Fiber Materials from Grain Straw with Steam Explosion
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Solution Overview
Problem
Existing methods for producing insulation mats or panels from renewable raw materials face challenges in achieving homogeneous distribution of components, leading to inadequate thermal insulation and stability, especially when using materials like hemp that contain shives.
Innovation Solution
A method involving pre-shredded grain straw treated with water and heat, followed by mechanical and chemical comminution using a refiner, and subsequent steam explosion to achieve a flexible state, ensuring a homogeneous distribution of components, with a high proportion of grain straw and a controlled amount of binding fibers, results in fiber materials with improved thermal insulation and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shives are separated from fiber material before processing, then processing reliability improves, but production complexity and cost increase
Solution Approach 1:
The patent converts the harmful effect of shives (which cause damage to rotating elements and blockages) into a beneficial feature by designing a processing system that specifically handles shives-containing material. The system uses a combination of pre-shredding, steam injection, and specific fiberization techniques that not only tolerate but effectively process shives, transforming them from problem-causing elements to acceptable input material.
Solution Approach 2:
The patent extracts shives from the problematic processing stage by using a pre-shredding step that separates and prepares shives before they enter the main fiberization process. This preliminary extraction and preparation of shives allows them to be processed alongside fibers without causing damage to equipment or blocking feed lines.
2Manufacturing precision
If complex milling and drying processes are used to produce fiberboards, then product quality improves, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent changes the physical and chemical parameters of the plant material through controlled steam injection and temperature management during processing. By adjusting moisture content, temperature, and pressure parameters during fiberization, the process achieves high-quality fiberboards without requiring complex multi-stage drying and treatment processes.
Solution Approach 2:
The patent merges multiple processing functions into a single integrated system. The fiberization process combines cutting, mixing, moisture control, and material distribution in one continuous operation, eliminating the need for separate milling, drying, and processing stages required by traditional methods.
3Strength
If more binder is used to reinforce fiber mats, then mechanical strength improves, but production cost and environmental impact increase
Solution Approach 1:
The patent enables the plant material to serve its own binding function through the natural lignin and hemicellulose present in the shives and fibers. The processing method activates these natural binding agents through controlled steam treatment and compression, allowing the material to bind itself without requiring external synthetic binders.
Solution Approach 2:
The patent creates a composite structure where shives and fibers work together synergistically. The shives provide structural framework and natural binding properties, while the fibers fill spaces and provide additional mechanical strength, creating a self-reinforcing composite material that reduces or eliminates the need for external binders.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces fiber materials with good thermal insulation properties comparable to foamed plastic insulation, while maintaining mechanical strength and stability, with a homogeneous distribution of components and reduced binder usage, allowing for cost-effective production of voluminous insulation materials.
Implementation Method 1
mechanical and optionally chemical shredding in at least one grinding unit, in particular a refiner
Implementation Method 2
subsequent comminution of the plant material obtained according to step d) using the steam explosion method
Implementation Method 3
treating the pre-shredded grain straw with water and/or heat and/or steam, so that the pre-shredded grain straw is converted into a state of higher flexibility
Data Source
AI summary
The present invention relates to a method for producing fibrous materials, comprising: - treating plant material equipped with a cuticle and not constituting bast plant material, so that this plant material is brought into a state of higher flexibility; - mechanically and optionally chemically comminuting the treated plant material in at least one grinding unit, in particular a refiner, and/or comminuting the treated plant material by means of steam explosion; - mixing the processed plant material with a binder and optionally with a comminuted bast plant material; - activating the binder and singulating the solidified mixture into fibrous materials.Furthermore, the invention relates to fiber materials obtainable according to the inventive method and the use of these fiber materials for noise and/or heat insulation or for the production of substrates for hydroponic systems or furniture components.