US20090114358A1

US20090114358A1 - Sawdust-reinforced pulp material and method of producing the same

Info

Publication number: US20090114358A1
Application number: US11/982,546
Authority: US
Inventors: Byung-Hoon Park
Original assignee: Elite Furniture Co Ltd
Current assignee: Elite Furniture Co Ltd
Priority date: 2007-11-02
Filing date: 2007-11-02
Publication date: 2009-05-07

Abstract

A sawdust-reinforced pulp material and its preparation method are herein disclosed Specifically, the method for preparing the sawdust-reinforced pulp material comprises the steps of: mixing 70% to 85% by weight of a pulp prepared from waste paper with 15% to 30% by weight of sawdust, based on the total weight of pulp and sawdust, to prepare a mixture of pulp and sawdust; blending the mixture with an adhesive in the weight ratio of 1:1; pouring the mixture blended with the adhesive into a mold to form a pulp material; and naturally drying the formed pulp material at an ambient temperature of 20 to 25 degrees C to produce the sawdust-reinforced pulp material.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to a reinforced pulp material and its preparation method. More specifically, the present invention relates to a sawdust-reinforced pulp material prepared from a mixture of pulp and sawdust or a mixture of pulp, sawdust and additive to increase the strength and moisture resistance of the material, and its preparation method.
2. Related Prior Art
Generally, packaging for electronic products, egg trays for supporting and protecting eggs, disposable and recyclable containers for picnic boxes, etc. which are made of synthetic resin are not environmentally friendly, and thus are now being made of environmentally friendly pulp.
A pulp mold is typically prepared in such a manner that, after being washed, a pulp is mixed with water to be dissolved, the mixture is stirred and is treated with chemicals, the resulting mixture is poured into a mold to form the pulp mold, and finally dried. In this case, in order to color the pulp mold, dye is added to a mixture of pulp and water.
However, a conventional pulp mold is susceptible to moisture absorption and has low strength. Thus, their applications are limited to packaging material for light-weight products such as electronic products or eggs. Further, there occurs a problem in that such pulp molds are disposable and thus wasted.

SUMMARY OF THE INVENTION

The present invention has been made in an effort to solve the above problems occurring in the prior art, and it is an object to provide a sawdust-reinforced pulp material prepared by using a mixture of pulp and sawdust or a mixture of pulp, sawdust and an additive composed of charcoal, yellow ocher, glass fiber, ceramic and silver to thereby have a deodorizing and antimicrobial effect, to radiate far infrared, to increase the strength of the material and to provide a moisture-proofing effect so that the lifespan of products is extended indefinitely, and to allow the extension of its application to the fields of sound-proofing material, roofing material, high strength protective material for transporting, etc.
To accomplish the above object of the present invention, a method of producing a sawdust-reinforced pulp material comprises the steps of: mixing 70% to 85% by weight of a pulp prepared from waste paper with 15% to 30% by weight of sawdust, based on the total weight of the pulp and the sawdust, to prepare a mixture of pulp and sawdust; blending the mixture with an adhesive in the weight ratio of 1:1; pouring the mixture blended with the adhesive into a mold to form a pulp material; and drying the formed pulp material at an ambient temperature of 20 to 25 ° C. to produce the sawdust-reinforced pulp material.
In the present method, the adhesive is a mixture of 80% to 90% by weight of water and 10% to 20% by weight of an environmentally friendly adhesive.
In another embodiment, the present method of producing a sawdust-reinforced pulp material comprises the steps of: mixing 60% to 70% by weight of a pulp prepared from waste paper, 15% to 20% by weight of sawdust and 5% to 10% by weight of an additive, based on the total weight of pulp, sawdust and additive, to prepare a mixture of the pulp, the sawdust and the additive; blending the mixture with an adhesive in the weight ratio of 1:1; pouring the mixture blended with the adhesive into a mold to form a reinforced pulp material; and naturally drying the formed pulp material at an ambient temperature of 20 to 25° C. to produce the sawdust-reinforced pulp material.
In the present method, the additive is a mixture of 30% to 50% by weight of charcoal powder, 20% to 25% by weight of yellow ocher powder, 15% to 20% by weight of glass fiber, 10% to 15% by weight of ceramic powder and 5% to 10% by weight of silver powder.
Another objective of the present invention is to provide an apparatus for preparing a sawdust-reinforced pulp material comprising: a means for mixing 70% to 85% by weight of a pulp prepared from waste paper with 15% to 30% by weight of sawdust, based on the total weight of pulp and sawdust, to prepare a mixture of the pulp and the sawdust, a means for blending the mixture with an adhesive in the weight ratio of 1:1, a means for pouring the mixture blended with the adhesive into a mold to form a pulp material; and a means for naturally drying the formed pulp material at an ambient temperature of 20 to 25 degrees C. to produce the sawdust-reinforced pulp material.
Further, other objective of the present invention is to provide the apparatus comprising, a means for mixing 60% to 70% by weight of a pulp prepared from waste paper, 15% to 20% by weight of sawdust and 5% to 10% by weight of an additive, based on the total weight.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the steps taken in carrying out the process of producing a sawdust-reinforced pulp material according to a first embodiment of the present invention.

FIG. 2 illustrates the steps taken in carrying out the process of producing a sawdust-reinforced pulp material according to a second embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, the present invention will be illustrated in detail with reference to the appended drawings.
Meanwhile, in case it is judged that a detailed description about the relevant function or construction commonly known in the art unnecessarily disturbs the understanding of the present invention, such a detailed description will not be included herein. The terms described below are defined in connection with the function of the present invention. The meaning of the terms may vary according to the user, the intention of the operator, usual practice, etc. Therefore, the terms should be defined based on the description rather than the specification.

Embodiment 1

FIG. 1 is a flow chart illustrating the preparation process of the sawdust-reinforced pulp material according to the first embodiment.
With reference to FIG. 1, the present method of producing a sawdust-reinforced pulp material comprises the step (S110) of mixing 70% to 85% by weight of a pulp prepared from waste paper with 15% to 30% by weight of sawdust, based on the total weight of the pulp and the sawdust, to prepare a mixture of pulp and sawdust; the step (S120) of blending the mixture with an adhesive in the weight ratio of 1:1; the step (S130) of pouring the mixture blended with the adhesive into a mold to form the reinforced pulp material; and the step (S140) of drying the formed, reinforced pulp material at ambient temperature of 20° C. to 25° C. to produce the dried reinforced pulp material, wherein the adhesive is a mixture of 80% to 90% by weight of water and 10% to 20% by weight of an environmentally friendly adhesive.
Hereinafter, the process is illustrated in detail with reference to FIG. 1.
First, waste paper (newspaper, magazine, milk packaging, etc.) is collected and, according to the conventional method, separated from foreign materials to remove them, bleached, and then dried, thereby obtaining the pulp to be used in the following step.
Then, finely powdered sawdust is mixed with the pulp so that the pulp is reinforced, wherein the sawdust and pulp can be easily mixed because they originate from the same source. Meanwhile, it is preferred that the powdered sawdust is processed with a magnet or the like to remove foreign materials such as metal.
The above pulp and sawdust are mixed in the ratio of 70% to 85% by weight of the pulp and 15% to 30% by weight of sawdust. To manufacture a soft product, 85% by weight of pulp and 15% by weight of sawdust are mixed, and to manufacture a hard product 70% by weight of pulp and 30% by weight of sawdust are mixed, which increases the strength of the material.
To the mixture of pulp and sawdust as prepared above is added an adhesive in the ratio of 1:1 of the mixture to the adhesive, wherein the adhesive is a mixture of 80% to 90% by weight of water with 10% to 20% by weight of an environmentally friendly adhesive. For the adhesive, it is preferred that the mixing ratio of water and the environmentally friendly adhesive is maintained within the above range.
Upon completion of blending the mixture of pulp and sawdust with the adhesive, the blend is inserted into a mold to form the reinforced pulp material and, subsequently, the molded and reinforced pulp material is dried naturally (that is, without using any drier) at an ambient temperature of 20° C. to 25° C., resulting in the end product of dried and reinforced pulp material. The process of drying can also be carried out with a drier.

Embodiment 2

FIG. 2 is a flow chart illustrating the preparation process of the sawdust, reinforced pulp material according to the 2nd embodiment.
With reference to FIG. 2, the present method of producing a sawdust-reinforced pulp material comprises the step (S210) of mixing 60% to 70% by weight of a pulp prepared from waste paper, 15% to 20% by weight of sawdust and 5% to 10% by weight of an additive, based on the total weight of the mixture, to prepare a mixture of pulp, sawdust and additive; the step (S220) of blending the mixture with an adhesive in the weight ratio of 1:1; the step (S230) of pouring the mixture blended with the adhesive into a mold to form a reinforced pulp material; and the step (S240) of drying the formed pulp material at an ambient temperature of 20° C. to 25° C. to produce the dried reinforced pulp material, wherein the additive is a mixture of 30% to 50% by weight of charcoal powder, 20% to 25% by weight of yellow ocher powder, 15% to 20% by weight of glass fiber, 10% to 15% by weight of ceramic powder and 5% to 10% by weight of silver powder, and wherein the adhesive is a mixture of 80% to 90% by weight of water with 10% to 20% by weight of an environmentally friendly adhesive.
Hereinafter, the process is illustrated in detail with reference to FIG. 2. First, waste paper (newspaper, magazine, milk packaging, etc.) is collected and, according to the conventional method, separated from foreign materials to remove them, bleached, and then dried, thereby obtaining the pulp to be used in the following step.
Then, finely powdered sawdust is mixed with the pulp so that the pulp is reinforced, wherein the sawdust and pulp can be easily mixed because they originate from the same source. Meanwhile, it is preferred that the powdered sawdust is processed with a magnet or the like to remove foreign materials such as metal.
The additive is a mixture of 30% to 50% by weight of charcoal powder for deodorizing and cleaning, 20% to 25% by weight of yellow ocher powder for radiating far infrared, 15% to 20% by weight of glass fiber for reinforcing the strength of the material and insulating against sound, 10% to 15% by weight of ceramic powder for radiating far infrared and 5% to 10% by weight of silver powder for an antimicrobial effect. The mixing ratio of each component can be freely changed within the range that is appropriate to the specific application field (for example, roofing material, floor material, soundproofing material, etc).
In a case where the charcoal powder is mixed in the amount of less than 30% by weight and the yellow ocher is mixed in the amount of less than 20% by weight, the effects of them are reduced. In case where the charcoal powder is mixed in the amount of more than 50% by weight and the yellow ocher is mixed in the amount of more than 25% by weight, the reinforced pulp material becomes heavy.
It is preferred that the length and width of the glass fiber is 5 to 25 mm and 20 to 100 μm, respectively. When the glass fiber is mixed in the amount of less than 15% by weight, the strength of the reinforced pulp material is reduced. When mixed in the amount of more than 20% by weight, the glass fiber is expelled from the mixture.
In a case where the ceramic powder is mixed in the amount of less than 10% by weight, its effect is reduced. In a case where the ceramic powder is mixed in the amount of more than 15% by weight, the color of the reinforced pulp material is changed and the material becomes heavy.
In a case where the silver powder is mixed in the amount of less than 5% by weight, its effect is reduced. In case where the silver is mixed in the amount of more than 10% by weight, the manufacturing cost is increased.
To manufacture a soft product, 70% by weight of pulp, 15% by weight of sawdust and 5% by weight of an additive are mixed. To manufacture a hard product, 60% by weight of pulp, 20% by weight of sawdust and 5% by weight of an additive are mixed, which increases the strength of the material.
To the mixture of the pulp, the sawdust and the additive as prepared above is added an adhesive in the ratio of 1:1 of the mixture to the adhesive, wherein the adhesive is a mixture of 80% to 90% by weight of water with 10% to 20% by weight of an environmentally friendly adhesive. For the adhesive, it is preferred that the mixing ratio of water and the environmentally-friendly adhesive is maintained within the above range of mixing.
Upon completion of blending the mixture with the adhesive, the blend is poured into a mold to form the reinforced pulp material and, subsequently, the molded and reinforced pulp material is dried naturally at an ambient temperature of 20° C. to 25° C., resulting in the end product of the dried and reinforced pulp material. The process of drying can also be carried out with a drier.
Therefore, since the reinforced pulp material of the present invention is prepared using a mixture of pulp and sawdust or a mixture of pulp, sawdust and an additive composed of charcoal, yellow ocher, glass fiber, ceramic and silver, the reinforced pulp material has light weight, high strength and improved resistance to water, which provides a long service life and, thus, can be used for diverse applications. Also, the reinforced pulp material has the environmental benefits of antibiotic activity, deodorizing, radiating far infrared and releasing anions.
As shown above, the present invention has a deodorizing effect, shows an antibiotic effect, radiates far infrared, increases the strength of the material and improves the moisture resistance, which extends the lifespan of the products thus prepared, and allows the applications to be extended to the fields of sound-proofing material, roofing material, protective material for transporting which requires high strength packaging material, etc.
While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention.

Claims

1. A method of producing a sawdust-reinforced pulp material, the method comprising the steps of:

mixing 70% to 85% by weight of a pulp prepared from waste paper with 15% to 30% by weight of sawdust, based on the total weight of pulp and sawdust, to prepare a mixture of the pulp and the sawdust;

blending the mixture with an adhesive in the weight ratio of 1:1;

pouring the mixture blended with the adhesive into a mold to form a pulp material; and

naturally drying the formed pulp material at an ambient temperature of 20 to 25 degrees C. to produce the sawdust-reinforced pulp material.

2. The method of claim 1, wherein the adhesive is a mixture of 80% to 90% by weight of water with 10% to 20% by weight of an environmentally friendly adhesive.

3. A method of producing a sawdust-reinforced pulp material, the method comprising the steps of:

mixing 60% to 70% by weight of a pulp prepared from waste paper, 15% to 20% by weight of sawdust and 5% to 10% by weight of an additive, based on the total weight of pulp, sawdust and additive, to prepare a mixture of the pulp, the sawdust and the additive;

blending the mixture with an adhesive in the weight ratio of 1:1;

4. The method of claim 3, wherein the additive is a mixture of 30% to 50% by weight of charcoal powder, 20% to 25% by weight of yellow ocher powder, 15% to 20% by weight of glass fiber, 10% to 15% by weight of ceramic powder and 5% to 10% by weight of silver powder.

5. An apparatus for preparing a sawdust-reinforced pulp material comprising:

a means for mixing 70% to 85% by weight of a pulp prepared from waste paper with 15% to 30% by weight of sawdust, based on the total weight of pulp and sawdust, to prepare a mixture of the pulp and the sawdust;

a means for blending the mixture with an adhesive in the weight ratio of 1:1;

a means for pouring the mixture blended with the adhesive into a mold to form a pulp material; and

a means for naturally drying the formed pulp material at an ambient temperature of 20 to 25 degrees C. to produce the sawdust-reinforced pulp material.

6. An apparatus of claim 5 further comprising: a means for mixing 60% to 70% by weight of a pulp prepared from waste paper, 15% to 20% by weight of sawdust and 5% to 10% by weight of an additive, based on the total weight of pulp, sawdust. and additive, to prepare a mixture of the pulp, the sawdust and the additive.