvested rice straw is stored loosely under aerated conditions to
further reduce moisture levels to about 1-12%, 3-10 % or preferably 6-8% on a dry
weight basis. Storage may be for between 1 day and about 12 months.
Suitably, the harvested rice straw is further reduced in size to no more than
about 6-8mm in length. This may be achieved, for example, by hammering the rice
straw through a suitably sized orifice. The rice straw is then passed through a sieve or
filter (e.g. a "Cyclone" type machine) to remove dust and very fine particles.
The rice straw is then mixed with bonding resin. A suitable ratio of rice straw to
bonding resin is about 2-20%, 5-15% or preferably about 10% by dry weight.
2817034v1
Suitably, the bonding resin is a phenolic resin. A non-limiting example of a
phenolic resin is a phenolic formaldehyde resin.
Typically, bonding occurs for sufficient time and at a suitable elevated
temperature and pressure to ensure or facilitate the bonding reaction and curing of the
rice straw/resin composite.
In one broad embodiment, the rice straw is compressed during bonding to
thereby produce a "flat" panel. In this context "flat" means having substantially planar
surfaces. In a non-limiting example, such panels are typically 1200mm x 2400mm in
size.
In a preferred form of this embodiment, compression is performed by a forming
press. Suitably, the forming press comprises one or more heating elements to provide an
elevated temperature suitable for bonding the rice straw and the phenolic resin. A
preferred elevated temperature is in the range 150-250C, 180-220 0 C or more preferably
200 0C. The forming press may be fitted with pre-heated mandrels at a temperature such
as described above and the rice straw and bonding resin pressed for a period of about 3
12 minutes, 5-10 minutes or preferably 7-8 minutes to allow the elevated temperature
and pressure to facilitate the bonding reaction and curing of the rice straw/resin
composite. In some embodiments, heating may be delivered by heated oil flow through
the mandrels.
In another embodiment, compression is achieved by extrusion. Extruded panels
may be suitable for use as tiles or specialty shapes for applications such as skirting
boards or architraves. In one particular embodiment, extrusion is by a screw press
equipped block press with an appropriately shaped extruding dye for the profile
required. Heating may be delivered by heated oil flow through the extrusion chamber
of the extrusion tool. The temperature is preferably between about 200 to 2500 C.
The panel disclosed herein is relatively light weight, mechanically strong,
resistant to moisture, vermin attack and damage and has a low level of flammability.
The panel can be in any pressed or extruded form that can have a variety of applications
in building and construction such as wall panels, ceilings, roofing, doors, tiles, flooring,
architraves and cornices, although without limitation thereto. In some embodiments, the
panel may provide a relatively cheap and simple product that can be produced and used
by third world communities that produce significant amounts of rice straw as a result of
rice grain production.
The panel disclosed herein may also provide significant environmental benefits.
2817034v1
Rice production across the world is typified by a large number of small
producers who may on average grow only 4-5 hectares of rice a year. Some climates
allow for two crops per year with an overall production of 12-16T/ha from that area.
Increasing the value of production will improve the living standards of millions of rice
growers world wide. Agriculture uses approx. 70% of all water harvested from rivers,
streams and underground sources. There is an expectation that this water is managed in
a sustainable way in the production of food and fibre. Irrigation farmers are continually
seeking to improve the water usage efficiency on their farms as irrigation allocations
change with seasonal and other factor impact on the amount of water available to grow
crops. Improvements to irrigation methods such as laser grading fields and changes to
flow rates are examples. Another way to obtain more value from the crops grown is to
utilise more of the plant for other purposes opposed to just selling the grain. This
process leads to higher returns for irrigation water used. The present invention provides
a new way of utilizing rice straw, which would normally be burnt or otherwise disposed
of without any economic benefit to the producer.
Greater utilisation of the rice crop residue after harvest eliminates waste material
having to be managed before the next crop can be planted and adds value to the crop
income as well as reducing costs of handling waste material.
It is also noted that the use of rice straw in producing panels as disclosed herein
may reduce pollution derived from burning the rice straw, also with the potential to
attract carbon credits.
Throughout the specification the aim has been to describe the preferred
embodiments of the invention without limiting the invention to any one embodiment or
specific collection of features. It will therefore be appreciated by those of skill in the art
that, in light of the instant disclosure, various modifications and changes can be made in
the particular embodiments exemplified without departing from the scope of the present
invention.
2817034v1
Claims (10)
1. A panel comprising compressed rice straw bonded with a phenolic resin.
2. A method of producing a panel, said method including the step of compressing
rice straw bonded with a phenolic resin to thereby produce the panel.
3. A panel produced according to the method of Claim 2.
4. A structure comprising the panel of Claim 1 or Claim 3 or produced according
to the method of Claim 2.
5. The panel of Claim 1 or Claim 3, the method of Claim 2 or the structure of
Claim 4, wherein the rice straw is bonded with the phenolic resin at about 2-20%
or preferably about 10% by dry weight.
6. The panel, method or structure of Claim 5, wherein bonding occurs for sufficient
time and at a suitable elevated temperature and pressure to ensure or facilitate a
bonding reaction.
7. The panel, method or structure of Claim 6, wherein the temperature is about
150-250 0C or preferably about 2000 C.
8. The panel, method or structure of Claim 6 or Claim 7, wherein the time is about
5-10 minutes or preferably about 7-8 minutes.
9. The panel, method or structure of any preceding claim, wherein the panel is a
flat panel.
10. The panel, method or structure of any preceding claim, wherein the panel is an
extruded panel.
2817034v1
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2016102484A AU2016102484A4 (en) | 2016-07-25 | 2016-07-25 | Panel and method of producing a panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2016102484A AU2016102484A4 (en) | 2016-07-25 | 2016-07-25 | Panel and method of producing a panel |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2016102484A4 true AU2016102484A4 (en) | 2023-07-13 |
Family
ID=87103804
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2016102484A Active AU2016102484A4 (en) | 2016-07-25 | 2016-07-25 | Panel and method of producing a panel |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2016102484A4 (en) |
-
2016
- 2016-07-25 AU AU2016102484A patent/AU2016102484A4/en active Active
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN106519728A (en) | Biodegradable material prepared through secondary fermentation by taking mushroom dregs of edible mushrooms as seeds and preparation method thereof | |
| Shikangalah et al. | A review of bush encroachment in Namibia: from a problem to an opportunity? | |
| US10843374B2 (en) | System for and method of manufacturing hemp products | |
| JP2009165469A (en) | Medium for pineapple cultivation, and cultivation method for pineapple | |
| AU2017348278B2 (en) | System for and method of manufacturing hemp products | |
| WO2018018079A1 (en) | Panel and method of producing a panel | |
| AU2016102484A4 (en) | Panel and method of producing a panel | |
| Zied et al. | " Indoor" method of composting and genetic breeding of the strains to improve yield and quality of the almond mushroom Agaricus subrufescens. | |
| CN106922377A (en) | Implantation methods of the grey mushroom (abalonelike) in walnut forest land | |
| Zied et al. | Characteristics, production, and marketing of the sun mushroom: the new medicinal cultivated mushroom | |
| US20170042105A1 (en) | Integrated bamboo plantations with non-bamboo vegetation and bamboo | |
| Haldhar et al. | Population dynamics of lemon butterfly (Papilio demoleus) in Bael [Aegle marmelos] as influenced by abiotic factors in arid region of Rajasthan | |
| Patil et al. | Cotton plant stalk-an alternate raw material to board industry. | |
| Mihai et al. | Growing species Pleurotus ostreatus M 2175 on different substrates under household. | |
| Rishi et al. | Pest problems of some commercially important bamboo species in Assam, India | |
| Exconde | Potential hedgerow species for alley cropping systems in Philippine upland farms | |
| Mărăcineanu et al. | Analyses of the influence of crop load on biological and productive characteristics of some table grape varieties grown in the Severin vineyard. | |
| Tiwari et al. | Influence of weather parameters on population dynamics of rice leaf folder (RLF) in rice crop at Raipur district of Chhattisgarh | |
| KR20100056871A (en) | Method to manufacture plant growth regulator using peat moss | |
| Rathour et al. | Chapter-5 Bamboo as a Component of Secondary Agriculture | |
| Çoban | Effects of plastic covering on yield, physical and chemical characteristics of some table grapes (Vitis vinifera L.) | |
| NL2017805B1 (en) | Cultivation substrate material | |
| Szydło | Restoration of mixed forest | |
| CN110723931A (en) | Method for fully utilizing and recycling straws | |
| Olaiya et al. | Comparison of potential pod yield and loss in old and rehabilitated cocoa plots |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FGI | Letters patent sealed or granted (innovation patent) |