Bio-based composite panel in sandwich construction with hemp core and thermoplastic lignin matrix
A hemp-based sandwich panel with a thermoplastic lignin matrix and kraft paper reinforcement addresses the environmental and mechanical limitations of conventional drywall, achieving lightweight, eco-friendly, and cost-effective mass production for sustainable construction.
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Utility models
- Current Assignee / Owner
- JORDAN SVEN
- Filing Date
- 2026-01-23
- Publication Date
- 2026-05-21
AI Technical Summary
Conventional drywall panels have a high CO2 footprint, are difficult to handle, and rely on finite mineral resources or synthetic binders, while ecological alternatives are often expensive or less mechanically robust.
A sandwich structure composed of a hemp core bound by a thermoplastically activated lignin matrix, with kraft paper or non-woven fabric as cover layers, produced through a continuous rolling process without additional drying cycles.
The solution provides a lightweight, eco-friendly alternative with a negative CO2 balance and 30% weight reduction, suitable for sustainable interior design and modern construction, offering mechanical resilience and efficient mass production.
Smart Images
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Abstract
Description
[0001] 1. Technical Field: The invention relates to a lightweight panel for drywall construction and a method for its continuous production. The panel serves as an ecological and weight-reduced alternative to conventional gypsum plasterboard in interior construction.
[0002] 2. Technical problem: Conventional drywall panels have a high CO2 footprint, are difficult to handle, and are often based on finite mineral resources or synthetic binders. Existing ecological alternatives are frequently expensive to dry or less mechanically robust.
[0003] 3. Solution to the problem: The invention solves this problem through a sandwich structure according to Fig. 1. A core of hemp shives, fibers and rods is bound by means of a thermoplastically activated lignin matrix.
[0004] This matrix also acts as an adhesive for the double-sided cover layers made of kraft paper or non-woven fabric, which serve as tensile reinforcement.
[0005] The production is carried out according to Fig. 2 in a continuous rolling process in which the dry mixture is pressed directly into an endless plate under the influence of heat and pressure without additional drying cycles.
[0006] 4. Application Area: The primary application area is sustainable interior design, timber frame construction, and energy-efficient renovation. Due to its negative CO2 balance and approximately 30% weight reduction compared to gypsum boards, the invention is particularly suitable for modern lightweight construction and ecological certifications in the building industry.
[0007] Due to the composite structure of the panel, it can also be used in general drywall construction.
[0008] In the long term, the board is intended to serve as a broad alternative to plasterboard. Fig. 1: The strategic sandwich structure
[0009] In this drawing we show that it is not a simple "plate", but a technically sophisticated composite system. • Layers 1 & 3 (The top layers): The kraft paper acts like reinforcement (like steel in concrete). It absorbs tensile forces. Without this paper, the hemp board would be brittle; with paper, it becomes highly resilient. • Number 2 (The hemp core): This is where the volume is located. The hemp shives (fibers and spores) provide lightness and insulation. • Number 4 (The Lignin Matrix): The drawing clearly shows that the lignin is not a foreign substance, but rather surrounds the hemp particles in the core and simultaneously forms the bridge to the paper. Fig. 2: The industrial process (scalability)
[0010] This figure demonstrates that the product is suitable for mass production. • Number 5 (roll material): We work "endlessly". This is much more efficient than a static press where each sheet is inserted individually. • Numbers 1 & 6 (spreading): Here we show the dry process. Since no wet glue is sprayed, the expensive and energy-intensive drying after pressing is eliminated. • Numbers 7 & 8 (heating rollers): This is the heart of the process. Here, the lignin becomes thermoplastic (meltable by heat). The rollers "activate" the adhesive as it passes through the machine. • Steps 9 & 10 (Finishing): The sheet leaves the machine fully finished and only needs to be cut. It is immediately ready for shipment.
[0011] Fig. 1 1 Top layer 2 core layer 3 Lower top layer 4 Lignin matrix Fig. 2 5 rolls 6 spreading units 7 Heating zone / infrared 8 pairs of rollers 9 Endless composite panel 10 Cutting unit / cutter
Claims
(Main claim): The lightweight panel for dry construction is characterized in that it consists of a core of hemp shives and / or hemp fibers, wherein the binding of the fibers is carried out exclusively or predominantly by thermally activated lignin powder and the core is bonded on both sides with a paper or nonwoven lamination. (Process-specific): Plate according to claim 1, characterized in that the connection between core and lamination is produced by the lignin contained in the core under the influence of pressure and heat in a continuous rolling process.