Method of molding powdered plant fiber into high density materials
First Claim
1. A method of manufacturing a high density plant fiber material comprising the steps of:
- (a) introducing powdered plant fiber particles containing protolignin and with a diameter less than 3000 microns into a mold;
(b) heating the contents of the mold to a temperature between 50 degrees C. to 220 degrees C.;
(c) compressing the powdered contents of the mold to an average density of at least 50 pounds per cubic foot;
(d) curing the compressed contents within the mold; and
(e) releasing the compressed contents from the mold.
1 Assignment
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Accused Products
Abstract
A high density fiber product is made from natural lignin containing plant fibers. Plant fibers ranging in size below about 3000 microns in diameter are used. Binding agents and other additives may be mixed with the fibers to enhance product or process performance. The plant fibers or mixture of fibers and additives are heated to between about 50 degrees C. to about 140 degrees C. The heated fibers are compressed in a mold to an average density of about 50 pounds per cubic foot to about 100 pounds per cubic foot. Compression pressures of about 500 psi to about 2500 psi are used to achieve product densities within this range. The compressed fibers are cured under these temperature and pressure conditions. After the curing time has elapsed, the compressed fiber product is released from the mold and the mold may be reused. A high density product made from small plant fibers is provided.
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Citations
40 Claims
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1. A method of manufacturing a high density plant fiber material comprising the steps of:
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(a) introducing powdered plant fiber particles containing protolignin and with a diameter less than 3000 microns into a mold; (b) heating the contents of the mold to a temperature between 50 degrees C. to 220 degrees C.; (c) compressing the powdered contents of the mold to an average density of at least 50 pounds per cubic foot; (d) curing the compressed contents within the mold; and (e) releasing the compressed contents from the mold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 32)
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27. A method of forming a high density plant fiber product comprising the steps of:
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(a) providing plant fibers containing protolignin and containing less than 20 per cent water by weight, the fibers being between 50 microns to 3000 microns in diameter; (b) blending a fluidized mixture of plant fibers and one or more of the group of additives consisting of a thermoset binding agent, a pigment, a releasing agent, a catalyst, a flame retardant, a flame resistant agent, a fire resistant agent, and a lubricating agent; (c) introducing the fluidized mixture of plant fibers and additives into the cavity of a mold; (d) compressing the mixture by applying a pressure of at least 500 psi to the surface of the mixture; (e) heating the contents of the mold cavity to between 50 degrees C. to 220 degrees C.; (f) curing the compressed contents; and (g) removing the compressed contents from the mold. - View Dependent Claims (28, 29, 30, 31)
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33. A method of manufacturing a high density plant fiber material comprising the steps of:
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(a) preparing a particulate mixture comprising plant fibers less than 1500 microns in diameter and containing protolignin, a thermoset binding agent, and one or more of the group of additives consisting of a pigment, a releasing agent, a catalyst, a flame retardant, a flame resistant agent, and a lubricating agent; (b) introducing the particulate mixture into a mold; (c) heating the particulate mixture to a temperature between 60 degrees C. and 220 degrees C.; (d) compressing the mixture to an average density of at least 60 pounds per cubic foot within the mold; and (e) removing the compressed contents from the mold. - View Dependent Claims (34, 35, 36, 37, 38, 39, 40)
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Specification