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(11) | EP 4 414 491 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | METHOD FOR THE PRODUCTION OF A SEMIFINISHED PRODUCT OF HEMP AND OF A PRODUCT MADE THROUGH SAID SEMIFINISHED PRODUCT AND RELATED SYSTEMS |
| (57) Method for the production of a semi-finished product (S) starting from hemp plants
comprising fibre and hemp shives. Said method comprising the following successive
steps: - creating a shapeless vegetable mass comprising fibre and hemp shives starting from hemp plant biomass; - executing a first selection phase on said shapeless vegetable mass, thereby obtaining a first product having a lower hemp shives percentage than said shapeless vegetable mass; - creating a nonwoven mat or felt having a known or desired thickness starting from at least said first product; - distributing at least one glueing agent in said mat or felt, thereby obtaining a basic product; - applying heat and pressure to said basic product, thereby obtaining said semi-finished product (S). |
[0001] The present invention relates to a method for producing a semi-finished hemp product at low production costs, from which a plurality of products can be manufactured. In addition, the present invention also relates to a system for the production of said semi-finished product. A further aspect of the present invention concerns a method for manufacturing products by using the semi-finished hemp product, and a system for manufacturing said products. Lastly, the present invention concerns a hemp product as such.
[0002] It is known that, in the last decades, the hemp industry has been the subject of renewed interest, without however any company operating in the mechanical and agricultural engineering fields having expressed the desire to invest in the planning and construction of a modern hemp processing plant.
[0003] As is known, hemp is a strong annual plant with a rigid, upright stalk, the height of which varies depending on the species or variety of the plant and on the habitat and method of cultivation.
[0004] A ripe hemp plant is composed of roots, stem, the latter including fibre, comprised in its external part or bark, and shives, the latter being the internal woody part of the stem, plus leaves, inflorescences and seeds. All parts of a hemp plant can be subjected to a number of processing operations to produce a very wide range of finished or semi-finished products that can be used for many applications. In particular, fibre and shives, when suitably processed, can be used as raw materials to give products for the building, paper, textile, breeding and plastic industries. It is known in the art that, before being processed and marketed, such raw materials must undergo accurate pre-transformation or pre-processing. In the current state of the art, such pre-transformation of hemp is aimed at separating, as accurately as possible, the fibre from the hemp shives in order to obtain a final product meeting specific quality and cleanliness standards. This aspect is particularly important, for example, for the production of high-quality fibre, wherein any residual traces of shives and dust have to be removed.
[0005] Specific industrial plants are known for pre-processing hemp straw. While such plants can effectively process hemp biomass for the production of high-quality, low-dust fibre and shives, they are not however immune to some criticalities that limit their diffusion on the market. The main causes are: high cost, since one such plant costs, on average, two million euros; and the profitability of such plants, which is bound to the availability of large amounts of hemp straw. By way of example, for a single plant to operate profitably, the estimated necessary hemp production would be at least one thousand cultivated hectares.
[0006] Another demand which is particularly felt in the field of industrial hemp concerns the possibility of counting on cultivations concentrated in areas as close as possible to the transformation plant; this is also due to the fact that, for the low unit values of hemp-based products to become profitable, production costs must be kept low, including those incurred for transporting the raw material, which, therefore, will have to be concentrated as much as possible in cultivations within an acceptable distance from the processing plant.
[0007] In light of the above, the possibilities of starting up a business dealing with the pre-transformation of hemp straw are nowadays very limited, because of the high investment costs incurred and, more generally, a widespread situation of economic and social crisis. Finally, it must be considered that the industrial hemp sector is just at its dawn. Therefore, competitors are few, the market is still underdeveloped, and a supply chain is essentially non-existent.
[0008] It is known that the various traditional industrial hemp processing plants differ according to the final product to be obtained, and hence according to the quality of the fibre that must be used. When producing objects requiring the use of fibres having particularly high quality and purity, it is necessary to resort to costly plants equipped with complex and advanced technologies. None of the industrial plants currently known for pre-processing the raw material makes use of simple machines, e.g. like those typically employed in agricultural farms, and this results in increased investment costs.
[0009] Furthermore, it must be pointed out that many useful characteristics have now been unanimously recognized in hemp fibre. In the first place, it is considered to be one of the strongest and toughest fibres. Also, it is resistant to ultraviolet rays, reflecting up to 950 of UV rays. It has sound-absorbing and insulating properties, and is resistant to fire and bacteria. Moreover, hemp is a bad electric conductor, is non-allergenic and antiseptic, and does not absorb odours. In addition to being an insulating material, by interacting with the indoor and outdoor atmosphere it can ensure a high level of thermal comfort within buildings, regulating the level of humidity therein.
[0010] It is known that insulating wool made of hemp fibre is, just like hemp panels, being increasingly appreciated by users, for both ecological and economical reasons. As a matter of fact, the costs incurred for disposing of hemp wool and panels are much lower than those necessary for insulating materials of mineral origin, in addition to reducing the health risks arising from their use.
[0011] Furthermore, hemp is known to improve soil quality; in fact, in addition to requiring small amounts of water, fertilizers, pesticides and herbicides, it contributes to improving the structure and fertility of the soil, which is beneficial for rotated crops. This is due to the fact that the fast growth, also depthwise, of the root apparatus of hemp, which can adapt itself to a wide variety of soil types, can slow down erosion, while at the same time enrichening the soil in terms of fertility and microbiotic contents. What is more, the harvest scraps left on the land constitute a fertilizer containing nutritional substances for the soil.
[0012] Lastly, methods are known for the production of semi-finished and finished products from coconut fibre. Such processes are focused on processing the coconut's exocarp and mesocarp, from which the fibre can be easily extracted. It is also known that, unlike hemp fibre, coconut fibre can be easily processed. Therefore, the methods and systems used for processing coconut cannot be employed for processing hemp, since hemp fibre is much stronger and would cause the machines used for processing coconut to fail.
[0013] Moreover, storage and preservation of the semi-finished products necessary for manufacturing the final products are still a problem in the current state of the art. In particular, there is an ever increasing demand for semi-finished products which can be easily stored and readily used for manufacturing final products.
[0014] In general, the present invention aims at solving these and other technical problems concerning the processing of hemp fibres, which have been partially described above, by providing a method for the production of a semi-finished hemp product which permits reducing the production costs, thus being profitable, and which can stimulate investments in this field and, more generally, give a valid contribution to relaunching hemp, which has a potential for many applications in many different places and climates on Earth, facilitated by the great adaptability of such plant to many different environmental contexts.
[0015] One aspect of the present invention concerns a method for the production of a semi-finished product having the features set out in the appended claim 1.
[0016] Another aspect of the present invention concerns a system for the production of a semi-finished product having the features set out in the appended claim 10.
[0017] A further aspect of the present invention concerns a method for manufacturing a product having the features set out in the appended claim 14.
[0018] A further aspect of the present invention concerns a system for manufacturing a product having the features set out in the appended claim 16.
[0019] Lastly, yet another aspect of the present invention concerns a product according to claim 18.
[0021] The features and advantages of the methods, systems and product will become clear and apparent in light of the following description of several possible embodiments and implementations thereof, provided herein by way of non-limiting example, as well as from the annexed drawings, wherein:
- Figure 1 shows a perspective side view of one possible embodiment of a drum sieve;
- Figures 2A and 2B show one possible embodiment of an opener; in particular, Figure 2A shows the opener in a side view, whereas Figure 2B shows the opener in a front view;
- Figures 3A, 3B and 3C show one possible embodiment of a press with an associated mould; in particular, Figure 3A shows a front view of the press with a mould; Figures 3B and 3C show the two shells of a mould for the production of a product in the form of a vase;
- Figures 4A and 4B show, by way of non-limiting example, said semi-finished product and said product; in particular, Figure 4A shows said semi-finished product;
[0022] With reference to the above-listed figures, the method according to the present invention is intended for the production of a semi-finished product "S" starting from hemp plants, which comprise fibre and shives. The method according to the present invention implies, therefore, the presence of both hemp fibre and hemp shives in the semi-finished product "S".
[0023] The method according to the present invention comprises the following successive steps:
- creating a shapeless vegetable mass comprising fibre and hemp shives starting from hemp plant biomass, preferably obtained from previously polled plants;
- executing a first selection phase on said shapeless vegetable mass, thereby obtaining a first product having a lower hemp shives percentage than said shapeless vegetable mass;
- creating a nonwoven mat or felt having a known or desired thickness starting from at least said first product;
- distributing at least one glueing agent in said mat or felt, thereby obtaining a basic product;
- applying heat and pressure to said basic product, thereby obtaining said semi-finished product "S".
[0024] The method according to the present invention makes it possible to obtain a semi-finished product "S" which can then be used to obtain many possible final products "P" at very low implementation costs, thus being profitable. Since the operating costs of the method described herein are very low, it is clear that high profitability can be gained from the semi-finished product "S", and hence from the product "P" obtained from said semi-finished product "S". In fact, the method starts by creating a shapeless mass, which is cheap. Moreover, said semi-finished product "S" is stable and easy to preserve, transport and store.
[0025] For the purposes of the present description, the term "shapeless mass" refers to a mass of hemp plant biomass, which comprises hemp shives, fibre, dust and other residues, such as inflorescence and/or seeds, distributed randomly in substantially the same percentages in which they are present in the hemp plant from which said shapeless mass is obtained.
[0026] More generally, the semi-finished product "S" obtained from the method according to the present invention is a composite material essentially comprising fibre, hemp shives and glueing agent.
[0027] The method for the production of the semi-finished product "S" according to the present invention permits the use of simple machines, which are easily available on the market at low cost, resulting in lower investment costs; as a matter of fact, the method according to the present invention even allows, as will be explained hereinafter, resorting to machines that are deemed to be obsolete, e.g. dating back to the first half of the 20th century.
[0028] In a preferred embodiment of the method, the step of executing a first selection phase on said vegetable mass is followed by a further step of: executing a second selection phase on said first product, thereby obtaining a second product with a flocked structure, wherein said second product has a lower hemp shives percentage than said first product. In the present implementation, the step of creating a nonwoven mat or felt having a known or desired thickness is carried out starting from said second product.
[0029] The present embodiment makes it easier to obtain a semi-finished product "S", since the step of creating a nonwoven mat or felt is faster and easier to carry out, in addition to giving a semi-finished product "S" with less imperfections, such as, for example, holes and/or uneven distribution. As a matter of fact, said second product is easier to manipulate, so that a more uniform and stable mat or felt can be obtained.
[0030] Without going into details about hemp plant cultivation techniques, the present description will just describe the procedures that are carried out at the end of the life cycle of hemp. A first operation that is advantageously executed prior to hemp harvesting is called polling, during which the apical parts of the plants, including inflorescences and seeds, are cut and optionally set apart for other commercial uses, which do not fall within the scope of the present invention.
[0031] In a preferred embodiment of the method according to the present invention, said step of creating a shapeless vegetable mass is carried out by shredding hemp plant biomass, preferably obtained from previously polled plants.
[0032] Biomass shredding may occur directly in the field on green or ripe plants. Also, the shredding operation may be executed either on a plant that has already been cut and laid on the ground, e.g. by means of a mower, or on a plant that is still in the upright condition. Furthermore, the shredding operation may be executed either after harvesting or after a maceration phase, preferably executed in the field, that follows the cutting of the plants.
[0033] The in-field maceration procedure will not be described in further detail herein, since it is known to a person skilled in the art.
[0034] In one possible embodiment of the method according to the present invention, said step of creating a shapeless vegetable mass is carried out starting from in-field macerated hemp plant biomass.
[0035] More generally, the biomass that remains in the field after polling, essentially consisting of the stems of the hemp plant, is what will be used for creating said shapeless vegetable mass. The shredding operation may be carried out by using one of the most basic and widespread agricultural implements, called shredder, which is normally used for removing weeds and vegetable residues, e.g. a self-moving shredder, a stalk shredder and/or a horizontal-axis shredder.
[0036] Alternatively, said step of creating a shapeless vegetable mass is carried out by using a biochipper, into which the stems of the hemp plants are inserted.
[0037] More generally, through said step of creating a shapeless vegetable mass one obtains a vegetable mass comprising fibre, hemp shives and dust.
[0038] More generally, the different methods of creation of the shapeless vegetable mass of hemp permit obtaining a semi-finished product "S" that may have different colours and different shive contents, and also different humidity levels.
[0039] Said shapeless vegetable mass may even be of very low quality, compared with a quality benchmark for fibre to be used in the textile industry. For example, said shapeless vegetable mass may even be non-marketable biomass, since the method according to the present invention does not require high quality from the raw materials, in particular fibre and hemp shives, to be used for making the semi-finished product "S" according to the present invention.
[0040] In a preferred embodiment of the method according to the present invention, said step of executing a first selection phase is carried out by means of a sieving machine. Even more preferably, said sieving machine is a drum sieve 3.
[0041] A drum sieve 3 is an extremely simple machine, which comprises a slightly inclined rotary grated drum 32 divided into sections (32A, 32B, 32C, 32D), wherein each section comprises grated walls with apertures 34, said apertures 34 having different diameters in each section. Preferably, the minimum diameter of apertures 34 is 15mm.
[0042] Sieving involves collecting the oversieve fraction at the end of grated drum 32, from which said first product will then come out, while the undersieve fraction is collected under grated drum 32 and includes dust, seeds and some hemp shives.
[0043] More generally, this step of the method according to the present invention executes a selection, in particular a sieving operation, e.g. a very rough sieving operation, wherein, for example, an incoming shapeless vegetable mass composed of approximately 70% of hemp shives and 200 of fibres, will leave in said first product up to 20% of the amount of hemp shives fed to the sieving machine. This step also permits removing from the fibre any excessively large woody shive parts, e.g. bigger than 15 mm. Furthermore, this step also permits removing dust and other residues, such as seeds.
[0044] The method according to the present invention is, therefore, particularly simple to implement, with reduced system costs, due to the fact that the use of a sieving machine makes it possible to reduce the implementation costs, while also being easy to use and service.
[0045] More generally, in the method according to the present invention the shapeless vegetable mass is subjected to a first selection, in particular through a sieving machine, which separates the fibre from part of the hemp shives, in addition to, advantageously, removing dust at least partly.
[0046] In a preferred embodiment of the method according to the present invention, said step of executing a second selection phase is carried out by means of an opener machine.
[0047] For the purposes of the present description, opener machine 4 is a machine capable of reducing into flocks a fibre-containing material. Said opener machine is, for example, an opener, a tearing machine and/or a tigering machine, such machines being normally employed for processing textile fibres like cotton, wool, etc. in order to open, brush and tear fibre and/or mesh or fabric. Opener machine 4 opens said first product to obtain flocks, which are then cleaned of any large impurities, such as, for example, dust, seeds and shive residues.
[0048] Preferably, said first product exiting the sieving machine is then processed by an opener machine 4 for textile applications.
[0049] More generally, this step of the method provides a second product that will be easier to process during the subsequent steps of the method for the production of the semi-finished product "S", by creating a nonwoven mat or felt resulting in a homogeneous, knotless semi-finished product "S". In fact, the second product coming out of opener machine 4 is soft, with a density similar to commercial cotton, and has no knots or balls that might hinder the next processing steps and phases for producing the semi-finished product "S" and for manufacturing products "P" according to the present invention. Moreover, the step of executing a second selection phase by opening said first product makes it possible to extract a further percentage of hemp shives that had remained in the fibre, in addition to removing further impurities, such as dust and seeds.
[0050] More generally, this optional step of the method for the production of a semi-finished product provides a second product having a greater volume than said first product, so that said second product can be better exploited to form the final semi-finished product "S" according to the present invention. In fact, from this step of the method one obtains a soft and loose second product that, being more malleable and ductile, can be handled more easily and can be spread into fibrous layers similar to mats or felts.
[0051] The second product is a product of higher quality or category than said first product, because it has more hemp fibre and less hemp shives.
[0052] In a preferred embodiment of the method for the production of a semi-finished product "S", said second product is used during the step of creating a nonwoven mat or felt. Since said second product is in flock form, i.e. with open fibre, one or more layers can be created in the form of mats or felts.
[0053] In general, during said step of creating a nonwoven mat or felt it is nevertheless possible to use said first product, being still able to create one or more layers in the form of mats or felts.
[0054] In one possible implementation of the present step, three stacked layers, equal in size and thickness, can be created to form a single three-layer mat or felt. As an alternative, said layers may have different thicknesses.
[0055] In the embodiment wherein two or more layers are created, the same layers are mutually superimposed to form said nonwoven mat or felt. Such superimposition permits creating a homogeneous nonwoven mat or felt composed of filaments of fibres and hemp shives more evenly distributed in both its surface and its volume, and having the desired dimensions. Even more preferably, said layers are mutually superimposed with the fibres of each layer disposed in a criss-cross pattern.
[0056] Preferably, said nonwoven mat or felt must have no knots and a homogeneous distribution of its components, in particular fibre and hemp shives, with an even thickness and no holes. This can be obtained, for example, by using said second product.
[0057] More generally, the step of creating a nonwoven mat or felt may be carried out either manually or by means of suitable machines capable of forming one or more layers, mats or felts. Such machines are per se known to a person skilled in the art.
[0058] The step of creating a nonwoven mat or felt is followed by the step of distributing at least one glueing agent in said mat or felt, thereby obtaining said basic product.
[0059] In a preferred embodiment of the method according to the present invention, said glueing agent is at least one of the following: natural latex; synthetic latex; glucose; maltose, and/or natural resins.
[0060] In a preferred embodiment of the method according to the present invention, said glueing agent is dispersed in a liquid solution. Alternatively, said glueing agent is in powder form.
[0061] In the embodiment of the method wherein said glueing agent is provided as a liquid solution, the distribution of the glueing agent in the nonwoven mat or felt occurs in accordance with at least one of the following methods: sprinkling; nebulization; brushwork; immersion; dripping; by roller or similar techniques. The above-listed methods are per se known to a person skilled in the art, and for this reason they will not be described in more detail herein.
[0062] More generally, the glueing agent causes the basic product, obtained by means of the method according to the present invention, to become a semi-finished product "S" according to the present invention, which in turn can then become a product "P" according to the present invention. In fact, the glueing agent ensures cohesion of the fibres and hemp shives, resulting in a solid structure, e.g. a composite material.
[0063] The selected type of glueing agent shall essentially depend on the type of semi-finished product "S" to be created and/or the type of product "P" to be manufactured using a semi-finished product "S" according to the present invention. By way of example, when an environmentally sustainable semi-finished product "S" and/or product "P" is to be made, any glueing agent of natural origin may be used, e.g. selected among those belonging to the glucose, maltose, resin or latex families.
[0064] This choice will also be dictated by the final destination of the semi-finished product "S" and/or product "P". In fact, each glueing agent has specific properties and will require compliance with specific application procedures to produce semi-finished product "S" and/or product "P".
[0065] By way of example, latex is an impermeable glueing agent. Furthermore, without referring to particular scientific theories, experiments and tests have shown that natural latex does not dry up, but coagulates following an increase in pressure. In this regard, for example, a temperature of 50°C on average, variable depending on the latex type, and an appropriate pressure, preferably in excess of 50 bar, e.g. ranging between 90 bar and 150 bar, e.g. between 100 bar and 140 bar, will be sufficient to obtain the reaction of the material. To the touch, a semi-finished product "S" and/or a product "P" obtained from a basic product comprising natural latex is rough and similar in density to rubber or silicone. Furthermore, the main property of latex glue is its flexibility; therefore, latex will produce elastic and versatile semi-finished products "S" and/or products "P", which will nevertheless maintain good characteristics of strength and resilience.
[0066] Synthetic latex, on the other hand, while it has the same qualities as natural latex, is, unlike the latter, smooth to the touch.
[0067] Glueing agents made from glucose and maltose syrups and/or powders, although they are resistant to water and moisture, are not impermeable. Without referring to any particular scientific theories, experiments and tests have shown that glueing agents made from glucose and maltose syrups and/or powders do not coagulate, as is the case of glueing agents belonging to the latex family, but react by drying up. The temperatures necessary for glueing agents belonging to the glucose and maltose families to dry up vary according to the type of glueing agent in use, but such temperatures are nonetheless higher than the temperatures required for latex, e.g. equal to or higher than 120°C. Semi-finished products "S" and/or products "P" produced by using these type of glueing agents are very stiff, hard and strong.
[0068] Referring back to the embodiments of the method wherein said glueing agent is provided as a liquid solution, the distribution of the glueing agent in the mat or felt may occur in accordance with the different methods described below, as a function of the dimensions of the basic product, the characteristics of the glueing agent, and the characteristics of semi-finished product "S" and/or product "P" to be obtained from the basic product. In particular, for semi-finished products "S" and/or products "P" that require the basic product to be particularly humid or the nonwoven mat or felt to be particularly thick, thus requiring in-depth penetration of the glueing agent, and/or to have any particular property, such as impermeability, or for products "P" and semi-finished products "S" intended for use in particularly humid environments or requiring the semi-finished product "S" to be particularly thick, it is advisable to adopt a method selected among immersion, brushwork and/or roller; on the other hand, when a specific spatial distribution is deemed appropriate, e.g. in some places only or more concentrated in other places, or on the surface only, and/or when a particular property is required, such as perception to the touch, or more generally when pursuing a reduction in the quantity of glueing agent, it is advisable to adopt a method selected from sprinkling; nebulization; and/or dripping.
[0069] The step of distributing at least one glueing agent is followed by the step of applying heat and pressure.
[0070] During this step, pressure and heat are applied to said basic product. The combination of fibre, hemp shives, glueing agent, pressure and heat will result in semi-finished product "S". This step triggers a reaction of the glueing agent, or at least part thereof, to obtain a desired semi-finished product "S", which will thus become a composite product.
[0071] Application of pressure and heat may occur through one or more machines, e.g. a press or one or more pressure rollers, under which the basic product is pressed. Such one or more machines may also apply heat, e.g. being said press or said roller heated to the desired temperature.
[0072] As an alternative, the step of applying heat and pressure comprises, in turn, two sub-steps, wherein during one sub-step heat is applied to the basic product, e.g. by a first machine, e.g. an oven, and during another sub-step pressure is applied, e.g. by another machine, like a press and/or one or more rollers.
[0073] Preferably, the basic product obtained after the step of distributing at least one glueing agent has substantially no knots, and fibre and hemp shives are distributed evenly therein, so that the application of heat and pressure to the basic product will cause the latter to arrange itself uniformly under the action of said one or more machines, so that homogeneous semi-finished products "S" can be obtained which will have no holes, no difference in thickness, flat walls, and the desired degree of rigidity. This aspect is particularly apparent in the embodiment wherein said basic product is made by using said second product.
[0074] The dimensions, times, temperatures, pressures, fibre types and glue types must be chosen as a function of semi-finished product "S" and/or product "P" to be made.
[0075] In a preferred embodiment of the method, said step of applying heat and pressure is carried out by means of a heated heavy roller, e.g. a calender, or by means of a heated mould press. The method for the production of semi-finished product "S" according to the present invention turns out to be easy to implement, requiring low system and material costs, and provides a ductile semi-finished product "S" that can be used for manufacturing a wide variety of different products "P".
[0076] Semi-finished product "S" thus obtained will still have a certain percentage of hemp shives, notwithstanding the selection phases it has been subjected to, in particular the sieving phase and, optionally, the opening phase. The presence of such residue will not jeopardize the making of semi-finished product "S" nor, as a consequence, the making of product "P".
[0077] As previously stated, semi-finished product "S" according to the present invention may have any thickness and size according to specific requirements.
[0078] More generally, said semi-finished product "S" looks like a panel, i.e. a flat element, wherein two dimensions prevail upon the third dimension, i.e. thickness, the stiffness of which will vary depending on its thickness, the amount of hemp shives, the glueing agent employed, the temperature and pressure applied, etc.
[0079] As required, and depending on the size of semi-finished product "S" in panel form, the latter will then be divided into sections for further processing, e.g. for manufacturing products "P", e.g. by means of a laser, a mould press, a blade, etc.
[0080] Figure 4A shows, by way of non-limiting example, two different possible embodiments of said semi-finished product "S". In particular, the portion that is visible on the left belongs to a semi-finished product "S" made starting from a shapeless vegetable mass obtained from in-field macerated hemp; conversely, semi-finished product "S" in the centre of the figure has a discoidal shape and is a semi-finished product "S" made starting from a shapeless vegetable mass obtained from hemp that was not macerated in the field.
[0081] The shapes, thicknesses and dimensions of semi-finished products "S" shown in Figure 4A are merely illustrative and non-limiting. What emerges from said Figure 4A is that such semi-finished products "S" have a panel-like planar structure with a desired degree of rigidity. In Figure 4A it is clearly visible that semi-finished product "S" comprises also, in addition to fibre, hemp shives that are easily identifiable.
[0082] The method for the production of a semi-finished product "S" is particularly suitable for implementation by means of a system for the production of a semi-finished product "S" according to the present invention. In fact, the system for the production of a semi-finished product "S" according to the present invention implements the method for the production of semi-finished product "S" according to the present invention.
[0083] The system for the production of a semi-finished product "S" comprises: a first selection device adapted to remove hemp shives from the shapeless vegetable mass, thereby obtaining a first product; and at least one machine adapted to apply heat and pressure to the basic product. In particular, said first selection device is a sieving machine; while said at least one machine is at least one heated roller and/or one heated press, preferably of the mould type.
[0084] Preferably, said system for the production of semi-finished product "S" comprises a second selection device adapted to remove hemp shives from said first product, thereby obtaining a second product having a flocked structure, wherein said second selection device is an opener machine 4.
[0085] One possible embodiment, which is merely illustrative and non-limiting, of the system for the production of a semi-finished product "S" according to the present invention comprises a shredder. Said shredder is adapted to produce a shapeless vegetable mass comprising fibre and hemp shives, starting from biomass of hemp plants, preferably polled beforehand.
[0086] In an alternative embodiment of the system for the production of a semi-finished product "S" according to the present invention, such system comprises a chipper.
[0087] Said sieving machine is preferably a drum sieve 3 comprising a support structure 30, a grated drum 32, in turn comprising an inlet aperture 3A and an outlet aperture 3B. Said grated drum 32 is rotatably mounted on said support structure 30 with its axis of rotation "R" inclined relative to a horizontal axis, particularly such that said inlet aperture 3A is lower than said outlet aperture 3B. Said grated drum 32 is divided into sections (32A, 32B, 32C, 32D). Each section (32A, 32B, 32C, 32D) has a plurality of apertures or holes 34 evenly distributed on the sidewalls of the cylindrical structure of the section of grated drum 32. The diameter, or equivalent diameter, of apertures or holes 34 in the various sections (32A, 32B, 32C, 32D) is different; in particular, the diameter of said apertures or holes 34 becomes progressively smaller going from the first section 32A, located at inlet aperture 3A, to the last section, e.g. fourth section 32D, located at outlet aperture 3B.
[0088] Said grated drum 32 is rotated about said axis of rotation "R" by an actuator 36, e.g. an electric motor, and a transmission system.
[0089] Figure 1 shows a perspective side view of one possible embodiment of a drum sieve 3. In Figure 1 grated drum 32 is arranged on the support structure 30 in a manner such that inlet aperture 3A remains lower than said outlet aperture 3B, and such that its axis of rotation "R" is inclined relative to a horizontal axis. Said grated drum 32 comprises four sections (32A, 32B, 32C e 32D), each one of which has apertures or holes 34 of different sizes. In particular, starting from the first section 32A located at said inlet aperture 3A, such section has apertures or holes 34 of greater diameter than those of the other sections (32B, 32C and 32D). On the contrary, fourth section 32D located at said outlet aperture 3B has apertures or holes 34 of smaller diameter than those of the other sections (32B, 32C and 32A) . More particularly, the diameter of said apertures or holes 34 decreases progressively from said first section 32A towards said fourth section 32D.
[0090] Said grated drum 32 is rotatably driven by an electric motor 36, which causes said drum to rotate about said axis of rotation "R".
[0091] The oversieve material will thus come out through outlet aperture 3B, while the undersieve material will come out gradually at the various sections (32A-32D) and will be collected into suitable containers.
[0092] Continuing the description of a preferred embodiment of the system for the production of semi-finished product "S", said opener machine 4 is an opener, a tearing machine or a tigering machine. Said opener machine 4 comprises a support structure 40 comprising a rotary spiked roller 42 placed inside a housing 41. Said housing 41 comprises an inlet aperture 41A, through which the first product is made to enter housing 41, and an outlet aperture 41B, through which the second product, in flock form, comes out.
[0093] Spiked roller 42 turns with high torque, so that, as it acts upon the hemp fibres, it can always decorticate and/or tear them, reducing them into thin filaments that will generate flocks, while at the same time not being subject to jamming because of the presence of hemp shives. Said spiked roller 42 is rotatably driven by an actuator 43, e.g. an electric motor.
[0094] Preferably, at inlet aperture 41A there are a series of squashing rollers 44 adapted to press and flatten the first product before it comes in contact with said spiked roller 42.
[0095] In one possible, but merely illustrative and non-limiting, embodiment, immediately downstream of said outlet aperture 41B of opener machine 4 there is a conveying and squashing device. Preferably, said conveying and squashing device can also stack layers of said second product. Preferably, said conveying and squashing device can also produce said nonwoven mat or felt.
[0096] Figures 2A and 2B show one possible embodiment of said opener machine, in the form of an opener 4. In particular, Figure 2A shows opener 4 in a side view, wherein a cover 410 of housing 41 is open to make visible the inside of housing 41, in particular spiked roller 42. In Figure 2A one can also see actuator 43, which rotatably drives, through belts and wheels, both said spiked roller 42 and a plurality of squashing rollers 44. Said squashing rollers 44, which include a conveyor belt, are arranged in proximity to inlet aperture 41A of said housing 41.
[0097] Figure 2B shows a front view of opener 4, illustrating further construction details of said opener 4, and particularly of spiked roller 42 and of squashing rollers 44.
[0098] More generally, a preferred embodiment of the system for the production of semi-finished product "S" according to the present invention comprises a conveying and squashing device which can produce said nonwoven mat or felt starting from said first product or, preferably, from said second product exiting opener 4. Said nonwoven mat or felt will have a desired thickness. The thickness and the dimensions of the nonwoven mat or felt shall depend on the characteristics of semi-finished product "S" and/or product "P" to be produced.
[0099] A preferred embodiment of the system for the production of a semi-finished product "S" according to the present invention includes a device for distributing the glueing agent in the nonwoven mat or felt. In one possible embodiment, said distribution device is a sprinkler; a nebulizer; at least one brush or roller; an immersion system; and/or a dripping system. Such implementations refer to glueing agents in the liquid phase.
[0100] If said glueing agent is solid, e.g. powder, said distribution device will be a shaker, a dispenser and/or a sifter.
[0101] More generally, depending on specific requirements, and particularly on the type of semi-finished product "S" and/or product "P" to be produced, said dispenser device shall be constructed as a function of the characteristics of the glueing agent to be used for obtaining desired semi-finished product "S".
[0102] In one possible, but merely illustrative and non-limiting, embodiment (not shown) of the system for the production of semi-finished product "S", at least said machine adapted to apply heat and pressure to the basic product is provided in the form of one or more heated rollers capable of squashing said basic product and simultaneously applying heat. Alternatively, said machine is a heated press, preferably a mould press.
[0103] The pressure and heat applied to the basic product by the machine are such as to cause the glueing agent, or at least part thereof, to react, e.g. to coagulate, dry up and/or solidify, in order to produce semi-finished product "S".
[0104] In some possible embodiments, said one or more heated rollers are calenders for textile use. Said calenders for textile use comprise one or more heated cylinders or rollers which can compress and apply heat to said basic product. Said calender for textile use will not be described any further herein, since it is known to those skilled in the art.
[0105] In one possible, but merely illustrative and non-limiting, embodiment (not shown) of the system for the production of a semi-finished product "S", there are conveyor belts and/or conveyors which can move the shapeless vegetable mass, the first product and (optionally) the second product, the nonwoven mat or felt, and said basic product towards the various machines and devices included in the system for the production of semi-finished product "S".
[0106] As aforementioned, a further aspect of the present invention concerns a method for manufacturing a hemp product "P", comprising the following steps:
- providing a semi-finished hemp product "S" according to the present invention;
- providing a mould "M" having the shape of desired product "P";
- providing a press 6;
- positioning mould "M" in press 6;
- arranging semi-finished product "S" in mould "M";
- activating press 6;
- removing product "P" from mould "M".
[0107] The method for manufacturing hemp products "P" exploits semi-finished product "S" obtained by following the method for the production of a semi-finished product "S" according to the present invention.
[0108] Said semi-finished product "S", obtained after pressing and heating the basic product, will then undergo the action of press 6, through mould "M", to give desired product "P".
[0109] In a preferred implementation, said steps of arranging semi-finished product "S" in mould "M"; activating press 6; and removing product "P" from mould "M" are repeated cyclically, e.g. until all semi-finished product "S" has been used up and/or the desired number of products "P" has been reached.
[0110] More generally, in order to become a three-dimensional product "P", semi-finished product "S" undergoes the action of press 6 through a mould "M" that may be of any type and may have any shape. The pressing operation carried out through the use of a three-dimensional mould will provide product "P" according to the present invention.
[0111] More generally, the method for manufacturing a product "P" involves transforming semi-finished product "S", which is substantially two-dimensional, into an object that may be three-dimensional.
[0112] Depending on product "P" to be obtained and semi-finished product "S" used for manufacturing said product "P", said semi-finished product "S" will undergo a different action of press 6, through mould "M", and heat may optionally be applied thereto to obtain desired product "P".
[0113] Preferably, the pressure, and optionally the heat, applied to semi-finished product "S" by said press 6 will differ from those applied by the machine to the basic product in order to obtain said semi-finished product "S".
[0114] More generally, in one possible, but merely illustrative and non-limiting, embodiment of the method, said method comprises one or more steps of executing at least one processing operation on said semi-finished product "S". During said at least one step of executing at least one processing operation, semi-finished product "S" may undergo hydration, exsiccation, addition of a further glueing agent and/or sectioning. Such step of executing at least one processing operation is carried out prior to the step of arranging semi-finished product "S" in mould "M", i.e. before it undergoes the action of press 6.
[0115] In general terms, the humidity rate of semi-finished product "S" used in the method for manufacturing product "P" must lie within a predetermined range; this is because any excess humidity might jeopardize the strength of product "P", making it too ductile and flexible. Likewise, an excessively dry semi-finished product "S" would be insufficiently pliable and less responsive to the action of press 6.
[0116] By way of example, the method for manufacturing product "P" according to the present invention may comprise a step of exsiccating said semi-finished product "S". This step is carried out when semi-finished product "S" has been found to have a relative humidity above a predetermined threshold. By reducing the relative humidity of semi-finished product "S", it will be possible to obtain a compact, solid and strong semi-finished product. This additional step will make it possible to reduce the pressing time after the activation of press 6 when manufacturing product "P" from semi-finished product "S".
[0117] As an alternative, should it be impossible to execute a step of exsiccating semi-finished product "S" prior to the step of activating press 6, during the step of activating press 6 one may increase the pressing temperature and/or the duration of the pressing operation performed by press 6. Of course, should finished product "P" be still too humid, it will be possible to reuse it for a new pressing process.
[0118] Still by way of example, the method for manufacturing product "P" according to the present invention may comprise a step of hydrating said semi-finished product "S". This step is carried out when said semi-finished product "S" has a relative humidity below a specific threshold. This step makes semi-finished product "S" properly ductile, flexible and malleable, so that desired product "P" can be obtained following the activation of press 6.
[0119] Still by way of example, the method for manufacturing product "P" according to the present invention may comprise a step of distributing at least one glueing agent in said semi-finished product "S". This step is substantially similar to the one previously described with reference to the method for the production of a semi-finished product "S", and will not therefore be described any further.
[0120] Still by way of example, the method for manufacturing product "P" according to the present invention may comprise a step of sectioning said semi-finished product "S". During this step, semi-finished product "S" is cut to the most suitable size and shape, depending on product "P" to be obtained and/or mould "M" in use. This step may be useful to avoid the need for a subsequent step of finishing off said product "P", or to simplify the execution of the same step of finishing off said product "P".
[0121] Referring back to the method for manufacturing product "P", the combination of semi-finished product "S" according to the present invention, said press 6 and said mould "M" will make it possible to create said product "P", which will be the desired final product. In fact, said press 6 and said mould "M" will transform said semi-finished product "S" into product "P" by subjecting semi-finished product "S" to appropriate pressures and, optionally, temperatures.
[0122] As previously described herein, semi-finished product "S" that will be used in the method for manufacturing product "P" is shaped as a layer or panel. As aforementioned, semi-finished product "S" has no holes and no thickness differences, and has flat walls with the desired degree of rigidity.
[0123] The use of a press 6 together with mould "M" will produce an even pressure distribution on semi-finished product "S" to give a product "P" having flat walls with desired levels of smoothness and rigidity.
[0124] The method according to the present invention makes it possible to obtain products "P" with flat and rigid walls independently of the quantity or quality of the fibre contained in semi-finished product "S" used for making product "P".
[0125] The steps of providing a press 6, providing a mould "M", and positioning mould "M" in press 6 may vary according to the type of product "P" to be obtained and the type of semi-finished product "S" in use. As a matter of fact, depending on the characteristics of product "P" to be obtained, and particularly also on the characteristics of semi-finished product "S" that will be used, press 6 and mould "M" shall have different technical and functional characteristics. Furthermore, a single press 6 may be used which can house a mould "M" in which more than one piece of said product "P" can be simultaneously produced. The two shells (M1, M2) of mould "M" may, in fact, contain several elements capable of simultaneously producing several units of at least one product "P".
[0126] Preferably, the dimensions of said semi-finished product "S" will be such as to cover a shell, preferably said first shell "M1", of mould "M". In this respect, the method may comprise a step of selecting said semi-finished product "S" as previously described herein.
[0127] During the step of activating press 6 as both shells (M1, M2) of mould "M" come in contact with semi-finished product "S", since the latter has flat walls and no knots, twisted filaments, holes or thickness differences, a possible movement of any filaments will not prevent extended portions of semi-finished product "S" from moving. Indeed, if semi-finished product "S" had knots, balls and/or thickness differences, the result would be an uneven product, with additional holes and/or marked thickness differences. Therefore, semi-finished product "S" made in accordance with the previously described method will prove easier to manipulate and control, also when positioning said semi-finished product "S" in mould "M".
[0128] The dimensions and thickness of semi-finished product "S" to be positioned in mould "M" may vary depending on the characteristics of desired product "P" to be obtained, and particularly as a function of the thickness of the walls of product "P" and/or of the strength thereof.
[0129] More generally, based on the above description, it can be inferred that, depending on the combination of the following factors: fibre percentage; hemp shives percentage; glueing agent percentage; pressure and heat applied to the basic product; and characteristics of press 6 and mould "M", in particular heating temperature and pressing time, the above-described production and manufacturing methods permit obtaining many different types of semi-finished products "S" and products "P" fulfilling the specifications of the designer of product "P".
[0130] More generally, a press 6 is a manufacturing machine that, by compressing the raw material, creates a semi-finished product "S" or a product "P"; therefore, a press can be used in a broad range of steps, whether preparation or finishing ones. In general, when a press is used for moulding operations, it operates slowly, generating very high pressures. As a consequence, a press must have mechanical and operating characteristics designed to suit the raw materials to be processed.
[0131] In the method for manufacturing a product "P" according to the present invention, during the step of activating press 6 it is possible, by adjusting the properties and power of said press 6, to define the size of mould "M" depending on whether one wants to make, during a single run, just one bigger product "P" or several smaller products "P". Furthermore, based on the characteristics and power rating of press 6, it is possible to establish the productivity level to be achieved per time unit as a function of the type(s) of semi-finished products "S" to be used for manufacturing products "P".
[0132] In a preferred implementation of the method for manufacturing a product "P", in order to allow semi-finished product "S" to immediately come off mould "M" after the pressing operation without leaving any residues, mould "M", which determines the shape of products "P" that can be manufactured, is advantageously made of metal material, preferably non-stick metal material.
[0133] In an exemplary, but non-limiting, embodiment of the method for manufacturing a product "P" according to the present invention, a step of finishing off said product "P" is comprised.
[0134] During such step, product "P" is finished off, e.g. by removing any excess semi-finished product "S" used for the production of product "P".
[0135] This step can be carried out either during the step of activating press 6 or at a later stage, e.g. during the step of removing product "P" from mould "M", or even later. This step can be carried out by using one or more blades capable of cutting hemp fibres and hemp shives.
[0136] More generally, the method for manufacturing a product "P" requires a semi-finished product "S" made in accordance with the method for the production of a semi-finished product and having fibres with no knots or twists, wherein the fibres, and hence the hemp shives as well, are evenly distributed in the mat or felt, with no holes and/or thickness variations in semi-finished product "S".
[0137] In the method for manufacturing product "P", by changing the shape of mould "M" and by adjusting: the characteristics of semi-finished product "S" as concerns the fibre, the hemp shives and the glueing agent, and also the temperature and pressure applied to the basic product; pressure; heat; and time, it will be possible to create a very large number of different products "P" having different shapes and dimensions.
[0138] The method for manufacturing a product "P" is particularly suited for implementation by means of a system for manufacturing a product "P" according to the present invention.
[0139] The system for manufacturing a product "P" according to the present invention comprises: a mould "M", having a shape complementary to that of product "P" to be manufactured; and a press 6 adapted to create a pressure and/or a temperature suitable for manufacturing said product "P".
[0140] Said mould "M" comprises a first shell "M1", whereon semi-finished product "S" is arranged in order to be pressed, preferably being the static part of mould "M". Mould "M" comprises also a second shell "M2", complementary in shape to said first shell "M1" for forming product "P". Said second shell "M2" is movable, being driven by said press 6.
[0141] Mould "M", which may of course have as many shapes as various products "P" that can be produced, is advantageously made of non-stick metal to allow product "P" to immediately come off mould "M" after the pressing operation without leaving any residues.
[0142] In one possible, but merely illustrative and non-limiting, embodiment, said mould "M" comprises blades adapted to precisely trim the edges of product "P". Preferably, both said first shell "M1" and said second shell "M2" are fitted with blades. Said blades are, for example, ceramic blades capable of cutting the strong hemp fibres.
[0143] More generally, said system for manufacturing a product "P" according to the present invention comprises tools adapted to finish off product "P" once it has been extracted from mould "M". Said tools are, for example, ceramic blades comprised in mould "M" or in press 6, or comprised in separate automatic and/or semi-automatic devices.
[0144] In one possible, but merely illustrative and non-limiting, embodiment, said mould "M", e.g. said second shell "M2", comprises an internal depressurization hole for decreasing the pressure generated by the combined action of humidity, heat and pressure in mould "M".
[0145] More generally, to mould "M" a control system 64 of press 6 is connected which, through temperature sensors and heating systems, can generate the desired pressure and temperature between the two shells (M1, M2) of mould "M" to produce desired product "P".
[0146] As previously mentioned, a press is a manufacturing machine that, by compressing the raw material, can be used for executing a broad range of processing operations. Said press 6 is adapted to generate high pressures, e.g. higher than 50 bar, e.g. ranging between 50 bar and 200 bar, e.g. between 100 bar and 140 bar.
[0147] Based on the specifications of adopted press 6, it will be possible to define the size of mould "M" for manufacturing either a single unit of product "P" or a plurality of units of one same product "P" at the same time.
[0148] Furthermore, the specifications of adopted press 6 will define the level of productivity attainable per time unit.
[0149] More generally, said press 6 comprises a support structure 60 to which one shell of mould "M", in particular said first shell "M1", is connected.
[0150] Said press 6 further comprises an actuator 62 adapted to generate the pressure required for form product "P" in mould "M". To said actuator 62 one shell of mould "M", in particular said second shell "M2", is mechanically connected. Said actuator 62 is adapted to move said second shell "M2" to dispose semi-finished product "S" in mould "M", in particular on said first shell "M1". Said actuator 62 is, for example, a hydraulic ram.
[0151] As aforementioned, said press 6 comprises a control system 64 adapted to control said actuator 62 when said press 6 is activated. Said control system 64 is also adapted to control the temperature and the pressure inside mould "M", e.g. by means of sensors and heating systems. Said control system 64 comprises connection cables which can receive data from the sensors and control heating systems included in mould "M", e.g. in both shells (M1, M2). Preferably, said control system 64 can control and manage as needed the temperature of each shell (M1, M2) of the mould.
[0152] Figures 3A, 3B and 3C show one possible embodiment of a press 6 with an associated mould "M".
[0153] In particular, Figure 3A shows a front view of press 6 with mould "M". In Figure 3A a support structure 60 is visible, which can support both the first shell "M1" of mould "M" and actuator 62, implemented as a hydraulic ram, to which said second shell "M2" is connected.
[0154] Figure 3A also shows control system 64, which is enclosed in a protective casing. Said control system 64 is connected to mould "M", particularly to both shells (M1, M2), and also to said actuator 62.
[0155] Figures 3B and 3C show the two shells (M1, M2) of a mould "M" for manufacturing a product "P" in the form of a vase. In particular, Figure 3B shows a first shell "M1" adapted to define the internal shape of the vase. Said first shell "M1" will be connected to support structure 60 of press 6. Cables are connected to said first shell "M1" from control system 64, which are useful to obtain the desired temperature and pressure for manufacturing product "P" in the form of a vase.
[0156] Figure 3C shows a second shell "M2" adapted to define the external shape of the vase. Said second shell "M2" will be connected to actuator 62 of press 6. Cables are connected to said second shell "M2" from control system 64, which are useful to obtain the desired temperature and pressure for manufacturing product "P" in the form of a vase.
[0157] A further aspect of the present invention concerns a hemp product "P" manufactured by following the method for manufacturing product "P" according to the present invention.
[0158] By way of non-limiting example, said product "P" is one of the following products: vase; tray; separator; support; container; panel, and other objects that can be made by using a press 6 and a mould "M".
[0159] Moreover, as aforementioned, due to the numerous possible combinations of the various parameters involved in the production of semi-finished product "S" and of product "P", a wide range of different products "P" can be manufactured, intended for many applications. As a matter of fact, a product "P" having the above-described properties, including structure, rigidity, impermeability, strength, resilience, compactness, etc., can be used for many different applications and purposes.
[0160] In one possible embodiment, said product "P" is a compostable vase, i.e. a vase that will degrade after having been inserted into the soil to grow the plant germinated therein.
[0161] Said vases may have different volumes, e.g. ranging between 0.35 litres and 20 litres, e.g. 3, 4, 5, 7, 10, 12, and 15 litres.
[0163] In addition, said vases may have different wall thicknesses, e.g. ranging between 1mm and 4mm.
[0164] By way of non-limiting example, in order to produce a vase useful for seed germination, which must have thin walls and degrade rapidly once placed into the soil, and which will be useful for the first twenty days of the life of the plant and for the subsequent transplantation of the same in open ground, a thin semi-finished product "S" should be used. By way of example, starting from a semi-finished product "S" with a density of 15 gr/cm2, it will be possible to obtain a rigid, light and thin vase with smooth walls having a height and a diameter of 10 cm. Such a vase, although it can be easily deformed, e.g. by a user's hand, will still be capable of containing loam while being thin enough to allow the roots of the plant, as they grow, to come out and cling to the surrounding soil, thus avoiding the need for transplantation and preventing the plant from suffering further shocks. This can also be ascribed to the biodegradability of the vase material, which essentially consists of fibre, hemp shives and glueing agent. Biodegradable vases are therefore ideal for seed germination or for growing the root apparatus of cuttings. The vase made in accordance with the present invention has a service life of 20 to 30 days, corresponding to the time necessary for the initial development of the plant to occur. Preferably, in order to produce such vases, and in particular semi-finished product "S", a natural glueing agent with fast biodegradability and low resistance to water should be used. By way of example, vases intended for long-term use in a plant nursery will require the use of a different semi-finished product "S" made by following the method for the production of semi-finished product "S" according to the present invention, other than the one used for manufacturing the above-described small vases for germination/transplantation use. In fact, nursery vases must last longer, e.g. about 6 months, during which time the vase may have to remain continuously in contact with water, moisture and pesticides. Therefore, such a vase will have to be made stronger and impermeable, in order to prevent it from degrading earlier than expected, which would impair product marketability. For such a vase, a glueing agent made of natural, synthetic or protein latex may be used when producing the semi-finished product, in order to guarantee impermeability.
[0165] Furthermore, product "P" may be an ornamental vase having desired aesthetic characteristics that make it usable in private or public environments, both indoors and outdoors.
[0166] Figure 4B shows said product "P" in the form of a vase. The product has a three-dimensional shape, with desired undercuts and flares defined by means of mould "M".
[0167] In Figure 4B one can see that product "P" comprises hemp fibre and hemp shives. The impermeability, rigidity and degradability properties will depend on the thickness of semi-finished product "S" and on the characteristics of the glueing agent employed, as previously specified herein.
[0168] Said product "P" and/or said semi-finished product "S" may be a structural or finishing panel for domestic environments or for automotive use, as well as for doors and/or buildings.
[0169] Product "P" and/or said semi-finished product "S" may be a structural element to be used for manufacturing other objects. For example, it may be a stiffening panel to be used, for example, for stiffening the bottom and/or the sides of a handbag.
[0171] Said product "P" and/or said semi-finished product "S" may also be a safety structure for packaging use, e.g. a structure or element used for separating fragile items, e.g. bottles.
[0172] Furthermore, said product "P" and/or said semi-finished product "S" may be a support structure, e.g. a glass or bottle coaster, a flat tray or a tray with raised edges, e.g. a box, or a container for liquids and solids, such as glasses and dishes, or flatware and crockery in general.
[0173] Said product "P" may be a writing support, like blackboards and/or documents, or a support for writing means, such as pen holders and/or writing and/or stationary items.
[0174] Said product "P" may also be a structure intended to contain food products, e.g. containers and/or trays for containing and/or protecting food, e.g. fragile food like eggs.
[0176] As aforementioned, the present invention permits using low-quality fibre with a non-negligible content of hemp shives trapped therein, so that many semi-finished products "S" and products "P", differing in their technical and structural characteristics, can be obtained while ensuring high quality and durability of product "P" for the intended purposes.
[0177] The present invention makes it possible to obtain semi-finished products "S" that are stable, easy to preserve, transport and store, through the use of simple devices and machines that can be used for processing hemp plants, the vegetable mass and the products; such machines being already widely used in many technical fields, and in some cases being even considered to be obsolete, thus clearly leading to lower investment costs.
[0178] The present invention makes it possible to obtain products "P" in a simple and economical manner by using simple devices and machines to obtain product "P", such machines being already widely used in many technical fields, and in some cases being even considered to be obsolete, thus clearly leading to lower investment costs.
[0179] The present invention ensures low investment and operating costs and minimal waste production, resulting in lower disposal costs, since waste material and discarded semi-finished products "S" and products "P" can be reused for creating other semi-finished products "S" and products "P" according to the present invention.
[0180] The present invention allows for extensive calibration of the systems employed for producing semi-finished product "S" and for manufacturing product "P" based on raw material availability. By way of example, the systems according to the present invention are believed to be profitable starting from 15 hectares of cultivation available in close proximity.
[0181] The present invention offers broad possibilities of rapidly orienting and varying the production of semi-finished product "S" and of product "P" to react to changing market demands.
[0182] The present invention represents, therefore, an incentive to invest in the hemp cultivation and processing sector, due to the possibility of creating many production units spread over the territory.
[0183] The present invention also provides easy availability of the necessary raw material, resulting in a shorter supply chain, reduced environmental pollution, and lower production costs.
[0184] Furthermore, without referring to any specific theoretical principles, it can be stated that hemp cultivation increases the absorption of atmospheric CO2; in fact, the fast growth of such plants enhances the CO2 conversion rate, which CO2 is permanently fixed in the vegetable mass.
[0185] Semi-finished products "S" and products "P" according to the present invention are biodegradable, thus considerably reducing the environmental impact.
[0186] Thanks to hemp cultivation, the present invention makes it possible to improve the quality of soils.
[0187] Any alternative embodiments of the methods and systems which have not been described in detail herein, but which will be apparent to a person skilled in the art in light of the contents of the present patent application, shall be considered to fall within the protection scope of the present invention.
REFERENCE NUMERALS
[0188]
| Drum sieve | 3 |
| Inlet aperture | 3A |
| Outlet aperture | 3B |
| Support structure | 30 |
| Grated drum | 32 |
| Sections | (32A, 32B, 32C, 32D) |
| Apertures | 34 |
| Actuator | 36 |
| Opener | 4 |
| Support structure | 40 |
| Housing | 41 |
| Cover | 410 |
| Inlet aperture | 41A |
| Spiked roller | 42 |
| Actuator | 43 |
| Squashing rollers | 44 |
| Press | 6 |
| Support structure | 60 |
| Actuator | 62 |
| Control system | 64 |
| Mould | "M" |
| First shell | "M1" |
| Second shell | "M2" |
| Product | "P" |
| Axis of rotation | "R" |
| Semi-finished product | "S" |
1. Method for the production of a semi-finished product (S) starting from hemp plants
comprising fibre and hemp shives;
said method comprising the following successive steps:
said method comprising the following successive steps:
- creating a shapeless vegetable mass comprising fibre and hemp shives starting from hemp plant biomass;
- executing a first selection phase on said shapeless vegetable mass, thereby obtaining a first product having a lower hemp shives percentage than said shapeless vegetable mass;
- creating a nonwoven mat or felt having a known or desired thickness starting from at least said first product;
- distributing at least one glueing agent in said mat or felt, thereby obtaining a basic product;
- applying heat and pressure to said basic product, thereby obtaining said semi-finished product (S).
2. Method according to claim 1, wherein the step of executing a first selection phase
on said vegetable mass is followed by a further step of:
executing a second selection phase on said first product,
thereby obtaining a second product with a flocked structure having a lower hemp shives percentage than said first product.
3. Method according to claim 1, wherein said step of executing a first selection phase
is carried out by means of a sieving machine.
4. Method according to claim 2, wherein said step of executing a second selection phase
is carried out by means of an opener machine (4).
5. Method according to one of the preceding claims, wherein said step of creating a shapeless
vegetable mass is carried out by shredding hemp plant biomass.
6. Method according to claim 5, wherein said step of creating a shapeless vegetable mass
is carried out starting from in-field macerated hemp plant biomass.
7. Method according to one of the preceding claims, wherein said glueing agent is selected
among at least one of the following:
- natural latex;
- synthetic latex;
- glucose;
- maltose;
- natural resins.
8. Method according to one of the preceding claims, wherein said glueing agent is provided
as a liquid solution, and the glueing agent is distributed in the nonwoven mat or
felt by using at least one of the following methods:
- sprinkling;
- nebulization;
- brushwork;
- immersion;
- dripping;
- by roller.
9. Method according to one of the preceding claims, wherein said step of applying heat
and pressure is carried out by means of a heated heavy roller or by means of a heated
mould press.
10. System for the production of a semi-finished product (S) by implementing the method
according to claim 1, comprising:
- a first selection device adapted to remove hemp shives from the shapeless vegetable mass, thereby obtaining a first product;
- at least one machine adapted to apply heat and pressure to the basic product;
wherein:- said first selection device is a sieving machine;
- said at least one machine is at least one heated roller and/or heated press.
11. System according to claim 10, comprising a second selection device adapted to remove
hemp shives from said first product, thereby obtaining a second product having a flocked
structure; wherein said second selection device is an opener machine (4).
12. System according to claim 10, comprising a device for distributing the glueing agent
in said mat or felt, wherein said distribution device is a sprinkler, a nebulizer;
at least one brush or roller; an immersion system; and/or a dripping system.
13. System according to claim 10, comprising a shredding machine adapted to create a shapeless
vegetable mass comprising fibre and hemp shives starting from hemp plant biomass.
14. Method for manufacturing a hemp product (P), comprising the following steps:
- providing a semi-finished hemp product (S) according to claim 1;
- providing a mould (M) having the shape of the desired product (P);
- providing a press (6);
- positioning the mould (M) in the press (6);
- arranging the semi-finished product (S) in the mould (M) ;
- activating the press (6);
- removing the product (P) from the mould (M).
15. Method according to claim 14, comprising a step of finishing off the product (P).
16. System for manufacturing a product (P) by implementing the method according to claim
11, comprising:
- a mould (M) having a shape which is complementary to that of the product (P) to be manufactured;
- a press (6) adapted to create a pressure and/or a temperature suitable for manufacturing said product (P).
17. System according to claim 16, comprising tools adapted to finish off the manufactured
product (P) once it has been removed from the mould (M).
18. Hemp product (P) made by using the method according to claim 14, wherein said product
(P) is one of the following products:
- vase;
- tray;
- separator;
- support;
- container;
- panel.