WO2016141389A1 - Systèmes et procédés de fabrication de panneaux de cellulose moulés sophistiqués - Google Patents

Systèmes et procédés de fabrication de panneaux de cellulose moulés sophistiqués Download PDF

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Publication number
WO2016141389A1
WO2016141389A1 PCT/US2016/021281 US2016021281W WO2016141389A1 WO 2016141389 A1 WO2016141389 A1 WO 2016141389A1 US 2016021281 W US2016021281 W US 2016021281W WO 2016141389 A1 WO2016141389 A1 WO 2016141389A1
Authority
WO
WIPO (PCT)
Prior art keywords
manufacturing
slurry
based composition
cellulose based
cellulose
Prior art date
Application number
PCT/US2016/021281
Other languages
English (en)
Inventor
Robert Noble
Original Assignee
Noble Environmental Technologies Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Noble Environmental Technologies Corporation filed Critical Noble Environmental Technologies Corporation
Priority to CN201680026269.4A priority Critical patent/CN107750293A/zh
Publication of WO2016141389A1 publication Critical patent/WO2016141389A1/fr
Priority to US15/691,511 priority patent/US20180127921A1/en

Links

Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J3/00—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/72—Coated paper characterised by the paper substrate

Definitions

  • the subject matter described herein relates generally to systems and methods of making manufacturing engineered cellulose based panels, and the products produced via these systems and methods.
  • building materials made of byproducts and associated manufacturing systems and methods for their production - forming cellulosic containing alloys or desired structural properties - including one or more of high tensile or compressive strength, water resistance, fire resistance or acoustically insulating.
  • the types of these building materials and associated manufacturing systems and methods for production are described in detail by way of various embodiments, which are only examples.
  • FIG. 1 is an illustration of a material manufacturing process and apparatus in accordance with the invention
  • FIG. 2 is an illustration of a material manufacturing process and apparatus in accordance with the invention.
  • FIG. 3 is an illustration of a material manufacturing process and apparatus in accordance with the invention including application of a second slurry
  • FIG. 4 A is a cross-sectional view of a curved manufactured product in accordance with the invention.
  • FIG. 4B is a cross-sectional view of a panel product in accordance with the invention.
  • FIG. 1 is an example embodiment of a material manufacturing process and end products. In the example embodiment numerous steps are shown which can be utilized in manufacturing a material, such as a building material. [017] Initially a composition, mixture or recipe as shown in FIG 1 can be used to create particular material slurry 10. This can be accomplished by combining desired material components in measured amounts, adding water or other appropriate liquid substances which can aid in entraining components in a slurry, and binding as a board is formed. The sluny may be input into a screen, tray or mixing table, as illustrated with reference number 20, which can have a flat surface in some embodiments or have predetermined or prefabricated shape in other embodiments.
  • a complementary press 30 as illustrated in FIG. 2 can then be applied to squeeze liquid out of the slurry by applying force in an appropriate direction, such as downward on an upward facing tray or screen, while retaining the material components in the tray or screen. Liquid can be squeezed out for example through holes, slits, or other appropriate cavities 40.
  • FIG. 3 After an appropriate period, which can be short in some embodiments, additional layers of slurry can be added and liquid pressed out, as illustrated in FIG. 3. As shown in FIG. 3, a first pressed portion is shown as reference number 50 and an additional layer of sluny is illustrated as reference number 60. Likewise, a second press may be used for a further pressing step. This second press is illustrated in FIG. 3 as reference number 70.
  • a resin or other agent optionally can be applied or infused which in some embodiments can serve as a fire retardant, sealing agent, solidification agent or other purpose before a final building material is finished.
  • Infusion of resin 80 to a pressed product 90 is illustrated in FIGS. 4A and 4B. Some steps described above can be done cold while others can require heating.
  • finished building materials can be a flat panel, side by side flat panels glued or otherwise adhered to a corrugated central component or can have slits in appropriate locations to provide flexibility or undulating surfaces.
  • Infusion of resin 80 in two examples of such product configurations 90 are illustrated in FIG. 4A for a shaped product, and FIG, 4B for a flat panel product.
  • At least five classes of material technology can be used in various embodiments with numerous combinations and permutations possible from there forming an alloy like end product containing various desired combinations of input materials.
  • One can be a raw material technology that can include fiber sources, preparations and alloys.
  • a second can be high strength engineered molded cellulose such as a fiber mix, with or without additives and with or without resin infusion.
  • a third can be water resistant engineered molded cellulose such as a fiber mix, with or without additives, and with or without resin infusion.
  • a fourth can be a fire resi stant engineered molded cellulose such as a fiber mix, with or without additives, with or without resins (such as by resin infusion) and coatings.
  • a fifth can be an acoustic engineered molded cellulose such as a fiber mix, additives, with or without resins (such as by resin infusion), specific geometric paneling and custom surface(s).
  • Fiber and material alloys can be created using a variety of fiber types providing specialized performance characteri tics and manufacturing efficiencies with at least one product performance enhancement. These can include natural paper based cellulose fibers, agricultural fiber, high strength and high performance mineral fibers, synthetic fibers, and hard materials. Natural paper based cellulose fibers can include recycled cardboard, recycled craft or kraft paper, recycled office paper, recycled newsprint and others. Agricultural fibers can include wheat straw, corn straw or silage, rice straw, cotton, hemp, kenaf, sugarcane bagasse, bamboo, and other fibers resulting from underutilized or waste streams as a result of agri-business or manufacturing processes. High strength and high performance mineral fibers can include glass fiber, carbon fiber, and others. Synthetic fibers can include various textile fibers. Hard materials can include coffee grounds, nut shells, husks, egg shells, glass beads, minerals and others.
  • the natural paper-based fiber sources can be mixed and introduced into a hydro pulping process, such as mixing the fiber and water to create a pulp, which is readied as a "base” for additional fiber and materials and next steps toward a forming and pressing process.
  • a hydro pulping process such as mixing the fiber and water to create a pulp
  • base for additional fiber and materials and next steps toward a forming and pressing process.
  • These can be used to comprise the base because they are commodities and are broadly available, and this base mix provides a ready source of materials and commercial use of waste or byproducts.
  • the synthetic, mineral and organic "performance fiber/materials” can be introduced into the pulp at a hydro pulper to be integral with the natural furnishing through forming and pressing stages of the manufacturing process, or can be introduced at later stages of the production process.
  • Agricultural fiber can be in chopped, raw or unprocessed form when integrated into the base pulp.
  • Various agricultural fiber textiles can be added in granulated or digested form directly into a base pulp.
  • Agricultural fibers can be laid on a pulp and form a wet mat after forming on a mold before the combination is entered into a hot press for final formation.
  • Agricultural fibers can also be laid on a finished panel before a resin is applied to bond the agricultural fibers to create finished panels.
  • High strength and high performance mineral and synthetic fibers such as glass fiber, carbon fiber and synthetic fibers can be in in chopped, raw or unprocessed form when integrated into the base pulp.
  • High strength and high performance mineral and synthetic fibers such as glass fiber, carbon fiber and synthetic fibers can be added in granulated or digested form directly into a base pulp.
  • High strength and high performance mineral and synthetic fibers such as glass fiber, carbon fiber and synthetic fibers can be laid on a pulp and form a wet mat after forming on a mold before the combination is entered into a hot press for final formation.
  • High strength and high performance mineral and synthetic fibers such as glass fiber, carbon fiber and synthetic fibers can be laid on a finished panel before a resin is applied to bond the agricultural fibers to create finished panels.
  • High strength and high performance mineral and synthetic fibers such as hard materials can be in hopped, raw or unprocessed form when integrated into the base pulp.
  • High strength and high performance mineral and synthetic fibers such as hard materials can be added in granulated or digested form directly into a base pulp.
  • High strength and high performance mineral and synthetic fibers such as hard materials can be laid on a pulp and form a wet mat after forming on a mold before the combination i s entered into a hot press for final formation.
  • High strength and high performance mineral and synthetic fibers such as hard materials can be laid on a finished panel before a resin is applied to bond the agricultural fibers to create finished panels.
  • Resin infusion on panels can be added to each of the embodiments listed above.
  • This post production process of resin infusion coupled with the fiber compositions and processes listed above can produce products, which have higher tensile strength and in some cases increased fire resistance. This can allow for an inexpensive and efficient processes for creating high- performance composites,
  • Hard materials can provide increased compressive strength and increased hardness and an ability to create a smoother services from sanding and polishing for variety of applications.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne des matériaux de construction constitués de sous-produits agricoles et d'autres sous-produits de cellulose et des procédés pour leur production. Lors de la production de ces matériaux, des alliages contenant de la cellulose sont formés en fournissant une suspension épaisse des sous-produits souhaités, asséchés par l'intermédiaire d'une presse à pression, facultativement grâce à de multiples étapes de pression et d'application de suspension épaisse. La presse présente facultativement des propriétés souhaitées, par exemple pour une modification acoustique du panneau obtenu. Des résines sont infusées dans les panneaux pour obtenir des propriétés souhaitées de résistance à l'eau ou d'autres propriétés.
PCT/US2016/021281 2015-03-05 2016-03-07 Systèmes et procédés de fabrication de panneaux de cellulose moulés sophistiqués WO2016141389A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CN201680026269.4A CN107750293A (zh) 2015-03-05 2016-03-07 制造经设计的模制纤维素板件的系统和方法
US15/691,511 US20180127921A1 (en) 2015-03-05 2017-08-30 Systems and methods of manufacturing engineered molded cellulose panels

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201562128967P 2015-03-05 2015-03-05
US201562128971P 2015-03-05 2015-03-05
US62/128,967 2015-03-05
US62/128,971 2015-03-05

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US15/691,511 Continuation US20180127921A1 (en) 2015-03-05 2017-08-30 Systems and methods of manufacturing engineered molded cellulose panels

Publications (1)

Publication Number Publication Date
WO2016141389A1 true WO2016141389A1 (fr) 2016-09-09

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PCT/US2016/021281 WO2016141389A1 (fr) 2015-03-05 2016-03-07 Systèmes et procédés de fabrication de panneaux de cellulose moulés sophistiqués

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US (1) US20180127921A1 (fr)
CN (1) CN107750293A (fr)
WO (1) WO2016141389A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6667841B1 (ja) * 2019-08-21 2020-03-18 株式会社Ｓａｍｕｒａｉ Ｔｒａｄｉｎｇ 繊維成形品の製造方法、繊維成形品
JP6829451B2 (ja) * 2020-07-30 2021-02-10 株式会社Ｓａｍｕｒａｉ Ｔｒａｄｉｎｇ パルプモールドの製造方法、パルプモールド

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6598700B1 (en) * 1999-04-15 2003-07-29 Ernest C. Schroeder Compression molded cellulose (CMC) loudspeaker cabinets and method for making same
US20050061463A1 (en) * 2003-09-22 2005-03-24 Scobie Michael A.N. Lignocellulose fiber-resin composite material
US20080160294A1 (en) * 2006-12-27 2008-07-03 United States Gypsum Company Multiple layer gypsum cellulose fiber composite board and the method for the manufacture thereof
US20090255205A1 (en) * 2008-03-28 2009-10-15 Robert Noble Engineered Molded Fiberboard Panels and Methods of Making and Using the Same
US20130292077A1 (en) * 2010-09-07 2013-11-07 Daniel Baroux Method for forming a fire resistant cellulose product, and associated apparatus

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101638874B (zh) * 2008-08-28 2013-06-12 陈集双 利用湿法工艺制备纤维墙板的方法

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6598700B1 (en) * 1999-04-15 2003-07-29 Ernest C. Schroeder Compression molded cellulose (CMC) loudspeaker cabinets and method for making same
US20050061463A1 (en) * 2003-09-22 2005-03-24 Scobie Michael A.N. Lignocellulose fiber-resin composite material
US20080160294A1 (en) * 2006-12-27 2008-07-03 United States Gypsum Company Multiple layer gypsum cellulose fiber composite board and the method for the manufacture thereof
US20090255205A1 (en) * 2008-03-28 2009-10-15 Robert Noble Engineered Molded Fiberboard Panels and Methods of Making and Using the Same
US20130292077A1 (en) * 2010-09-07 2013-11-07 Daniel Baroux Method for forming a fire resistant cellulose product, and associated apparatus

Also Published As

Publication number Publication date
CN107750293A (zh) 2018-03-02
US20180127921A1 (en) 2018-05-10

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