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Patent 3134821 Summary

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(12) Patent Application: (11) CA 3134821
(54) English Title: SYSTEM FOR AND METHOD OF MANUFACTURING HEMP PRODUCTS
(54) French Title: SYSTEME ET PROCEDE DE FABRICATION DE PRODUITS DE CHANVRE
Status: Examination Requested
Bibliographic Data
(51) International Patent Classification (IPC):
  • B27N 3/04 (2006.01)
  • B32B 5/12 (2006.01)
  • D04H 3/12 (2006.01)
(72) Inventors :
  • WILSON, GREGORY A. (United States of America)
(73) Owners :
  • WILSON, GREGORY A. (United States of America)
(71) Applicants :
  • WILSON, GREGORY A. (United States of America)
(74) Agent: LAVERY, DE BILLY, LLP
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 2020-03-25
(87) Open to Public Inspection: 2020-10-01
Examination requested: 2021-11-09
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US2020/024771
(87) International Publication Number: WO2020/198393
(85) National Entry: 2021-09-23

(30) Application Priority Data:
Application No. Country/Territory Date
16/364,089 United States of America 2019-03-25

Abstracts

English Abstract

A manufactured hemp product comprising a plurality of adhesively bonded and pressed hemp strands where the majority of the hemp strands are of generally the same length and comprise 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 permeated by an adhesive. The hemp strands are oriented roughly parallel to one another along their length. The manufactured hemp product comprises an amount of adhesive between about 5% to about 49% by weight. The manufactured hemp product can be used as a wood substitute in terms of appearance and performance. The manufactured hemp products may have aesthetic and structural qualities that are suitable for high traffic, high visibility applications such as boards, blocks, beams, panels, flooring, furniture, building materials and other wood products.


French Abstract

La présente invention concerne un produit de chanvre fabriqué comprenant une pluralité de bandes de chanvre liées par adhésif et pressées, la majeure partie des bandes de chanvre étant généralement de la même longueur et comprenant une structure interne généralement allongée d'origine naturelle s'étendant généralement le long d'un axe de la bande qui a été au moins partiellement rompue latéralement et au moins pénétrée par un adhésif. Les bandes de chanvre sont orientées approximativement en parallèle les unes par rapport aux autres le long de leur longueur. Le produit de chanvre fabriqué comprend une quantité d'adhésif se situant entre environ 5 % et environ 49 % en poids. Le produit de chanvre fabriqué peut être utilisé comme substitut du bois en termes d'apparence et de performance. Les produits de chanvre fabriqués peuvent présenter des qualités esthétiques et structurales qui sont appropriées pour des applications en zones de passage important et de grande visibilité telles que des planches, des blocs, des poutres, des panneaux, des planchers, des meubles, des matériaux de construction et d'autres produits en bois.

Claims

Note: Claims are shown in the official language in which they were submitted.


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CLAIMS
1 1. A manufactured hemp product comprising:
2 a plurality of adhesively bonded and pressed hemp strands, wherein:
3 each of said hemp strands is of generally the same length and each of
said
4 hemp strands includes bast fiber and hurd;
each of said hemp strands comprises a naturally-occurring, generally
6 elongate internal structure extending generally along one axis of the
strand
7 that has been at least partially laterally broken and at least
partially
8 permeated by an adhesive;
9 said hemp strands are oriented roughly parallel to one another along
their
length;
11 said manufactured hemp product comprises an amount of adhesive in the
12 range of 5% by weight to 49% by weight and said manufactured hemp
13 product comprises an amount of hemp strands of greater than 50% by
14 weight;
said manufactured hemp product has a generally uniform density in the
16 range of 600 kg/m3 to 1200 kg/m3; and
17 said manufactured hemp product can be used as a wood substitute in
18 appearance and technical properties.
1 2. The manufactured hemp product in claim 1, wherein said manufactured
hemp
2 product has a dimensional stability coefficient of change that is at
least 10% more
3 stable than an original hemp stalk according to the dimensional stability
coefficient of
4 change.
1 3. The manufactured hemp product of claim 1, wherein said manufactured
hemp
2 product has a hardness greater than 5 kN according to the Janka Hardness
scale.
1 4. The manufactured hemp product of claim 1, wherein one or more of
the
2 partially broken hemp strands are derived from replenishable indoor plant
or
3 agricultural outdoor plant grown and harvested in less than 1 year.
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1 5. The manufactured hemp product of claim 1, wherein one or more of
the
2 partially broken hemp strands is from hemp stalks that have a density in
the range of
3 200 kg/m3 to 900 kg/m3.
1 6. The manufactured hemp product of claim 1, wherein said hemp strand
is from
2 a stem/stalk from at least one of Cannabis Sativa, Cannabis Indica and
Cannabis
3 Ruderalis.
1 7. The manufactured hemp product of claim 1, wherein said manufactured
hemp
2 product is a block, board, beam or panel and said manufactured hemp
product can be
3 used in a finished product such as flooring, furniture and other wood
products.
1 8. The manufactured hemp block or panel of claim 1 wherein said hemp
fiber or
2 added conductive fibers conducts current such as but not limited to
electric or
3 temperature for practical uses including but not limited to heating,
color change, or
4 programable smart wood.
1 9. The manufactured hemp product of claim 1 wherein said adhesive is
an
2 agricultural based adhesives suitable for the product of at least one of
soy based
3 adhesives, hemp based adhesive, a wheat based adhesive, and a flower
based
4 adhesive.
1 10. The manufactured hemp product of claim 1 wherein said adhesive is
a fossil
2 fuel based adhesive from at least one of urea formaldehyde, phenol
formaldehyde,
3 melamine urea formaldehyde, polyvinyl acetate, polyurethane, emulsion
polymeric
4 isocyanates, emulsion and solution acrylics, emulsion and solution
styrene-acrylics,
emulsion and solution methacrylics, and emulsion and solution styrene-
methacrylics,
6 and melamine formaldehyde.
1 11. The manufactured hemp product of claim 1 wherein said adhesive
includes
2 both said agricultural based adhesive said fossil fuel based adhesive.
1 12. A manufactured hemp product comprising:
2 a plurality of adhesively bonded partially broken hemp strands
wherein each
3 partially broken hemp strand includes both bast fiber and hurd,
wherein:
4 each of said partially broken hemp strands maintains its original
structure
5 from an appearance point of view;
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6 each partially broken hemp strand comprises a naturally-occurring,
7 generally elongate internal structure extending along the length of
the strip
8 that has been at least partially broken and at least partially
permeated by an
9 adhesive;
said partially broken hemp strands are oriented approximately parallel to
11 one another along their length;
12 said manufactured hemp product comprises an amount of adhesive in the
13 range of 5% by weight to 49% by weight and an amount of hemp stalk
14 strands of greater than 50% by weight;
said manufactured hemp product has a generally uniform density in the
16 range of 600 kg/m3 to 1200 kg/m3; and
17 said manufactured hemp product can be used as a wood substitute in
18 appearance and technical properties.
1 13. The manufactured hemp product in claim 12, wherein said
manufactured
2 hemp product has a dimensional stability coefficient of change that is at
least 10%
3 more stable than an original hemp stalk according to the dimensional
stability
4 coefficient of change.
1 14. The manufactured hemp product of claim 12, wherein said
manufactured
2 hemp product has a hardness greater than 5 kN according to the Janka
Hardness scale.
1 15. The manufactured hemp product of claim 12, wherein at least one
of said
2 partially broken hemp strands are from replenishable indoor plant or
agricultural
3 outdoor crop grown and harvested in less than 1 year.
1 16. The manufactured hemp product of claim 12, wherein one or more of
said
2 partially broken hemp strands is from hemp stalk that has a density in
the range of 200
3 kg/m3 to 900 kg/m3.
1 17. The manufactured hemp product of claim 12, wherein said hemp
strands are
2 from the stalk, petiole, nodes and internodes from at least one of
Cannabis Sativa,
3 Cannabis Indica and Cannabis Ruderalis.
1 18. The manufactured hemp product of claim 12, wherein said
manufactured
2 hemp product is a block, board, beam or panel and said manufactured hemp
product
3 can be used in a finished products such as flooring, furniture and other
wood products.

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1 19. The manufactured hemp product of claim 12 wherein said adhesive is
an
2 agricultural based adhesives suitable for the product of at least one of
soy based
3 adhesives, hemp based adhesive, a wheat based adhesive, and a flower
based
4 adhesive.
1 20. The manufactured hemp product of claim 12 wherein said adhesive is
a fossil
2 fuel based adhesive from at least one of urea formaldehyde, phenol
formaldehyde,
3 melamine urea formaldehyde, polyvinyl acetate, polyurethane, emulsion
polymeric
4 isocyanates, emulsion and solution acrylics, emulsion and solution
styrene-acrylics,
emulsion and solution methacrylics, and emulsion and solution styrene-
methacrylics,
6 and melamine formaldehyde,
1 21. The manufactured hemp product of claim 12 wherein said adhesive
includes
2 both said agricultural based adhesive said fossil fuel based adhesive.
1 22. The manufactured hemp block or panel of claim 12 wherein said hemp
fiber or
2 added conductive fibers conducts current such as but not limited to
electric or
3 temperature for practical uses including but not limited to heating,
color change, or
4 programable smart wood.
1 23. A process of manufacturing a manufactured hemp product comprising:
2 cutting a number of hemp strands to generally the same length wherein
each of
3 said hemp strands comprises a naturally-occurring, generally elongate
internal
4 structure extending generally along one axis of the strand; and each of
said
5 hemp strands includes both bast fiber and hurd wherein said step of
cutting
6 includes at least partially laterally breaking said hemp strands;
7 orientating said number of hemp strands to be roughly parallel to one
another
8 along their length;
9 bonding said number of hemp strands together by adding an amount of
adhesive such that said manufactured hemp product includes 5% by weight to
11 49% by weight of said adhesive and includes an amount of hemp strands of
12 greater than 50% by weight;
13 permeating at least some of the broken hemp strands with said adhesive;
14 pressing said broken hemp strands and adhesive together;
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15 creating said manufactured hemp product which has a generally uniform
16 density in the range of 600 kg/m3 to 1200 kg/m3; and where said
17 manufactured hemp product can be used as a wood substitute in appearance
18 and technical properties.
1 24. A process of manufacturing a manufactured hemp product
comprising:
2 cutting a number of partially broken hemp strands that contain both bast
fiber
3 and hurd to generally the same length wherein each of said partially
broken
4 hemp strands comprises a naturally-occurring, generally elongate
internal
structure extending generally along one axis of the strand that has been at
least
6 partially laterally broken and at least partially permeated by an
adhesive, and
7 wherein said partially broken hemp strands include:
8 permeating at least some of the broken hemp strands with said adhesive;
9 orientating said number of hemp strands to be roughly parallel to one
another
along their length;
11 bonding said number of hemp strands together by adding an amount of
12 adhesive such that said manufactured hemp product includes 5% by weight
to
13 49% by weight of said adhesive and includes an amount of hemp strands of
14 greater than 50% by weight; and
creating said manufactured hemp product which has a generally uniform
16 density in the range of 600 kg/m3 to 1200 kg/m3; and where said
17 manufactured hemp product can be used as a wood substitute in appearance
18 and technical properties.
17

Description

Note: Descriptions are shown in the official language in which they were submitted.


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SYSTEM FOR AND METHOD OF MANUFACTURING HEMP PRODUCTS
TECHNICAL FIELD
[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
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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
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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/m3 to about 900 kg/m3 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
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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. 2A 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. 6A 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.
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[0028] FIG. 11A is a drawing of the monolithic hemp piece being cut into a
block.
[0029] FIG. 11B 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. 11D 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
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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, Internodes
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,
Internodes
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
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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
7

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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
8

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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
9

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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 11A is a drawing of the monolithic hemp piece 905 being cut into
board
(Figure 11B), board (Figure 11D), block (Figure 11A) 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 11D 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

CA 03134821 2021-09-23
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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
Test Results
Natural Hemp Manufactured Hemp
Stalk* Product*
Density (kg/m3)
Internodes/Petiole 476 748
Main Stalk 502 813
Dimensional
Change Co-
efficient
Internodes/Petiole 0.00190 0.00140
Main Stalk 0.00179 0.00134
Janka Hardness
Internodes/Petiole 3.9 PV 6.4
A
Main Stalk 5.5 PF 9.3
*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, internodes 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
11

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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.
12

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

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Administrative Status

Title Date
Forecasted Issue Date Unavailable
(86) PCT Filing Date 2020-03-25
(87) PCT Publication Date 2020-10-01
(85) National Entry 2021-09-23
Examination Requested 2021-11-09

Abandonment History

There is no abandonment history.

Maintenance Fee

Last Payment of $50.00 was received on 2024-01-16


 Upcoming maintenance fee amounts

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Next Payment if small entity fee 2025-03-25 $100.00
Next Payment if standard fee 2025-03-25 $277.00

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Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee 2021-10-05 $204.00 2021-10-05
Request for Examination 2024-03-25 $408.00 2021-11-09
Maintenance Fee - Application - New Act 2 2022-03-25 $50.00 2022-02-09
Maintenance Fee - Application - New Act 3 2023-03-27 $50.00 2023-03-14
Maintenance Fee - Application - New Act 4 2024-03-25 $50.00 2024-01-16
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
WILSON, GREGORY A.
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 2021-09-23 1 59
Claims 2021-09-23 5 205
Drawings 2021-09-23 17 739
Description 2021-09-23 12 612
Patent Cooperation Treaty (PCT) 2021-09-23 1 62
International Search Report 2021-09-23 1 50
National Entry Request 2021-09-23 10 453
Correspondence 2021-10-05 6 161
Request for Examination 2021-11-09 4 89
Cover Page 2021-12-08 1 38
Examiner Requisition 2023-01-09 3 157
Amendment 2023-05-04 16 619
Claims 2023-05-04 5 292
Representative Drawing 2024-01-09 1 11
Maintenance Fee Payment 2024-01-16 3 49
Examiner Requisition 2024-01-19 3 171
Office Letter 2024-03-28 2 188
Amendment 2024-05-16 17 702
Claims 2024-05-16 5 313