Banana fiber composite material

• US 10,072,357 B2
• Filed: 07/23/2014
• Issued: 09/11/2018
• Est. Priority Date: 07/25/2013
• Status: Active Grant

• Current Assignee: Geophia, LLC
• Original Assignee: Geophia, LLC
• Inventors: Hondroulis, Dimitrios G., Gorman, William W.
• Primary Examiner(s): Theisen, Mary Lynn F
• Application Number:
  US14/907,338
• Publication Number:
  US 20160168753A1
• Time in Patent Office: 1,511 Days
• Field of Search: None
• CPC Class Codes: B29B 15/08 of reinforcements or fillers chemical aspects C08J, C08K
• CPC Class Codes: B29B 7/905 with means for pretreatment of the charges or fibres
• CPC Class Codes: B29B 9/14 fibre-reinforced
• CPC Class Codes: C08K 7/02 Fibres or whiskers
• CPC Class Codes: D01B 1/10 Separating vegetable fibres from stalks or leaves
• CPC Class Codes: D01B 1/22 with crushing or breaking rollers or plates
• CPC Class Codes: D01B 1/48 Drying retted fibres

Abstract

A system and method for producing bio composite materials by mixing pelletized plant fiber dust and virgin or recycled plastic. The system may comprise a reducer, a press, a dryer, a pelletizer, and a mixer. The reducer separates the fibers of the plant material and the press removes liquid from the separated fibers. The dryer further reduces the moisture content of the pressed fibers and generates dust which is extracted by sifting, screening, or another suitable method. The pelletizer compresses and/or treats the fiber dust with solutions, adhesives, or other processes that cause the fiber dust to adhere together. The fiber dust pellets are then mixed with virgin or recycled plastic to produce a bio composite material.

Claims

1. A system for producing a plant fiber bio composite material comprising:

a reducer for separating fibers of the plant material;

a press for pressing the fibers and removing liquids from the plant material;

a dryer for reducing the moisture content of the pressed fibers and generating plant fiber dust;

a pelletizer for forming pellets from the plant fiber dust; and

a mixer for mixing the dust pellets with virgin or recycled plastic.

2. The system of claim 1, wherein the reducer separates the fibers by cutting, grinding, shredding, or a combination thereof.

3. The system of claim 2, wherein the reducer comprises a bladed roller that draws plant material into a series of rotating cutting implements to separate the fibers.

4. The system of claim 2, wherein the reducer comprises a grinder neck through which the plant material fibers are delivered to the press.

5. The system of claim 1, wherein the separated plant material fibers are washed to facilitate the removal of latex or other liquids prior to being delivered to the press.

6. The system of claim 1, wherein the plant material comprises banana stalks.

7. The system of claim 1, wherein a system of conveyors is used to transfer separated fibers from the reducer to the press.

8. The system of claim 7, wherein the system of conveyors incorporates agitation paddles to further separate or aerate the fibers.

9. The system of claim 1, wherein the dryer employs heating, agitating, aerating, or a combination thereof to reduce the moisture content of the pressed fibers.

10. The system of claim 1, wherein the dryer employs a non-thermal, kinetic disintegration, pulverization device to further process the pressed fibers.

11. The system of claim 1, wherein plant fiber dust is extracted from the pressed fibers using sifting, screening, or a combination thereof.

12. The system of claim 1, wherein the pelletizer compresses and/or treats the plant fiber dust with solutions, adhesives, or processes that cause the fiber dust to adhere together.

13. The system of claim 1, wherein the mixer generates a bio composite material comprising equal portions of plant fiber dust pellets and virgin or recycled plastic.

14. A method for producing a plant fiber bio composite material comprising the steps of:

reducing plant material to form separated fibers of a desired length;

pressing the separated fibers to remove liquids;

drying the pressed fibers to reduce moisture content and generate plant fiber dust;

pelletizing the plant fiber dust; and

mixing the fiber dust pellets with virgin or recycled plastic.

15. The method of claim 14, wherein the step of reducing plant material to form separated fibers comprises cutting, grinding, shredding, or a combination thereof.

16. The method of claim 15, wherein the step of reducing plant material to form separated fibers comprises using a bladed roller to draw plant material into a series of rotating cutting implements.

17. The method of claim 15, wherein the step of reducing plant material to form separated fibers comprises delivering the plant material fibers to the press through a grinder neck.

18. The method of claim 14, further comprising the step of washing the plant material fibers to facilitate the removal of latex or other liquids prior to being delivered to the press.

19. The method of claim 14, wherein the plant material comprises banana stalks.

20. The method of claim 14, further comprising the step of transferring the separated fibers from the reducer to the press using a system of conveyors.