TECHNICAU FIEUD

[0001] Disclosed herein are manufactured hemp products and methods of making the same. More particularly, the manufactured hemp products described herein may include hemp composite boards, blocks, beams, panels, flooring, furniture, building materials and other wood products wherein the grain of the product is displayed, as in some composite or wood products.

BACKGROUND

[0002] Today’s increased demand for wood products, coupled with unbridled

deforestation, has led to a scarce supply of timber sources. Many species of majestic rainforest trees are endangered or are approaching extinction. In addition to a reduced supply of trees, many trees traditionally coveted for their wood take many years to reach maturity. Thus, even if these trees are replanted, it will take many years to replenish the supply. This scarcity of natural wood may be particularly noticeable in those industries that rely on the particular aesthetic and structural qualities of the natural wood, such as the wood flooring, furniture, building materials or other wood industries.

[0003] Substitutes for natural wood can include, for example, plywood, particle board, and the like. However, many of these substitutes are derived from natural wood but do not have visual or technical attributes of natural wood. Furthermore, they may not address the issue of finding and maintaining a sustainable raw material supply for the future.

SUMMARY

[0004] A method and system have been developed that allows for the use of hemp stalks from Cannabis Sativa, Cannabis Indica or Cannabis Ruderalis plants (as well as plants with similar properties) which can be grown as replenishable plants indoors (or agricultural crops outdoors) to replace hardwood used in flooring, furniture and other wooden products. These products derived from hemp stalks provide the same or better hardness, stability, and density.

[0005] One embodiment of the method of preparing hemp stalks for use in a manufactured hemp product may include beginning with a hemp stalk piece from a cannabis plant. As one of ordinary skill in the art would appreciate, a hemp stalk consists of an outer layer (typically called the Epidermis), a first inner layer (typically called the Bast Fiber, a second inner layer (typically called the Hurd or Core) and a hollow inner core. The bast fiber has proven to be able to carry low level electrical current. The hemp stalk piece is generally rectangular or cylinder and it may have a thickness in the range of about 0.1 mm to about 75 mm. The hemp stalk piece typically includes an internal surface area which is accessible from the outside of the hemp stalk piece. The hemp stalk piece generally has a naturally-occurring, generally elongate internal structure extending along one axis of the hemp stalk piece.

[0006] In harvesting, the hemp stalk is cut above the roots and the branches are (typically) removed. In outdoor agricultural crops, a farming combine is used to cut off the top (including leaves and flower (buds)) of the plant to be used for other products. The stalk is then allowed to dry (or ret) in the field. In replenishable indoor plants the top of the plant including leaves and flower (buds) are removed. This provides an elongate hemp stalk piece from the cannabis plant. The internal volume of the hemp strand is capable of absorbing fluid accessible from the outside of the hemp stalk piece. Additionally, breaking at least a portion of the naturally-occurring generally elongate internal structure parallel to the axis increases the surface area of the hemp stalk piece such that the ability of the hemp piece to absorb an adhesive solution increases by at least 10% than the surface area of the hemp stalk piece prior to breaking at least a portion of the internal structure. In outdoor agricultural crops, the stalks are cut down and bailed/bundled breaking at least a portion of the naturally occurring generally elongated internal structure of the hurd.

[0007] In some embodiments the hemp stalk piece is cut to size after which the hemp stalk piece may be deskinned, split and crushed to further open the internal lignocellulosic plant structure. Different methods of harvesting or bailing may deskin, split, and crush the hemp stalk piece into a hemp strand. This optional step is typically based on visual observation and the adhesive application. In addition, boiling the hemp stalk pieces in H20 or in a mild H202 solution or carbonizing with pressured steam may occur. The hemp strands are dried then submersed in a fossil fuel or agricultural based adhesive solution for about 0.5- 20 minutes. Anyone skilled in the art will understand, there are multiple suitable methods of adhesive application, including roller, submersion, waterfall, etc. Subsequent to this submersion, the hemp strands are air or heat dried to a second total water content of between about 5% to about 20% by weight for thermal set adhesives. If a cold set adhesive is going to be used, the hemp strands are not typically dried beyond filed drying (retting). The hemp strand includes adhesive in the range of between about 5% to about 49% by weight. Typically, the adhesive-applied strands for thermoset adhesives are dried, but adhesive-applied strands are not dried for cold set adhesives.

[0008] Subsequent steps normally include placing the adhesive-applied strands into a mold either parallel or perpendicular to one another with a lid; and applying pressure to the hemp strands. When thermoset adhesives are used, heat is typically applied to the mold while pressure is applied (hot press). Alternately, a lid can be used to maintain pressure on the strands during adhesive curing. For cold set adhesives (Cold Press) while no heat is required, pressure is applied or, alternatively, a lid can be used to maintain pressure during adhesive curing.

[0009] Once the applied adhesives are cured, the pressure is released (or the mold lids are opened) and the manufactured hemp product is removed. The short ends of the manufactured product are trimmed/cut to form a uniform edge. The manufactured hemp product is then allowed to stabilize in ambient air conditions. The manufactured hemp product is then in the form of board, block beam or panel and is allowed to stabilize in ambient atmosphere conditions. Afterward, the manufactured hemp product is then dried with air or heat to obtain the required moisture content.

[0010] The manufactured hemp product is comprised of a plurality of hemp stalk strands from a cannabis (or similar) plant less than one year old and typically has a density in the range of about 200 kg/m ³ to about 900 kg/m ³ with the desired amount of adhesive. The density and hardness of the final product is a result of: (1) the extent to which the lignocellulosic structure is opened, (2) the density of the adhesive solution, (3) the amount of time that the hemp stalk strands are submersed, and (4) the pressure applied to the mold.

[0011] The manufactured hemp product comprises an amount of hemp strands greater than 50% and an amount of adhesive in the range of 5% to about 49%. The manufactured hemp product has a generally uniform density in the range of between about 600 kg/m3 to about 1200 kg/m3; and the manufactured hemp product has an aesthetically pleasing appearance. The manufactured hemp product has a dimensional stability coefficient of change that is at least 10% more stable than the original hemp stalk according to the dimensional stability coefficient of change. Test results have shown the manufactured hemp product to have an improved hardness over natural hemp stalks according to the Janka Hardness Test. When hemp products are connected together (example, click flooring) the bast fiber from one board can pass currents to the adjoining board bast fiber allowing a current to flow throughout the entire installation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The drawings are meant to illustrate the principles of the invention and do not limited the scope of the invention. The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements in which:

[0013] FIG. 1 is a process flow chart illustrating one embodiment of a system described herein.

[0014] FIG. 2 A is a drawing of an outdoor hemp plant.

[0015] FIG. 2B is a drawing of an indoor hemp plant.

[0016] FIG. 3 is a drawing of a hemp stalk being cut/trimmed to length.

[0017] FIG. 4 is a drawing of a hemp stalk piece being skinned, split and crushed to create a hemp strand (degree of split, skin and crushed varies or may be omitted).

[0018] FIG. 5 is a drawing of a hemp strand being boiled or carbonized (optional).

[0019] FIG. 6 A is a drawing of a first dried hemp strand.

[0020] FIG. 6B is a magnified view of the dried hemp strand of FIG. 6A.

[0021] FIG. 7 is a drawing of the adhesive application to hemp strands.

[0022] FIG. 8A is a drawing of the adhesive applied hemp strands being loaded into molds in parallel.

[0023] FIG. 8B is a drawing of the adhesive applied hemp strands being loaded into molds in cross directional layers.

[0024] FIG. 9A is a drawing of the molded hemp strands being pressed into a block.

[0025] FIG. 9B is a drawing of the molded hemp strands being pressed into a panel.

[0026] FIG. 10A is a drawing of the mold being opened and the pressed hemp strands comprising a monolithic hemp piece trimmed.

[0027] FIG. 10B is a drawing of the mold being opened and the pressed hemp strands being trimmed. [0028] FIG. 11 A is a drawing of the monolithic hemp piece being cut into a block.

[0029] FIG. 1 IB is a drawing of the monolithic hemp piece being cut into boards.

[0030] FIG. 11C is a drawing of the monolithic hemp piece being cut into panels.

[0031] FIG. 1 ID is a drawing of the monolithic hemp piece being cut into boards.

[0032] FIG. 12Ais a drawing of a manufactured hemp product.

[0033] FIG. 12B is a drawing of a hot press cross directional panel.

[0034] FIG. 12C is a drawing of is a hot press cross directional board.

DETAILED DESCRIPTION

[0035] Figure 1 illustrates a process flow chart of one embodiment of the present invention. The flow chart begins with a hemp plant in Step 105. As one of ordinary skill in the art would appreciate, a hemp stalk consists of an outer layer (typically called the Epidermis), a first inner layer (typically called the Bast Fiber, a second inner layer (typically called the Hurd or Core) and a hollow inner core. In Step 110 the hemp stalk is trimmed/cut to length. In Step 115, the cut lengths of the hemp stalk piece (stalks and petiole) are skinned, split and/or crushed; creating hemp strands. Each of these steps (i.e., the skinned, split and/or crushed steps) is optional. In Step 120 the hemp strands may be boiled or carbonized. In step 125 the boiled/carbonized/natural hemp strands are dried/stabilized (acclimatized). In Step 130 the first dried hemp strands have

resin/glue/adhesive (generally referred to as adhesive) applied. In Step 135 the hemp strands with the adhesive applied are loaded into molds. In Step 140 pressure is applied to the unpressed hemp strands. Pressure can be applied through direct pressure or through the use of a lid. In Step 145 heat is optionally applied to the pressed hemp strands. After Step 140 or Step 145, the adhesive has cured and the heated hemp strands and adhesive have bonded together creating a monolithic molded hemp piece. The monolithic hemp piece is then removed from the mold in Step 150. In Step 155, after the monolithic unmolded hemp piece is allowed to stabilize/rest, it is then cut into boards, blocks, beams or panels. In step 160 the manufactured hemp product is ready for use for its intended purpose.

[0036] Figure 2 is a drawing of hemp plants. The manufactured hemp product uses the hemp stalks from Cannabis Sativa, Cannabis Indica or Cannabis Ruderalis plants (as well as plants with similar properties), which can be grown as replenishable hemp plants indoors (Figure 2B) or agricultural hemp plants outdoors (Figure 2A). The agricultural hemp plants shown in Figure 2A can grow up to 2.5 meters in one growing season, which is generally less than one year. Agricultural hemp plants (grown outdoors) (Figure 2A) have been tested to have fiber content of 50-60% with generally elongated stalks. Indoor grown hemp plants (Figure 2B) are usually smaller in height and thinner in stem diameter with a fiber content lower than naturally grown outdoor hemp plants (Figure 2A). Each type of hemp plant includes Roots 205, Main Stalk 210, Nodes 215, Intemodes 220, Petoile 225, and Fan Leaf 230. Preferably, the manufactured hemp products of the present invention use the Main Stalks 210, but may also incorporate the Nodes 215, Intemodes 220 and Petoile 225. Hemp stalk are known to have higher fiber content than many trees species; with research showing standard tree species < 50% fiber content with hemp having up to 57% fiber content.

[0037] Figure 3 is a drawing of the hemp stalk being cut/trimmed to length. Some embodiments disclosed herein are directed to a method of preparing hemp stalks for use in a manufactured hemp product. This embodiment includes providing a hemp stalk piece from a cannabis plant 305, wherein the hemp stalk piece is generally rectangular or cylinder and has a thickness < 75 mm. The internal surface area of the hemp stalk piece is accessible from the outside of the hemp stalk piece, with the hemp stalk piece having a naturally-occurring, generally elongate internal structure extending along one axis of the hemp stalk piece. Cutting the hemp stalk above the roots and removing the Petiole at the Nodes 310, provides an elongate hemp stalk 315 from a, for example, cannabis plant, where the hemp stalk has a length and a width, generally rectangular or cylinder in cross section 320, and has a thickness in the range of between about 0.1 mm to about 75 mm. Additionally, the internal volume of the hemp stalk is capable of absorbing fluid accessible from the outside of the hemp piece because the hemp stalk piece has a naturally-occurring, generally elongate internal structure extending generally along the length of the hemp stalk piece.

[0038] Figure 4 is a drawing of a hemp stalk piece 320 being skinned 405, split 415, and crushed 420 to create a hemp stalk strand. A skinned hemp stalk piece is shown by reference number 410. One of ordinary skill in the art would appreciate that the degree of the hemp stalk piece being skinned, split, and/or crushed varies or these processes may be omitted entirely. Some embodiments disclosed herein are directed to a method of preparing hemp stalk for use in a manufactured hemp product that includes a hemp stalk piece from a cannabis plant 310. Splitting 415 at least a portion of the naturally-occurring generally elongate internal structure of the hemp stalk parallel to the axis of the hemp stalk 320 increases by at least 10% than the surface area of the hemp stalk piece prior to breaking at least a portion of the internal structure. The breaking step increases the surface area of the hemp stalk piece thereby increasing the ability of the hemp stalk piece to absorb an additional amount of the adhesive solution. In some embodiments after the hemp stalk piece is cut to size, the skin is removed 405 leaving a hemp stalk piece which is unskinned 410, it is split into strands 415, and/or crushed 425 to further open the internal lignocellulosic plant structure. The optional step of splitting the strand is similar to splitting a log. The optional step of crushing is generally performed through a rolling action. The crushing process results in crushed hemp stalk 420. The amount of splitting, skinning and crushing the hemp stalk piece to create a hemp strand varies in accordance with the required strength and visual appearance of the finished product. Reducing or eliminating the skinning, splitting and crushing allows less adhesive to penetrate the hemp strand and provides a“more busy” (or more complexed) visual appearance of the final product.

[0039] Figure 5 is a drawing of a hemp strand being boiled or carbonized. These steps of boiling or carbonizing the hemp strands are optional. Some embodiments disclosed herein are directed to a method of preparing hemp stalk for use in a manufactured hemp product that can include providing a hemp strand. The optional steps of boiling the hemp strand in H20 or a mild H202 (2%) solution will remove natural sugars in the strand creating better adhesive penetration/bonding and a more uniform color to the end product. Boiling is generally conducted at above 100° C for a minimum of 2 hours. Carbonizing the hemp strand with pressured hot steam above 120° C will darken the color of the end

manufactured hemp product by carbonizing the sugars for 2-4 hours to reach required color darkness.

[0040] Figure 6 is a drawing of a hemp strand (after the optional boiling or carbonizing) (Figure 6A) after the drying process which shows individual strands of similar size 605. A magnified drawing (Figure 6B) indicates stress fractures from the optional crushing process 420. At this point, the hemp stalk strand is dried to a first total water content preferably of less than 20% by weight. Drying the hemp stalk strand can be done by using forced air, heat, sunshine or ambient air conditions. Best practice is using natural elements such as sunshine, but wood drying room, kiln or microwave technology are also acceptable. Boiling the hemp strands is optional after de-skinning/splitting/crushing creates more uniform colors removing some of the green color of the live plant. Adding H202 to the water solution for boiling improves the chemical bonding for phenol formaldehyde adhesives. Carbonizing the hemp strands is optional after cutting splitting/de-skinning. It is the process of pressure steaming the hemp strands to create a darker brown color by carbonizing the sugars in the stalk.

[0041] Figure 7 is a drawing of the adhesive application to the first dried hemp strands. Some embodiments disclosed herein are directed to a method of preparing hemp stalk for use in a manufactured hemp product that can include providing a hemp strand 605. The hemp strands are submersed in a container 705 full of fossil fuel or agricultural based adhesive solution 710 for between about 0.5-20 minutes. Agricultural based adhesives may include but are not limited to; soy, hemp, wheat or flowers. Petro based adhesives may include but are not limited to; urea formaldehyde, phenol formaldehyde, melamine urea formaldehyde, polyvinyl acetate, polyurethane, emulsion polymeric isocyanates, emulsion and solution acrylics, emulsion and solution styrene-acrylics, emulsion and solution methacrylics, and emulsion and solution styrene-methacrylics, or melamin formaldehyde. Afterward, the hemp strands with applied adhesive is air or heat dried to a second total water content of between about 5% to about 20% by weight for thermal set adhesives. Alternatively, the drying step is eliminated for cold set adhesives. The hemp strand includes adhesive in the range of between about 5% to about 49% by weight.

[0042] Agri based adhesives are derived from natural occurring organic compounds, and are more eco-friendly and the preferred choice by end users for the manufactured hemp product. Cost, technical properties and ease of use sometimes limit the use of these eco- friendly adhesives. Fossil fuel based adhesives are derived from petroleum or other fossil fuels and include curing or crosslinking agents such as isocyanates, phenol, urea, melamine, acrylics, methacrylics, vinyl-functionalized agents, or acetates. These products are not eco-friendly but typically create a stronger and more cost efficient product.

[0043] Cold Set Adhesives- can cure at room temperature (5-40° C) and do not require an applied heat source, curing time is generally longer than thermoset adhesives. These adhesives generally have a higher viscosity and are applied more to the surface of the hemp strands, penetrating the hemp strand cell structure to a lesser degree than the diluted thermoset adhesives. Thermoset Adhesives- cure at higher temperatures (examples UF 70° C and PF 120° C) and require an applied heat source, curing time is generally shorter than cold set adhesives. Thermoset adhesives can be applied via a H20 dilution technique which includes using a 50% diluted adhesive to lower the viscosity in turn increasing the penetration of the plant structure. Following the flooding of the cell structure of the hemp strands the H20 is dried out of the hemp stalk but the adhesive remains clinging to the internal cell structure of the plant. These dried strands will require a heat curing system to trigger chemical bonding in some cases.

[0044] Figure 8A is a drawing of the adhesive applied hemp strands 605 being loaded into molds 805 in a parallel to make a cold press block. Some embodiments disclosed herein are directed to a method of making a manufactured hemp product that can include providing a plurality of hemp strands, and placing the adhesive-applied strands into a mold, where the mold has an interior width greater than the width of an individual adhesive applied hemp strand.

[0045] Figure 8B is a drawing of the adhesive applied hemp strands 605 being loaded into molds 810 in cross directional layers to make a hot press panel. Some embodiments disclosed herein are directed to a method of making a manufactured hemp product that can include providing a plurality of hemp strands, and placing the adhesive-applied strands into a mold, where the mold has an interior width greater than the width of an individual adhesive applied hemp strand.

[0046] Figure 9A is a drawing of the molded hemp strands being cold pressed into a block. Some embodiments disclosed herein are directed to a method of making a manufactured hemp product that can include providing a plurality of adhesive applied hemp strands 905 placed into a mold 805 with a lid 910, using a press 915 and applying pressure 920 to the molded hemp strands in the mold to thereby form a manufactured hemp product. The amount of pressure 920 applied depends on the required density and hardness of the finished product. For thermoset adhesives heat is applied to the mold with pressure still applied or a lid attached to maintain pressure during adhesive curing. For cold set adhesives no heat is required, but pressure remains applied or a lid attached to maintain pressure during adhesive curing.

[0047] Figure 9B is a drawing of the molded hemp strands being hot pressed into a panel. Some embodiments disclosed herein are directed to a method of making a manufactured hemp product that can include providing a plurality of adhesive applied hemp strands 925 placed into a mold 810 with a lid 930, using a press 935 and applying pressure 940 to the molded hemp strands in the mold to thereby form a manufactured hemp product. The amount of pressure 940 applied depends on the required density and hardness of the finished product. For thermoset adhesives heat is applied (hot pressing) to the mold with pressure still applied or a lid attached to maintain pressure during adhesive curing. When hot pressing a panel, layering the hemp strands perpendicular to the ones above and below allows for greater stability.

[0048] Figure 10A is a drawing of the cold press block mold 805 being opened and the pressed hemp strands being trimmed. Some embodiments disclosed herein are directed to a method of making a manufactured hemp product including hemp strands and a desired amount of adhesive. Once the adhesives are cured, the pressure is released 1005 and the mold lids 910 are opened and the manufactured hemp product is removed 905. The short ends of the manufactured product are trimmed/cut to form a uniform edge. The manufactured hemp product is then allowed to stabilize in ambient air conditions.

[0049] Figure 10B is a drawing of the hot press panel mold 810 being opened and the pressed hemp strands being trimmed. Some embodiments disclosed herein are directed to a method of making a manufactured hemp product including hemp strands and a desired amount of adhesive. Once the adhesives are cured, the pressure is released 1010 and the mold lids 930 are opened and the manufactured hemp product is removed 925. The short ends of the manufactured product are trimmed/cut to form a uniform edge. The manufactured hemp product is then allowed to stabilize in ambient air conditions.

[0050] Figure 11 A is a drawing of the monolithic hemp piece 905 being cut into board (Figure 1 IB), board (Figure 1 ID), block (Figure 11 A) or panel (Figure 11C). A board is generally 15: 1-3: 1 (width:height). A block is generally 1 : 1-1 :2 (width:height). A beam is generally 3: 1-2: 1 (width:height). A panel is generally 16: 1-50: 1 (width:height). The manufactured hemp product many then be cut, sanded or formed into board, block, beam or panel. Once in board, block, beam or panel shape the product is allowed to stabilize for preferably 2-10 days pending environmental conditions. Fig 11 B is a cold press board and Fig 1 ID is a hot press board.

[0051] Figure 12A is a drawing of a manufactured hemp product 1105. Figure 12B is a hot press cross directional panel. Figure 12 C is a hot press cross directional board. Some embodiments disclosed herein are directed to a manufactured hemp product that can include a plurality of adhesively bonded and pressed hemp strands; where: (1) each of the hemp strands is of generally the same length; (2) each hemp strand comprises a naturally- occurring, generally elongate internal structure extending generally along one axis of the strand that has been at least partially laterally broken and at least partially permeated by an adhesive; (3) the hemp strands are oriented roughly parallel to one another along their length; (4) the manufactured hemp product comprises an amount of adhesive in the range of between about 5% to about 49% by weight; and (5) the manufactured hemp product has a generally uniform density in the range of between about 600 kg/m3 to about 1200 kg/m3. The manufactured hemp product has a dimensional stability coefficient of change that is at least 10% more stable than the original hemp stalk according to the dimensional stability coefficient of change. The manufactured hemp product has a hardness pending adhesive used and density. Test results have shown the manufactured hemp product to have an improved hardness over natural hemp stalks according to the Janka Hardness Test.

[0052] Test Results

* Source 24 week old hemp plant

[0053] Some embodiments herein are directed to a manufactured hemp product that can include a plurality of adhesively bonded partially broken hemp strands; wherein each of the partially broken hemp strands maintains its original structure from an appearance point of view; the majority of the partially broken hemp strands from the stalk are the same length, but pieces from nodes, intemodes and petiole may be of varying size; each partially broken hemp strand comprises a naturally-occurring, generally elongate internal structure extending along the length of the strand that has been at least partially broken and at least partially permeated by the adhesive; the partially broken hemp strands are oriented approximately parallel to one another along their length.

[0054] In some instances hemp fiber has been shown to conduct electric current. In addition other conductive fibers can be added to the manufactured hemp product to conduct current more efficiently as desired. Amount of conductive fibers added being at a minimum to conduct current from one board to the next on the board ends in an installation.