# US 12,594,688 B2 · Recycled board manufacturing method and recycled board

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- Number: US 12,594,688 B2
- Document ID: US12594688B2
- Status: Granted
- Kind: B2
- Application number: 18/021,338
- Filed: 2021-06-01
- Published: 2023-08-17
- Granted: 2026-04-07
- Earliest claimed: 2021-06-01
- Assignees: Workstudio Corporation
- Applicants: Workstudio Corporation
- Inventors: Kazuhiro Hara
- Web page: https://patentgrep.com/patent/US12594688B2

## CPC

- B27N 3/007: {and at least partly composed of recycled material}
- B27N 3/04: from fibres
- B27N 3/02: from particles
- B27N 5/00: Manufacture of non-flat articles
- B27N 7/00: After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
- B27N 3/203: {with heating or cooling means}
- Y02W 30/62: Plastics recycling; Rubber recycling
- B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00)
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

A recycled board manufacturing method including a fibrous material generation process of generating a fibrous material by grinding recovered goods containing fibers into a fiber form, an adhesive application process of applying an adhesive having thermosetting properties to the fibrous material generated in the fibrous material generation process, a molding process of molding the fibrous material applied with the adhesive in the adhesive application process into a board shape, and a pressing-heating process of pressing and heating the fibrous material molded into the board shape in the molding process.

## Claims

### Claim 1

A recycled board manufacturing method comprising:
a fibrous material generation process of generating a fibrous material by grinding recovered goods containing fibers into a fiber form, wherein the fibrous material generated from the recovered goods includes first fibers colored a first color, second fibers of a different type from the first fibers and colored a second color different from the first color, and third fibers of the same type as the first fibers and colored a third color different from the first color;
an adhesive application process of applying an adhesive having thermosetting properties to the fibrous material generated in the fibrous material generation process to generate a fibrous material mixture;
a molding process of molding the fibrous material mixture into a board shape to produce a molded fibrous material mixture; and
a pressing-heating process of pressing and heating the molded fibrous material mixture to produce the recycled board, wherein the first fibers, the second fibers, and the third fibers are exposed on a surface of the recycled board, without the surface being coated with a binder, so that a texture of the fibers is expressed on the surface of the recycled board.

### Claim 2 (depends on 1)

The recycled board manufacturing method of claim 1, wherein the fibrous material is generated in the fibrous material generation process by grinding the recovered goods so as to obtain an average fiber length no less than 0.5 mm and no greater than 10 mm.

### Claim 3 (depends on 1)

The recycled board manufacturing method of claim 1, wherein:
the recovered goods are leather containing fibers of leather; and
a recycled board including the fibers of leather as the fibrous material is manufactured.

### Claim 4 (depends on 1)

The recycled board manufacturing method of claim 1, wherein:
the recovered goods are textiles; and
a recycled board containing natural fibers and synthetic fibers as the fibrous material is manufactured.

### Claim 5 (depends on 4)

The recycled board manufacturing method of claim 4, wherein a recycled board having a contained mass of the synthetic fibers that is greater than a contained mass of the natural fibers is manufactured.

### Claim 6 (depends on 4)

The recycled board manufacturing method of claim 4, wherein a recycled board having a contained mass of the natural fibers that is greater than a contained mass of the synthetic fibers is manufactured.

### Claim 7 (depends on 1)

The recycled board manufacturing method of claim 1, wherein:
the manufacturing method further comprises a blending process of blending other fibers with the fibrous material generated in the fibrous material generation process; and
the adhesive application process includes applying the adhesive having thermosetting properties to the fibrous material blended with the other fibers in the blending process.

### Claim 8 (depends on 1)

The recycled board manufacturing method of claim 1, wherein, in the fibrous material generation process, the fibrous material is generated in a state in which the first fibers, the second fibers, and the third fibers are blended by grinding plural recovered goods containing different types of fibers all together.