MATERIAL

Description

[0001] The invention relates to a material with components from palm plants, a processing device for processing plant raw materials, preferably from palm plants, and a method for producing a material.

[0002] A material can be produced from the raw materials, for example plant waste.

[0003] The care and cultivation of palm trees, such as date palms, coconut palms and / or oil palms, produces large quantities of plant waste that decomposes slowly.

[0004] Sustainable, regular care of the plants is not only essential for the beauty of the palms, but especially necessary for maintaining their health and protecting them against pests.

[0005] The trunk is usually cleared of dead palm fronds from the lowest row at annual intervals. After several years, the parts of the so-called frond sheaths that remain on the trunk during maintenance are also removed.

[0006] In the United Arab Emirates alone, approximately 475,000 tons of this bio-based material are generated annually.

[0007] In the past, the resulting material was mostly stored unused or burned, which is harmful to the environment and is now partly prohibited by law.

[0008] Processing devices for palm waste are known. These typically use the trunk, which is then chopped into wood chips. These wood chips are pressed into boards together with other materials. However, these boards lack high stability.

[0009] The stems and / or leaves of the palm tree are also not used.

[0010] EP0411589A2 discloses a material comprising elongated palm fibers and a binder, wherein the length of the fibers is 100-300 mm.

[0011] JP2006225547A discloses a processing device for processing the fibers of coconuts, comprising a splitting device for splitting the raw products into elongated semi-finished products, a fiberizing device for fiberizing the semi-finished products, and a further processing device for forming the fiberized semi-finished products into a material.

[0012] It is therefore an object of the invention to create a stable material and to improve a processing device of the type mentioned above in such a way that large quantities of plant raw materials, in particular stems and / or leaves of the palm, can be processed into stable, new materials in a simple and cost-effective manner.

[0013] This problem is solved by the subject matter or procedure of independent claims.

[0014] According to the invention, the material comprises elongated, frayed lamellae of palm plants, as well as a binding agent.

[0015] In particular, the material may be a fiber composite material.

[0016] The starting material for palm-related products, i.e., the palm material, comes primarily from date, coconut, and / or oil palms. For example, the elongated stems, also called panicles, can be processed.

[0017] Palm panicles consist primarily of fibers made of cellulose and hemicellulose, which provide reinforcement for tensile and flexural strength. Between the fibers is a matrix of parenchyma, mainly lignin and other substances, which, for example, ensures compressive strength.

[0018] These raw materials are generated in large quantities as waste during plant care. Ideally, the raw material comes 100% from plant care, so that no plants need to be harvested, no trees felled, and / or no plantation cleared.

[0019] The frayed lamellae, or the fibers obtained from the lamellae, are elongated. Preferably, they are not chopped. The elongated structure gives the material high stability.

[0020] Further developments of the invention can also be found in the dependent claims.

[0021] According to a non-inventive embodiment, the length of the lamellae is at least 7 cm. In contrast to shorter lamellae, the material is therefore significantly more stable.

[0022] Not according to the invention, the length of the frayed lamellae, i.e., the fibers, is at least 8 cm or at least 9 cm. According to the invention, the length of the frayed lamellae is at least 10 cm, 15 cm, 20 cm, 25 cm, 30 cm, 40 cm, 50 cm, 60 cm, 70 cm, 80 cm, 90 cm or 100 cm.

[0023] At least two lamellae or fibers, preferably all lamellae or fibers, of the material can be oriented parallel to each other.

[0024] Alternatively, at least two lamellae or fibers, preferably half of the lamellae or fibers, of the material can be oriented at right angles to each other. The lamellae or fibers can therefore be oriented crosswise.

[0025] Furthermore, it is also possible that the lamellae or fibers are randomly oriented. The orientation of the lamellae or fibers can be chosen according to the requirements of the material.

[0026] According to a further embodiment, the filler material of the palm plant, in particular parenchyma, is separated from the lamellae or fibers, in particular by suction. Specifically, the filler material is dissolved during fiberization.

[0027] The filler can be completely or at least partially separated, i.e., removed. For example, at least 50%, 70%, 80%, 90%, or 95% of the filler can be removed. In particular, the material is at least substantially free of, for example, compacted filler.

[0028] Without the filler, or without a large part of the filler, the lamellae or fibers are wetted with binder, resulting in a homogeneous material.

[0029] Exemplary tests yielded the following results: In a fiber-reinforced composite material, e.g., a panel made from palm fronds and palm leaves, where the filler is not removed and is pressed against the fibers (i.e., compacted), the thickness swelling is approximately 74%. With a bulk density of 940 kg / m³ and an initial thickness of 12.0 mm, the thickness increases to 20.9 mm after 24 hours of water immersion.

[0030] In the case of a fiber-reinforced composite material, for example a panel made from palm fronds and palm leaves, where approximately 50% of the filler has been removed and the remaining filler is not compacted, the thickness swelling is approximately 8%. With a bulk density of 920 kg / m³ and an initial thickness of 12.0 mm, the thickness increases to 12.9 mm after 24 hours of water immersion.

[0031] In the case of a fiber-reinforced composite material, for example a sheet made from palm panicles and palm leaves, where approximately 80% of the filler has been removed and the remaining filler is not compacted, the thickness swelling is approximately 1%. With a bulk density of the test specimen < 960 kg / m³ and an initial thickness of 12.0 mm, the thickness increases to 12.1 mm after 24 hours of water immersion.

[0032] In the case of a fiber-reinforced composite material, for example a panel made from palm panicles and palm leaves, where approximately 95% of the filler has been removed and the remaining filler is not compacted, the thickness swelling is approximately 0%. With a bulk density of 980 kg / m³ and an initial thickness of 12.0 mm, the thickness remains at 12.0 mm after 24 hours of water immersion.

[0033] In comparison, the thickness swelling of a low-swelling chipboard for use in humid environments is 17.5%. With a test specimen density of 680 kg / m³ and an initial thickness of 12.0 mm, the thickness increases to 17.5 mm after 24 hours of water immersion.

[0034] The tests showed that removing just 50% of the filler significantly improves the bonding of the lamellae or fibers. The more filler is removed and / or the less compacted it is, the better the swelling behavior of the material.

[0035] The filler, containing ingredients such as starch, lignin and / or tannin, does not have a negative effect on the material, especially if the filler adhering to the fibers is not compacted and can thus absorb the binder like a sponge.

[0036] The fiber, which consists primarily of cellulose and hemicellulose, is largely separated from the parenchyma and lignin. Thus, the fiber is detached from the matrix. The resulting fiber is therefore cellulose and no longer lignocellulose, as only the cellulose fibers are used.

[0037] According to another embodiment, the proportion of lamellae or fibers made from lamellae is between 40 and 95 percent by weight. The lamellae or fibers made from lamellae therefore constitute a high proportion of the total weight of the material.

[0038] In particular, the proportion of lamellae or fibers made from lamellae is between 50 and 60 percent by weight, for example 50, 51, 52, 53, 54, 55, 56, 57, 58, 59 or 60 percent by weight.

[0039] According to a further embodiment, the binder is designed as an aminoplast, in particular phenolic resin, PF resin, melamine and / or urea resin, as an adhesive, in particular glue or epoxy resin, as a dispersion, in particular PVAC, PMDI, polyurethane, as a thermoplastic elastomer, as clay, as loam and / or as cement.

[0040] The glue in question could be, in particular, white glue.

[0041] Biological binders can preferably be used.

[0042] The binder can, for example, be a hybrid binder with an amino resin and PMDI, such as isocyanate. Isocyanates, in particular, have the property of ensuring reliable bonding of potentially waxy components in the fibers.

[0043] The resin can be, in particular, a mixed resin, e.g., MUF with PVAc or MUPF with PVAc.

[0044] For example, the mixed resin may contain or consist of urea-formaldehyde (UD).

[0045] The mixed resin may also contain or consist of melamine-formaldehyde (MF).

[0046] Furthermore, the mixed resin can comprise or consist of polyvinyl acetate (PVAc) with a hardener and a formaldehyde scavenger. The formaldehyde scavenger can serve to release less or no free formaldehyde after curing.

[0047] A binder may, for example, contain 100 kg UF, 25 kg MF, 30 kg PVAc, 30 kg formaldehyde scavenger, 4 kg hardener and 65 kg water.

[0048] Preferably, at least one additive can be added to the binder, e.g., boric acid, borate salts, aluminum hydroxides, and / or ammonium phosphates. This can increase the fire protection properties.

[0049] The proportion of binder can be less than 10% by weight. For example, the proportion can be between 1% and 10% by weight.

[0050] According to the invention, the material comprises a further plant-based raw material in the form of palm leaves.

[0051] The leaves are also particularly frayed.

[0052] Preferably, so-called penetration enhancers are used in leaves. For example, the proportion of the other plant raw material can be between 5 and 60 percent by weight, e.g., between 25 and 40 percent by weight. In particular, the proportion can be between 25 and 30 percent by weight and / or between 30 and 40 percent by weight.

[0053] The total proportion of fibrous material, i.e., fibers from the panicles or lamellae and the leaves, in the material can be more than 90 percent by weight. This fibrous material can consist of, for example, approximately 60% lamellae (i.e., stems) and approximately 40% leaves.

[0054] According to another embodiment, the material is designed as a pressed material.

[0055] In another embodiment, the material is available as sheets, beams, or molded parts. This makes it suitable for various applications. For example, the material can have a density between 251 and 500 kg / m³. These lightweight fiber-reinforced composites particularly meet the requirements for lightweight materials, the required thermal properties as insulation, and / or the ever-increasing ecological and sustainability demands of the market.

[0056] Alternatively, the material can have a density value between 510 and 850 kg / m³. These medium-density fiber composites meet general material requirements, and especially the ever-increasing ecological and sustainability demands of the market.

[0057] Alternatively, the material can have a density value of more than 850 kg / m³. These dense fiber-reinforced composites meet the highest static, acoustic, and / or fire protection requirements. Last but not least, they also satisfy ecological and sustainability requirements.

[0058] For example, a slab and / or board made from the original materials, panicles and possibly leaves, can have a bulk density of approximately 1,000 kg / m³, e.g., 1,007 kg / m³. Its fire behavior can meet EuroClass B-s1, d0. The thermal conductivity can be, for example, 0.25 W / mK. The diffusion resistance can be, for example, µ = 300. The swelling after 24 hours of water immersion can be less than 1%.

[0059] The tensile strength can be as low as 0.24 N / mm², while the flexural strength, i.e. the modulus of elasticity, can be as high as 87.5 N / mm².

[0060] In all respects, a panel and / or board made of stalks and possibly leaves performs better than glulam (BSH), oriented strand board (OSB), and beech veneer laminated timber (LVL): The density can be 380 kg / m³ (BSH), 550 kg / m³ (OSB), or 730 kg / m³ (LVL), the fire behavior meets EuroClass D-s2, d0, the thermal conductivity is 0.13 W / mK (BSH and OSB) or 0.17 W / mK (LVL), and the diffusion resistance is µ = 40 (BSH), µ = 200-300 (OSB), or µ = 75-200 (LVL). Swelling after 24 hours of water immersion can be 18% (BSH), 25% (OSB), or 23% (LVL). Tensile strength can be 0.25 N / mm² (BSH), 0.18 N / mm² (OSB), or 0.15 N / mm² (LVL), while flexural strength can be 26.5 N / mm² (BSH), 20 N / mm² (OSB), or 45 N / mm² (LVL).

[0061] Tests have shown that a beam made from a palm tree, 300 mm high and 133 mm wide, can exhibit a characteristic bending moment of Mk = 139.7 kNm. A steel beam, 300 mm high with a flange width of 150 mm, can exhibit a characteristic elastic bending moment of Mel,k = 130.9 kNm. Reinforced concrete, 300 mm high and 150 mm wide, can exhibit a characteristic bending capacity of Mk = 30.9 kNm. Parallam® with a cross-section of 133 mm x 300 mm can exhibit a characteristic bending moment of 47.88 kNm.

[0062] In particular, the material can be designed as a multi-layered material consisting of at least two, three, four, five, six or more layers with different density values. For example, layers of lightweight, medium-density and / or dense fiber-reinforced composites can be combined.

[0063] The disclosure also relates to the use of a material according to the invention as a fire protection material.

[0064] Because the material is only slightly flammable, it is preferable to wood from a fire safety perspective. In particular, fire doors can be made from this material. Furthermore, the material is especially water-resistant.

[0065] The material can be used in a variety of ways, for example in building construction, interior design (e.g., as furniture, flooring, etc.), vehicle manufacturing, and mechanical engineering (e.g., as machine tables, etc.). It can also be used as a raw material for the processing industry. Mixed resin as a binder is particularly suitable for many applications.

[0066] The material can contain binders such as clay, loam, and / or cement. This allows it to be used, for example, in construction with natural materials. The fibers are added to the clay, for instance, to reinforce it. Unlike straw, the fibers have the particular advantage of not decomposing, or only decomposing very slowly.

[0067] In particular, the material can be designed as a clay slab mixed with fibers.

[0068] The invention also relates to a processing device for processing elongated, plant-based raw materials, preferably from palm trees.

[0069] The raw materials come primarily from date, coconut, and / or oil palms. For example, the elongated stems, also called panicles, can be processed. These raw materials are generated in large quantities as waste during plant maintenance. Ideally, the raw material originates 100% from plant care, so that no plants need to be harvested, no trees felled, and / or no plantations cleared.

[0070] The processing device includes a splitting device for splitting the raw products into elongated lamellae. The length of the raw products and / or the lamellae can be, for example, at least 5 cm, 6 cm, 7 cm, 8 cm, 9 cm, 10 cm, 15 cm, 20 cm, 25 cm, 30 cm or more.

[0071] The raw products are therefore split lengthwise. They are not chopped into wood chips or fine shavings.

[0072] Furthermore, the processing device includes a fiberizing unit for fiberizing the lamellae. During fiberizing, preferably only minimal pressure is applied to the lamellae, as the filler material parenchyma, containing, among other things, starch, lignin, and / or tannin, would have a negative effect on the material.

[0073] In the fiberizing device, the lamellae are preferably oriented at right angles, longitudinally or arbitrarily to the conveying direction.

[0074] Finally, the processing device includes a further processing device for processing the frayed lamellae into a material.

[0075] The material in question can be a strong and / or stable material, such as a fiber-reinforced composite. For example, the material can be in the form of a sheet, particularly a high-strength fiber-reinforced composite sheet (e.g., with phenolic resin), a beam, a strip, and / or a molded part. The material can be used, for example, similarly to wood, as a building material, for instance in structural engineering, interior design, but also in vehicle construction and / or industry.

[0076] Because the material is only slightly flammable, it is preferable to wood from a fire safety perspective. In particular, fire doors can be made from this material. Furthermore, the material is especially water-resistant.

[0077] Because the stable fibers of the raw materials are preserved during processing, the material is extremely stable.

[0078] Conveyor devices, e.g. conveyor belts, can preferably be provided between the splitting device, the fiberizing device and the further processing device.

[0079] The processing device forms a unit, i.e., the raw materials are fed to the individual devices one after the other in order to obtain the material at the end.

[0080] The processing device allows large quantities of plant raw materials, especially stems and / or leaves of the palm, to be processed into stable materials in a simple and cost-effective manner.

[0081] According to one embodiment, the splitting device comprises a set of knives with one or more blades arranged in parallel and / or in a grid pattern.

[0082] The raw products are preferably oriented parallel to the conveying direction and are pushed through the set of knives. Preferably, the blades are also oriented parallel to each other and / or parallel to the conveying direction. For example, at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or more blades can be provided.

[0083] When the blades penetrate the raw material, they are split and form elongated lamellae. The raw material is particularly easy to split because there is no strong bond between the fibers.

[0084] The blade spacing can preferably be between 1 mm and 10 mm, more preferably between 2 mm and 5 mm, and most preferably between 3 mm and 4 mm. The resulting lamellae are of a corresponding thickness.

[0085] In particular, the raw products can first be bundled by a feeding device, for example by vertically oriented bundling rollers. The axes of rotation of the bundling rollers can preferably be oriented perpendicular to the conveying direction or conveying surface. Two bundling rollers can, for example, be arranged side by side on opposite sides of a conveying device.

[0086] For example, raw products can be pressed through the knife set via two horizontally oriented rollers arranged one above the other. The axes of rotation of the horizontal rollers can preferably be oriented perpendicular to the conveying direction or parallel to the conveying surface and / or perpendicular to the axes of rotation of the bundling rollers.

[0087] According to a further embodiment, an admixture device for adding another plant-based raw material, in particular leaves, is provided between the splitting device and the fiberizing device.

[0088] Since certain plant genera, such as Acrea phoenix (date palm), have a roughly equal ratio of panicles to leaves, it is unnecessary to separate the leaves from the panicles before fiberizing. The panicles and leaves can be fed into the fiberizing machine together.

[0089] This raw product also preferably comes from palm trees, such as oil palms, coconut palms, and / or date palms. This allows for the use of all palm plant waste, preferably the entire palm frond including stem and leaves.

[0090] The other plant-based raw material, e.g., the leaf material, can preferably be added to the split lamellae in measured amounts. This dosage ensures a homogeneous distribution.

[0091] The remaining plant-based raw material is fed to the fiberizing device along with the split lamellae and is also fiberized.

[0092] According to a further embodiment, the fiberizing device comprises a friction device. During fiber deconstruction by friction, little or no pressure is exerted on the lamellae and / or the leaf material. This releases the fibers from the natural structure without, for example, compressing the filler materials of the palm panicle, such as parenchyma. Pressure on the material would cause the undifferentiated filler material, which is embedded between the fibers of the panicle, to be pressed against the fiber and thus adhere to it.

[0093] Compacted filler material, pressed against the fibers, has negative effects on the material. For example, the adhesive quality decreases. The material may also exhibit adverse swelling behavior.

[0094] Without compacted or pressed-on filler, a binder is absorbed like a sponge, resulting in a homogeneous material, as the filler, when compressed, lies between the fibers like the natural starting material.

[0095] During the fiberization process, the filler detaches from the fibers and is vacuumed up.

[0096] According to another embodiment, the friction device comprises at least two friction devices arranged one above the other.

[0097] The lamellae and / or blades are transported between the friction devices in the conveying direction. These are preferably oriented at right angles, longitudinally, or arbitrarily to the conveying direction.

[0098] The friction devices preferably grip the lamellae and / or leaves from below and from above.

[0099] Preferably, the friction devices are grooved and / or profiled. The structure of the friction device significantly improves the fiberization process.

[0100] The friction devices can have the same ribbing or profile. Alternatively, they can have different ribbing or profiles.

[0101] In particular, the friction devices can have the same or different directions of rotation. This ensures that the lamellae and / or blades at the top and bottom are moved in the same direction, for example.

[0102] For example, the friction devices can include or consist of conveyor belts, rollers, and / or discs. The conveyor belts can, in particular, include chain plates. If the friction devices are designed as rollers, several rollers can be arranged one behind the other in the conveying direction.

[0103] According to another embodiment, the distance between the friction devices decreases in the conveying direction. This makes the space for the lamellae and / or blades increasingly narrow, so that they eventually fray.

[0104] The space between the friction devices preferably narrows conically.

[0105] According to another embodiment, the speeds of the friction devices are different.

[0106] Preferably, the speed of the upper friction device, e.g. at least 1.1 times, 1.2 times, 1.3 times, 1.4 times, 1.5 times, 1.6 times, 1.7 times, 1.8 times, 1.9 times, 2 times, 2.5 times, 3 times, 4 times, 5 times, 6 times, 7 times, 8 times, 9 times or 10 times, is greater than the speed of the lower friction device.

[0107] In principle, the reverse case is also conceivable, that the speed of the lower friction device is greater than the speed of the upper friction device.

[0108] According to a further embodiment, a sensor device, e.g. a fiber classifier, is provided for analyzing the fiberized lamellae, wherein the speed of at least one friction device can be controlled by means of a control device based on the data determined by the sensor device.

[0109] For example, the fiber thickness or fineness and / or the degree of fiberization can be measured. If the result is insufficient, the control device can regulate or control the speed of at least one friction device accordingly. The speed can be increased or decreased.

[0110] Preferably, the control device regulates only the speed of the upper friction device. The speed of the lower friction device can, in particular, correspond to the normal conveying speed and / or remain constant.

[0111] Alternatively, only the speed of the lower friction device can be regulated, while the speed of the upper friction device remains constant.

[0112] Finally, the speeds of the upper and lower friction devices can also be regulated.

[0113] According to the invention, an extraction device is provided in the area of ​​the fiberizing device and / or between the fiberizing device and the further processing device.

[0114] The extraction device is designed to extract a filler material that precipitates during fiberization.

[0115] In particular, powdery material that precipitates during fiber decongestion or pulping can be separated or extracted. Due to its constituents, such as starch, glucose, tannin, and / or lignin, this material can be used as a raw material for various applications, e.g., as bioplastics or, when foamed, as non-combustible insulation, or for energy generation. Specifically, electricity and process heat can be produced from biogas and / or methanol. The material can also be used, for example, as animal feed.

[0116] According to another embodiment, the further processing device comprises a binding device, in particular a gluing device.

[0117] Suitable binders include, in particular, glue, an aminoplast such as phenolic resin, PF resin, melamine and / or urea resin, an adhesive, a dispersion such as PVAC, PMDI, polyurethane, epoxy resin, loam, clay and / or cement.

[0118] According to a further embodiment, the processing device comprises at least one pressing device. The frayed lamellae and / or sheets coated with the binding agent can be pressed into a material, e.g., a plate or a beam.

[0119] The invention also relates to a method for processing elongated, plant-based raw products from palm trees using a processing device according to the invention.

[0120] The raw materials generated during the care process can be delivered to collection points, for example. Here, the material can undergo initial processing.

[0121] For example, the so-called frond sleeve can be cut off, e.g. using a crosscut saw. The resulting dust can then be extracted.

[0122] The frond sleeve contains relatively little fiber material in relation to its mass and is therefore only conditionally suitable for the method according to the invention, although this is fundamentally possible.

[0123] Preferably, however, the frond sleeve is shredded into wood chips in a chipper and stored, for example. This material is then used in other production areas.

[0124] The palm fronds can be cleaned of coarse dirt, such as sand, particularly by brushing them through the system. Preferably, a preventative spraying with a fungicide is then carried out, if necessary, to prevent mold growth. According to one embodiment, a penetration promoter is provided. In particular, a spray device can be provided for spraying the penetration promoter onto the palm plant, especially the panicles and / or the leaves.

[0125] Depending on the requirements of the binder used or the material itself, it can optionally be sprayed with a chemical solution that dissolves the natural wax layer on the surface of the material, i.e., the cuticle, particularly on both stems and leaves. This significantly improves the penetration of the binder and thus the adhesive quality.

[0126] The surface of the panicles and / or especially the leaves consists of a wax layer. Wax acts as a release agent on many binding agents, meaning that fiber components containing wax do not form a secure bond or adhesive.

[0127] To prevent delamination caused by these waxy fiber components, a chemical penetration enhancer, such as an alkylcarboxylic acid amide, can be applied beforehand or added to the binder as an additive during the manufacturing process. Such agents are known from the use of plant protection products. These penetration enhancers dissolve the natural plant wax layer of the cuticle, which is primarily found on the surface of leaves and the bract sheath, thus enabling penetration of the binder. This results in improved bonding and / or higher strength. Furthermore, it prevents bonding defects in the materials.

[0128] In the next production step, the palm leaves, which unlike the panicles consist almost entirely of strong fibers, can be mechanically separated from the panicles, for example using a blade rotor. The resulting dust can then be vacuumed up.

[0129] The leaves can then be pressed into compact bales, for example in a baling press, which reduces storage volume and simplifies storage and / or transport.

[0130] After separation, the panicles can be cut to a defined length, in particular by trimming, in a continuous process. The length can depend, in particular, on the size of the fiberizing device. The panicles can then be bundled.

[0131] The panicles, cut to the defined length, can form the elongated, plant-based raw products.

[0132] In the actual process, the raw products are split into elongated lamellae.

[0133] In contrast to the production of wood-based panels, the raw materials are not chopped into wood chips and / or fine shavings, but the natural fibers, which give the palm frond its enormous stability, for example, are retained as long fibers in order to transfer the positive material properties to the material.

[0134] Before fiber extraction, the stems are pressed lengthwise, for example through a set of knives, which splits the compact stem into elongated lamellae. In this way, the fibers are exposed.

[0135] Optionally, another plant-based raw material, such as the previously separated leaves, can now be added. The addition can be measured to ensure a homogeneous distribution.

[0136] The gills and / or leaves are then shredded. This process extracts the fibers from their natural structure. The pure fibers are obtained, in particular, without the components of the panicle that negatively affect the final product.

[0137] Fiber dissolution is achieved primarily through friction, in order to avoid exerting pressure on the material if possible.

[0138] In a fiber classifier, for example, the recovered fibers can be sorted again and prepared for further use.

[0139] The shredded lamellae and / or sheets are then further processed into a material.

[0140] According to one embodiment, the frayed lamellae are coated with a binder and pressed.

[0141] After fiberization, the fibers can be transported further by an airflow, wetted or sprayed with a binder, e.g. adhesive, and / or dried as required when using liquid binders, for example by an infrared drying device.

[0142] Depending on the requirements of the material, various binders can be used, which can harden during application through different physical and / or chemical processes.

[0143] The fibers can be formed into a so-called fiber cake, whereby the thickness and / or bulk density of the material is defined.

[0144] For example, fiber-reinforced composite materials, such as sheets, can be produced from this fiber cake, preferably in a hot press, using high pressure and / or high heat. The pressure and / or heat leads in particular to a reaction and / or curing of the binder, such as the adhesive.

[0145] The fibers, coated with a binder, can be pressed together, especially under the influence of pressure and / or heat, to form, for example, flat sheet materials, beams and / or molded parts.

[0146] For example, after gluing, a fiber mat can be formed in a forming station, thereby defining the raw density of the material. The fiber mat can then be compacted and / or calibrated in a pre-press and a subsequent curing unit designed as the main press.

[0147] A wide variety of panel thicknesses, beam cross-sections and / or shaped parts are possible.

[0148] After hardening, the materials can be further processed, for example by shaping them into panels and / or beams.

[0149] The disclosure also relates to a material obtained by the inventive method.

[0150] All embodiments and components of the device described herein are specifically designed to be operated, for example by means of a control device, according to the method described herein. Furthermore, all embodiments of the device and all embodiments of the method described herein can be combined with one another, particularly independently of the specific configuration in which they are mentioned.

[0151] The invention is described below by way of example with reference to the drawings. The drawings show: Fig. 1 a schematic top view of an embodiment of a machining device according to the invention, Fig. 2 a top view of an embodiment of a splitting device of a machining device according to the invention, Fig. 3 a sectional view of the splitting device cut along line AA according to Fig. 2 Fig. 4 shows a side view of an embodiment of a fiberizing device of a processing device according to the invention, Fig. 5 shows a top view of the fiberizing device according to Fig. 4Fig. 6 is a perspective view of an embodiment of a material according to the invention, Fig. 7 is a perspective view of an embodiment of an insulating material, Fig. 8 is a sectional view of a palm frond, Fig. 9 is a sectional view of a palm frond split into lamellae, Fig. 10 is a sectional view of a single lamella, Fig. 11 is a cut-away side view of an embodiment of a fiberizing device of a processing device according to the invention, and Fig. 12 is a front view of fiberized lamellae.

[0152] It should first be noted that the embodiments shown are purely exemplary. Individual features can be implemented not only in the combination shown, but also individually or in other technically feasible combinations. For example, the features of one embodiment can be combined with features of another embodiment as desired. Furthermore, other plant-based raw materials can be used instead of panicles and / or leaves.

[0153] If a figure contains a reference numeral that is not explained in the immediately associated descriptive text, reference is made to the corresponding preceding or subsequent explanations in the figure description. Thus, the same reference numerals are used for identical or comparable components in the figures and are not explained again.

[0154] Fig. 1Figure 1 shows a processing device in which elongated, plant raw materials 10, e.g. panicles of palm plants, are fed to a splitting device 14 in the direction of conveyance (see arrow) via a conveying device designed as a conveyor belt 12.

[0155] The raw products 10, which have been split into lamellae, are then deflected by a further conveying device 12 and now lie perpendicular to the conveying direction.

[0156] An optional mixing device 16 is used to add another plant-based raw material 18, e.g., leaves. Since certain plant genera, such as Acrea phoenix (date palm), have an equal ratio of panicles to leaves, it is unnecessary to separate the leaves from the panicles before fiberizing. The panicles and leaves can be fed to the fiberizing device together. In this case, a mixing device 16 is not required.

[0157] The split panicles 10 and leaves 18 enter a fiberizing device 20 and are fiberized there.

[0158] Powdered substances produced in this process can be separated using a suction device 22.

[0159] A further processing device 24 for further processing of the shredded panicles 10 and leaves 18 is attached.

[0160] The further processing device 24 comprises a binding device designed as a gluing device 26.

[0161] In a continuous pre-press 28 of the further processing device 24, the glued panicles 10 and leaves 18 are pressed into raw mats.

[0162] An optional diagonal saw 30 can cut the raw mats to size.

[0163] The raw mats can be temporarily stored in a buffer of 32, for example.

[0164] The raw mats can be glued in a mat gluing device 34. This is followed by a dosing device 36, which may include a scale.

[0165] In a main press 38, the glued raw mats are pressed. In particular, the main press 38, using high pressure and / or high heat, defines the raw density and / or the thickness of the material.

[0166] This is followed by an outfeed conveyor and / or a cooling star 40. The materials can be destashed by means of a destacking device 42.

[0167] The stacking device 42 can in particular have a maturation storage area for the materials.

[0168] The materials can be destacking, grinding, sawing and / or singulating, for example.

[0169] Sawing can be done particularly well using a multi-blade saw. Dust can be extracted during the process.

[0170] Fig. 2 Figure 1 shows a detailed view of a splitting device 14 with a knife set 44. The knife set 44 comprises a plurality of blades oriented parallel to each other and / or parallel to the conveying direction.

[0171] The raw products 10 are pressed lengthwise through the knife set 44. For this purpose, they can first be bundled by two vertically oriented bundling rollers 46. The distance between the bundling rollers 46 and / or the degree of bundling can be adjusted, for example, hydraulically and / or pneumatically.

[0172] Two horizontally oriented rollers 48, arranged one above the other, press the raw products 10 through the knife set 44. The lower roller 48 is shown in the section along line AA according to Fig. 3 to see.

[0173] The Figs. 4 and 5 show detailed views of a fiberizing device 20 with two friction devices 50.

[0174] Optionally, an alignment device 52 can be provided for aligning the supplied material.

[0175] The friction devices 50 are designed, for example, as grooved conveyor belts. The distance between the friction devices 50 decreases in the conveying direction. The panicles 10 and / or leaves 18 conveyed transversely to the conveying direction are thus frayed by friction.

[0176] The upper friction device 50 can rotate counterclockwise, while the lower friction device 50 can rotate clockwise. The rotational speed of the upper friction device 50 is preferably significantly higher than the rotational speed of the lower friction device 50.

[0177] The quality or fineness of the fibers can be checked in a sensor device designed as a fiber classifier 54. For example, the recovered fibers can be sorted again. The speed of at least one friction device 50, preferably the upper friction device 50, can also be adjusted using the determined data.

[0178] Fig. 6 shows a material formed as a beam 56 with elongated, frayed lamellae 58, i.e. fibers, of palm plants and a binder 60.

[0179] The shape of material 56 is basically arbitrary. For example, instead of beams 56, plates or the like can also be formed.

[0180] The binder 60 can in particular be a mixed resin, e.g. urea-formaldehyde.

[0181] Alternatively, in addition to fiberized lamellae 58, the material can also contain, for example, melamine-formaldehyde as a binder 60.

[0182] Furthermore, the material 56 can, in addition to fiberized lamellae 58, contain as a binder 60 e.g. polyvinyl acetate with a hardener and a formaldehyde scavenger.

[0183] In addition to the frayed lamellae 58, the material 56 also comprises palm leaves 18 as a further plant-based raw material. The leaves 18 may preferably also be frayed.

[0184] Material 56 is in particular a fiber composite material. For example, it may have been produced in a processing device according to the invention.

[0185] In Fig. 7 An insulating material 62 is shown, which can be produced by foaming filler 64.

[0186] The filler 64 is extracted during the production of a material 56.

[0187] In particular, the filler 64 can be ground, e.g., by means of a friction mill, and / or mixed with a liquid, e.g., water. The ground filler 64 is mixed with the liquid to form a suspension, whereby, e.g., starch and / or lignin are released. The mixing can be carried out, in particular, by means of a roller mill and / or a mixer.

[0188] In particular, a physical foaming agent, e.g., knitted fabric and / or baking soda, can be added. The mixture will then foam up.

[0189] Upon heating, the liquid evaporates and the insulating material 62 remains.

[0190] The shape of the insulating material 62 is basically arbitrary. For example, it can be formed into sheets.

[0191] In particular, molded parts can also be produced, e.g. for packaging and / or vehicle construction.

[0192] For example, the insulating material can have a bulk density value between 72 and 250 kg / m 3<.

[0193] Fig. 8 shows a cross-sectional view of a palm panicle 10 with fibers 58, filler material 64, in particular parenchyma, and a wax layer 68, in particular cuticle.

[0194] In Fig. 9 The palm panicle 10 was split into lamellae 70. The fibers 58 are naturally bonded to the filler 64. The splitting process exposes the fibers 58, at least partially. The lamellae 70 can now be separated.

[0195] In Fig. 10 A single lamella 70 is shown.

[0196] As in Fig. 11 As can be seen, the lamella 70 is fiberized in the fiberizing device 20, whereby the natural bond is broken down by friction and thereby separated into elongated fibers 58 and filler in 64 in the form of powdered material.

[0197] This represents a significant difference to the production of conventional materials from bamboo, since with bamboo the obtained lamellae are not fiberized, but are either directly or after crushing coated with a binder and pressed into a material.

[0198] With bamboo, the waxy cuticle is usually removed, for example mechanically, to allow for gluing. Heat treatment, such as carbonization, is also frequently carried out.

[0199] In contrast, the cuticle of palm trees does not need to be removed before it becomes fibrous. Heat treatment is also unnecessary.

[0200] Fig. 12Figure 1 shows a front view of the frayed lamellae 58. These fibers 58 can be produced, in particular, from the palm panicle 10 by means of fiber disruption through the action of friction. In this process, the natural bond is broken down, resulting in stable, elongated, and as pure as possible fibers 58. List of reference signs

[0201] 10 Raw product, panicle 12 Conveyor belt, conveying device 14 Splitting device 16 Mixing device 18 Further raw product, sheet 20 Fibreing device 22 Extraction device 24 Further processing device 26 Gluing device, binding device 28 Pre-press 30 Diagonal saw 32 Buffer 34 Mat gluing device 36 Metering device 38 Main press 40 Cooling star 42 Stacking device 44 Knife set 46 Bundling rollers 48 Rollers 50 Rubbing device 52 Alignment device 54 Fiber sifter, sensor device 56 Beam, material 58 Fibreeded lamella, fiber 60 Mixed resin, binder 62 Insulating material 64 Filler, parenchyma 68 Wax layer, cuticle 70 Lamella

Claims

1. A material (56), comprising elongated, defibrated lamellae (58) from palm trees, and a binding agent (60), wherein the length of the defibrated lamellae (58), i.e. the fibres, is at least 20cm, and wherein the material (56) includes palm leaves as another plant-based raw product (18).

2. The material (56) according to claim 1, characterised in that the filler (64) parenchyma of the palm tree is separated from the defibrated lamellae (58).

3. The material (56) of claim 1 or 2, characterised in that the portion of defibrated lamellae (58) is between 40 and 95 percent by weight.

4. The material (56) according to claim 3, characterised in that the portion of defibrated lamellae (58) is between 50 and 60 percent by weight.

5. The material (56) according to any preceding claim, characterised in that the binding agent (60) is formed as an aminoplast, PF resin, melamine and / or urea resin, as an adhesive, as a dispersion, as a thermoplastic elastomer, as loam, as clay and / or as cement.

6. The material (56) according to any preceding claim, characterised in that the material is formed as a pressed material (56).

7. The material (56) according to any preceding claim, characterised in that the material has a bulk density value of between 251 and 500kg / m3, or the material has a bulk density value of between 510 and 850kg / m3, or the material has a bulk density value of greater than 850kg / m3.

8. The material (56) according to any preceding claim, characterised in that the material is formed as a multi-layer material including at least two, three, four, five, six or more layers with different bulk density values.

9. A processing device for processing elongated, plant-based raw products (10) from palm trees, comprising a splitting device (14) for splitting the raw products (10) into elongated lamellae (58), a defibration device (20) for defibrating the lamellae (58) and palm leaves (18), and a further processing device (24) for further processing the defibrated lamellae (58) and the defibrated palm leaves (18) into a material (56), wherein the length of the defibrated lamellae (58), i.e. the fibres, is at least 20cm, and wherein a suction device (22) is provided in the area of the defibration device (20) and / or between the defibration device (20) and the further processing device (24) for extracting the filler (64) parenchyma of the palm tree by suction.

10. The processing device according to claim 9, characterised in that the splitting device (14) comprises a set of knives (44) including multiple blades arranged in parallel and / or in grids.

11. The processing device according to claim 9 or 10, characterised in that an admixing device (16) is provided between the splitting device (14) and the defibration device (20) for admixing the palm leaves (18).

12. The processing device according to any of claims 9 to 11, characterised in that the defibration device (20) comprises a friction device.

13. A method for processing elongated, plant-based raw products (10) from palm trees including a processing device according to any of the claims 9 to 12, wherein the raw products (10) are split into elongated lamellae (58), the lamellae (58) and palm leaves (18) are defibrated, and the defibrated lamellae (58), i.e. the fibres, and the defibrated palm leaves (18) are further processed into a material (56), wherein the length of the defibrated lamellae (58) is at least 20cm, and wherein the filler (64) parenchyma of the palm tree is extracted by suction from the lamellae (58) during defibration.

14. The method according to claim 13, characterised in that the defibrated lamellae (58) are applied with a binding agent (60) and pressed.