Patent Description:
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.

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.

The document <CIT> discloses a wood substitute which may alternatively contain hemp fibers bonded together by a thermoset resin, wherein at least some of the fibres in a mass of loose separate fibres having been physically aligned before being bonded together and said fibres having a minimum length of one inch.

A method and system have been developed that allows for the use of hemp stalks from Cannabis Sativa, Cannbis 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.

One method of preparing hemp stalks for use in a manufactured hemp product may include beginning with a hemp stalk piece from a cannabis plant. The hemp stalk piece is generally rectangular or cylinder and it may have a thickness in the range of about <NUM> to about <NUM>. 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.

In harvesting, the hemp stalk is cut above the roots and the branches are (typically) 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 <NUM>% than the surface area of the hemp stalk piece prior to breaking at least a portion of the internal structure.

The hemp stalk piece may be cut to size after which the hemp stalk piece may be deskinned, split and crushed to further open the internal lignocellulosic plant structure. This optional step is typically based on visual observation and the adhesive application. In addition, boiling the hemp stalk pieces in H2O or in a mild H2O2 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 <NUM>-<NUM> minutes. Subsequent to this submersion, the hemp strands are air or heat dried to a second total water content of between about <NUM>% to about <NUM>% by weight for thermal set adhesives. If a cold set adhesive is going to be used, the hemp strands are not typically dried. The hemp strand includes adhesive in the range of between about <NUM>% to about <NUM>% by weight. Typically, the adhesive-applied strands for thermoset adhesives are dried, but adhesive-applied strands are not dried for cold set adhesives.

Subsequent steps normally include placing the adhesive-applied strands into a mold 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. Alternately, a lid can be used to maintain pressure on the strands during adhesive curing. For cold set adhesives while no heat is required, pressure is applied or, alternatively, a lid can be used to maintain pressure during adhesive curing.

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.

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 <NUM>/cm<NUM> to about <NUM>/cm<NUM> with the desired amount of adhesive. The density and hardness of the final product is a result of: (<NUM>) the extent to which the lignocellulosic structure is opened, (<NUM>) the density of the adhesive solution, (<NUM>) the amount of time that the hemp stalk strands are submersed, and (<NUM>) the pressure applied to the mold.

The manufactured hemp product comprises an amount of hemp strands greater than <NUM>% and an amount of adhesive in the range of <NUM>% to about <NUM>%. The manufactured hemp product has a generally uniform density in the range of between about <NUM>/m3 to about <NUM>/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 <NUM>% 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.

The drawings are meant to illustrate the principles of the invention, wherein the invention per se is defined in the appended claims. 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:.

<FIG> illustrates a process flow chart of one embodiment of the present invention. The flow chart begins with a hemp plant in Step <NUM>. In Step <NUM> the hemp stalk is trimmed/cut to length. In Step <NUM>, 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 <NUM> the hemp strands may be boiled or carbonized. In step <NUM> the boiled/carbonized/natural hemp strands are dried/stabilized (acclimatized). In Step <NUM> the first dried hemp strands have resin/glue/adhesive (generally referred to as adhesive) applied. In Step <NUM> the hemp strands with the adhesive applied are loaded into molds. In Step <NUM> pressure is applied to the unpressed hemp strands. Pressure can be applied through direct pressure or through the use of a lid. In Step <NUM> heat is optionally applied to the pressed hemp strands. After Step <NUM> or Step <NUM>, 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 <NUM>. In Step <NUM>, after the monolithic unmolded hemp piece is allowed to stabilize/rest, it is then cut into boards, blocks, beams or panels. In step <NUM> the manufactured hemp product is ready for use for its intended purpose.

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

<FIG> 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 <NUM>, wherein the hemp stalk piece is generally rectangular or cylinder and has a thickness < <NUM>. 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 <NUM>, provides an elongate hemp stalk <NUM> from a, for example, cannabis plant, where the hemp stalk has a length and a width, generally rectangular or cylinder in cross section <NUM>, and has a thickness in the range of between about <NUM> to about <NUM>. 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.

<FIG> is a drawing of a hemp stalk piece <NUM> being skinned <NUM>, split <NUM>, and crushed <NUM> to create a hemp stalk strand. A skinned hemp stalk piece is shown by reference number <NUM>. 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 <NUM>. Splitting <NUM> at least a portion of the naturally-occurring generally elongate internal structure of the hemp stalk parallel to the axis of the hemp stalk <NUM> increases by at least <NUM>% 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 <NUM> leaving a hemp stalk piece which is unskinned <NUM>, it is split into strands <NUM>, and/or crushed <NUM> 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 <NUM>. 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.

<FIG> 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 H2O or a mild H2O2 (<NUM>%) 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 <NUM> C for a minimum of <NUM> hours. Carbonizing the hemp strand with pressured hot steam above <NUM> C will darken the color of the end manufactured hemp product by carbonizing the sugars for <NUM>-<NUM> hours to reach required color darkness.

<FIG> is a drawing of a hemp strand (after the optional boiling or carbonizing) (<FIG>) after the drying process which shows individual strands of similar size <NUM>. A magnified drawing (<FIG>) indicates stress fractures from the optional crushing process <NUM>. At this point, the hemp stalk strand is dried to a first total water content preferably of less than <NUM>% by weight. Drying the hemp stalk strand can be done by using forced air, heat, sunshine or ambient air conditions. Best practice is using natural elements such as sunshine, but wood drying room, kiln or microwave technology are also acceptable. Boiling the hemp strands is optional after de-skinning/splitting/crushing creates more uniform colors removing some of the green color of the live plant. Adding H2O2 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.

<FIG> 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 <NUM>. The hemp strands are submersed in a container <NUM> full of fossil fuel or agricultural based adhesive solution <NUM> for between about <NUM>-<NUM> 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 or melamin formaldehyde. Afterward, the hemp strands with applied adhesive is air or heat dried to a second total water content of between about <NUM>% to about <NUM>% 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 <NUM>% to about <NUM>% by weight.

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 linking agents such as isocyanates, phenol, urea, melamine or acetates. These products are not eco-friendly but typically create a stronger and more cost efficient product.

Cold Set Adhesives- can cure at room temperature (<NUM>-<NUM> 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 <NUM> C and PF <NUM> C) and require an applied heat source, curing time is generally shorter than cold set adhesives. Thermoset adhesives can be applied via a H2O dilution technique which includes using a <NUM>% 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 H2O 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.

<FIG> is a drawing of the adhesive applied hemp strands <NUM> being loaded into molds <NUM>. 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.

<FIG> is a drawing of the molded hemp strands being pressed. 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 <NUM> placed into a mold <NUM> with a lid <NUM>, using a press <NUM> and applying pressure <NUM> to the molded hemp strands in the mold to thereby form a manufactured hemp product. The amount of pressure <NUM> 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.

<FIG> is a drawing of the molds <NUM> 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 <NUM> or the mold lids <NUM> are opened and the manufactured hemp product is removed <NUM>. 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.

<FIG> is a drawing of the monolithic hemp piece <NUM> being cut into board, block, beam or panel <NUM>. 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 <NUM>-<NUM> days pending environmental conditions.

<FIG> is a drawing of a manufactured hemp product <NUM>. Some embodiments disclosed herein are directed to a manufactured hemp product that can include a plurality of adhesively bonded and pressed hemp strands; where: (<NUM>) each of the hemp strands is of generally the same length; (<NUM>) 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; (<NUM>) the hemp strands are oriented roughly parallel to one another along their length; (<NUM>) the manufactured hemp product comprises an amount of adhesive in the range of between about <NUM>% to about <NUM>% by weight; and (<NUM>) the manufactured hemp product has a generally uniform density in the range of between about <NUM>/m3 to about <NUM>/m3. The manufactured hemp product has a dimensional stability coefficient of change that is at least <NUM>% 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.

Claim 1:
A manufactured hemp block (<NUM>) comprising:
a plurality of adhesively bonded partially broken hemp strands (<NUM>), wherein:
each of said partially broken hemp strands (<NUM>) maintains its original structure from an appearance point of view;
each partially broken hemp strand (<NUM>) comprises a naturally-occurring, generally elongate internal structure extending along the length of the hemp strand, that has been at least partially broken parallel to axis of the elongate internal structure, and that is at least partially permeated by an adhesive;
said partially broken hemp strands (<NUM>) are oriented approximately parallel to one another along their length;
said manufactured hemp block (<NUM>) comprises an amount of adhesive in the range of <NUM>% by weight to <NUM>% by weight and an amount of hemp strands of greater than <NUM>% by weight;
said manufactured hemp block (<NUM>) has a generally uniform density in the range of <NUM>/m<NUM> to <NUM>/m<NUM>; and
said manufactured hemp block (<NUM>) is suitable for being used as a wood substitute in appearance and technical properties.