A method of manufacturing an insulation panel comprising hemp hurd, an insulation panel and an apparatus for manufacturing an insulation panel

Abstract

An insulation panel comprising hemp hurd, a method of manufacturing the insulation panel and an apparatus for manufacturing the insulation panel, the method comprising the steps of: - providing a container comprising a receiving space arranged for receiving hemp hurd; - receiving, by the container, pieces of hemp hurd in the receiving space thereof; - vibrating, by a vibrating apparatus, the container comprising the pieces of hemp hurd for compacting the hemp hurd provided in the receiving space and obtaining the insulation panel.

Description

Title: A method of manufacturing an insulation panel comprising hemp hurd, an insulation panel and an apparatus for manufacturing an insulation panel Description: According to a first aspect, the present disclosure relates to a method of manufacturing an insulation panel comprising hemp hurd. According to a second aspect, the present disclosure relates to an insulation panel comprising hemp hurd obtained from a method according to first aspect of the present disclosure. According to a third aspect, the present disclosure relates to an apparatus for manufacturing an insulation panel according to the second aspect of the present disclosure. Hemp stalks comprise two main types of fibre: bast or long fibres found in the bark and hurd, also referred to as hemp hurd, hemp shive and hemp core, located in the core of the stem. The bast fibres may be divided into two types primary and secondary bast fibres. The primary bast fibres typically make up 70-90% of the bast. They are characterized by a relative long length of up to 50 mm, a relative high cellulose content in the range of 50% to 70% and a relative low lignin content of about 7%. These fibres are the most valuable part of the stalk. The secondary bast fibres are about 2 mm, more lignified as compared to the primary bast fibres and hence of lower value. It is known to use the bast or long fibres to make an insulation material. The flexibility and toughness of the bast fibres during compression allows for compression and a relative easy implementation as a building material. The insulation material comprising the bast fibres may also be easily adjusted to different sizes and shapes by cut during the installation process. Hurd comprises relative short fibres of about 0.5 mm and are woodier than the bast fibres. Hurd accounts for 70-80% of the stalk and typically contains 20-30% lignin. The inner fibres typically have low value industrial applications, such as mulch, animal bedding, and litter. The present disclosure aims at providing a method and apparatus for manufacturing a product having a relative high value as compared to mulch, animal bedding, and litter. The objective is achieved by the method according to the first aspect of the present disclosure. The method comprising the steps of: - providing a container comprising a receiving space arranged for receiving hemp hurd; - receiving, by the container, pieces of hemp hurd in the receiving space thereof; - vibrating, by a vibrating apparatus, the container comprising the pieces of hemp hurd for compacting the hemp hurd provided in the receiving space and obtaining the insulation panel. The present disclosure relies at least partly on the insight that by vibrating a volume of hemp hurd, the hemp hurd may be compacted resulting in a relative dimensionally stable product such as an insulation panel. Preferably, during the step of vibrating, additives other than a binder material are present in the receiving space. In this regard, it is beneficial if the additives are chosen from the list comprising biocides, chalk, salts, amino acids and magnesium. Adding a biocide to the hemp hurd is beneficial to destroy, deter, render harmless, or exert a controlling effect on any harmful organism that may be present in the hemp hurd. Within the context of the present disclosure, a biocide is to be understood as a diverse group of poisonous substances including preservatives, insecticides, disinfectants, and pesticides used for the control of organisms that are harmful to human or animal health or that cause damage to natural or manufactured products. Chalk and / or magnesium as an additive to the hemp hurd is beneficial for increasing fire resistance. Adding a salt and / or an amino acid is beneficial for regulating the humidity of the hemp hurd and / or the insulation panel. In addition, a salt and an amino acid may be antimicrobial. Preferably, during the step of vibrating, the receiving space is free from a binder material. The absence of hemp hurd is beneficial for producing an insulation panel at a relative low cost, since the cost for the binder are avoided. In an embodiment of the method according to the present disclosure, during the step of vibrating, pieces of hemp hurd mutually attach, preferably mutually attach by hooking. The present disclosure relies at least partly on the insight that individual pieces hemp hurd may comprise splinters that cause a hooking action when the hemp hurd is vibrated, thereby causing the individual pieces of hemp hurd to mutually attach. In an embodiment, the method according to the present disclosure further comprises the step of: - removing, the insulation panel from the container. Removing the insulation panel from the container is beneficial for allowing the container to be used for the manufacturing of a plurality of insulation panels, thereby allowing to reduce an insulation panel at a relative low cost. Preferably, during the step of vibrating, further hemp hurd is added to the receiving space. This is beneficial for allowing to fill the container to a relative large extent, thereby allowing to manufacture a relative large insulation panel using a relative small container. In an embodiment, the method according to the present disclosure further comprises at least one of the steps of: - drying the hemp hurd; and - breaking the hemp hurd into pieces having a size in the range of 0.5 to 4 cm. Preferably, during the step of receiving, by the container, pieces of hemp hurd in the receiving space thereof, the hemp hurd, has a humidity in the range of 10% to 20%, preferably a humidity in the range of 15% to 18%. Preferably, the step of adding additives is performed before performing the step of vibrating. It is advantageous, if, during the step of vibrating, the container is vibrated at a frequency in the range of 500 to 4000 Hz, preferably in the range of 1250 to 3500 Hz. It was found that vibrating the hemp hurd in the range of 500 to 4000 Hz causes the hemp hurd to compact to an extent that corresponds to an insulation value that is attractive for instance for insulating a building. The preferred range of 1250 to 3500 Hz resulted in a surprising effect in that the compacted hemp hurd has a relative high insulation value allowing for the use of a relative thin insulation panel. A relative thin insulation panel is attractive for manufacturing an insulation panel having a relative low cost due to the relative low amount of hemp hurd required. According to the second aspect, the present disclosure relates to an insulation panel obtained from a method according to the first aspect of the present disclosure. Embodiments of the insulation panel correspond to embodiments of the method according to the first aspect of the present disclosure. The advantages of the insulation panel correspond to advantages of the method according to first aspect of the present disclosure presented previously. Preferably, pieces of hemp hurd, preferably all pieces of the hemp hurd, of the insulation panel are mutually mechanically interlocked. In a practical embodiment of the insulation panel, pieces of hemp hurd, preferably all pieces of the hemp hurd, of the insulation panel are attached to each other without a binder material. It is beneficial if the insulation panel comprises a housing surrounding the hemp hurd, wherein the pieces of hemp are provided in an interior of the housing. Preferably, the insulation panel has a width and / or height in the range of 0.5 to 8.5 m and a thickness in the range of 0.1 0.5 m. In an embodiment of the insulation panel, the insulation of the hemp hurd is in the ranged of 0.045 W / mK and 0.05 W / mK determined according to NEN-EN 12664:2001. Preferably, the density of the hemp hurd is in the range of 120 kg / m3 to 200 kg / m3, preferably in the range of 150 kg / m3 to 180 kg / m3. In this regard, it is noted that a relative low density corresponds to the presence of relative large spaces between individual pieces of hemp hurd which allows for the presence of a relative large amount of air which is beneficial for realising a relative high insulation value. The present invention relies at least partly on the insight that a balance between the compaction and the insulation value is to be made, wherein a relative high compaction level results in a relative robust hemp hurd product having a lower insulation value and a relative low compaction level resulting in a somewhat more fragile hemp hurd product having a relative high insulation value. According to the third aspect the present disclosure relates to an apparatus for manufacturing an insulation panel according to the second aspect of the present disclosure, the apparatus comprising: - a support arranged for supporting a container provided with a receiving space for receiving hemp hurd; - a vibration arrangement, mechanically coupled with the support, arranged for generating a vibration at a predetermined frequency and amplitude. Embodiments of the apparatus correspond to embodiments of the method according to the first aspect of the present disclosure. The advantages of the apparatus correspond to advantages of the method according to first aspect of the present disclosure presented previously. Preferably, the apparatus further comprises: - a damping arrangement arranged for supporting the apparatus at a ground surface and further arranged for damping, during use of the apparatus, vibrations transmitted to the ground surface. In this regard, it is advantageous if the damping arrangement is coupled, via the support, with the vibration arrangement. In an embodiment, the damping arrangement comprises a first damping unit and a second damping unit, wherein the vibration arrangement is attached to the support between the first damping unit and the second damping unit. Preferably, the vibration arrangement comprises an amplitude setting device arranged for setting the amplitude of the vibration generated, during use, by the vibration arrangement. It is beneficial, if the vibration arrangement comprises a frequency setting device arranged for setting the frequency of the vibration generated, during use, by the vibration arrangement. In this regard, it is advantageous if the frequency setting device is arranged for setting the frequency of the vibration generated, during use, by the vibration arrangement in the range of 500 to 4000 Hz, preferably in the range of 1250 to 3500 Hz. Preferably, the vibration arrangement comprises an unbalance motor. The above-mentioned and other features and advantages of the invention are illustrated in the following description with reference to the enclosed drawings which are provided by way of illustration only and which are not limitative to the present invention. Fig. 1 shows schematically an embodiment of an insulation panel comprising hemp hurd according to the second aspect of the present disclosure; Fig. 2 shows schematically an embodiment of a method according to the first aspect of the present disclosure, for manufacturing the insulation panel of Fig. 1; Fig. 3 shows schematically an embodiment of an apparatus according to the third aspect of the present disclosure, for manufacturing an insulation panel of Fig. 1. Figure 1 shows schematically an embodiment of an insulation panel 2 comprising hemp hurd 1 according to the second aspect of the present disclosure. The pieces of hemp hurd 1 are mutually mechanically interlocked and are attached to each other without a binder material. The insulation panel 2 comprises a housing 5, 6 surrounding the hemp hurd 1, wherein the pieces of hemp 1 are provided in an interior 7 of the housing 5, 6. The housing comprises a bottom housing part 5, having a bottom wall and side walls, and an upper housing part 6, for enclosing the hemp hurd 1 inside the interior 7 of the housing. The insulation panel 2 furthermore has a width and a height in the range of 0.5 to 8.5 m and a thickness in the range of 0.1 0.5 m, wherein the density of the hemp hurd 1 is in the range of 150 kg / m3 to 180 kg / m3 and the insulation value of the hemp hurd 1 is in the ranged of 0.04 W / mK and 0.05 W / mK determined according to NEN- EN 12664:2001. Figure 2 shows schematically an embodiment of a method 100 according to the first aspect of the present disclosure. The method 100 is arranged for manufacturing the insulation panel 2 as described above and comprises the steps of: - Drying 101 the hemp hurd 1. - Breaking 102 the hemp hurd 1 into pieces of hemp hurd 1 having a size in the range of 0.5 to 4 cm. - Providing 103 a container 20 comprising a receiving space 21 arranged for receiving hemp hurd 1. - Receiving 104, by the container 20, pieces of hemp hurd 1 in the receiving space 21 thereof. - Vibrating 105, by a vibrating apparatus 31, the container 20 comprising the pieces of hemp hurd 1 for compacting the hemp hurd 1 provided in the receiving space 21 and obtaining the insulation panel 2. - Removing 106, the insulation panel from the vibrating apparatus or from the container. During the step of drying 101, the hemp hurd 1 is dried such that the hemp hurd 1 has a humidity in the range of 15% to 18% during the step of receiving 104 the pieces of hemp hurd 1 in the receiving space 21 of the container 20. During the step of vibrating 105 the pieces of hemp hurd 1 mutually attach to each other by hooking. Optionally, additives 3 other than a binder material, for example biocides, chalk, salts, amino acids and magnesium, are present in the receiving space 21 of the container 20, while the receiving space 21 is free from a binder material. Preferably, the additives 3 are mixed with the hemp hurd 1 prior to receiving the hemp hurd by the container 20. During the vibrating 105, the container 20 is vibrated at a frequency in the range of 1250 to 3500 Hz for compacting the hemp hurd 1, and further hemp hurd 1 is added to the receiving space 21 for completely filling the receiving space 21 of the container 20. In an embodiment, the container 20 is the housing of the insulation panel 2, in particular the bottom housing part 5 with the upper housing part 6 removed. After receiving 104 the pieces of hemp hurd 1 in the housing and vibrating 105 the housing, the housing is completely filled with compacted hemp hurd 1. After removing 106 the housing from the vibrating apparatus 31, the upper housing part 6 is attached to the bottom housing part 5 for enclosing the hemp hurd 1 inside the interior 7 of the housing and realizing the insulation panel 2. In another embodiment, the container 20 is a dedicated container, optionally fixed to the vibrating apparatus 31. After receiving 104 the pieces of hemp hurd 1 in the container 20, the container 20 is vibrated 105 and completely filled with hemp hurd 1 for realizing an insulation panel 2 without a housing 5, 6. The insulation panel 2 is removed 106 from the container, wherein the insulation panel 2 for example can be applied to a structural building part. Optionally, a further step of applying 107 an adhesive layer to a side of the insulation panel 2 is performed, wherein the insulation panel 2 is provided with a vapor barrier and / or and reflective foil. Figure 3 shows schematically an embodiment of an apparatus 10 according to the third aspect of the present disclosure, for manufacturing the insulation panel 2 as described above. The apparatus 10 for the manufacturing of an insulation panel 2, comprises a support 31, arranged for supporting the container 20 provided with the receiving space 21 for receiving hemp hurd 1, and a vibration arrangement 32, mechanically coupled with the support 31, arranged for generating a vibration at a predetermined frequency and amplitude. The apparatus 10 furthermore comprises a damping arrangement 33, arranged for supporting the apparatus 10 at a ground surface 34 and further arranged for damping, during use of the apparatus 10, vibrations transmitted to the ground surface 34. The damping arrangement 33 comprises a first damping unit and a second damping unit, wherein the vibration arrangement 32 is attached to the support 31 between the first damping unit and the second damping unit. The vibration arrangement 32 comprises an amplitude setting device 37, arranged for setting the amplitude of the vibration generated during use by the vibration arrangement 32, and a frequency setting device 38, arranged for setting the frequency of the vibration generated preferably in the range of 1250 to 3500 Hz during use by the vibration arrangement 32. The vibration arrangement 32 furthermore comprises an unbalance motor 39.

Claims

1. A method (100) for making an insulation panel (2) that hemp wood (1) includes, where the method (100) includes the steps of: - providing (103) a container (20) that a reception area (21) includes which is equipped for receiving hemp wood (1); - receiving (104), by the container (20), pieces of hemp wood (1) in the reception area thereof; - the vibration (105), by a vibrating device (31), of the container (20) which the pieces of hempwood (10) include for compacting the hempwood (1) that is installed in the reception area (21) and obtaining the insulation panel (2).

2. The method (100) according to conclusion 1, whereby during the step of the vibrate (105), additives (3) other than a binding agent are present in the receiving room (21).

3. The method (100) according to claim 2, where the additives (3) are selected from the list comprising biocides, lime, salts, amino acids and magnesium.

4. The method (100) according to one of the preceding conclusions, whereby during the vibration step (105), the receiving room (21) is free of a binding agent.

5. The method (100) according to one of the preceding conclusions, whereby during the step of the vibration (105), connect pieces of hemp wood (1) together, at Preferably connect by hooking.

6. The method (100) according to one of the preceding conclusions, whereby the method further includes the step of: - removing the insulation panel (2) from the container (20) - 106 7. The method (100) according to one of the preceding conclusions, whereby during the vibrating step (105), further hemp wood (1) is added to the reception area (21).

8. The method (100) according to one of the preceding conclusions, whereby the method (100) further includes the steps of: - drying (101) of the hemp wood (1); and - breaking (102) the hemp wood (1) into pieces of a size in the range of 0.5 to 4 cm.

9. The method (100) according to one of the conclusions 1 to 8, whereby during the step of receiving (104), through the container (20), pieces of hemp wood (1) in the reception area (21) thereof, the hemp wood (1) has a moisture content in the prepared from 10% to 20%, preferably with a humidity in the range of 15% to 18%.

10. The method (100) according to one of the conclusions 1 to 9, whereby during the step of the vibration (105), the container (20) is vibrated at a frequency in the range of 500 to 4000 Hz, preferably in the range of 1250 to 3500 Hz.

11. An insulation panel (2) containing hemp wood (1) obtained according to a method (100) according to one of the preceding conclusions.

12. The insulation panel (2) according to claim 11, with pieces of hemp wood (1) the insulation panel (2) are mechanically locked together.

13. The insulation panel (2) according to claim 11 or 12, where the pieces The hemp wood (1) of the insulation panel (2) is connected to each other without a binder.

14. The insulation panel (2) according to one of the conclusions 11 to 13, where the insulation panel (2) includes a casing (5, 6) that surrounds the hemp wood (1), where the pieces of hemp (1) are placed in an inner (7) of the housing (5, 6).

15. The insulation panel (2) according to one of the conclusions 11 to 14, where the insulation panel (2) has a width and / or height in the range of 0.5 to 8.5 m and a thickness in the range of 0.1 - 0.5 m.

16. The insulation panel according to one of claims 11 to 15, where the hemp wood insulation (1) is in the range of 0.04 W / mK and 0.05 W / mK, determined according to NEN-EN 12664:2001.

17. The insulation panel (1) according to one of the conclusions 11 to 16, where the density of the hemp wood (1) is in the range of 120 kg / m3 to 200 kg / m3, preferably lies in the range of 150 kg / m³ to 180 kg / m³.

18. A device (10) for making an insulation panel (2) according to one of the claims 11 to 17, where the device (10) comprises: - a support (31), designed to support a container (20) which is equipped with a reception area (21) for receiving hemp wood (1); - a vibration arrangement (32), mechanically coupled with the support (31), designed to generate a vibration at a predetermined frequency and amplitude.

19. The device (10) according to claim 18, whereby the device (10) further includes: - a damping arrangement (33) designed to support the device (10) on a ground surface (34) and further equipped for damping, during use of the device (10), of vibrations that are transmitted to the ground surface (34) transferred.

20. The device (10) according to claim 19, where the damping arrangement (33) is linked, via the support (31), to the vibration arrangement (32).

21. The device (10) according to claim 19 or 20, where it damping arrangement (33) a first damping unit and a second damping unit includes, where the vibration arrangement (32) is attached to the support between the first damping unit and the second damping unit.

22. The device (10) according to one of the claims 18 to 21, where the vibration arrangement (32) includes an amplitude adjustment device (37) which is designed for the setting the amplitude of the vibration produced by the vibration arrangement during use (32) is generated.

23. The device (10) according to one of the claims 18 to 22, where the vibration arrangement (32) includes a frequency adjustment device (38) which is designed for the setting the frequency of the vibration that, during use, is produced by the vibration arrangement (32) is generated.

24. The device (10) according to claim 23, where the frequency adjustment device (38) is equipped for setting the vibration frequency during use by the vibration arrangement (32) in the range of 500 to 4000 Hz, preferably in the range of 1250 up to 3500 Hz.

25. The device according to one of the claims 18 to 24, whereby the vibration arrangement (32) includes an unbalanced motor (39).

Images