Method for the producing structural elements made from naturally derived materials

Abstract

A method for producing structural elements made from at least one naturally derived material, comprising the steps of physically treating said at least one naturally derived material and aggregating said at least one naturally derived material to produce an aggregate.

Description

[0001] METHOD FOR THE PRODUCING STRUCTURAL ELEMENTS MADE FROM NATURALLY DERIVED MATERIALS

[0002] The present invention relates to a method for producing structural elements made from naturally derived materials.

[0003] Field of the invention

[0004] The invention falls within the technical field of methods for reusing naturally derived materials, in particular within the technical field of methods that use naturally derived materials such as shells, skins or peels.

[0005] In particular, the invention refers to a method for producing materials that can be used in various fields from food waste and / or crops.

[0006] Prior art

[0007] The current economy and industry produce a great deal of waste and refuse that is difficult to recycle or reuse.

[0008] In fact, terms such as “circular economy”, “recycling”, “sustainability”, etc. are becoming increasingly important in the everyday lives of individuals, industries and businesses.

[0009] The agricultural and food industry also produces a large amount of waste and refuse that is often not reused or recycled due to the high difficulty, high cost or lack of means and capacity.

[0010] For example, considering those areas of the planet, generally belonging to poor regions, where the economy is based exclusively on a single crop.

[0011] It often happens that monoculture farming leads to enormous problems related to the management and failure to dispose of the waste products of that crop, such as shells, rinds or peels.

[0012] These waste products are generally accumulated in huge piles that invade the territory, with the risk of fires, the proliferation of bacteria, an increase in diseases and other negative factors for the community and for human and animal health.

[0013] Instead, these waste products could be used to obtain natural derivatives as an alternative to materials such as wood or paper.

[0014] In this way, not only would waste products be reused, but the further production of wood or paper would be avoided, reducing the impact of industries and economies on the planet.

[0015] Field of the inventionThe aim of this invention is therefore to provide a method for producing structural elements made from naturally derived materials that can resolve the aforementioned drawbacks and critical issues.

[0016] Another aim of this invention is to create a method for producing elements made from naturally derived materials that allows for the disposal of waste from crops, particularly monocultures.

[0017] A further aim of the present invention is to provide a method for producing elements made from naturally derived materials that improves health and reduces the risk of fire in areas subject to monocultures.

[0018] Another aim of the present invention is to provide a method for producing sound-absorbing elements as well as building materials such as

[0019] bio-perforated and bio-bricks.

[0020] Another aim of the present invention is to provide a method for producing elements made from naturally derived materials that fits within the concept of the circular economy.

[0021] A further aim of the present invention is to provide a method for producing elements made from naturally derived materials that can replace structural elements, such as cardboard and insulating and sound-absorbing panels, as well as building materials.

[0022] Another aim of the present invention is to provide a method for producing structural elements made from natural materials that is simple to perform and economical to implement.

[0023] A further aim of the present invention is to provide a method for producing structural elements made from natural materials that can include pre-treatments and modifications in order to modify the obtainable product based on the requirements and needs of the case.

[0024] Another aim of the present invention is to provide a method for producing structural elements made from naturally derived materials that allow the recycling of products used in packaging and containers, particularly in single-serve coffee packaging.

[0025] These and other aims are achieved by a method for producing structural elements made from naturally derived materials according to the attached independent claim.Other materials that can be produced in addition to those already mentioned include pencils and crayons, furniture, non-slip flooring, OSB (Oriented Strand Board) and MDF (Medium Density Fibreboard) panels, formwork panels, construction site panels, packaging crates, fruit crates, advertising signs and materials for various types of sports.

[0026] Further detailed technical characteristics are provided in the attached dependent claims.

[0027] Detailed description

[0028] In the following, a preferred embodiment of a method for producing elements made from naturally derived materials according to the invention is described.

[0029] In this embodiment, the method according to the invention aims to treat naturally derived materials, such as waste from the agricultural and / or food industry, for the production of elements that can be used in everyday life, for example as an alternative to wood, paper or other materials.

[0030] In the following description, natural materials refer, for example, to peanut shells.

[0031] It is understood that other shells, skins, peels or elements from the agricultural and / or food industry can also be used as natural materials without departing from the inventive concept of the present invention.

[0032] For example, walnut shells, hazelnut shells, pistachio shells, coconut shells, etc. could be used as an alternative or in combination with peanut shells.

[0033] Advantageously, to compensate for the lack of certain fibres that may be scarce in a particular natural material, it is possible to combine several materials in order to obtain the advantages of all the materials used.

[0034] Examples of this include the use of materials such as wool and fabric, which contain natural fibres.

[0035] Furthermore, for certain processes, it may be necessary to embed other plantbased materials such as jute, flax, hemp, etc. within the mass produced with these natural fibre composites.

[0036] In other cases, ferrous and non-ferrous materials may be present, such as plastics of various origins.

[0037] In some specific processes, it may also be necessary to combine natural fibres with other materials such as cement powder, lime, gypsum powder, clay and others.A particular example involving the use of jute is particularly advantageous for the production of elements with joints.

[0038] In particular, these joints can be found, for example, in parallelepiped boxes with a bottom and walls in which there are folds between the bottom and the walls.

[0039] Another advantage is that multi-layer elements can be created in which each layer is composed of a different natural material. This solution is particularly effective in the production of thermal insulation or sound-absorbing panels.

[0040] In particular, it is possible to use less refined layers in which there is a greater quantity of shells (natural materials) and / or the materials are less finely treated.

[0041] In particular, the material can be treated more or less finely depending on the processing and uses.

[0042] This form of implementation is particularly effective, for example, for soundabsorbing and thermal insulation panels.

[0043] On the other hand, more refined layers can be used for other purposes depending on requirements and needs.

[0044] In other words, depending on the refinement of the material produced, which may depend on the treatment of the material or its composition, more or less refined elements can be created for different and appropriate applications.

[0045] Advantageously, the different methods of processing naturally derived materials can allow the final product to favour the interweaving of fibres naturally present in the material used or to create, with different processes, other types of elements made from multiple materials (depending on requirements and needs), which exploit the properties of all the materials used.

[0046] An example of this is the replacement of OSB (Oriented Strand Board) and chipboard panels.

[0047] In a preferred embodiment of the invention, the method for producing elements made from naturally derived materials comprises the steps of:

[0048] - physically treating at least one naturally derived material;

[0049] - aggregating said at least one naturally derived material.

[0050] In a particular embodiment of the invention, the physical treatment of the naturally derived materials is carried out by hammering the materials with machinery designed to flatten them.Advantageously, this machinery flattens the naturally derived materials without breaking the fibres but promoting their elongation in order to facilitate their reciprocal interlacing.

[0051] This hammering is not a dimensional reduction process as described in the prior art, but a specific physical treatment aimed at achieving a precise technical effect, namely flattening the material to stretch and intertwine the fibres rather than breaking them.

[0052] The technical effect resulting from this aspect is the creation of an aggregate in which the fibres, being longer, intact and intertwined, give greater cohesion and structural integrity to the final element.

[0053] This condition of the aggregate, which is achieved even before the binder completes its action, gives the final structural element greater internal cohesion, improving its mechanical properties such as flexural strength and toughness, even with the same binder used.

[0054] Crushing and compression with different types of machinery can also be used to achieve the purpose of composing the fibres and their alignment.

[0055] In particular, rollers with different pressures can be used to compact the material, increasing or decreasing its concentration and density.

[0056] In the aggregation phase, starting from the physically treated natural material, an aggregate is obtained.

[0057] Advantageously, the aggregation phase includes a sub-phase of gluing and a sub-phase of pressing.

[0058] In the pressing sub-phase, based on the force applied to press the material, the density of the element to be obtained can be determined according to the requirements of specific uses.

[0059] In particular forms of implementation, it may be necessary to use liquids, vapours, jets of cold or hot air, or to use a vacuum or place the material in rooms at high or low temperatures.

[0060] The fibres are aggregated through the pressing phase and the subsequent bonding with a bonding agent, such as vinyl glues, starch and / or amides of various origins.

[0061] Advantageously, one or more bonding agents can be used. In una forma realizzativa preferita, in particolare per la produzione di elementi per gli alimenti, pud essere utilizzato I’amido proveniente dal riso.This aggregation can be advantageously reinforced with a sub-phase involving the insertion of plant fibres such as hemp, jute, flax and other fibres in order to improve or add certain specific properties.

[0062] For example, it is thus possible to increase the toughness of the final element or to create materials which, having different types of fibres, also have greater properties than materials composed of a single type of fibre.

[0063] Furthermore, thanks to the integration of different fibres, it is possible to obtain elements capable of performing different functions.

[0064] Advantageously, depending on the end use of the element produced by the method according to the invention, this method may include pre-treatments in order to give the naturally derived material specific properties that may be required for the applications of the structural element produced.

[0065] These pre-treatments can be applied to the naturally derived material before the physical treatment phase of the material.

[0066] For example, fungicide, fireproofing, waterproofing, etc. treatments may be provided.

[0067] Furthermore, these pre-treatments are environmentally friendly and have zero impact.

[0068] Advantageously, if a low-weight final element is desired, the aggregate could be moulded in such a way as to obtain voids that reduce the mass of the product but not its toughness.

[0069] For example, if a lighter panel or insert is desired, honeycomb structures could be created so that the toughness of the element is maintained but its weight is reduced.

[0070] This application could also be particularly suitable for the production of packaging, as an alternative to traditional cardboard.

[0071] Alternatively, pyramid structures could also be created.

[0072] Another advantage is that, to reduce weight, it is also possible to inject air bubbles or other gases, for example small ones, sized so as not to cause the material to lose its toughness.

[0073] Advantageously, once the aggregate has been obtained through the aggregation phase, it is possible to apply and / or spray and / or deposit this aggregate on dies that will give the final shape of the element to be obtained.Depending on the different construction methods, the compound can be applied mechanically by spraying or spreading, or even using other application techniques.

[0074] The aggregate obtained will have a consistency and properties particularly suited to the creation of the final structural element to be obtained.

[0075] In other words, the aggregate can be applied and / or positioned, sprayed or deposited in a mould chosen according to the final element to be obtained.

[0076] In a particular embodiment of the method according to the invention, in order to lighten the final structure, an element with hollow inserts could also be created.

[0077] Advantageously, it is possible to obtain elements made almost exclusively from naturally derived materials, which have only undergone cleaning.

[0078] Such elements can be particularly useful in protective packaging fillings that can subsequently be disposed of in a completely natural and environmentally friendly manner.

[0079] Equally advantageously, it is possible to create composite elements formed from portions originating from different naturally derived materials.

[0080] For example, it is possible to produce a panel having at least one wall made from peanut shells and internal layers made from plant fibres.

[0081] Advantageously, the material produced using the method according to the invention can, at the end of its life, be subjected to regeneration treatments and can be reused as is or with the addition of other materials.

[0082] In a particular form of implementation, the element or material produced using the method according to the invention can be used for the production of packaging.

[0083] Appropriately, the element produced can also be coupled with other materials, for example, derived from fibres, including paper or cardboard pulp or other materials

[0084] This coupling can be achieved through various techniques and treatments, which may include spraying, spreading, depositing and various applications.

[0085] In addition, the material may also undergo special transformations and be used for other purposes.

[0086] The description provided clearly illustrates the features of the method for producing structural elements made from natural materials, which is the subject of the invention, as well as its advantages.Finally, it is clear that numerous other variations can be made to the method in question without departing from the principles of novelty inherent in the inventive idea, just as it is clear that, in the practical implementation of the invention, the materials, shapes and dimensions of the details illustrated may be any depending on requirements and may be replaced with other equivalents.

[0087] Where the features and techniques mentioned in any claim are followed by reference signs, such reference signs have been included for the sole purpose of increasing the intelligibility of the claims and, consequently, such reference signs have no limiting effect on the interpretation of each element identified by way of example by such reference signs.

Claims

CLAIMS1. Method for producing structural elements made from at least one naturally derived material, in particular peanut shells, comprising the steps of:- physically treating said at least one naturally derived material, wherein said physically treating step comprises a hammering of the naturally derived material which flattens the material, preventing the fibres from breaking but promoting their elongation in order to facilitate their reciprocal interlacing;- aggregating said at least one naturally derived material to produce an aggregate.

2. Method for producing elements made from the at least one naturally derived material according to claim 1 characterised in that said aggregation step of said at least one naturally derived material comprises in the order- a gluing sub-step;- a pressing sub-step.

3. Method for producing elements made from at least one naturally derived material according to claim 2 characterised by the fact that in said gluing sub-step, vinyl glues, starch and amides of different derivation are used individually or in combination.

4. Method for producing elements made from at least one naturally derived material according to claim 2 characterised by the fact that said aggregating step also comprises a sub-step of inserting vegetable fibres, in particular peanut husks, into said aggregate.

5. Method for producing elements made from at least one naturally derived material according to one or more of the preceding claims characterised by providing for pre-treatments of said at least one naturally derived material.

6. Method for producing elements made from at least one naturally derived material according to claim 6 characterised by the fact that said pre-treatments may be fungicide, fireproofing, waterproofing pre-treatments.

7. Method for producing elements made from at least one naturally derived material according to one or more of the preceding claims characterised by the fact that subsequent to said aggregation step there is a shaping step of said aggregate.

8. Method for producing elements made from at least one naturally derived material according to one or more of the preceding claims characterised by the fact that subsequent to said aggregation step there is a step of applying and / or spraying and / or depositing said aggregate on a die or mould.

9. Structural element made by the method according to one or more of the preceding claims.