Patent Application
20190323148
The stalks of the Hemp plant and other plants contain bast fibers that when removed from the plants can be used to produce textiles and other industrial and consumer goods. Within recent years federal laws have changed making the cultivation of the hemp plant legal.
However, to make use of the desirable bast fibers, they must be removed from the remainder of the stalk, and more particularly, the stalk's hurd. Unfortunately, prior art machinery to accomplish this task, also known as a decorticator, were designed nearly one hundred years ago and before, and accordingly, do not take advantage of modern materials, modern design, and modern manufacturing technology. Prior art machinery is very expensive and because of this as well as the machinery's size and weight, it is ill-suited to use by smaller producers.
A modular decorticating machine (or decorticator) is described.
Embodiments of the machine comprise modular drum assemblies of different tooth and surface patterns that are installed between pairs of left and right, lower and upper rails. The modular drum assemblies (usually provided in upper and lower drum pairs) and the number thereof can be chosen based on the particulars of the type of stalk being processed. One embodiment described herein comprises four drum assemblies; wherein another embodiment utilizes ten drum assemblies of which three comprise comb drum assemblies. However, the embodiments shown herein are not to be considered limiting. In fact, an end user may find a particular configuration that that works best through experimentation on specific types of stalks.
The drum assemblies each typically include: (1) upper and lower drums having a specific surface tooth pattern depending on the specific operation to be performed by the pair; (2) left and right bearing shafts for each drum that are received in the associated drum along the drum's longitudinal axis; left and right bearing blocks for each drum that include a bearing bore in which a bearing surface of associated bearing shaft is rotationally received, (3) a pair of securing bolts that pass through bores in bearing blocks as well as bores in associated rail pairs to secure the bearing block and accordingly the drum assembly to the rails; (4) a pair of coil springs or elastomeric polymer springs/bumpers for biasing the upper and lower drums against each other; and (5) appropriate gears and/or pulleys attached to the ends of the bearing shafts to facilitate the rotational movement and operation of the drum assemblies and the machine.
The rails typically comprise elongated metal (typically steel or aluminum) members, such as a rectangular tubing or C-section. The length can vary depending on the number of drum assemblies that are going to be attached to the rails. Along their length, the rails include bore holes spaced to align with the associated bores in the bearing blocks that are configured to receive the securing bolts therethrough. The bores of the bottom rails may also be threaded or have threaded nuts secured thereto to threadably receive the threaded ends of the bolts therein.
In addition to the rails and drum assemblies, additional gears, pulleys, belts and motors are typically provided to facilitate the rotational and operational movement of the various components. In some embodiments, one or more pulley wheels are attached to one or both the bearing shafts of the lower drums and are operationally connected by one or more belts. One of the belts is further coupled to an electric motor to drive the bottom drums. Spur gears are typically provided on the ends of bearing shafts on one side of the machine that operatively couple the upper drums to the lower drums allowing them to turn in unison albeit opposite rotational directions. In yet other embodiments of the decorticator, one of the drums may further include a hub motor, which acts to drive the associated drum as well as the other drums connected to it by way of pulleys wheels or gears.
While the various components of the drum assemblies can be made using any suitable materials and any manufacturing means, in some embodiments the drums, bearing shafts and/or bearing blocks can be cast injection molded or 3D printed using reinforced or unreinforced plastics. The use of plastic components in contrast to machined and forged metal components greatly reduces the cost and weight of the machine. Further, 3d printing allows replacement parts to be quickly fabricated as needed, and further permits design changes, such as modification of the teeth comprising a drum to accommodate the particularities of a certain type of stalk, to be easily implemented.
The terms and phrases as indicated in quotation marks (“ ”) in this section are intended to have the meaning ascribed to them in this Terminology section applied to them throughout this document, including in the claims, unless clearly indicated otherwise in context. Further, as applicable, the stated definitions are to apply, regardless of the word or phrase's case, to the singular and plural variations of the defined word or phrase.
The term “or” as used in this specification and the appended claims is not meant to be exclusive; rather the term is inclusive, meaning either or both.
References in the specification to “one embodiment”, “an embodiment”, “another embodiment, “a preferred embodiment”, “an alternative embodiment”, “one variation”, “a variation” and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment or variation, is included in at least an embodiment or variation of the invention. The phrase “in one embodiment”, “in one variation” or similar phrases, as used in various places in the specification, are not necessarily meant to refer to the same embodiment or the same variation.
The term “couple” or “coupled” as used in this specification and appended claims refers to an indirect or direct physical connection between the identified elements, components, or objects. Often the manner of the coupling will be related specifically to the manner in which the two coupled elements interact.
The term “directly coupled” or “coupled directly,” as used in this specification and appended claims, refers to a physical connection between identified elements, components, or objects, in which no other element, component, or object resides between those identified as being directly coupled.
The terms “approximately” and “substanitally” as used in this specification and appended claims, refers to plus or minus 10% of the value given.
The terms “about” and “generally” as used in this specification and appended claims, refers to plus or minus 20% of the value given.
Directional and/or relationary terms such as, but not limited to, left, right, nadir, apex, top, bottom, vertical, horizontal, back, front and lateral are relative to each other and are dependent on the specific orientation of a applicable element or article, and are used accordingly to aid in the description of the various embodiments and are not necessarily intended to be construed as limiting.
A first embodiment of a decorticating machine 10 is illustrated in
Each drum assembly 16-22 comprises: a matching pair of drums 28 to 34; a pair of bearing shafts 36 associated with each drum; a pair of bearing blocks 38 associated with each drum; left and right pairs of elongated securing bolts 40; left and right pairs of coil springs 42 to press the upper drum against the lower drum with a desired degree of force, upper and lower spur gears 44; and a worm gear 46.
The upper and lower left rails 12a-b and the upper and lower left and right rails 12,14 can best be seen in
The rails 12,14 are typically comprised of metal tubing or metal angle. Metal tubing is shown in the figures although angle having a C-section, L-section or another suitable cross section could be used as well. The rails are typically comprised of either an aluminum or steel alloy although other materials having suitable strength and stiffness, such as a carbon fiber composite, can be used as well. Each rail includes several pairs, four in the first embodiment, of spaced bore holes (in which securing bolts 40 are received in
A drum assembly 16-22, comprises upper and lower drum subassemblies that are operatively coupled together when installed in the decorticator between the pairs of rails 12,14. The essential component of the drum subassembly is the drum 28-34. Except for the smooth drums 28, the drums typically comprises cylindrical member having longitudinally or circumferentially extending rows of outwardly projecting teeth that are distributed on an exterior surface. The number, size, height and shape of the teeth can all vary depending on specific function of the drum.
The drums 28-34, 54 and combs-type drums 48-52 can have any suitable effective diameter and length depending on the particulars of the decorticator 10 in which the drum and associated drum assembly is installed. The drum and combs also include a center longitudinal bore 56 in which a bearing shaft 36 can be received and secured. In at least one embodiment, the longitudinal bore has a hexagonal cross section although any suitable shape can be utilized that would facilitate the rotation of the drum in unison with the associated shafts. Other variations are also contemplated wherein the bore cross section can be substantially circular with the drum rotating around a stationary shaft.
The drums 28-34, 48-54 can be manufactured by any suitable means and out of any suitable material; however, in some variations the drums are produced using 3D printing using a suitable reinforced or unreinforced plastic material. For example, a substantially unfilled polyamide material may be suitable as may a polymeric material filled with short carbon fibers to enhance strength and durability. The use of 3D printing may permit an end user to print his/her own drum such as when a replacement is needed. Additionally, the end user may be able to modify the specific configuration of the drum such as the drum's teeth tailoring the drum's functionality for use with the stalk of a particular plant. In some instances, the manufacturer of the decorticator can provide software that permits the user to modify and print drums as necessary.
The drums can be manufactured by other means as well including but not limited to injection molding and casting using a reinforced or unreinforced polymeric material. Drums comprised of metal, such as aluminum or steel alloy, that have been cast, forged, and/or machined are also contemplated.
Associated with each drum 28-34 on the first embodiment machine 10 are a pair of bearing shafts 36 that are typically fixedly received into the ends of the longitudinal bore 56. These shafts serve as axles received in bearing blocks 38 facilitating rotation of the drums during machine operation. Each shaft as best shown in
The drum interface portion 58 is adapted to be fixedly and securely received in the longitudinal bore 56 of a drum. As shown the drum interface portion has a hexagonal cross section to match that of the longitudinal bore although other shapes can be used. In some variations, the shaft 36 is slidably received in the bore and can be easily slid there from to facilitate the replacement of the shaft or the drum as necessary. On other variations, the shaft can be one or more of interference fit, bonded or mechanically joined to the drum.
Similar to the drum interface portion, the drive wheel interface 62 portion located on the opposite end of the shaft also typically has a non-circular cross section so that it may fixedly receive a center bore of a spur or worm gear over it.
In-between the drum and drive gear interface portions is the bearing portion 60. Unlike the other portions, it has a circular cross section to facilitate rotational movement in a round bore 64 of the bearing block. The surface of the bearing portion is typically smooth to minimize rotational friction and heat generation.
The bearing shaft 36 can be made of any suitable material but in at least one embodiment the shaft is comprised of a polymeric material. Like the drum, the shaft can be 3D printed from a suitable filled or unfilled polymeric material. Typically to reduce friction during rotation, the polymeric material comprising the shaft can be filled with carbon particulate, short carbon fibers and/or another suitable filler to provide a solid lubrication of the shaft's bearing portion's surface. The shaft can also be cast or injection molded. When comprised of a metal material, the shaft can be cast, forged or machined. In some variations utilizing a plastic shaft, a metal bearing sleeve can be fitted over the bearing portion to provide a more heat resistant surface that can receive liquid lubricants.
The bearing block 38 serves two primary purposes: to provide a stationary bearing surface against which the drum through its bearing shafts 36 can rotate freely during operation and to secure the associated drum subassembly to the decorticating machine 10. The bearing block typically comprises a rectangular block having a center bore 64 in which a bearing portion of a bearing shaft is received. Further, the block includes two spaced substantially vertical bores 66 that extend from a top surface of the block through to a bottom surface of the block. When assembled into a decorticator, a bottom surface of lower bearing block of the lower drum subassembly on each of the left and right sides of the machine generally rests on the top surface of the bottom rail 14; whereas, an upper bearing block of the associated drum assembly is located above the lower bearing block and underneath the upper rail 12 with the associated securing bolts 40 running through the upper rail, the upper block, the lower block and the bottom rail respectively.
Like the drum and bearing shaft, the bearing block 38 can be 3D printed. Because the block contains a bearing surface in the center bore 64 that interfaces with the bearing portion 60 of the bearing shaft 36, the polymeric material comprising the shaft can be filled with carbon particulate, short carbon fibers and/or another suitable filler to provide a solid lubrication.
The block can also be cast or injection molded. When comprised of a metal material, the block can be cast, forged or machined.
In some variations utilizing a plastic bearing block 38, a metal bearing sleeve can be fitted inside of the center bore 64 to provide a more heat resistant surface that can receive liquid lubricants. In other variations, the bearing block's center bore and the bearing portion of the bearing shaft 36 can be sized and configured to receive a suitably sized cartridge bearing. The cartridge bearing can be interference fit or otherwise secured to the bearing block.
As indicated above, the drum assembly 16-22 comprising upper and lower drum subassemblies is secured to the upper and lower rails 12,14 by way of the left and right pairs of securing bolts 40. Pair of left and right coil springs 42 are provided and are received over the securing bolts between the top surface of an upper bearing block and the lower surface of an upper rail. These spring pairs act to bias the upper drum against the lower drum but permit upwardly movement as stalks of plant material are passed between the respective drums. As can be appreciated, the strength of the coil springs can be varied as desired to accommodate different types of plant material and more effectively perform the desired operation on the stalks. Alternatively, elastomeric springs/bumpers comprised of a suitable polymer can be inserted between the upper bearing block and the top rail to perform the same function as coil springs.
As illustrated in
The specific gearing and mechanisms for driving the drums can vary substantially and significantly from the illustrated embodiment. In some variations belts and pulleys can be utilized to drive the drums in some variations, such as the drums having longitudinally extending teeth, the lower drum meshes with and drives the upper drum obviating the need for intermeshing gears for this purpose on the ends of the bearing shafts. In yet another variation, a motor is located within the drum of one or more of the drum assemblies obviating the need for an external motor.
As shown, the first embodiment decorticator includes a first drum assembly 16 comprising a pair of smooth roller drums 28 that crush or smash the plant stalks flat. The second drum assembly comprises circumferentially ribbed drums 30 that act to split the flattened stalks. The third drum assembly comprises a first rotating pair of spiked drums 32 having course longitudinally extending teeth that act to break up the non-fibrous hurd of the stalk. The fourth and final drum assembly also comprises a drum 34 having longitudinally extending teeth with flat peaks that further break and separate the hurd from the bast fibers. As can be appreciated, the configuration of drum assemblies is merely exemplary and can be varied as desired to accommodate different types and sizes of stalks. Given the ease of manufacturing the drums, such as by 3d printing, a user may customize the type and order of drum assemblies to most efficiently and most effectively separate the fibers from the remainder of the stalk.
With reference to
As indicated above, the various components of the drum assemblies 16-22, 68-72 can be fabricated by any suitable means, but in at least some embodiments, one or more of the bearing shafts, the bearing blocks, the drums and various gears are fabricated using a 3D printer. Any suitable polymeric materials can be used in the fabrication. In some variations, the polymeric materials are reinforced with short fiber fiberglass and/or carbon fiber. In other variations, additives such as carbon black may be incorporated into the polymeric material to provide a dry lubrication to the bearing surfaces on the bearing shaft and the bearing block.
3D printing fabrication permits an end user with the appropriate file to print his/her own replacement parts as necessary provided he/she has a suitable 3D printer limiting down time in case of a failure of one or more of the machine's components. Furthermore, a user may be able to modify a particular component, such as the drum, to accommodate the particularities of the plant material being processed. Accordingly, the configuration of a resulting machine can be customized for maximum efficiency, effectiveness and utility.
Even when the end user does not have access to a printer, he/she can potentially easily order a replacement part from the manufacturer who can print it on demand even to the particular specifications of the user. In some embodiments, a user may be able to modify a CAD file to his/her particular configuration and submit it to the manufacturer over the Internet for fabrication.
The construction and assembly of a decorticating machine 10, 100 can be relatively straight forward and simple. First, the number and type of drum and comb assemblies the machine will require are determined which dictates the length of rails required as well as the location of the bore pairs in each rail to mount the assemblies thereto.
In one method of assembly, such as can pertain to the assembly of the first embodiment of
Coil springs 42 are placed over the bolts and then preassembled upper drum subassemblies are then lowered over the bolt pairs. After the upper drum subassemblies have been placed the corresponding preassembled lower drum assemblies are lowered in place over the bolts. Finally, the lower rails 14 are threadably secured to the ends of the bolts. The machine is flipped over and final tightening of the bolts is performed. The bore holes in the lower rail can be threaded. For instance, if the lower rail is 3D printed of carbon fiber polymers, threaded bore holes can be printed into the rail.
Although not shown, in some embodiments cross bars may also be specified to couple the left and right rails together and create a more rigid framework.
The finished decorticator can also be mounted to a supporting framework or stand, which is typically open so that hurd and other parts of the stalk removed from the fiber during the machines operation can fall to the floor or catch bin(s) located below the machine. Before operation can commence the drive system is coupled with the associated gears of the drum assemblies.
Assembly of the drum subassemblies is best described with reference to
Once the decorticator machine 10, 100 is up and running, stalks of a fibrous plant are fed into the machine at the first drum assembly, which as previously described typically comprises smooth rollers that act to pull the stalks into the machine and crush them.
As the stalks proceed through machine, the stalks are crushed, split, and the hurd is broken into pieces. Typically, most if not substantially all of the pieces of hurd separate from the bast fibers and fall downwardly from the machine. With some types of plant material, one or more combing operations may be required to remove the final pieces of hurd. The combing operations can be integrated into the machine as shown in the second embodiment of
The resulting fiber can be used in any suitable manner. For instance, it can be spun into thread or yarn and subsequently used to make fabric or rope. Further, the fibers can be processed to create high strength carbon, which can be used in the fabrication of advanced composite structures.
The various embodiments and variations thereof, illustrated in the accompanying Figures and/or described above, are merely exemplary and are not meant to limit the scope of the invention. It is to be appreciated that numerous other variations of the invention have been contemplated, as would be obvious to one of ordinary skill in the art, given the benefit of this disclosure. All variations of the invention that read upon appended claims are intended and contemplated to be within the scope of the invention.
This application claims priority to and incorporates fully by reference U.S. Provisional Patent Application No. 62/65,9484 filed on Apr. 18, 2018 entitled Machine and Process for Decorticating Plant Matter and having the same inventor as the present application.
| Number | Date | Country | |
|---|---|---|---|
| 62659484 | Apr 2018 | US |
