Fiber panel manufacturing method and apparatus

Apparatus and method for forming structural panel members from fiber crop material such as rice, straw and the like. The fiber crop material is bailed into circular or rectangular bails which bails are placed in a debailer/shredder. The fiber material is cut to a predetermined length and conveyed pneumatically to a compression chamber. A ram compresses the fiber into a rectangular slot between upper and lower platen members. Paper is applied with glue to the upper and lower surfaces of the fiber and is folded up to cover the sides of the fiber. The glue is cured on a curing table and the fiber is severed in a cutting section into desired lengths.

INTRODUCTION 
This invention relates to a method and apparatus for the manufacture of 
wall material and, more particularly, for the manufacture of wall 
components or panel members from fiber material. 
BACKGROUND OF THE INVENTION 
The use of fiber material such as fibrous waste products from agricultural 
material, conveniently straw, to manufacture architectural material or 
wallpanels is known. Such techniques are disclosed, for example, in U.S. 
Pat. No. 4,451,322 (Dvorak) entitled APATUS FOR FORMING STRUCTURAL 
SHEETS FROM FIBROUS BIOLOGICAL WASTE. This patent teaches using waste 
products such as the residue from sugar cane and cereal grains crops. Such 
products are compressed into panels which can then be used for structural 
panels in building activities. 
In the apparatus disclosed in the aforementioned '322 reference, there are 
numerous disadvantages. For example, the straw material is introduced into 
the apparatus by way of a hay bail off a forklift. The straw is manually 
separated from the bail and a conveyor introduces the separate fiber into 
the ram which creates the panel members by compression. The use of a 
conveyor does not enhance fiber separation since the various fibers lie 
clumped together as they are being transported. This is disadvantageous 
since it is desirable that the individual fibers be separated as much as 
possible prior to introduction into the ram in order to form a consistent 
panel. 
A further disadvantage with the apparatus illustrated and described in the 
'322 patent is the position of the paper rolls which paper is used to 
surround the panel which is extruded with the ram. The paper rolls are 
positioned underneath the curing table with axes of rotation generally 
perpendicular to the longitudinal axis of the curing table. This restricts 
the size of the paper rolls to a non-standard one and requires 
inconvenient positioning of the paper rolls beneath the conveyor when used 
rolls are removed and new rolls are installed. 
Yet another disadvantage of the '322 apparatus involves the use of 
electrical heating plates to cure the envelope surrounding the panels. The 
reciprocating nature of the machine will shake and vibrate the electrodes 
used for the electrical heating plates unless they are rigidly contained. 
The machine shaking may cause wire connection failures and electrode 
casement damage. Clamps or spring retainers are not successful. This so 
because access to tighten the clamps is restricted. Clamps also loosen and 
springs lose tension because of heating and cooling inherent in the 
machine operation. 
Yet a further disadvantage of the '322 apparatus lies in the design of the 
curing table which is required to be lengthy in order to completely cure 
the envelope surround the panel. The curing table often is required to be 
transported from site to site or to be disassembled. The design of the 
curing table in the '322 patent does not allow for convenient disassembly 
and minimal transportation space to be occupied when the apparatus is 
transported. 
Yet a further disadvantage lies in the use of the ram which compresses the 
fiber material into the panel member. The ram according to the '322 patent 
is connected through a connecting rod to a rotating crank. There is no 
counterweight to dynamically balance the crankshaft assembly. The 
resultant shaking causes failures in the frame components of the ram 
assembly. In addition, large and unwieldy base members are required in an 
attempt to stabilize the movement of the machine. 
Yet a further disadvantage relates to the shear assembly which shears the 
fiber as the ram advances into the shear opening. A flywheel in the '322 
apparatus provides inertial force. If a foreign object such as a rock or 
other debris is encountered by the shear, a clutch in the flywheel 
releases the driving action of the flywheel from the ram. This is intended 
to prevent damage to the shear, ram and associated components. Because of 
the rotating speed of the crank assembly, however, damage will have 
occurred before the clutch has disengaged. In addition, movement of the 
heavy ram and crank assembly has high kinetic energy, so damage can occur 
while it decelerates regardless of whether the clutch is engaged or 
disengaged. 
Yet a further disadvantage of the '322 apparatus relates to the method used 
to adjust the space between the upper and lower platens which space must 
be adjusted in order to regulate the proper density of the fiber panel. A 
wedging and bolting apparatus was used to do this in the apparatus 
according to the '322 patent. This mechanism was difficult to properly 
adjust and was unnecessarily complicated. 
Yet a further disadvantage of the '322 apparatus relates to the mounting of 
the rollers within the ram carrier and guide roll assembly. The rollers of 
the Dvorak apparatus are mounted in a V-type bearing configuration. When 
the position of the rollers needs to be changed, the adjustment is complex 
and unnecessarily time consuming since adjusting one roller will effect 
the position of the remaining rollers. 
SUMMARY OF THE INVENTION 
According to one aspect of the invention, there is provided apparatus to 
form a panel from fibrous material comprising a debailer/shredder, said 
debailer/shredder having a rotary cylinder, a plurality of adjustable 
knives in the bottom of said cylinder to remove fibers of a predetermined 
length from a bail placed in said cylinder while said cylinder is rotating 
and a collector chamber located beneath said rotary cylinder to collect 
said fiber removed from said bail.

DESCRIPTION OF SPECIFIC EMBODIMENT 
Reference is now made to the drawings and, in particular, to FIG. 1A. The 
panel forming apparatus according to the invention is generally 
illustrated at 10. It comprises several sections, namely the 
debailer/shredder section generally illustrated at 11 into which the fiber 
is placed, a conveyor section generally illustrated at 12 which transports 
the separated fibers from the debailer/shredder section 11, the feeder 
section generally illustrated at 13 which receives the shredded 
transported fiber from the conveyor section 12, the ram slot fiber-panel 
assembly area 14 in which the fiber from the feeder section 13 is 
assembled and forced into the compaction area 15 and pressed into the 
panel shape, the glue application area generally illustrated at 20 which 
applies glue to the envelope paper and, thereafter, the paper to the 
fiber, the envelope forming area generally illustrated at 21 which forms 
the envelope surrounding the fiber material, the paper feeder section 
generally illustrated at 22 which feeds the paper from the paper rolls to 
the envelope forming area 21, the longitudinal curing table section 
generally illustrated at 23 on which the glue and paper surrounding the 
panel members are cured, the sizing saw section generally illustrated at 
24 which receives the cured panel members and cuts them at the desired 
length and the finishing section generally illustrated at 30 which 
receives the completed cured and sized panels. 
Referring now to the rightward area of the panel forming apparatus 10 and 
with reference to FIG. 1B(a), the debailer/shredder section 11 includes a 
debailer 31 which is commercially available for cutting the baled fiber 
which is in a circular or rectangular bale configuration as is known. The 
bale (not shown) is placed in a rotary cylinder 32 which rotates about 
vertical axis 33 and has a plurality of knives 34 which are height 
adjustable and which allow the fiber of the bale to be cut relatively long 
or relatively short as the cylinder 32 rotates. 
A chamber 40 is formed below the rotary cylinder 32 and a conveyor 41 
receives the severed fibers from the chamber 40 and transports the fibers 
to feeder section 13 (FIG. 1B(a)). The conveyor 41 is connected to a 
source of air pressure, conveniently a centrifugal blower 42, which blows 
the fiber received from the chamber 40 into the feeder section 13. 
The feeder section 13 includes a wig wag distributor 43 (FIG. 2A) which 
receives the blown fibers from duct 44 (FIG. 2A) and reciprocates through 
about 90 degrees (FIG. 2B) as illustrated thereby evenly depositing the 
fiber in a battery of four (4) helical screw conveyors or augers 50. 
With reference now to FIG. 3, the ram assembly is seen in plan and is 
generally illustrated at 51. It includes a ram head 52 removably attached 
to the ram body 53. The ram head 52 has detachable side plates 501 that 
may be removed or interchanged with different side plates to change the 
width of the panel being manufactured. The ram body 53 and ram head 52 
reciprocate on roller rails 54 with the use of rollers 60,65. Rollers 60 
rotate about axes 66 (FIG. 6) which axes are generally parallel to the 
plane of movement of the ram body 53 on the roller rails 54. Rollers 65 
rotate about axes 67 (FIG. 7) which are generally transverse to the plane 
of movement of the ram body 53 on the roller rails 54. Ram body 53 is 
connected to the crank shaft assembly generally illustrated at 61 (FIGS. 
3B and 4). A connecting rod 62 is connected to the crank arm 63 and to the 
wrist base 64 of the ram body 53 (FIG. 3B). Crank throw 63 has a 
counterweight 70 attached thereto as also seen in FIG. 5. The flywheel 71 
rotates on the outside of a pillow block 72 (FIG. 4). The crank arm 63, 
counterweight 70 and connecting rod 62 rotate with the flywheel pulley 71 
and outside pillow block 73. 
The ram slot assembly is generally illustrated at 74 in FIGS. 3B and 8. The 
ram slot assembly 74 comprises three components, namely a lower plate 56, 
an upper plate 55 and a shear 81. The ram head 52 reciprocates within the 
ram slot assembly 74 with the furthest advanced position of the ram head 
52 being shown at 80 (FIG. 3B). The shear assembly is generally 
illustrated at 81 and is shown in more detail in FIGS. 9A, 9B and 9C. A 
shear release mechanism 83 comprises two links 90, 91 which allow relative 
motion therebetween about axis 92. Link 91 is connected at the end remote 
from axis 92 to a pneumatic cylinder 93 at axis 95. Link 90 is connected 
to the shear 82 at axis 94 and axis 92 is slightly offset if a line is 
drawn between axes 94, 95. A cam 100 is mounted and rotatable about axis 
101. If a rock or other hard debris 102 is encountered by the shear 82 as 
the ram advances, the shear will be forced backwards pushing the links 91, 
92 against the holding force of cylinder 93. As link 91 moves backwards, 
cam 100 rotating around pin 101, forces the link 91 to rotate clockwise 
about axis 95. This unlocks the over-center rigidity between links 91, 92 
thereby allowing axes 94, 95 to come more closely together. Shear 82, 
pivoted about axis 84, is allowed to swing away from obstruction 102 and 
is held clear by the upward motion of piston rod 104 of pneumatic cylinder 
103. Cam 502 mounted on shear 82 arm trips limit switch 503 which 
terminates operation of the entire panel system to prevent damage. When 
the rock 102 has been removed, pneumatic cylinder 103 will act downwardly 
extending piston 104 and returning the shear 82 to its operating position. 
The platen assembly is generally illustrated at 15 in FIGS. 10A and 10B. It 
comprises a primary set with an upper adjustable platen 111 and a lower 
fixed platen 110 (FIG. 10A). There is also a secondary set with an upper 
adjustable and hinged platen 506 and a lower fixed platen 505 (FIG. 10A). 
The primary set forms the extruder unit whereby the fiber from the ram 
slot assembly 74 (FIG. 3B) is compacted to form a dense panel. The width 
dimension of the fiber panel is determined by assemblies 112 (FIG. 10B). 
The side assemblies 112 consist of three components, a lower bar 507 
affixed to lower platen 110, an upper bar 508 affixed to upper platen 111 
and a closure "T" shaped blade 509 attached to bar 508 and resting against 
the inner faces of bars 507, 508. Regardless of any adjustment made to 
upper platen 111, the side assemblies 112 keep the sides enclosed such 
that the fiber panel width is uniform and smooth. If a narrower panel is 
desired, these side assemblies 112 are replaced with a different set of 
bars 509, 508, as may be desired. 
The density or compaction of the fiber panel is determined by the position 
and taper imposed upon the upper platen 111. This is done by adjusting jam 
nuts on the adjusting screws 504 (FIG. 10A). 
The secondary platens 505, 506 (FIG. 10A) receive glue lined paper from the 
gluer assembly 10 (FIG. 1B) and form it into an envelope around the 
advancing compacted fiber. The paper enters the platens around curved 
shoes 510 (FIG. 10A). The paper is propelled by the advancing fiber. Upper 
platen 506 is pivoted about axis 511. It is rotated upward by pneumatic 
cylinder 511. This provides access for cleaning and inspecting the 
secondary platens. 
The paper feed apparatus is illustrated generally at 114 in FIG. 1B and 
11A. Two separate paper systems are used to provide paper for the paper 
envelope of the panel member. The first paper line 701 provides the wrap 
for the upper face of the fiber panel and the second paper line 702 
provides wrap for the lower face of the panel. Only the lower or second 
paper line 702 will be described as the operation of both lines is 
similar. 
First and second paper rolls 120, 121 are positioned on spindles 122, 123, 
respectively, which are rotatable on brackets, 124, 124, respectively. The 
axes of rotation of the spindles 122, 123 and, thus, the paper rolls 120, 
121 are longitudinal or parallel to the longitudinal axis of the paper 
forming apparatus 10 (FIGS. 1A and 1B). The paper rolls 120, 121 are 
mounted so as to allow for rolls of standard sizes to be used thereby 
reducing the expense involved in obtaining paper rolls of custom 
configuration. The paper 130 extends from the first paper roll 120, under 
first guide roller 131, to a turning bar 132 which uses air to lubricate 
the paper 130 which passes under and then over the turning bar 132 where 
the direction of movement of the paper 130 turns through an angle of 
ninety (90) degrees and passes over the applicator or doctor roller 133 of 
the glue applicator apparatus 140. Glue from the glue tray 513 is picked 
up by transfer roller 134, transferred to doctor roller 133 and, thence, 
onto paper 130. 
The paper 130 with the glue applied to the under surface 141 passes over a 
second guide roller 142 and around wave rectifier roller 514 and thence 
upwardly to the lower platen 505 where it contacts the fiber (not shown) 
compressed by the ram head 52 (FIG. 3B) moving between the platens 110, 
111, 505, 506. The paper 130 forms the envelope for the fiber as will be 
explained. 
The wave rectifier 514 consists of a roller 533 mounted on a crank arm 
assembly 534 that rotates about axis 535. A pneumatic cylinder 536 
connects to the crank arm at pin 537. 
The cylinder holds outward force on the roller 533. The crank arm moves 
back and forth with the jerking motion of the paper. If the flow of 
incoming paper 130 to the roller 533 becomes restrained, the force of the 
cylinder 536 will be overcome allowing the crank arm to move to an 
over-travel position 538 where it trips limit switch 539 thereby 
terminating operation of the system. 
When paper roll 120 is nearly unrolled and the end of the paper approaches, 
the leading edge of the paper roll 121 is taped to it. This automatically 
feeds the paper 130 from the new roll 121 into the system. 
Tensioners 143, 144 (FIG. 1B and FIG. 11A) may also be used in the paper 
feed apparatus 114. The tensioners 143, 144 keep the paper web 150 at the 
correct tension. The tensioners are adjustable counterweighted floating 
devices that impart a frictional drag to the movement of the paper, if 
required, such that slack does not develop in the paper. The wave 
rectifier roller 514 is an air cylinder cushioned device that oscillates 
to smooth out the jerking motion on the paper 130 caused by the cycling of 
the ram 51. This assists in reducing paper tear and paper breaking. 
The envelope former assembly 151 is illustrated generally in FIG. 1B and, 
in greater scale and diagrammatically, in FIGS. 12A and 12B. Two helical 
bar pieces 152, 153 are positioned on each side at the top and bottom and 
outside the edges. It also shuts the system down before a break occurs 
(FIG. 11B). The paper 130 which extends outside the width of the fiber 
panel 154 as illustrated in FIG. 12B initially contacts the helical bar 
152. As the panel 154 moves in the direction of the arrow (FIG. 12A), the 
paper 130 extending beyond the width of the fiber panel 154 is folded 
downwardly (FIG. 12B). Likewise, the paper 130 on the bottom of the panel 
154 contacts the helical bar 153 which similarly folds the paper upwardly 
(FIG. 12B). An envelope is formed on each side of the endless fiber panel 
fiber panel 154. 
Heating electrodes 515 on the sides of the lower folding bars 153 
accelerate bonding of the edges of the paper together and to the edges of 
fiber panel 154 before it leaves the enclosure of the envelope forming 
area 21 (FIG. 1B). 
The platens 110, 111, 505, 506 are assembled with a hollow plenum chamber 
522 outside their contact plates 523. Inlet manifold 524 and vent openings 
525 allow hot gases to enter to heat the plates 523. The gases pass across 
the plenum chamber and escape through vent openings 526 and out exhaust 
manifold 527 (FIGS. 10A, 10B). The heat provides preliminary curing and 
bonding of the fiber envelope before it passes onto section 23 of the 
curing table (FIG. 1B). The hot gases are conveniently provided by one of 
several sources depending on what is available at the installation 
location. Steam, electricity, gas or oil burners are convenient sources, 
for example. An industrial model gas fired unit 528 is illustrated in FIG. 
18. A duct manifold 529 carries the hot gases to the platens 110, 111, 
505, 506. 
Return ducts 530 recycle the exhaust gases to the heating unit 528. A 
circulating fan 531 on the exhaust ducting moves the gases through the 
system. 
The panel 154 enters the area of the curing table 160 (FIG. 13A) where the 
glue and the paper surrounding the fiber of the panel 154 complete the 
bonding and cooling. 
Curing table 160 is long as viewed in FIG. 1B and it is designed to be of a 
length that will allow the paper and glue on the panel to become bonded 
together depending upon the speed of the panel on the curing table 160 
which is determined by the reciprocating speed of the ram head 52. To 
assist the transport of the curing table when the panel forming apparatus 
10 is moved to a new location or is stored, the curing table 160 is 
collapsible and can be broken apart in sections. A typical section 161 
(FIG. 13B) comprises two longitudinal channels 162, 163 with a plurality 
of rollers 164 which support the panel 154 and allow it to advance on the 
top of the channels 162, 163 as viewed in FIGS. 13A and 13B. 
Each section 161 is connected to adjacent sections by connected plates 170 
which can be disconnected and the units 161 separated for transport or 
storage. A plurality of legs 171, one pair for each section 161, is 
connected to the channels 162, 163 with a pair of bolts 172, and extend 
downwardly to contact the foundation 173 on which the curing table is 
mounted. A leg brace 174, one for each leg 171, extends diagonally 
downwardly from each channel 162 and connects with leg 171 when the curing 
table 160 is in its operating position. The brace 174 can likewise be 
removed from each leg 171 when it is intended to disassemble and transport 
the curing table 160. A diagonal brace 180 (FIG. 13B) is connected between 
the two channels 162, 173 as illustrated. Brace 181, 182 extend between 
the legs 171 as illustrated. They maintain their position when the legs 
171 are folded into transport position. 
The sizing or cutoff saw 183 (FIG. 14A and 14B) moves with the flow of 
panels, the flow being illustrated "F" in FIG. 14B. The cutoff saw 183 
moves on a frame 184 which moves under the influence of the fiber panel 
154 and is assisted by a pneumatic cylinder 190 on rollers 192 to match 
the flow of fiber panels. The circular saw 191 moves transversely to the 
flow as is illustrated in FIG. 14A. Circular saw 191 is mounted on a 
carriage or trolley 193. The carriage 193 cuts the panel to the desired 
length with one pass through the panel as illustrated in FIG. 14A. When 
the single pass is complete, the sizing saw assembly 184 has moved to 
position 194 from position 193. When the next cut is made through the 
fiber, the carriage with saw 184 moves from its position 194 back to 
position 193 as illustrated in FIG. 14A. 
Reference is made to FIG. 14C where a clamping system apparatus 516 engages 
the fiber panel 154 and is mounted within frame 184. A pneumatic cylinder 
200 extends between the frame and an arm 201 which is rotatable about axis 
202. Arm 203 is connected to a clamping plate 204 which contacts the 
panel. The frame 184, therefore, will be carried along with the panel 
until the press 204 is released after the cutting operation. 
With reference to the outfeed area 210 (FIG. 1B), a plurality of driven 
outfeed rollers 211 (FIGS. 15A and 15B) will separate the severed panel 
member 212 by being driven more quickly than the uncut panel 213 which is 
being driven by the ram head 52 (FIG. 3). Thus, the panel 212 will 
separate from the uncut panel 213 and pass a photoelectric sensor 214. The 
transfer belts 220 will rise and move the panel 212 ninety degrees and at 
right angles to the direction of the curing area as illustrated in FIGS. 
15A and 15B. This moves the sized panel 212 off to the side to position 
222 and out of the way of oncoming panel 213 from the sizing saw. The 
transfer belt recedes after panel 212 has cleared. The roll case 211 is 
now clear to receive the next panel 212 (FIG. 15B). 
The lift mechanism of transfer belt 220 operates in the following sequence 
(FIG. 15B). When the fiber panel 212 passes the photo-electric sensor 214, 
it activates pneumatic cylinder 216 which raises the end portion 215 of 
transfer belt 220, by pivoting it about axis 221. The cylinder 216 acts 
through crank 217 that rotates about axis 218 and connects to the transfer 
belt through linkage 219. 
When the fiber panel 212 reaches position 222, it passes photoelectric 
sensor 532 which stops the belt 220. 
Reference is now made to the finishing area 30 (FIG. 1A) where the fiber 
panel is completed by enclosing the exposed ends with prepared paper end 
caps 519, 520 (FIGS. 16A and 6B). When transfer belt 220 begins its next 
cycle, fiber panel 212 is transferred to continuously operating transfer 
belt 223. When it passes photo electric sensor 224, skid stops 225 raise 
and stop the panel from advancing. 
The skid stops 225 (FIG. 16C) consist of a set of bars 540 with end pieces 
541 that project upward. The skid stop rotates about axis 542 and is 
connected to a pneumatic cylinder 543 through crank arm 544. All skid 
stops are tied together and to the cylinders 543, 546 through a connecting 
rod 545. The cylinders action rotates the crank 544 about axis 542 raising 
or lowering the skid stop (FIG. 16D). In the "down" position 233, the 
panel 212 is resting on transfer belt 223 and is free to advance with the 
belt. In the intermediate position 234 with cylinder 543 activated only, 
the end pieces project above the transfer belt 223, stopping the oncoming 
panel. Through electrical sequencing cylinder 546 is activated raising the 
skid stop bars 540 to the full up position 235 (FIG. 16D) which lifts the 
panel off the belt 223. The panel 212 is held in this position until the 
operator at the first end capping station 227 wishes to advance it. When 
the operator releases the skid stop 225, the fiber panel moves forward 
onto roof top transfer chain 226 (FIG. 16E). 
When the panel passes photoelectric sensor 232, the skid stop 228 is 
activated to its intermediate position with the end stop pieces 541 
projecting above the transfer chain 226. This stops the fiber panel and 
indexes it precisely at the first end capping station 227. The skid stops 
rotate to their full up position 235 and the operator applies the first 
end cap 519. The end caps 519, 520 are precut and notched paper with heat 
setting adhesive (FIG. 16B). The operator arranges the paper on the end of 
the fiber panel and sets it with a hot iron. 
The skid stops 228 are then released allowing the fiber panel to advance to 
the second end capping station 229. The panel passes photoelectric sensor 
233 which activates the raising of flanged roll case rolls or transfer 
rolls 230. This raises the roll case 230 to its intermediate position with 
the flanges 236 projecting above the transfer chains 226 (FIG. 16E). This 
stops and indexes the fiber panel 212 for the second end capping station 
229. Reference is made to the vacuum system 29 (FIG. 19). Sawdust from 
cutoff saw 191 is collected by sawdust pickup 801 above the saw and the 
saw slot pickup 802 below the saw. It is sucked into the pipeline 803 by 
the vacuum generated by blower 808. Removable end caps 804 are provided so 
that residue accumulating around the machinery may be cleaned up and 
disposed of in the vacuum system. To neutralize the air pressure in the 
feeder 13 generated by the blower 42 of the debailer/shredder, a negative 
pressure line 807 provides piping between the feeder and blower 808. The 
degree of negative pressure is controlled by opening adjusted by the 
negative pressure regulator gate 806 and the free air cap and opening 
plate 805. 
The blower 809 exhausts the collected particles in the air stream through 
pipe 809 into the dust collector 810. The dust collector 810 centrifugally 
separates particulate matter from the conveying air, allowing the air to 
escape through exhaust opening 813 while the dust particles settle to the 
bottom. The dust is discharged through air lock 811 and down discharge 
spout 812 where it is recycled to the debailer cylinder 32. 
Through electrical sequencing the transfer roll case 230 raises to its full 
up position, lifting the panel off of the transfer chain 226, and moves 
the panel endwards into a stop bumper 231 at the second end capping 
station. Upon contacting the bumper, the roll case 230 stops, the operator 
applies the second end cap 520 as was done at the first end capping 
station 227. 
The operator will lower the roll case 230 allowing the transfer chain to 
carry the finished panel 521 to the stop bars 547 at the end of the finish 
line. Here the finished panel 521 is removed for storage stacking or 
prepared for shipping. A finished panel (one length only) is illustrated 
in FIG. 17. 
OPERATION 
In operation, the straw or other fiber like crop will be bailed into round 
or rectangular bales as is known. 
The individual bale (not illustrated) is introduced to the debailer 31 
(FIG. 10) where it rotates within rotary cylinder 32. The cutting knives 
34 are adjustable and cut the fiber into shorter or longer lengths as 
desired as the cylinder 32 rotates. 
The fiber pieces drop to chamber 40 and are conveyed by air pressure up 
conveyor duct 44 (FIG. 1B and 2A) to the wig wag 43 (FIG. 2B) where the 
fiber is distributed evenly into four augers 50 which even the flow of 
fiber material and force it within the chamber 57 on top of the ram head 
52. Ram head 52 reciprocates within the slot formed by the shear 81 and 
lower platen 55 and applies pressure to the fiber which is alternatively 
pushed forwardly between the slot formed by the upper and lower plates 55, 
56. 
Each return movement of the ram head 52 will allow more fiber from chamber 
57 to enter the slot ahead of the ram 52 whereby it will be forced between 
shear 81 and plate 55 above and plate 56 below, and then into the space 
between platens 110, 111. The platens 110, 111 are adjusted so as to cause 
resistance to the advancing fiber which forms it into a uniform densely 
compacted fiber panel 154. 
As the fiber proceeds through the platens 505, 506, paper from the lower 
paper rolls 124, 125 will pass through the glue applicator roll 133 and 
contact the panel (FIG. 1B) on the top and bottom surface. The paper 
extending widthwise a greater distance than the width of the panel will be 
turned down and up by the action of the helical bar pieces 152, 153 (FIG. 
12A) in the envelope forming area 21 (FIG. 1B). 
The panel proceeds to the curing table 160 (FIG. 13A) which is of a length 
sufficient to allow the paper and glue to bond and, thence, the panel 
enters the sizing saw section 24 where it is cut to its desired length 
through the action of the saw 191, the frame 184 and the carriage assembly 
193 (FIG. 14A) as has been described. 
The panel member 212 then travels to the outfeed area 210 (FIG. 1B) where 
the ends of the envelope surround the panel 212 are closed by adding paper 
end caps 519, 520 also as has been described. The panel is ready for 
shipment or other operations as desired (FIG. 16A). 
While specific embodiments of the invention have been described, many 
modifications will readily occur to those skilled in the art to which the 
invention relates. The description, therefore, should be considered as 
illustrative of the invention only and not as limiting its scope as 
defined in accordance with the accompanying claims.