Plant Stalk Processing System for Intact Bast Fiber Separation
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Solution Overview
Problem
Conventional decorticators damage bast fibers during the processing of plant stalks, leading to weakened fibers unsuitable for reinforcement materials and contamination of hurds with small-size micro-biomass, which is not suitable for common applications like paper or construction composites.
Innovation Solution
A plant-processing system comprising a crusher module to disrupt stalks without damaging bast fibers, a decorticator module to separate bast fibers, and a screening module to produce intact bast fibers and selectively-sized hurds and green microfibers, utilizing high-speed kinematic action to maintain fiber integrity and separate micro-biomass effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional decorticators use hammer mill mechanism to beat plant stalks for separating bast fibers, then bast fibers can be separated from stalks, but the bast fibers are damaged and their structural strength is weakened
Solution Approach 1:
The patent replaces the conventional hammer mill beating mechanism with a decorticator that uses a rotating drum equipped with protruding elements that rub and friction against the plant stalks. This friction-based mechanical action gently separates bast fibers from stalks without the violent impact forces that cause fiber damage, thereby maintaining fiber structural strength while achieving effective separation.
2Productivity
If conventional decorticators use hammer mill mechanism, then bast fibers are separated, but hurds are contaminated with small-size micro-biomass unsuitable for common applications
Solution Approach 1:
The patent incorporates a screening module with multiple screens of different mesh sizes that divides the processing into stages. The first screen separates larger hurds from smaller micro-biomass, while a second screen further separates micro-hurds from fine micro-biomass. This segmented multi-stage screening approach ensures that hurds are cleanly separated from contaminated micro-biomass, improving hurd quality for various applications.
3Productivity
If conventional decorticators are used, then processing can be completed, but dust is generated and fiber integrity is compromised
Solution Approach 1:
The patent replaces the high-impact hammer mill mechanism with a friction-based decortication system using a rotating drum with protruding elements. This gentler mechanical action reduces fiber breakage and dust generation while maintaining processing throughput, as the friction-based separation is equally effective but causes less mechanical disruption to the plant material.
Data Source
AI summary
A system for processing plant materials is described. The plant materials have at least plant stalks, and the plant stalks comprise at least bast fibers. The system has a crusher module for disrupting the plant materials without breaking or damaging the bast fibers thereof, thereby obtaining disrupted plant stalks and a first plant-remainder; a decorticator module coupled to the crusher module for separating the disrupted plant stalks into bast fibers as a first product and a second plant-remainder; and a screening module coupled to the decorticator module for separating at least the second plant-remainder to microfibers and hurds as a second and a third product, respectively.