System and apparatus for manufacturing insulation made from hemp, and product made therefrom

Abstract

A system for processing hemp biomass into fibers includes at least one processor defining an opening through which biomass is urged towards a mechanism for separating hemp fibers from hurd; a portion of the hemp fibers and the hurd generated in the processor is diverted to a first condenser having a housing and an associated fan that pulls material under vacuum from the processor into a condenser intake, an internal condenser screen retains the hemp fiber and hurd, the screen having openings through which the undesirable dust and small particles are pulled, and an internal rotating scraper which collects the desirable hemp fiber and hurd from the screen; and a shaker table receives the hemp fiber and hurd collected by the condenser rotating scraper, the shaker table has an upper perforated vibrating surface that retains the hemp fiber and allows the hurd to fall through the perforations.

Description

RELATED APPLICATION

[0001] The present application is a Non-Provisional of, and claims 35 U.S.C. 119 priority from, U.S. Provisional Application No. 63 / 747,743 filed Jan. 21, 2025, the entire contents of which are incorporated by reference herein.BACKGROUND

[0002] The present invention relates generally to the production of blown building insulation, and more specifically to the use of hemp fibers to create such insulation.

[0003] Conventional blown insulation is a loose material that retains heat in or keeps heat out of buildings, usually a residential structure. Installation is achieved using an electrically powered, adjustable-rate blower and associated tubing or ducting of differing lengths and or diameter to enter the attic or wall spaces of homes or buildings. Blown insulation presently is sourced from four main materials. A first, referred to as glass-type, is made from tiny glass fibers ranging from 3 to 4 microns in diameter. Glass insulation is increasingly more sustainably sourced from recycled glass waste streams. These waste streams, in the future, will become more difficult to source in terms of consistency and general availability. Glass is an excellent insulant possessing a stated and standardly accepted R-value of R 2.7 to 3.0 per inch, and a weight per cubic foot, installed, of 0.46 pounds to 0.57 pounds.

[0004] Another type is rock wool or mineral wool derived from blast furnace slag, or certain types of rock. Rock wool possesses a standardly accepted R-value of R 3.0 to R 3.3, and a weight per cubic foot, installed, of ~1.7 pounds. Rock / Mineral wool fibers are hazardous if inhaled. Rock wool is relatively dense, but requires significant energy to produce, and is costlier than other types of insulation.

[0005] A third type of blown insulation, cellulose is made from recycled newspaper or other wood products. While cellulose insulation is considered to be more ecologically friendly since it is primarily derived from recycled sources, it must be treated to be flame retarding due to a high degree of flammability. Fire or flame retardance is achieved primarily using scrutinized chemicals. Inhaling these chemicals and / or skin contact during installation are considered potentially hazardous to one's health. Cellulose insulation has an R-value of R-3.6 to 3.7 per inch, with a weight per cubic foot installed of 1.25 pounds to 1.64 pounds.

[0006] A fourth type is wood fibers, obtained through shredding or milling wood, primarily young pine trees or wood generated through traditional tree removal, forest management and / or lumber production activities. While wood fibers could be a promising source of insulation, there are problems with the unpredictability of supply, especially if the material needs to be scaled up to industrial volume. Wood fiber blown insulation has an R value of R-3.8 per inch, and like cellulose, needs to be treated with fire retardant chemicals.

[0007] Thus, since each main material has advantages and disadvantages, there is an interest in the industry for alternatives to the above-listed materials. Alternatives would preferably and successfully achieve a low production cost, a lower density of the installed product when compared to alternative materials, possess an elevated R-value, be readily handled and applied by installers and be fire resistant.

[0008] Hemp biomass is a renewable, recyclable, and compostable. Hemp plants include the variety “Cannabis sativa” also known as “federally legal industrial hemp” due to their very low “THC” content, tall stature, and vertical growth. Industrial hemp is distinguished from plants used for other purposes by the fact that it is genetically chosen to grow tall and thin for its fiber content rather than short and “bushy” for flowering capability. Hemp plants from differing genetics, acclimated by climatic region and more importantly by latitude, are relatively easy to grow in most climates with a fast yield, typically reaching maturity in 90-100 days. This capability to be grown almost anywhere creates flexibility for site location and the ability to reduce the transportation footprint, decreasing logistics requirements and fossil fuel emissions generated in shipping. This distributed model is equally important to farmers and farm payrolls by offering alternative crops that enrich rather than degrade soil health and use far less water than traditional grain, cotton, or sugar cane crops. Hemp has the highest yield per acre of any natural fiber approved for farming in the U.S. Further, hemp fiber is approximately ten times stronger than wood fiber, is lighter and less expensive to produce than wood, and is far more sustainable.

[0009] Hemp “bast” fiber is taken from the exterior layer or “bark” of the plant, which is distinct from the internal woody core or “hurd.” A challenge to manufacturers is achieving the successful mechanical separation of the hurd from the fiber. While many systems claim to be effective in this process, they are limited by a lack of ability to accept varying degrees of size and diameter of hemp biomass, therefore breaking, choking, or rendering the system useless based on a high biomass / thick stalk yield. Biomass yield and production throughput are two major considerations in determining final cost of the product, therefore the system must be designed to handle the amount and type of high yield and thick biomass that is desirable to the farmer and the finished insulation producer. The hurd has undesirable properties when used as blown insulation, or as a component in the blown insulation, therefore a suitable production system has a goal of separating the hurd and fiber to reduce, and if possible, eliminate the level of hurd / cellulose in the final product.

[0010] Hemp fiber and hurd have been combined for use as insulation in batt or roll form, in which the R-value is approximately R 2.8 to R3.5 per inch thickness of the batt, with an approximate density per cubic foot of 2.5 to 2.8 pounds. Hemp insulation has a reputation for superior thermal performance, breathability and resistance to both pests and mold. A 2-inch-deep hemp batt has a stated R value of R7 and a 7.5-inch-deep hemp batt has an R value of R 28. However, the hemp batts are not considered as flexible as sheep or mineral wool, and hemp fiber has not been used for blown insulation due to the inability to suitably separate the intertwined hemp fibers or to sufficiently reduce the hurd content.

[0011] Accordingly, there is a need for an improved system for treating or processing hemp fibers so that they can be used in blown insulation.SUMMARY

[0012] The above-listed need is met or exceeded by the present system for processing hemp biomass into hemp fibers and hurd, and for separating the hemp fibers from the hurd and consolidating them so that the fibers are suitable for use as blown in building insulation. Beginning with harvested, baled or bulk hemp biomass, the present system subjects the hemp biomass to a sequence of coordinated impacts, combing actions and the use of gravity to tease the hemp fibers away from the hurd, and also to separate a significant proportion of the hurd from the fibers. The resulting separated fibers have a cottony appearance with a much reduced percentage of entwined hurd.

[0013] A feature of the present system is, after at least one and preferably multiple impacts and separation steps, here referred to as processor steps, on the biomass, the semi-separated hemp fibers and hurd are directed to a condenser apparatus, which subjects the hemp materials to vacuum and physical separation. An internal screen in the condenser, which is sized to retain separated fiber and hurd as “desirable material”, captures the fiber and hurd against the screen under vacuum, which is then “wiped” off the screen, allowing the less desirable material to pass through the appropriately sized holes and on to dust collection or other means of collection. A rotating wiper then collects the trapped fibers and hurd which have been separated and pushes them downward towards the exit portion of the condenser where, preferably using an air lock to maintain the internal condenser vacuum, the collected fibers are preferably delivered to a shaker table, which promotes further separation of the hurd via gravity, while the fibers are again retained upon a vibrating screen surface. Next, the fibers entrained on the screen surface are directed, including but not limited to, using a conveyor or under vacuum, to devices for further processing.

[0014] In some embodiments, the hemp fibers and hurd are conveyed or sucked by vacuum into a hammermill chamber defined by a perforated cylindrical screen or cage, which encloses an impeller to which a plurality of bar-like hammers are pivotally secured. Rotating at approximately 2500-4500 RPM, the hammermill further teases and impacts the fibers and hurd so that they pass through openings in the hammermill screen after being appropriately sized for insulation.

[0015] In a preferred embodiment, the hemp is sent to a second condenser where it is subject to another collection of desirable fiber and hurd from the scraping operation under vacuum. Lastly, the hemp fiber, at this point largely devoid of hurd, is dropped upon a second shaker table in a dispersed format from the rotary lock that further separates the hemp fiber from the residual hurd.

[0016] At this point, a suitable flame retardant, and other potential additives, are preferably added to the hemp fiber. In some instances, post additive treatment, the hemp is subjected to another cycle of hammermill, condenser and shaker table, individually, coupled, or in concert. The resulting fiber is suitable for machine blowing, similar to competitive glass and cellulose blown insulation.

[0017] Additionally, as suggested here, the solution presented is 100% sustainable and recyclable, grows and is harvested in a 90-to-100-day cycle which is significantly less than any known wood alternatives, and presents no harm to the installer or the homeowner from either chemical flame retardants or inhalation. Installers of insulation made under the present process benefit greatly from the reduced skin contact with other types of insulation that cause “itching”, as hemp fiber will not penetrate the skin as some other types of insulation do when blown into a space to be insulated.

[0018] More specifically, a system for processing hemp biomass into fibers useful as insulation includes at least one processor having a housing defining an access opening through which the biomass is urged towards a first sizer configured for sizing hemp fibers and hemp hurd; the hemp fibers and the hurd generated in the at least one processor is collected and diverted to a first condenser having a housing and an associated fan that pulls material under vacuum from the at least one processor into a condenser housing intake, in the condenser housing is an internal screen against which the hemp fiber and hurd is retained, and the screen having openings through which the undesirable dust and small particles are pulled through, and an internal rotating scraper which collects the desirable hemp fiber and hurd from the screen; and a shaker table receives the hemp fiber and hurd collected by the rotating scraper from the condenser screen, the shaker table has an upper perforated vibrating surface that retains the hemp fiber and allows the hurd to fall through the perforations.

[0019] In an embodiment, the system further including a second condenser receiving the fibers passing through the shaker table surface and using a second condenser vacuum, causes the fibers to be separated against an internal screen, hurd passing through the internal screen, and the collected fibers being collected by a rotating wiper; and a second shaker table constructed and arranged for receiving the hemp fibers collected by the second condenser and transporting the hemp fibers for further processing.

[0020] In an embodiment, the system includes an applicator configured for applying fire retardant to the hemp fibers collected on the second shaker table. In a preferred embodiment, the applicator includes an applicator housing enclosing a rotating auger, the housing receiving incoming hemp fibers under air pressure, the auger suspending the hemp fibers within the housing, and an atomizer sprayer associated with the applicator housing applying fire retardant solution under pressure to the suspended fiber particles.

[0021] In an embodiment, the system includes a second rotating hammermill configured for receiving the hemp fibers treated with fire retardant and subjects the fiber to impact from second rotating hammers operating within a second chamber defined by a circular screen, the fibers are then passed through a second hammermill outlet.

[0022] In an embodiment, the system includes a third condenser configured for receiving hemp fiber under vacuum power from the second rotating hammermill, and having a third wiper removing collected fiber from an internal condenser screen.

[0023] In an embodiment, the system includes a third shaker table configured for receiving the hemp fibers from the third condenser.

[0024] In an embodiment, the first condenser is located above the shaker table so that hemp fibers fall by gravity from the condenser upon said upper perforated vibrating surface.

[0025] In an embodiment, the fiber emitted from the first condenser has a density in the range of 0.5-0.8 lb / ft3.

[0026] In an embodiment, the fiber emitted from the first condenser has a thermal conductivity in the range of 0.280-0.380 BTU-in / ft2-hr-° F.

[0027] In an embodiment, the system includes providing a second sizer for receiving material from the at least one processor, the second sizer generating hemp fibers and hurd particles with a designated length range, and transmitting the generated fibers and particles to the condenser.

[0028] In a preferred embodiment, the second sizer generates hurd particles and hemp fibers having a length in the range of up to 2 inches (5.0 cm).

[0029] In an embodiment, the shaker table includes a second and a third vibrating surface below the upper vibrating surface, the second and third surfaces collecting a combination of hemp fibers and hurd, the combination of hemp fibers and hurd being transmitted to an inclined auger where the hemp fibers collect about a rotating auger shaft and hurd fall by gravity and are segregated for separate handling.

[0030] In an embodiment, the system includes performing an operational separation method (OSM2) downstream of at least one processor. In a preferred embodiment, the OSM2 method includes sending the mixture of hemp fibers and hurd to multiple loops of the condenser and the shaker table.

[0031] In an embodiment, a method is disclosed of generating hemp fibers useful as blown insulation using the present system.

[0032] In an embodiment, the present system generates hemp fibers having a thermal conductivity in the range of 0.280-0.380 BTU-in / ft2-hr-° F. and a density in the range of 0.5-0.8 lb / ft3.

[0033] In another embodiment, a system is provided for processing hemp biomass into fibers useful as insulation, and includes at least one processor having a housing defining an access opening through which the biomass is urged towards a first sizer configured for sizing hemp fibers and hemp hurd; the hemp fibers and the hurd generated in the at least one processor is collected and diverted to a first condenser having a housing and an associated fan that pulls material from the at least one processor, into a condenser housing intake, in the condenser housing is an internal screen against which the hemp fiber and hurd is retained, and the screen having openings through which dust and small particles fall through, and an internal rotating scraper which collects the hemp fiber and hurd from the screen; a shaker table receives the hemp fiber collected by the rotating scraper from the condenser screen, the shaker table has an upper perforated vibrating surface that retains the hemp fiber and allows the hurd to fall through the perforations; a second condenser receives the fibers and hurd and using a second condenser vacuum, causes the fibers to be separated against an internal screen, dust and unwanted particles passing through the internal screen, and the collected fibers and hurd being collected by a rotating wiper; and a second shaker table constructed and arranged for receiving the hemp fibers and hurd collected by the second condenser and separating the hemp fibers from hurd.

[0034] In an embodiment, the system includes providing a second sizer for receiving material from the at least one processor, the second sizer generating hemp fibers and hurd particles with a designated length range, and transmitting the generated fibers and particles to the first condenser.

[0035] In an embodiment, the shaker table includes a second and a third vibrating surface below said upper vibrating surface, the second and third surfaces collecting a combination of hemp fibers and hurd, the combination of hemp fibers and hurd being transmitted to an inclined auger where the hemp fibers collect about a rotating auger shaft and hurd fall by gravity and are segregated for separate handling.BRIEF DESCRIPTION OF THE DRAWINGS

[0036] FIGS. 1A-1C are an overhead schematic view of a preferred embodiment of the present system;

[0037] FIG. 2 is a schematic vertical cross-section of a first processor or bale breaker;

[0038] FIG. 3 is a schematic vertical cross-section of an alternate embodiment of the bale breaker of FIG. 2;

[0039] FIG. 4 is a schematic external side view of the bale breaker of FIG. 2;

[0040] FIG. 5 is a schematic vertical cross-section of another alternate embodiment of the present bale breaker;

[0041] FIG. 6 is a schematic vertical cross-section of the present pin shredder;

[0042] FIG. 7 is a schematic vertical cross-section of the present auto hopper;

[0043] FIG. 8 is a schematic vertical cross-section of the present step cleaner;

[0044] FIG. 9 is a schematic vertical cross-section of the present condenser;

[0045] FIG. 10 is a schematic vertical cross-section of the present shaker table;

[0046] FIG. 11 is a schematic vertical cross-section of the present hammermill;

[0047] FIG. 12, views 12A-12H are vertical cross-sections of various hammer profiles;

[0048] FIG. 13 is a graph of density and thermal conductivity of hemp fibers produced by the present system;

[0049] FIG. 14 is a graph of density and thermal conductivity of hemp fibers produced by the present system compared with conventional blown glass insulation and blown cellulose insulation;

[0050] FIG. 15 is a photo of combined hemp fiber and hurd generated by the bale breaker;

[0051] FIG. 16 is a photo of combined hemp fiber and hurd as fed to the condenser;

[0052] FIG. 17 is a photo of hemp fiber post hammermill, condenser and shaker table;

[0053] FIG. 18 is a photo of the processed hemp fiber being manually screeded prior to density measurement;

[0054] FIG. 19 is a photo of processed hemp fiber in a pair of test boxes prior to testing for density and thermal conductivity;

[0055] FIG. 20 is a schematic flow chart of an alternate embodiment of the present process;

[0056] FIG. 21 is a fragmentary top perspective view of a suitable sizer device employed in the embodiment of FIG. 20; and

[0057] FIG. 22 is a fragmentary perspective view of the impeller of the sizer of FIG. 21.

[0058] FIG. 23 is a side view of the present flame retardant applicator apparatus;

[0059] FIG. 24 is a fragmentary top perspective view of the apparatus of FIG. 23;

[0060] FIG. 25 is a schematic vertical cross-section of the present auger fiber collector and hurd separator;

[0061] FIG. 26 is a vertical section taken along the line 26-26 of FIG. 25 and in the direction indicated;

[0062] FIGS. 27A, 27B are a schematic flow chart of another embodiment of the present process; and

[0063] FIG. 28 is a schematic flow chart of another aspect of the embodiment of the present process depicted in FIGS. 27A-27B.DETAILED DESCRIPTION

[0064] Referring now to FIGS. 1A-1C, an overhead schematic view is provided of the present hemp fiber processing system, generally designated 10. Hemp biomass 12, referring to harvested hemp plants, is obtained from hemp farming activities in potentially 3 or more standard forms, round bailed, square bailed, or in bulk.

[0065] Bales or bulk formats of hemp biomass 12 are delivered to a processing facility including the system 10 for the process of “decortication,” typically referring to the process of separating the bast fibers of the outer surface / bark of the plant, referred to here as hemp fibers, from the inner woody cellulose core known as “hurd.”

[0066] Referring now to FIGS. 1A-4, the hemp biomass 12 provided in bale form will preferably be placed on a feed conveyor 14 which is operationally connected to a first processor 16, a machine commonly referred to as a “bale breaker,” preferably the primary or first contact point for the biomass. Prior to the bale breaker 16, other forms of pre-processing functions may be utilized to remove field dirt, rocks, or other foreign materials, including but not limited to trammel systems, or tumblers. Included on the bale breaker 16 is a bale breaker housing 18 defining a bale access opening 20 and enclosing an inner conveyor 22 that exerts a biasing force against the biomass 12 and forces the incoming material against a pair of toothed sizing rolls, designated an upper sizing roll 24 and a lower sizing roll 26.

[0067] Preferably, the sizing rolls 24, 26 are positioned one spaced generally vertically above the other, and both preferably rotated in the same direction by suitable electric motors 28 using V-belts 30 (FIG. 4) or the like. The rapidly rotating sizing rolls 24, 26, preferably operating in the range of 500-4000 RPM, with a preferred speed of 1800 RPM, each have multiple rows of radially projecting, rigid teeth, blades or bars 32 that engage the biomass 12 and begin the separation or crushing process. Roll speeds may vary depending on the application. Preferably, the rolls 24, 26 are each equipped with a VFD 34, or similar controllers that regulate the speed of an electric motor by varying the voltage and frequency of its power supply. In this application, the VFDs 34 are used to control the direction of flow of the generated material.

[0068] During operation of the system 10, the speed of the inner conveyor 22 is adjusted to regulate the force at which the biomass 12 is urged against the sizing rollers 24, 26. Also, using the VFDs 34, the rotational speed of the rollers is adjustable as well. Intermittent operation of the inner conveyor 22 is utilized for adjusting the breakdown of the biomass 12.

[0069] In a preferred embodiment, the VFDs 34 allow for a “tuned” rotation that can be utilized to manage the biomass 12 in differing and beneficial ways based on two critical factors. One factor is that the biomass stem diameter requires more force to begin to break down the inner woody core, cellulose material. The second factor is that there is a need to manage the type of bale or mass in which the biomass is provided. For example, the upper roll 24 can be slowed to allow material to be skimmed off the top of a “square” bale without unnecessary sizing occurring, or over break down of the biomass 12. Where a round bale or non-baled biomass is utilized, the speed of the upper roll 24 is optionally increased to pull more material over the top of the top roll to increase the amount of material flowing back into the rotating teeth 32. In either scenario, the speed of the rolls 24, 26 is adjustable to increase the benefits to the material being exited from the bale breaker 16 and reduce unnecessary destruction of the biomass 12. In another example, and in concert with the VFDs, the diameter of drive pulleys 36 (FIG. 4) on either the roll or a motor shaft are adjustable to increase the speed of the rolls 24, 26 as necessary based on the biomass size entering the bale breaker 16.

[0070] In a preferred embodiment, the top roll 24 is movable forward (to the left in FIGS. 2-4) towards the incoming bale, loose biomass, or moved rearward towards a main outlet 38 of the bale breaker 16. The top roll 24, when repositioned, typically will have a replacement drive belt 30 of differing length when repositioned to accommodate the adjustments.

[0071] Referring now to FIG. 4, a bale breaker motor deck 40 moves forwards and rearwards independently from the two rolls 24, 26. This is accomplished through two independent motor mounts 42 that are each secured on a separate platform 44 that allow the motors to be moved forward or rearward, upward or downward under operator control, and locked into position to accommodate the new position of the roll without the need for belt replacement. Motor movement is preferably accomplished with hydraulic mounts and / or rotating screw deck mounts 46 secured to a base 48.

[0072] Referring now to FIG. 2, at least one or both of the upper and lower bale breaker rolls 24, 26 have a vertical adjustment mechanism 50 that allows the lower roll to move upwards towards the top roll, closing the space between the rolls, or downwards towards the inner conveyor 22 that passes under the lower roll. This vertical movement increases the spacing between the rolls 24, 26 and therefore the ability to move more biomass between the rolls when in the lower position. The advantage is that the material will make less contact with the blades of the rolls, and therefore cause less contacts or strikes on the biomass and reduce shortening or destruction of the material. This is beneficial in that the biomass 12 may be of a “thinner stalk” type or variety or “younger material” which is harvested earlier in the farming process and requires less force to break down the inner woody core, while additionally preserving the outer bast fiber from unnecessary abuse in the process.

[0073] In another example, the lower roll 26 is optionally raised to exert more pressure on the material passing between the rolls 24, 26 to break down the inner woody core to a smaller and more manageable size that allows the follow-on machinery described herein to function more efficiently in the separation of the bast fiber from the woody core and in the fiber separation process. The effects of “mother nature” and weather patterns can extend a crop's life in the field due to an inability to harvest the crop at an ideal time, therefore extending the growth cycle of the crop producing larger diameter biomass stalk. In this case, the rolls may be moved in closer proximity to one another to allow for greater breakdown of the larger stalks.

[0074] In a preferred embodiment, at least one plate 52 is positioned within the bale breaker housing 18 and downstream of the sizing rolls 24, 26 to retain biomass 12 in engagement with the rolls and perform additional sizing action. In other words, the plate 52 causes recirculation of biomass back into the sizing rolls 24, 26. The plate 52 is removable and adjustable in an angle of inclination relative to the rolls 24, 26 to increase or decrease the amount of dwell time between the biomass and the rotating rolls. The plate 52 is inserted on an exit side of the rolls 24, 26 and is movable towards the rolls, or away from the rolls, at both top and bottom edges 54, 56 and secured into position at the desired angle. This serves multiple purposes in processing as it allows the plate 52 to capture material passing over the rolls 24, 26 to be directed back towards the lower roll 26 for additional reductions in size when the top of the plate edge 54 is moved outward, and the bottom plate edge 56 is moved inward. Additionally, the plate top edge 54 is movable inward, and / or outward, to allow for the release of more or less material from the lower roll 26, therefore reducing the pressure on the material to be directed back towards the rolls. It is contemplated that both rolls 24, 26 have plates 52.

[0075] Referring now to FIG. 5, in the event bulk material or non-baled biomass is provided the inner conveyor 22 is not utilized, and the bale breaker 16 is provided with a hopper 58 at an upper or feed end 60 of the bale breaker housing 18. In this scenario, instead of the inner conveyor urging the biomass 12 towards the rolls 24, 26, the weight of the incoming bulk material creates a force on a lowermost material as it impacts the sizing rolls. This pressure moves the biomass 12 into the rolls 24, 26 and for processing a described above. In another embodiment, the non-baled biomass is processed by utilizing the existing conveyor in concert with gravity pressure from the biomass 12.

[0076] As seen in FIG. 5, a conveyor 62 moves the bulk biomass 12 into the hopper 58, in which at least one and preferably three rotating crush rollers 64 are disposed, each having a plurality of radially projecting pins or beater bars 66 and being driven by suitable electric motors 68 with belt drives 70 or the like as known in the art. Optionally, some of the crush rollers 64 are provided with spring suspensions 72 that exert a compressible biasing force towards an adjacent roller. As such, opposing rollers 64 define a gap 74 through which the biomass 12 falls by gravity.

[0077] In another embodiment, the rolls 24, 26 of the bale breaker 16 are staggered to allow for adjusted processing and reduced destruction of the fiber where a square or round bale is provided for processing.

[0078] Referring to FIG. 15, a view of the combined partially processed hemp fiber and hurd is shown as emitted from the bale breaker 16. Optionally, a portion of the material emitted from the bale breaker 16 is diverted for separation as described below. Also, the bale breaker 16 is equipped with at least one dust exhaust 76, preferably connected to a blower-generated vacuum 78, to remove dust generated by the action of the bale breaker. In general, in the present system 10, the extraction of generated dust is important for operator comfort, and for reducing the surface area upon which fire retardant is applied. If excessive dust is in the material, excessive amounts of fire retardant are applied and wasted.

[0079] Referring now to FIGS. 1A-1C, 2 and 6, a majority of the material emitted from the bale breaker 16 is transferred through the main bale breaker outlet 38 in the housing 18 by a walking or outlet conveyor 80 (FIG. 2). However, a portion of the partially separated hurd and fibers falls by gravity and is collected at a supplemental or lower outlet 82 in the bale breaker 16 for separate processing described below.

[0080] From the main bale breaker outlet 38, the material is taken by the conveyor 80 to a second processor, a Fiber Separation Unit (FSU), also referred to as a pin shredder 84, to perform a further breaking down of the hurd and a separation action that again separates remaining hurd from the hemp fibers. In addition, the FSU 84 begins to separate the individual fibers from their bundles. Through the action of the bale breaker 16, the hemp biomass 12 is at least partially comminuted (FIG. 15), and the fibers become formed into tangled webs resembling soft steel wool, with a significant proportion of particles or larger pieces of hurd being intertwined with the fibers. As such, a main challenge for system designers is the separation of the bast fibers or “bark” of the stalk, from the hurd / cellulose inner core, commonly referred to as “decortication.” Continuing the process, the fiber is further separated into more individual fibers, but also from the smaller pieces of hurd, this latter process will be referred to as “cleaning,” while the former teasing or combing of fibers will be referred to as “separation” or “separating” in addition to “decortication.”

[0081] Referring now to FIG. 6, the FSU 84 has an FSU housing 86 with an upper end 88 having an inlet 90 configured to receive biomass 12 material conveyed by the outlet conveyor 80 from the bale breaker 16. The inlet 90 preferably takes the form of a fixed, angled baffle plate that directs the material falling by gravity into a gap 92 defined by a pair of vertically positioned, upper and lower rotating “catch” rollers 94, 96, designed to briefly stall the material entering the FSU 84, and a relatively larger diameter main hub 98 with radially projecting pins 100. Operational speeds of the rollers 94, 96 and the main hub 98 range from 500-4000 RPM, with a preferred speed of 1750 RPM, however, speeds may vary depending on the application. Also, it is contemplated that any of the rollers 94, 96, 98 are optionally equipped with a VFD 34, and that the respective speeds of the rollers 94, 96 and the main hub 98 are adjustable to vary the flow of material for enhanced hemp fiber output. A preferred individual pin 100 configuration for the main hub 98 is 8 mm×32 mm, however 3.5 mm×32 mm is considered suitable, and other pin configurations are contemplated depending on the application.

[0082] Both the catch rollers 94, 96 and the main large diameter hub 98 optionally have pins 100 of different styles and shapes based on the biomass size of desired outcome of the material, and each roll individually or in concert may have blended styles and sizes of pins based on final desired material exiting the system 10. Cross-sectional shapes of the pins 100 include but are not limited to, round, square, flat or curved. The pin distribution on the rollers 94, 96 and the hub 98 and sizing are adjustable to vary the amount of sizing and separation achieved by the FSU 84.

[0083] In addition to the pins 100 on the main hub 98, the catch rollers 94, 96 are also each provided with a plurality of radially extending pins or teeth 100 as referenced previously, with the intent to “catch or hold” the material in the gap 92 between the rolls to be combed by the main hub. The catch rollers 94, 96 are designed to be moved inward and outward in proximity to the main hub 98 using a distance setting mechanism 102 located on an exterior 104 of the FSU housing 86. The mechanism 102 enables increased or decreased pressure exerted on the material that is entering and paused by the catch rollers 94, 96. For example, the lower catch roller 96 is movable near the main hub 98, while the upper catch roller 94 is optionally kept in an outward-most position, allowing for more contact to be placed on the loose hurd or hurd still attached to the fibers or fiber bundles. In another example, the upper and lower catch rollers 94, 96 are movable in unison in close proximity to the main hub 98 to allow for increased contact with the hurd and the fiber to reduce the hurd size further and reduce the fiber length in unison.

[0084] In yet another example, the FSU 84 has the ability to create a slight elongation of the fiber to create a slight “curl” in the fibers. This curl is then enhanced by further operations at the following stages. Curling of the fiber creates structure in the end insulation product which creates additional air pockets to increase insulative value and reconstitution from compressed packaging.

[0085] At a lower end 106 of the FSU housing 86, at least one screened grid plate 108 is positioned adjacent a supplemental or secondary outlet 110 permits release of hurd that has been separated entirely from the fiber, and some small hurd that remains intertwined with small fibers. As is the case with the bail breaker 16, this separated material is optionally forwarded for separate downstream processing described below.

[0086] However, a majority of fibers, still with some hurd, is forwarded through centrifugal force, air velocity, and by gravity from a main FSU outlet 112 onto an FSU conveyor 114 that exits the FSU downstream of the bottom grid plates 108. Both pin size, and orientation of the main hub 98 to the catch rollers 94, 96 are adjustable to change comminution action, as previously described. Also, the FSU 84 is provided with an associated exhaust port 116 with optional suction fan 118 for removal of generated dust.

[0087] Referring now to FIGS. 1A-1C and 7, after the FSU 84, the material is conveyed by the FSU conveyor 114 to a third processor, a Fiber and Hurd Separation and Metering Machine (FHSM), also referred to as an Auto Hopper 120. The Auto Hopper 120 has an Auto Hopper housing 122 with an inlet 124 in communication with the FSU conveyor 114.

[0088] A main conveyor 126 located in the FHSM housing 122 receives incoming combined hemp fiber and hurd biomass 12 falling by gravity through the inlet 124 and directs the incoming material to an angled, needled apron, which is an angled conveyor 128. Preferably, the main conveyor 126 is provided in two stages 126a and 126b, representing separate conveyor belts 130 and drives 132, however a single belt and drive is contemplated, depending on the application.

[0089] Included on the angled apron conveyor 128 are multiple, linearly-spaced rows of upwardly projecting needles 134 that are perpendicular to a flat, moving belt surface 136 of the conveyor or slightly inclined toward the rising angle of the conveyor. These needles 134 may be of differing lengths, or shapes, including but not limited to round, flat or have a curved shape. As the mainly hemp fiber material travels on the main conveyor 126, where it finally reaches the needled apron 128, due to the entwined fibrous nature of the hemp fiber, the material forms a ball or “roll of material.” The needled apron 128 lifts up the balled fiber and removes or teases the fiber from the ball in small portions, allowing the captured hurd particles to fall out and down.

[0090] An Auto Hopper outlet 138 is located at a base of the apron conveyor 128 and receives these falling hurd particles, along with entwined hemp fibers, which are collected at a collection point 140. It is contemplated that the collection point 138 is optionally a conveyor belt or a tray from which a vacuum-powered conduit draws material for further processing described below. It is also contemplated that an angle of inclination of the apron conveyor 128 is adjustable. The speed of the apron is controlled by a VFD 142 to once again provide adjustability in the flow rate and metering of the material that is passing to the next machine in line.

[0091] At the top of the needled apron 128, a roll of brushes 144, controlled by a motor with an attached VFD 146, removes fiber from the needled apron and enhances the flow of fiber down a main Auto Hopper outlet 148, which is an inclined chute. Also, the FHSM 120 has at least one and preferably multiple associated exhaust ports 150 with optional suction fans 152 for dust removal.

[0092] Referring now to FIGS. 1A-1C and 8, from the FHSM or Auto Hopper 120, the material falls by gravity down the main outlet 148 into a fourth processor, a step Multi Roll Cleaning Machine (MRCM), also referred to as a Step Cleaner 154. Adjacent an inlet 156 of the MRCM 154 is mounted a first rotating beater roller 158 featuring a plurality of rows of radially projecting beater bars 160, each bar being rigid and extending radially several inches from the roller. The beater roller 158 is powered by a motor 162 shown hidden preferably with a VFD (not shown), located on an exterior of a MRCM housing 164 operating at a high speed, preferably in the range of 50-3600 RPM, and thus being configured to exert more impact on the separated fiber than the pins 100 on the pin shredder 84 described previously. The rotating beater roller 158 separates the fiber from the hurd, some particles of the latter fall by gravity upon a perforated grate 166 at a lower end of the MRCM for separate removal. In configuration, the beater bars are 160 contemplated as having a variety of cross-sections, including but not limited to, round, square, or flat to exert differing levels of precision on the material to separate it in a combing fashion. The beater bars 160 act to pull apart the balls of fiber and release any small hurd pieces that are entangled in the fiber.

[0093] Next, fiber is kicked up by rotation of the first beater roller 158 and is received by a second beater roller 158a located vertically higher and horizontally downstream of the first beater roller, which again removes more hurd, which falls through a second grate 166a. In sequence, the second beater roller 158a then kicks the material to a similarly constructed third beater roller 158b and a grate 166b, and then similarly onto a fourth beater roller 158c and grate 166c, for similarly separating or opening the fibers up and collecting hurd that falls through the grate. In the MRCM 154, the four grates 166-166c are horizontally oriented and are preferably generally cup or U-shaped, and are defined by bars extending horizontally. Similar to the beaters discussed above, the cross-section of these bars 160 is variable, including but not limited to round, square, triangular or polygonal in shape. Thus, the MRCM or Step Cleaner 154 subjects the incoming biomass material to four separate steps of beater rollers 158-158c and associated grates 166-166c for catching the separated hurd.

[0094] As is the case with the other processors 16, 84, 120 described above, the collected material from all the grates 166-166c is collected for optional separate processing through an outlet 168, in this case having an optional fan-induced vacuum at 170, and a main Step Cleaner outlet 172 located adjacent the fourth beater roller 158c. Also, the MRCM 154 is provided with at least one and preferably multiple exhaust conduits 174 and optional suction fans 176 for dust removal. Referring to FIG. 16, a view of the combined, further processed hemp fiber and hurd is shown as received from the Auto Hopper 120 and / or the Step Cleaner 154.

[0095] Referring now to FIGS. 1A-1C and 9, following the MRCM or Step Cleaner 154, the material is conveyed to a condenser 180, also referred to as a first condenser, including a condenser housing 182 that defines a main internal condenser chamber 184. Condensers of this type are commonly utilized in the processing of cotton fibers. At least one associated rotating fan 186, preferably mounted externally of the condenser housing 182, creates a vacuum force that sucks the material into the condenser chamber 184. As described above, a fan inlet duct 188 is preferably in fluid communication with, and connected at least to the separated material outlets 110, 140, 168 respectively of the FSU or pin shredder 84, the FHSM or Auto Hopper 120 and the MRCM or Step Cleaner 154, and optionally also to the associated outlet 82 of the bale breaker 16. As such, the fan 186 pulls material from the above-listed machines and directs it to the inlet of the condenser chamber 184. It is also contemplated that suitable belt conveyors 190 are provided to facilitate movement of material to the condenser 180 as seen in FIGS. 1A-1C.

[0096] Also, the fan 186 is constructed and arranged to create a vacuum within the condenser chamber 184. The fan blade type is configured to avoid damage to the material and instead, moves the material with an intent to avoid creating jams of hurd / cellulose in the material movement through the duct 188.

[0097] Referring now to FIG. 9, a vacuum outlet 192 is preferably located below or downstream of an arcuate, perforated screen 194 extending a length of the condenser housing 182 and forming an arch around the outlet. The vacuum force generated by the fan 186 causes the entwined fiber to be forced under vacuum pressure against an interior surface 196 of the screen 194. The objective in using the condenser 180 is for solid particles of fiber and hurd to be pulled against the screen and to remain in place on the screen until they are removed by wiping action from the surface 196. This allows the solids that are larger than the holes in the screen 194 to be passed out of the bottom of the condenser 180 and onto the next machine, and the dust or very small solids to be pulled through the screen 194 and exited via the outlet 192 from the system to a cyclone or other dust capturing device.

[0098] A rotating wiper 198 in the condenser chamber 184 has a plurality, preferably, but not limited to, two to four wiper blades 200 radiating from a central hub 202. The wiper blades 200 scrape hemp fiber and some hurd that are trapped against the interior screen surface 196 and cause them to fall by gravity to a condenser outlet 204. A rotating air lock 206 located at the condenser outlet 204 has resilient, rubber-like blades 208 that scrapingly engage walls 210 of the condenser outlet 204 and maintain the vacuum inside the condenser chamber 184, yet allow the material released from the screen 194 to fall by gravity from the outlet 204. Suitable motors (not shown) are provided for rotating the wiper 198 and the airlock 206. Also, an exhaust vent 212 and optional fan 214 are preferably provided to the condenser 180. The action of the wiping, in concert with the natural spreading of the material under vacuum within the condenser 180, separates the material and creates a distribution of the material as it transfers to the next machine. This action allows the separated material to fall out and onto the next machine in a fashion that allows the next machine to perform its functions more efficiently.

[0099] Referring now to FIGS. 1A-1C and 10, a vibratory conveyor or shaker table 220 is located in operational relationship to the condenser 180 for receiving hemp fiber and hurd that is released by the condenser through the airlock 206. Preferably, while other connections are contemplated, the shaker table 220 is located below the condenser 180 to directly receive this gravity-fed material. As is known in the art, the shaker table 220 has at least one upper deck 222 which is perforated, and which is subject to a gyrating force generated by an eccentric mechanism 224 driven by a motor 226. The motor 226 is configured for generating 300-500 RPM, which may vary to suit the application. A plurality of flexible plates 228 made of metal or fiberglass or the like, support the upper deck 222 upon a base 230.

[0100] The upper deck 222 is sized, depending on the application, to retain a desired material, here the hemp fiber, and the unwanted hurd is allowed to fall through the deck to at least one exit port 232. The collected hemp fiber is sent to a shaker table exit port or outlet 234.

[0101] Referring now to FIGS. 1A-1C, 11 and 12, from the exit port 234, the collected hemp fiber and some remaining hurd is sent via vacuum suction to an intake 236 in a hammermill housing 238 of a hammermill 240. Also, known in the art, the hammermill 240 features an impeller 242 rotating at 2500-7500 RPM, preferably at least 3600 RPM powered by a motor, preferably equipped with a VFD (both not shown), however other speeds are contemplated depending on the application. The impeller 242 is provided with a plurality of radially extending rigid bars or arms, referred to as hammers 244. Preferably, the hammers 244 are pivotally connected to the impeller 242. It is contemplated that hammer length, and, as seen in FIGS. 12a-12h, hammer cross-sectional configuration is variable depending on the condition of the material being passed through the hammermill 240. The hammers 244 are shown in different widths and configurations that produce unique and beneficial results based on the characteristics of the inbound fiber. While slight variations exist from different Cannabis sativa genetics and from growing and farming protocols, these hammer designs, hammer widths, impeller rotational speeds and mixing and matching of hammer types, assist in the final blended make-up of the insulation and increase its effectiveness as an insulative product.

[0102] Surrounding the rotating hammers 244 is a perforated cylindrical screen 246. Depending on the nature and / or status of the material being fed into the hammermill intake 236, the size of the perforations in the screen 246 is varied to obtain desired separation. In a preferred embodiment, the openings of the screen 246 range from ⅛ inch (0.318 cm) to ½ inch (1.27 cm) diameter. As the material enters the hammermill 240, it is specifically directed into the high-speed hammers 244 where the significant impact of the rapidly rotating hammers immediately cuts the hemp fibers where, under high vacuum the fibers are immediately exited via suction out a hammermill outlet 248. A suction fan 249 is preferably equipped with a VFD (not shown). Normal operation of the hammermill 240 is to continually have the hammers 244 contact an abundance of dense material, allowing for the material to gradually be sized down and fall through the screen 246 where the holes are sized to the desired final material size.

[0103] The action of the hammermill hammers 244 on the hemp fiber at this point results in the production of a cotton-like material, and removes pectin and lignans from the fibers by high-speed contact beyond a rate which most hammer mills operate, and importantly, the fiber-dominant material entering the hammer mill 240 is forced into contact with the rapidly moving hammers 244 rather than allowed to dwell in the machine and be destroyed by constant beating of the hammers or clogging of the screen 246. Given the low-density nature of fiber, normal hammer mills will not perform the function as described as the fiber will entangle in the hammer mill and create a jam within the mill itself. By forcing the fiber to enter the hammermill 240 in direct contact with the hammers 244 moving at an extremely high rate of speed, in conjunction with appropriate hammer width, hammer shape, and housing design, the proper material and goal is achieved.

[0104] Additionally, the hammer configuration, in combination with the inherent strength of hemp fiber, and the higher-than-normal speed operation of the hammermill 240, allow for a slight elongation and therefore “curl” to be placed in the fiber at the time of sizing. This “curl” creates increased structure in a blown fiber, and this allows the fiber to create a higher amount of air pockets beyond a “cut fiber.” While previous methods exist for cutting fibers, such methods do not allow increased structure.

[0105] Any fiber bundles that have passed through the hammermill 240 after contact and shortening, where a bundle is defined as “more than one fiber,” exhibit fraying where the end of the bundle allows for a slight separation of the two or more fibers and increased structure after blowing through a commercially available or smaller, retail rented type of blowing machine.

[0106] Referring now to FIGS. 1A-1C, after the hammermill 240, the fibers are pulled via vacuum from the hammermill outlet 248 to a second condenser 250, similar in construction and operation to the previously described condenser 180. Under vacuum force, the rotating wiper 198 scrapes the fiber again and the air lock 206 drops the fibers upon a second shaker table 260 in a distributed fashion, similar in construction to the first shaker table 220 described above. At this stage, the fibers are collected at the end of the second shaker table 260. Remaining hurd particles are collected from the bottom of the second shaker table 260 for separate handling or reuse in another application.

[0107] Referring now to FIG. 13, the resulting hemp fibers from the second shaker table 260 were evaluated for thermal conductivity and density. Thermal Conductivity was measured using a Fox 314 Meter made by TA Instruments-Waters LLC, New Castle, Delaware. The unit follows ASTM C518 and ISO 8301 and tests a 4-inch high sample of fibers and sandwiches the sample between two heated plates of differing temperatures. Samples of the present fibers obtained thermal conductivity measurements in the range of 0.280-0.380 BTU-in / ft2-hr-° F., with a more preferred range of 0.33-0.38 BTU-in / ft2-hr-° F.

[0108] Density was measured in lbs. / ft3. Obtained values of the present fiber ranged from 0.500-0.800 lbs / ft3. As seen in FIG. 14, the thermal conductivity values of the present hemp fiber obtained using the present system 10 ranges broadly from 0.280-0.380 BTU-in / ft2-hr-° F., at 90% contact thickness, which is comparable to similar parameters for conventional glass fiber and cellulose fiber blown insulation. Glass fiber insulation has a thermal conductivity range of 0.32 to 0.36 BTU-in / ft2-hr-° F. and a density of 45 to 0.55 lbs per cubic foot, while cellulose fiber has a thermal conductivity of 0.27 to 0.28 BTU-in / ft2-hr-° F. and a density of 1.25-1.65 lbs / ft3.

[0109] Referring now to FIGS. 18-19, samples were obtained for testing by preparing the blown insulation material and applying the fire retardant to the samples. Material was compacted to represent a “packaged product that is ready to ship to a customer”. The compacted material was loaded into a “commercial blowing unit” manufactured by Krendl Machine Company, Delphos, Ohio (Model 2300). Attached to the Krendl machine was 200 feet of “corrugated blowing hose” (MARK II) to transfer the blown material sample to the “sample boxes for test”. The length of the hose utilized is representative of the distance from the Krendl blowing machine to the attic of a house or commercial space where the insulation is to be installed. As seen in FIG. 18, the sample boxes 274 have 4 equal sides and an interior open space measuring 10.75 inches in length (27.305 cm)×10.75 inches in width (27.305 cm)×3.25 inches in height (8.25 cm), with an additional ½ inch (1.27 cm) of foam adhered to the top rim of the sample box encompassing the entire perimeter to allow variable testing heights. Attached to the bottom of the box is a screen to allow for proper heat transfer within the FOX 314 Meter described above. The sample boxes, with plates underneath them for transport to avoid any sagging of the screens on the bottom of the sample boxes, are collected with the blown insulation material and transferred to the laboratory where they are conditioned prior to testing for 24 hours at 75 degrees Fahrenheit (23.88° C.) and 40% humidity.

[0110] Referring now to FIG. 18 the sample boxes are “screeded” carefully through the use of a pick 276 and tongs 278 so that the blown material sample material height is 4 inches (10.16 cm) in the sample box. As seen in FIG. 19, the sample boxes 274, now considered prepared for testing, are carefully transferred to the FOX 314 Meter for thermal testing. When thermal testing has been completed the sample box is removed from the FOX 314 Meter. Next, the blown insulation sample material is removed from the sample box 274 and placed into a pre-weighed vessel and onto a scale for measuring the weight of the insulation sample. Finally, the insulation sample weight as measured is then converted to a “pounds per cubic foot” to achieve a resulting density for assessment against other industry standard materials.

[0111] Referring now to FIG. 17, the final fibers, which exhibit a high degree of separation, sizing, removal or pectens and lignans as well as dust, are now ready for flame retardant treatment. These fibers, with the “curl” that has been created in them through the aforementioned processes now possess the characteristics of insulation and possess an increased ability to be reconstituted from compaction for shipping. Multiple blow tests of untreated and treated flame retarded fibers show that the fiber will reconstitute or “fluff” back to an insulative state very easily once put through the present process. Natural fibers that are simply cut by any means do not exhibit the same properties and structure based on internal testing and lack structure that makes them perform as an insulative product. The importance of the presently achieved structure cannot be understated as it also lowers the density of the product while increasing the R-value. Lower density (lower installed weight) reduces the amount of product that needs to be purchased and installed to achieve the same R-value, this makes achieving energy efficiency more affordable for consumers.

[0112] Also seen in FIGS. 1A-1C, after the second shaker table 260, separated hurd is conveyed via a hurd conveyor 262 to a separated hurd hopper 264 for separate treatment or separate handling. Also, a suitable, environmentally-friendly fire retardant is applied to the fibers using an applicator 266, which is contemplated to apply fire retardant composition to the fibers by spraying or rollers or the like, after which the fibers are suitably dried. After application of the fire retardant, the hemp fibers are preferably subjected to a second hammermill 268, and optionally a third condenser 270 and a second shaker table 272.

[0113] Referring now to FIG. 20, a schematic flow chart of an alternate embodiment to the present system is generally designated 300. Shared components with the system 10 are designated with identical reference numbers. A main distinctive feature of the system 300 is the incorporation of a sizer 302 into the processing of the hemp biomass. The purpose of the sizer 302 is processing the already partially-broken up hemp fibers and hurd (FIG. 15) so that both the hemp fibers and the hurd have a length within the range of up to 2 inches (5.0 cm), and more preferably between 1-1.5 inches (2.5-3.75 cm). It has been found that normalizing or standardizing the length of the hemp fibers and hurd particles makes it easier to separate out the unwanted hurd particles from the fiber in the downstream processing steps of the system 300.

[0114] Referring now to FIGS. 21 and 22, for the purposes of the present system 300, a sizer 302 will be understood to mean a processing device configured for receiving hemp biomass and producing hemp fibers and hurd particles within the target length ranges described above. In the preferred embodiment, and while other devices are contemplated, the sizer 302 is of the type manufactured by Munson Machinery, Utica, New York under Model Nos. SCC Mini, SCC Magnum, SCC-15-SS or other comparable units. A sizer housing 304 has an inlet 306, preferably at an upper housing end 308 and encloses a rotating impeller 310 driven by a motor 312 (FIG. 21). As is the case with other processing devices used in the system 10, the impeller 310 is configured for high speed operation, with preferred operation in the range of 30-3600 RPM, although other speeds are contemplated depending on the application.

[0115] Mounted on the impeller 310 is a plurality of disk-like teeth or impact elements 314, each disk being rotationally offset from the next adjacent disks relative to a longitudinal axis of the impeller, to present an irregular surface to the incoming hemp biomass. Impact, or cutting edges 316 of the teeth 314 are replaceable carbide inserts. Rotation at high speeds has been found to produce a generally uniform length of both hemp fibers and hurd particles, which facilitates downstream separation of the hurd from the fiber. While a preferred configuration of the sizer is described here, it is also contemplated that alternate processing devices, including, but not limited to guillotine, chopper, single or multiple rotary or roll cutters are suitable sizer devices in the present context.

[0116] Below the impeller 310 is disposed a screen 318 (FIG. 22) having apertures sized for allowing passage of material within the desired size range. Longer hemp fibers are primarily pulled under vacuum through the screen apertures, and hurd particles are forced back to the impeller 310 until the hurd passes through the screen apertures under vacuum or by gravity.

[0117] Referring again to FIG. 20, the sizer 302 is preferably positioned to receive the material from the secondary outlet 110 of the pin shredder or FSU 84, and / or similarly receiving material from the collection point 140 of the auto hopper or FHSM 120, and / or similarly receiving material from the hurd outlet 168 of the Step Cleaner or MRCM 154, and / or alternately receiving material from the main step cleaner outlet 172. Also, the sizer 302 is positioned before or upstream in the flow of the biomass from the first condenser 180. Once the combined hurd and hemp fibers are sent from the sizer 302 to the first condenser 180, the operation of the system 300 is similar to that described above for the system 10. The various processing steps are designated by their previously-described reference numbers. In general, the material post sizer 302 is conveyed or driven by air to the condenser 180, then to the shaker table 220, then to the hammermill 240. Environmentally-friendly fire retardant is applied at 266, and the specific location of application is contemplated as varying per application or with the specific fire retardant composition. Also, the positioning of the second condenser 250, the second shaker table 260 are also depicted as described above.

[0118] It has been found that the use of the sizer 302, in combination with the condenser 180, the shaker table 220 and the hammermill 240 results in hemp fibers that are usable as blown insulation.

[0119] Referring now to FIGS. 1A-1C, 23 and 24, a preferred embodiment for the flame retardant applicator (FRA) 266 is described in greater detail. While other apparatus are contemplated, the preferred FRA 266 is based on a Ribbon Blender made by Colorado Mill Equipment, Canon City, Colorado, under model No. RB100. The FRA applicator 266 includes an FRA housing 320 that is free standing on a floor or other substrate, and defines an inner chamber 322 in which a generally horizontally-oriented helical auger or mixer 324 rotates with a mixer drive shaft 326. While other known drive systems are contemplated, the present drive shaft 326 is rotated using a V-belt 328 driven by an electric motor 330, preferably mounted to, or in operational relationship with, the FRA housing 320.

[0120] An FRA housing inlet 332 is connected to a blower 334 via a blower tube 336 that provides a supply of hemp fiber to be treated. Opposite the inlet 332, an FRA housing outlet 338 is located at a vertically lower point on the housing 320 to receive treated fibers that fall via gravity and air pressure and are drawn to an outlet tube 340 connected to at least one supplemental blower 342.

[0121] An atomizer sprayer 344 receives an aqueous solution of fire retardant solution from a nearby storage tank 346, flowing through line 347 and using a compressor 348 or other type of pump such as a peristaltic pump which pressurizes the solution, preferably in the range of 10-100 psi. The sprayer 344 is mounted to the FRA housing 332 to inject the atomized spray into the inner chamber 322. In an embodiment, the fire retardant active ingredient is magnesium sulfate, urea, aluminum tri-hydrate or calcium chloride, individually or in combination, however equivalent fire retardant materials are contemplated depending on the application. A preferred aqueous solution of fire retardant has between 5-25% active ingredient solids, and more preferably 10-20% active ingredient solids (solutions of 65% active ingredient have been achieved with some fire retardants), with the remainder of the solution being water.

[0122] In operation, the hemp fiber is circulated under air pressure into the FRA 266 via the FRA housing inlet 332. Within the inner chamber 322, the fiber is agitated by the spinning helical mixer 324 so that the fiber is momentarily suspended within the chamber. In this suspended state, the hemp fiber is sprayed with the fire retardant aqueous solution dispensed by the FRA atomizer 344. Once coated, the fibers become heavier, and tend to fall by gravity towards the bottom of the chamber 322. At this point, the coated fibers are drawn into the FRA housing outlet 338 and the outlet tube 340 from the air pressure provided by the primary and supplemental blowers 342. It is contemplated that the hemp material is preferably subject to multiple passes through the FRA 266 to achieve more efficient coverage of fibers by the fire retardant solution.

[0123] Besides the above-described FRA applicator 266, it is alternately contemplated to thinly spread hemp fibers on a moving conveyor, and spray the fire retardant composition upon the fibers as they move past the sprayers on the conveyor. Excess fire retardant composition is collected and reused if possible, and the treated fibers are dried. Alternatively, the fibers are placed on a conveyor which then travels through a soak tank containing the fire retardant composition, after which the fibers are drained of the aqueous solution, or mechanically assisted in the removal of the balance of the aqueous solution, then heated until considered dry.

[0124] Referring now to FIGS. 25-28, a further updated embodiment of the system 300 shown in FIG. 20 is generally designated 360. Components shared between the systems 300 and 360 are designated with identical reference numbers. An important distinctive feature of the system 360, as seen in FIGS. 27A-27B, is the additional treatment of the fibers between any of the bale breaker 16, the Pin Shredder FSU 84, the Auto hopper FHSM 120 or the Step Cleaner MRCM 154, downstream of the sizer 302 as well as upstream of the condenser 250, or optionally between the sizer 302 and the hammermill 240. In one embodiment, this additional treatment is generally referred to as an Optional Separation Method 2 (OSM2) 362.

[0125] Referring again to FIGS. 6 and 27A, the present system 10 features the ability to increase and decrease Variable Frequency Drive (VFD) speeds on the Bale Breaker 16 and FSU 84 in tandem or individually for the contact rolls and catch rolls of both machines, the biomass can be optimized for sizing and separation so as to not unnecessarily reduce fiber lengths or over process the material for the intended application. The result of the manipulation of these processes allows for the material to be directed towards differing pathways and follow on processes that therefore maintain the integrity of the fiber and reduce the need for unnecessary material contact. The Bale Breaker 16 and FSU 84 optimization will therefore direct material flow to one of 3 exit points 110, 114 and 118 of the FSU seen in FIGS. 6 and 27A. The path bearing AS 392 is optimized by amount of airflow (suction) created by an attached fan in combination with the speed of the main cylinder 98 (aka main roll) of the FSU 84 and the distance of the catch rolls 94, 96 to the main roll. These adjustments therefore allow for the desired material to be achieved based on evaluating and adjusting for the condition, size, diameter etc. of the inbound biomass. The material exiting the 3 ports 110, 114, 118 of the FSU 84 will be streams of different quantities of fiber and hurd. Each stream will contain differing lengths of fiber as well as differing lengths and diameters of hurd, these streams will then need to be further separated to remove the hurd from the fiber. Material transfer from these ports may be by air / fan, auger, conveyor, etc. to further cleaning and separation processes. During the transition of the material it is possible to remove hurd from fiber through modification of the material transfer equipment.

[0126] Referring now to FIGS. 25 and 26, the OSM2 362 preferably includes the use of an inclined rotating helical auger 364 driven by a motor 366 operating through a suitable power transmission or gear box 368. Loose fibers and hurd are introduced at a lower end 370 of an auger housing 372 that encloses the auger 364. In one embodiment, a hopper 374 introduces the loose fibers and hurd to the lower housing end 370. The loose fibers and hurd are obtained through the outlets of any of the Pin Shredder FSU 84, the Auto hopper FHSM 120, the Step Cleaner MRCM 154, the sizer 302 or the shaker table 220. The helical auger 364 transports the material upward in the auger housing 372. It has been found that through the axial rotating action of the auger 364 and gravity, the hemp fibers processed by any of the above-listed devices and fed into the auger 364 tend to collect around the auger blades or flutes, while heavier hurd particles are separated out and fall through screen-like openings 376 near an upper end 378 of the auger housing 372. It is contemplated that the angle of inclination of the helical auger 364 is adjustable to vary the hemp fiber dwell time as a function of the qualities of the hemp fiber being processed.

[0127] As seen in FIGS. 25 and 26, a self-cleaning knife block 380 on an upper bearing 382 of the helical auger 364 enhances the disengagement of the hemp fibers and some hurd from the auger at the upper end of the auger, and these fibers and hurd fall by gravity through an auger housing outlet 384. The material from the outlet 384 falls upon a designated shaker table 386 or an existing shaker table 220 (FIG. 10) where further separation action occurs through the shaking action of the table.

[0128] Referring now to FIG. 27A, one contemplated location of the auger 364 is just upstream of the sizer 302, where rotation of the auger 364 and gravity combine to separate hurd from the hemp fiber. Another application of the auger 364 is for enhancing the yield of recovered fibers from any of the several shaker tables 220, 260, 272.

[0129] Referring now to FIGS. 10 and 28, in a preferred embodiment, the shaker table 220, 260, 386 is a triple output type shaker table with three outlets, each using a different screen size. In addition to the upper deck 222 which usually has the largest mesh screen of all, for example ½ inch (1.25 cm), there is a second deck 388 with smaller screen openings, for example ¼ inch (0.625 cm), and a third deck 390which is closed to catch all falling material. It is contemplated that the size of the decks 222 and 388 may vary to suit the application, however, the upper deck 222 will always have a larger screen opening than the second deck 388. The goal is for the most hurd to fall through to the bottom or third deck 390. However, in practice, a significant percentage of hemp fibers falls through the upper deck 222. It has been found that hemp fiber recovery is increased by feeding the material falling on at least one of the second and third decks 388, 390 to a designated rotating, inclined auger 364 as shown in FIG. 25. This collected fiber material is then combined or blended with the output of the shaker tables 220 and 260 as seen in FIGS. 20 and 27B, preferably before the above described Fire Retardant application at 266. As seen in FIG. 28, the hurd that falls from the auger screen openings 376 is collected for separate handling. It will be appreciated that any of the shaker tables 220, 260, 386 are contemplated as being equipped with such inclined augers 364.

[0130] Referring again to FIG. 27A, another optional aspect of the OSM2 362 is a further air separator 392 mounted either just upstream of the sizer 302, or downstream of the shaker table 386. The air separator 392 is analogous to the condenser 180 and subjects the received moving hemp fiber and hurd mixture to air pressure, whereby the lighter fibers remain suspended in the air and hurd separate out due to gravity and are segregated for separate handling. It is noted that aspects of the OSM2 362 are contemplated as being performed in various locations of the system 360, including, but not limited to downstream of the Pin Shredder FSU 84, the Auto hopper FHSM 120, the Step Cleaner MRCM 154, the sizer 302 or the shaker table 220, between the condenser 250 and the shaker table 220, as well as downstream of the Fire Retardant Applicator 226. Also seen in FIG. 28 flow streams of processed hemp fiber are contemplated as being blended together at B.

[0131] Also, in FIGS. 27A and 27B, in the system 360 it is contemplated that fans are optionally employed at multiple locations for enhancing the movement of hemp fibers, hurd and / or dust in the system. To simplify the schematic of FIGS. 27A and 27B, these supplemental fans and their ducting were omitted.

[0132] Referring again to FIG. 27A, an alternate embodiment of the enhanced fiber recovery system (OSM2) 362 discussed above relating to the system 360 involves the use of further treatment of the hemp fibers after or downstream of the sizer 302 and before the material is fed to the hammermill 240. More specifically, the hemp fibers are sent to a first condenser 180, then to a first shaker table 220, at which time the hemp fibers from the upper deck 222 are collected, preferably by a generally triangular-shaped vacuum fitting known as a “fish lip” and are then carried by vacuum created by one of the fans mentioned above to a second condenser 180A and then to a second shaker table 220A before being sent to the hammermill 240. It is contemplated that such “condenser-shaker table” loops 180A-220A are optionally placed in the system 360 wherever a condenser 180 or 250 is shown. As described above, it is contemplated that any shaker table 220, 220A, 260 or 386 is preferably provided with an auger 364 for enhancing recover of hemp fibers from the lower shaker table decks 388, 390.

[0133] Referring now to FIGS. 27B and 28, as part of the separation processes that have been created to optimize the quality of the fiber, certain fiber lengths may be exited from the system 10, 300, 360 at different points in the line based on the process that the fiber is passing through For example, fiber passing over screens in shaker tables 220, 260, 386 designed to remove certain sizes of hurd may fall through the screen into another process, only to be recaptured as part of the next process. When these fibers are recaptured, they may be blended at B 394 back together and then through the follow-on processes to return them back to the final product as insulation. Additionally, these fibers may be collected after the insulation transformation process and blended back together by means of mechanical or air blending processes. In natural fiber processes and established markets for natural fibers, which would be predominantly the textile or non-woven markets, these short fibers are considered waste and existed from the system as such. However, in the present systems 10, 300, 360 for producing a natural insulation, these fibers have value as part of the structure of the final blown insulation as they “fill voids, create structure, and therefore increase R value as part of the final product”. One skilled in the art of natural fibers would view these fibers as waste. However, by creating a natural fiber insulation utilizing these “waste fibers,” they now have value, and through their recollection and incorporation, add performance value in the final product as well as contribute to a lower overall cost of the product through their utilization.

[0134] Referring now to FIG. 27B, as part of the fire retardant application 266, the hemp fiber that has been treated with fire retardant is preferably moved as by a conveyor and dried in an oven O 396 to remove excess retardant composition, then optionally conveyed to a cooling chamber CO 398. Also, after application of the fire retardant at 266, the hemp fiber is optionally processed through a hammermill 240. After blending at 394, it is contemplated that additional additives, such as but not restricted to anti-dusting agents are applied at 400, where at the same time, the hemp fiber is compressed for bagging, which occurs at step 402. Alternatively, the anti-dusting agents are optionally delivered in combination with the fire retardant solutions, or the fire retardant solutions are optionally formulated to reduce dust. It is also contemplated that at selected locations along systems 10, 300, 360, automatic gates AG 404 are installed for expedited removal and / or redirecting of material for enhancing fiber production. Further, in any of the systems 10, 300, 360, either continuous or batch production is contemplated.

[0135] Referring now to Table 1, the Fire Retardant (FR) applicator 266 described above in relation to FIGS. 23 and 24 was used to test hemp fiber processed according to the systems 10, 300 and 360. The hemp fiber was treated in the applicator 266 for 45 seconds with fire retardant compositions identified below, most prominently Alpha-21, Magnesium Sulfate (MgSO4) and Alpha-21 plus urea. Alpha-21 is a product name for a fire retardant composition including a combined polysaccharide base and a biostimulant disclosed in US 2025 / 028841 to Moseley et al. and developed by Black Finch Group, LLC, Austin, Texas. In Table 1, fire retardant tests were conducted on various hemp fiber samples according to ASTM C739, known as a Smoldering Combustion test.TABLE 1Smoldering Combustion Testing - ASTM C739Alpha-21 6% +Alpha-21MgSO4Urea 4%10.0%1.0%10.0%1.0%1.0%10.0%1.0%10.0%1.0%1.0%10.0%1.0%10.0%1.0%1.0%7.5%1.0%7.5%1.0%7.5%1.0%

[0136] In Table 1, there are two columns for each tested composition. The first, “Loading”, refers to the percentage of active Fire Retardant composition in solids, as a weight percentage of the fiber treated. It will be seen that, for example, Alpha-21 has a 10% solids add-on, Magnesium Sulfate ranged from 7.5 weight % to 10.0 weight % add-on, and the Alpha-21 plus urea had 6% add-on of Alpa-21 weight percent solids, and 4 weight percent solids add-on urea, applied in one solution. The second column, “Mass Loss” refers to the result of the Smoldering Combustion test according to ASTM C739, where an ignition source is placed within a closed container of fibers, and the resulting mass reduction is measured. According to industry standards applying this test, a Mass Loss reading of less than 15% is considered a “pass” or satisfactory fire retardant properties, while readings above 15% are considered a “fail” or unsatisfactory fire retardant properties. From the tests of the present compositions, it was found that hemp fibers generated by the present system 30, 300, 360 and treated with Alpha-21, Magnesium Sulfate and Alpha-21 blended with urea consistently achieved a 1% mass loss result. Accordingly, the treatment of hemp fibers treated as described above results in an insulation product which meets or exceeds industry fire retardant standards.

[0137] While a particular embodiment of the present method and apparatus for manufacturing insulation made from hemp, and product made therefrom has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.

Claims

1. A system for processing hemp biomass into fibers useful as insulation, comprising:at least one processor having a housing defining an access opening through which the biomass is urged towards a first sizer configured for sizing hemp fibers and hemp hurd;the hemp fibers and the hurd generated in said at least one processor is collected and diverted to a first condenser having a housing and an associated fan that pulls material under vacuum from the at least one processor into a condenser housing intake, in said condenser housing is an internal screen against which the hemp fiber and hurd is retained, and said screen having openings through which the undesirable dust and small particles are pulled through, and an internal rotating scraper which collects the desirable hemp fiber and hurd from the screen; anda shaker table receives the hemp fiber and hurd collected by said rotating scraper from said condenser screen, said shaker table has an upper perforated vibrating surface that retains the hemp fiber and allows the hurd to fall through the perforations.

2. The system of claim 1, further including a second condenser receiving the fibers passing through said shaker table surface and using a second condenser vacuum, causes the fibers to be separated against an internal screen, hurd passing through the internal screen, and the collected fibers being collected by a rotating wiper; anda second shaker table constructed and arranged for receiving the hemp fibers collected by said second condenser and transporting the hemp fibers for further processing.

3. The system of claim 1, further including an applicator configured for applying fire retardant to the hemp fibers collected on said second shaker table.

4. The system of claim 3, wherein said applicator includes an applicator housing enclosing a rotating auger, the housing receiving incoming hemp fibers under air pressure, the auger suspending the hemp fibers within the housing, and an atomizer sprayer associated with the applicator housing applying fire retardant solution under pressure to the suspended fiber particles.

5. The system of claim 3, further including a rotating hammermill configured for receiving the hemp fibers treated with said fire retardant and subjects the fiber to impact from second rotating hammers operating within a second chamber defined by a circular screen, the fibers are then passed through a hammermill outlet.

6. The system of claim 5 including a third condenser configured for receiving hemp fiber under vacuum power from said second rotating hammermill, and having a third wiper removing collected fiber from an internal condenser screen.

7. The system of claim 6, including a third shaker table configured for receiving the hemp fibers from said third condenser.

8. The system of claim 1, wherein said first condenser is located above said shaker table so that hemp fibers fall by gravity from said condenser upon said upper perforated vibrating surface.

9. The system of claim 1, wherein the fiber emitted from the first condenser has a density in the range of 0.5-0.8 lb / ft3.

10. The system of claim 1, wherein the fiber emitted from the first condenser has a thermal conductivity in the range of 0.280-0.380 BTU-in / ft2-hr-° F.

11. The system of claim 1, further including providing a second sizer for receiving material from said at least one processor, said second sizer generating hemp fibers and hurd particles with a designated length range, and transmitting the generated fibers and particles to said condenser.

12. The system of claim 11, wherein said second sizer generates hurd particles and hemp fibers having a length in the range of up to 2 inches (5.0 cm).

13. The system of claim 1, wherein said shaker table includes a second and a third vibrating surface below said upper vibrating surface, said second and third surfaces collecting a combination of hemp fibers and hurd, said combination of hemp fibers and hurd being transmitted to an inclined auger where the hemp fibers collect about a rotating auger shaft and hurd fall by gravity and are segregated for separate handling.

14. The system of claim 1, further performing an operational separation method (OSM2) downstream of at least one said at least one processor.

15. The system of claim 14, wherein said OSM2 method includes sending the mixture of hemp fibers and hurd to multiple loops of said condenser and said shaker table.

16. A method of generating hemp fibers useful as blown insulation using the system of claim 1.

17. Use of the system of claim 1 for generating hemp fibers having a thermal conductivity in the range of 0.280-0.380 BTU-in / ft2-hr-° F. and a density in the range of 0.5-0.8 lb / ft3.

18. A system for processing hemp biomass into fibers useful as insulation, comprising:at least one processor having a housing defining an access opening through which the biomass is urged towards a first sizer configured for sizing hemp fibers and hemp hurd;the hemp fibers and the hurd generated in said at least one processor is collected and diverted to a first condenser having a housing and an associated fan that pulls material from said at least one processor, into a condenser housing intake, in said condenser housing is an internal screen against which the hemp fiber and hurd is retained, and said screen having openings through which dust and small particles fall through, and an internal rotating scraper which collects the hemp fiber and hurd from the screen;a shaker table receives the hemp fiber collected by said rotating scraper from said condenser screen, said shaker table has an upper perforated vibrating surface that retains the hemp fiber and allows the hurd to fall through the perforations;a second condenser receives the fibers and hurd passing through said shaker table, and using a second condenser vacuum, cause the fibers to be separated against an internal screen, dust and unwanted particles passing through the internal screen, and the collected fibers and hurd being collected by a rotating wiper; anda second shaker table constructed and arranged for receiving the hemp fibers and hurd collected by said second condenser and separating the hemp fibers from hurd.

19. The system of claim 18 further including providing a second sizer for receiving material from said at least one processor, said second sizer generating hemp fibers and hurd particles with a designated length range, and transmitting the generated fibers and particles to said first condenser.

20. The system of claim 18, wherein said shaker table includes a second and a third vibrating surface below said upper vibrating surface, said second and third surfaces collecting a combination of hemp fibers and hurd, said combination of hemp fibers and hurd being transmitted to an inclined auger where the hemp fibers collect about a rotating auger shaft and hurd fall by gravity and are segregated for separate handling.

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