Arundo donax paper product

Abstract

Composite panels and pulp, and paper products of the pulp, are produced from Arundo donax. In the fabrication of the composite panels, Arundo donax is comminuted to a suitable size, combined with a binder, and consolidated into panels that meet standards for construction and / or furniture grade panels. The Arundo donax particulates may be combined with wood particulates to produce a mixed furnish that can be used in the preparation of composite panels. Comminuted Arundo donax is treated, in conventional pulping processes, to produce a high tensile strength pulp that can be used in the production of paper. The pulp has a lighter color than wood pulp, and thereby uses less bleaching chemicals to achieve a desired whiteness. The pulp can be combined with wood pulp to produce a variety of products.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation-in-part of copending international application number PCT / US99 / 13519, filed Jun. 16, 1999, which claims the benefit of the priority of the filing date of U.S. patent application Ser. No. 60 / 089,596, filed Jun. 17, 1998. The benefit of the priority of the filing dates of each is hereby claimed under 35 U.S.C. §§ 120 and 119, respectively. Each of the above-identified applications is incorporated herein by reference in its entirety.FIELD OF THE INVENTION [0002] The invention pertains to composite panels and engineered products made of Arundo donax (a type of grass), and pulp and paper produced from Arundo donax. BACKGROUND OF THE INVENTION [0003] There are several well-known technologies for producing particle board, using wood chips and other wood processing waste products. Indeed, these wood-based composite boards have found wide application particularly in building construction and the manufacture of ...

AI Technical Summary

Benefits of technology

[0008] In another aspect, the invention provides composites that include a binder matrix filled with Arundo donax particulates. In accordance with the invention, these composite boards use significantly less binder than wood-based composites, and exceed several of the physical properties of comparable wood-based composites, as measured by standards used in the industry.

[0009] The composites of the invention are produced by selecting nalgrass (a common name for Arundo donax), which is widely distributed as a native wild grass in many parts of the world. The nalgrass is charged to a flaker which contains sharp internal knife edges to reduce the nalgrass to small shards (e.g., flakes), which can then be charged to a hammermill for further size reduction. The resulting material is called a “furnish.” The hammermill furnish is sized, preferably into at least two fractions. Each of the two fractions of nalgrass particulates is separately combined with a proportion of a resin. A layered structure, having alternate layers of fine and coarse nalgrass-resin mixture is then produced. The layered structure is subjected to heat and pressure for consolidation into a composite product. Satisfactory products may be made with a single layer, two layers, or more. Many commercial operations blend a variety of wood sources, such as hardwoods, softwoods, and recycled wood waste, in the manufacture of composites. Those skilled in the field will seek the advantages of nalgrass by blending into their furnish a portion of nalgrass with their available wood sources.

[0010] The invention also provides paper pulp, and paper products made from nalgrass. The raw pulp produced from the nalgrass is of lighter color than the pulp produced from woods that are typically used in paper production. Accordingly, a smaller amount of chemical bleach must be added to bleach the pulp to a desired whiteness. Nalgrass pulp is also stronger than most common hardwoods, such as aspen. The pulp of the present invention can also be utilized in other cellulose-based products including building products and modified cellulosic fibers such as viscose (e.g., rayon).

Problems solved by technology

While the supply of wood for use in these products is “renewable,” it requires setting aside land for long periods of time for tree farming.

Moreover, when demand outstrips supply, because supply is based on forecasts of decades before when trees were planted, then a shortage inevitably develops.

Since the wood required for these uses results in cutting millions of acres of forest each year, such shortages lead to serious worldwide concerns about large scale deforestation and its contribution to global warming.

Extensive research had been conducted and production trials have been made in an effort to find a suitable non-wood fiber for composites and pulp but, until now, this work has met with very little success due to inferior properties, excessive costs and many commercial production drawbacks.

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