U.S. patent application number 11/982546 was filed with the patent office on 2009-05-07 for sawdust-reinforced pulp material and method of producing the same.
This patent application is currently assigned to Elite Furniture Co., Ltd.. Invention is credited to Byung-Hoon Park.
Application Number | 20090114358 11/982546 |
Document ID | / |
Family ID | 40586943 |
Filed Date | 2009-05-07 |
United States Patent
Application |
20090114358 |
Kind Code |
A1 |
Park; Byung-Hoon |
May 7, 2009 |
Sawdust-reinforced pulp material and method of producing the
same
Abstract
A sawdust-reinforced pulp material and its preparation method
are herein disclosed Specifically, the method for preparing the
sawdust-reinforced pulp material comprises the steps of: mixing 70%
to 85% by weight of a pulp prepared from waste paper with 15% to
30% by weight of sawdust, based on the total weight of pulp and
sawdust, to prepare a mixture of pulp and sawdust; blending the
mixture with an adhesive in the weight ratio of 1:1; pouring the
mixture blended with the adhesive into a mold to form a pulp
material; and naturally drying the formed pulp material at an
ambient temperature of 20 to 25 degrees C to produce the
sawdust-reinforced pulp material.
Inventors: |
Park; Byung-Hoon; (Suwon-Si,
KR) |
Correspondence
Address: |
GWIPS;Peter T. Kwon
Gwacheon P.O. Box 72, 119 Byeolyang Ro
Gwacheon City, Gyeonggi-Do
427-600
KR
|
Assignee: |
Elite Furniture Co., Ltd.
|
Family ID: |
40586943 |
Appl. No.: |
11/982546 |
Filed: |
November 2, 2007 |
Current U.S.
Class: |
162/181.4 ;
162/158; 162/181.6; 162/181.9; 162/315 |
Current CPC
Class: |
D21J 3/00 20130101 |
Class at
Publication: |
162/181.4 ;
162/158; 162/181.6; 162/181.9; 162/315 |
International
Class: |
D21F 11/00 20060101
D21F011/00 |
Claims
1. A method of producing a sawdust-reinforced pulp material, the
method comprising the steps of: mixing 70% to 85% by weight of a
pulp prepared from waste paper with 15% to 30% by weight of
sawdust, based on the total weight of pulp and sawdust, to prepare
a mixture of the pulp and the sawdust; blending the mixture with an
adhesive in the weight ratio of 1:1; pouring the mixture blended
with the adhesive into a mold to form a pulp material; and
naturally drying the formed pulp material at an ambient temperature
of 20 to 25 degrees C. to produce the sawdust-reinforced pulp
material.
2. The method of claim 1, wherein the adhesive is a mixture of 80%
to 90% by weight of water with 10% to 20% by weight of an
environmentally friendly adhesive.
3. A method of producing a sawdust-reinforced pulp material, the
method comprising the steps of: mixing 60% to 70% by weight of a
pulp prepared from waste paper, 15% to 20% by weight of sawdust and
5% to 10% by weight of an additive, based on the total weight of
pulp, sawdust and additive, to prepare a mixture of the pulp, the
sawdust and the additive; blending the mixture with an adhesive in
the weight ratio of 1:1; pouring the mixture blended with the
adhesive into a mold to form a pulp material; and naturally drying
the formed pulp material at an ambient temperature of 20 to 25
degrees C. to produce the sawdust-reinforced pulp material.
4. The method of claim 3, wherein the additive is a mixture of 30%
to 50% by weight of charcoal powder, 20% to 25% by weight of yellow
ocher powder, 15% to 20% by weight of glass fiber, 10% to 15% by
weight of ceramic powder and 5% to 10% by weight of silver
powder.
5. An apparatus for preparing a sawdust-reinforced pulp material
comprising: a means for mixing 70% to 85% by weight of a pulp
prepared from waste paper with 15% to 30% by weight of sawdust,
based on the total weight of pulp and sawdust, to prepare a mixture
of the pulp and the sawdust; a means for blending the mixture with
an adhesive in the weight ratio of 1:1; a means for pouring the
mixture blended with the adhesive into a mold to form a pulp
material; and a means for naturally drying the formed pulp material
at an ambient temperature of 20 to 25 degrees C. to produce the
sawdust-reinforced pulp material.
6. An apparatus of claim 5 further comprising: a means for mixing
60% to 70% by weight of a pulp prepared from waste paper, 15% to
20% by weight of sawdust and 5% to 10% by weight of an additive,
based on the total weight of pulp, sawdust. and additive, to
prepare a mixture of the pulp, the sawdust and the additive.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a reinforced pulp material
and its preparation method. More specifically, the present
invention relates to a sawdust-reinforced pulp material prepared
from a mixture of pulp and sawdust or a mixture of pulp, sawdust
and additive to increase the strength and moisture resistance of
the material, and its preparation method.
[0003] 2. Related Prior Art
[0004] Generally, packaging for electronic products, egg trays for
supporting and protecting eggs, disposable and recyclable
containers for picnic boxes, etc. which are made of synthetic resin
are not environmentally friendly, and thus are now being made of
environmentally friendly pulp.
[0005] A pulp mold is typically prepared in such a manner that,
after being washed, a pulp is mixed with water to be dissolved, the
mixture is stirred and is treated with chemicals, the resulting
mixture is poured into a mold to form the pulp mold, and finally
dried. In this case, in order to color the pulp mold, dye is added
to a mixture of pulp and water.
[0006] However, a conventional pulp mold is susceptible to moisture
absorption and has low strength. Thus, their applications are
limited to packaging material for light-weight products such as
electronic products or eggs. Further, there occurs a problem in
that such pulp molds are disposable and thus wasted.
SUMMARY OF THE INVENTION
[0007] The present invention has been made in an effort to solve
the above problems occurring in the prior art, and it is an object
to provide a sawdust-reinforced pulp material prepared by using a
mixture of pulp and sawdust or a mixture of pulp, sawdust and an
additive composed of charcoal, yellow ocher, glass fiber, ceramic
and silver to thereby have a deodorizing and antimicrobial effect,
to radiate far infrared, to increase the strength of the material
and to provide a moisture-proofing effect so that the lifespan of
products is extended indefinitely, and to allow the extension of
its application to the fields of sound-proofing material, roofing
material, high strength protective material for transporting,
etc.
[0008] To accomplish the above object of the present invention, a
method of producing a sawdust-reinforced pulp material comprises
the steps of: mixing 70% to 85% by weight of a pulp prepared from
waste paper with 15% to 30% by weight of sawdust, based on the
total weight of the pulp and the sawdust, to prepare a mixture of
pulp and sawdust; blending the mixture with an adhesive in the
weight ratio of 1:1; pouring the mixture blended with the adhesive
into a mold to form a pulp material; and drying the formed pulp
material at an ambient temperature of 20 to 25 .degree. C. to
produce the sawdust-reinforced pulp material.
[0009] In the present method, the adhesive is a mixture of 80% to
90% by weight of water and 10% to 20% by weight of an
environmentally friendly adhesive.
[0010] In another embodiment, the present method of producing a
sawdust-reinforced pulp material comprises the steps of: mixing 60%
to 70% by weight of a pulp prepared from waste paper, 15% to 20% by
weight of sawdust and 5% to 10% by weight of an additive, based on
the total weight of pulp, sawdust and additive, to prepare a
mixture of the pulp, the sawdust and the additive; blending the
mixture with an adhesive in the weight ratio of 1:1; pouring the
mixture blended with the adhesive into a mold to form a reinforced
pulp material; and naturally drying the formed pulp material at an
ambient temperature of 20 to 25.degree. C. to produce the
sawdust-reinforced pulp material.
[0011] In the present method, the additive is a mixture of 30% to
50% by weight of charcoal powder, 20% to 25% by weight of yellow
ocher powder, 15% to 20% by weight of glass fiber, 10% to 15% by
weight of ceramic powder and 5% to 10% by weight of silver
powder.
[0012] Another objective of the present invention is to provide an
apparatus for preparing a sawdust-reinforced pulp material
comprising: a means for mixing 70% to 85% by weight of a pulp
prepared from waste paper with 15% to 30% by weight of sawdust,
based on the total weight of pulp and sawdust, to prepare a mixture
of the pulp and the sawdust, a means for blending the mixture with
an adhesive in the weight ratio of 1:1, a means for pouring the
mixture blended with the adhesive into a mold to form a pulp
material; and a means for naturally drying the formed pulp material
at an ambient temperature of 20 to 25 degrees C. to produce the
sawdust-reinforced pulp material.
[0013] Further, other objective of the present invention is to
provide the apparatus comprising, a means for mixing 60% to 70% by
weight of a pulp prepared from waste paper, 15% to 20% by weight of
sawdust and 5% to 10% by weight of an additive, based on the total
weight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates the steps taken in carrying out the
process of producing a sawdust-reinforced pulp material according
to a first embodiment of the present invention.
[0015] FIG. 2 illustrates the steps taken in carrying out the
process of producing a sawdust-reinforced pulp material according
to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Hereinafter, the present invention will be illustrated in
detail with reference to the appended drawings.
[0017] Meanwhile, in case it is judged that a detailed description
about the relevant function or construction commonly known in the
art unnecessarily disturbs the understanding of the present
invention, such a detailed description will not be included herein.
The terms described below are defined in connection with the
function of the present invention. The meaning of the terms may
vary according to the user, the intention of the operator, usual
practice, etc. Therefore, the terms should be defined based on the
description rather than the specification.
Embodiment 1
[0018] FIG. 1 is a flow chart illustrating the preparation process
of the sawdust-reinforced pulp material according to the first
embodiment.
[0019] With reference to FIG. 1, the present method of producing a
sawdust-reinforced pulp material comprises the step (S110) of
mixing 70% to 85% by weight of a pulp prepared from waste paper
with 15% to 30% by weight of sawdust, based on the total weight of
the pulp and the sawdust, to prepare a mixture of pulp and sawdust;
the step (S120) of blending the mixture with an adhesive in the
weight ratio of 1:1; the step (S130) of pouring the mixture blended
with the adhesive into a mold to form the reinforced pulp material;
and the step (S140) of drying the formed, reinforced pulp material
at ambient temperature of 20.degree. C. to 25.degree. C. to produce
the dried reinforced pulp material, wherein the adhesive is a
mixture of 80% to 90% by weight of water and 10% to 20% by weight
of an environmentally friendly adhesive.
[0020] Hereinafter, the process is illustrated in detail with
reference to FIG. 1.
[0021] First, waste paper (newspaper, magazine, milk packaging,
etc.) is collected and, according to the conventional method,
separated from foreign materials to remove them, bleached, and then
dried, thereby obtaining the pulp to be used in the following
step.
[0022] Then, finely powdered sawdust is mixed with the pulp so that
the pulp is reinforced, wherein the sawdust and pulp can be easily
mixed because they originate from the same source. Meanwhile, it is
preferred that the powdered sawdust is processed with a magnet or
the like to remove foreign materials such as metal.
[0023] The above pulp and sawdust are mixed in the ratio of 70% to
85% by weight of the pulp and 15% to 30% by weight of sawdust. To
manufacture a soft product, 85% by weight of pulp and 15% by weight
of sawdust are mixed, and to manufacture a hard product 70% by
weight of pulp and 30% by weight of sawdust are mixed, which
increases the strength of the material.
[0024] To the mixture of pulp and sawdust as prepared above is
added an adhesive in the ratio of 1:1 of the mixture to the
adhesive, wherein the adhesive is a mixture of 80% to 90% by weight
of water with 10% to 20% by weight of an environmentally friendly
adhesive. For the adhesive, it is preferred that the mixing ratio
of water and the environmentally friendly adhesive is maintained
within the above range.
[0025] Upon completion of blending the mixture of pulp and sawdust
with the adhesive, the blend is inserted into a mold to form the
reinforced pulp material and, subsequently, the molded and
reinforced pulp material is dried naturally (that is, without using
any drier) at an ambient temperature of 20.degree. C. to 25.degree.
C., resulting in the end product of dried and reinforced pulp
material. The process of drying can also be carried out with a
drier.
Embodiment 2
[0026] FIG. 2 is a flow chart illustrating the preparation process
of the sawdust, reinforced pulp material according to the 2nd
embodiment.
[0027] With reference to FIG. 2, the present method of producing a
sawdust-reinforced pulp material comprises the step (S210) of
mixing 60% to 70% by weight of a pulp prepared from waste paper,
15% to 20% by weight of sawdust and 5% to 10% by weight of an
additive, based on the total weight of the mixture, to prepare a
mixture of pulp, sawdust and additive; the step (S220) of blending
the mixture with an adhesive in the weight ratio of 1:1; the step
(S230) of pouring the mixture blended with the adhesive into a mold
to form a reinforced pulp material; and the step (S240) of drying
the formed pulp material at an ambient temperature of 20.degree. C.
to 25.degree. C. to produce the dried reinforced pulp material,
wherein the additive is a mixture of 30% to 50% by weight of
charcoal powder, 20% to 25% by weight of yellow ocher powder, 15%
to 20% by weight of glass fiber, 10% to 15% by weight of ceramic
powder and 5% to 10% by weight of silver powder, and wherein the
adhesive is a mixture of 80% to 90% by weight of water with 10% to
20% by weight of an environmentally friendly adhesive.
[0028] Hereinafter, the process is illustrated in detail with
reference to FIG. 2. First, waste paper (newspaper, magazine, milk
packaging, etc.) is collected and, according to the conventional
method, separated from foreign materials to remove them, bleached,
and then dried, thereby obtaining the pulp to be used in the
following step.
[0029] Then, finely powdered sawdust is mixed with the pulp so that
the pulp is reinforced, wherein the sawdust and pulp can be easily
mixed because they originate from the same source. Meanwhile, it is
preferred that the powdered sawdust is processed with a magnet or
the like to remove foreign materials such as metal.
[0030] The additive is a mixture of 30% to 50% by weight of
charcoal powder for deodorizing and cleaning, 20% to 25% by weight
of yellow ocher powder for radiating far infrared, 15% to 20% by
weight of glass fiber for reinforcing the strength of the material
and insulating against sound, 10% to 15% by weight of ceramic
powder for radiating far infrared and 5% to 10% by weight of silver
powder for an antimicrobial effect. The mixing ratio of each
component can be freely changed within the range that is
appropriate to the specific application field (for example, roofing
material, floor material, soundproofing material, etc).
[0031] In a case where the charcoal powder is mixed in the amount
of less than 30% by weight and the yellow ocher is mixed in the
amount of less than 20% by weight, the effects of them are reduced.
In case where the charcoal powder is mixed in the amount of more
than 50% by weight and the yellow ocher is mixed in the amount of
more than 25% by weight, the reinforced pulp material becomes
heavy.
[0032] It is preferred that the length and width of the glass fiber
is 5 to 25 mm and 20 to 100 .mu.m, respectively. When the glass
fiber is mixed in the amount of less than 15% by weight, the
strength of the reinforced pulp material is reduced. When mixed in
the amount of more than 20% by weight, the glass fiber is expelled
from the mixture.
[0033] In a case where the ceramic powder is mixed in the amount of
less than 10% by weight, its effect is reduced. In a case where the
ceramic powder is mixed in the amount of more than 15% by weight,
the color of the reinforced pulp material is changed and the
material becomes heavy.
[0034] In a case where the silver powder is mixed in the amount of
less than 5% by weight, its effect is reduced. In case where the
silver is mixed in the amount of more than 10% by weight, the
manufacturing cost is increased.
[0035] To manufacture a soft product, 70% by weight of pulp, 15% by
weight of sawdust and 5% by weight of an additive are mixed. To
manufacture a hard product, 60% by weight of pulp, 20% by weight of
sawdust and 5% by weight of an additive are mixed, which increases
the strength of the material.
[0036] To the mixture of the pulp, the sawdust and the additive as
prepared above is added an adhesive in the ratio of 1:1 of the
mixture to the adhesive, wherein the adhesive is a mixture of 80%
to 90% by weight of water with 10% to 20% by weight of an
environmentally friendly adhesive. For the adhesive, it is
preferred that the mixing ratio of water and the
environmentally-friendly adhesive is maintained within the above
range of mixing.
Upon completion of blending the mixture with the adhesive, the
blend is poured into a mold to form the reinforced pulp material
and, subsequently, the molded and reinforced pulp material is dried
naturally at an ambient temperature of 20.degree. C. to 25.degree.
C., resulting in the end product of the dried and reinforced pulp
material. The process of drying can also be carried out with a
drier.
[0037] Therefore, since the reinforced pulp material of the present
invention is prepared using a mixture of pulp and sawdust or a
mixture of pulp, sawdust and an additive composed of charcoal,
yellow ocher, glass fiber, ceramic and silver, the reinforced pulp
material has light weight, high strength and improved resistance to
water, which provides a long service life and, thus, can be used
for diverse applications. Also, the reinforced pulp material has
the environmental benefits of antibiotic activity, deodorizing,
radiating far infrared and releasing anions.
[0038] As shown above, the present invention has a deodorizing
effect, shows an antibiotic effect, radiates far infrared,
increases the strength of the material and improves the moisture
resistance, which extends the lifespan of the products thus
prepared, and allows the applications to be extended to the fields
of sound-proofing material, roofing material, protective material
for transporting which requires high strength packaging material,
etc.
[0039] While the present invention has been described with
reference to the particular illustrative embodiments, it is not to
be restricted by the embodiments but only by the appended claims.
It is to be appreciated that those skilled in the art can change or
modify the embodiments without departing from the scope and spirit
of the present invention.
* * * * *