US 12,654,355 B2Granted

Coextruded hemp composite board

OwnerJohn D. Graham, John J. Bradleyinventors

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Abstract

A co-extruded hemp composite board (CHB) is provided. By combining hemp feedstocks with virgin and/or recycled binder materials and subsequently coextruding them into a coextruded extrudate sheet, an environmentally friendly alternative to traditional construction materials is created. Secondary feedstocks and waste products from other production streams may be added during the coextrusion process to enhance the physical characteristics of the coextruded extrudate sheet as well to reduce waste/cost of production and create a more environmentally friendly construction material. The coextruded extrudate sheet produced using such materials possesses superior physical properties when compared to traditional construction materials due to the structural characteristics of dispersed hemp feedstocks; the complete encapsulation of hemp feedstocks in the binder material; and the lower hygroscopic and higher pest resistance properties of hemp feedstocks. A downstream extrusion arrangement may be used to pattern the extrudate sheet and/or create molded shapes that are difficult to achieve in traditional construction materials, increasing the customization potential of finished CHB products relative to traditional construction materials.

Claims21

Dependent claims

A coextruded hemp board (CHB) comprising:

at least one flexible, substrate layer configured to accept a mixed extrudate on at least one surface,
wherein said at least one flexible, substrate layer forms a first layer of a rigid composite board,
wherein said rigid composite board comprises a bottom surface, top surface, first edge, second edge, upper edge, and lower edge, and
at least one mixed extrudate layer comprising said mixed extrudate,
wherein said at least one mixed extrudate layer forms one or more additional layers of said rigid composite board,
wherein said mixed extrudate comprises a binder material and a hemp feedstock that is not coated in a coupling agent,
wherein each layer of said at least one mixed extrudate layer has a density that is consistent throughout and a concentration of said hemp feedstock that is consistent throughout,
wherein components of said hemp feedstock comprise hemp hurd and hemp bast fiber,
wherein said hemp hurd and said hemp bast fiber are separate components of a hemp biomass,
wherein said hemp hurd is separated from said hemp bast fiber prior to creation of said mixed extrudate,
wherein said at least one mixed extrudate layer is extruded onto said at least one flexible, substrate layer,
wherein said mixed extrudate comprises at least 5% of a total volume percentage of a hemp feedstock and no more than 50% of said total volume percentage of said hemp feedstock,
wherein said mixed extrudate comprises at least 50% of said total volume percentage of binder material,
wherein said hemp feedstock is substantially encapsulated by said binder material within said mixed extrudate,
wherein said mixed extrudate is substantially oriented within said binder material in a single output direction of an extruder due to a shear force acting on said mixed extrudate as it was ejected from a manifold.

12 more elements

A coextruded hemp board (CHB) comprising:

at least one flexible, substrate layer configured to accept a mixed extrudate on at least one surface,
wherein said at least one flexible, substrate layer forms a first layer of a rigid composite board,
wherein said rigid composite board comprises a bottom surface, top surface, first edge, second edge, upper edge, and lower edge,
at least one mixed extrudate layer comprising said mixed extrudate,
wherein said at least one mixed extrudate layer forms one or more additional layers of said rigid composite board,
wherein said mixed extrudate comprises a binder material and a hemp feedstock that is not coated in a coupling agent,
wherein components of said hemp feedstock comprise hemp hurd and hemp bast fiber,
wherein each layer of said at least one mixed extrudate layer has a density that is consistent throughout and a concentration of said hemp feedstock that is consistent throughout,
wherein said hemp hurd and said hemp bast fiber are separate components of a hemp biomass,
wherein said hemp hurd is separated from said hemp bast fiber prior to creation of said mixed extrudate,
wherein said mixed extrudate comprises at least 5% of a total volume percentage of a hemp feedstock and no more than 50% of said total volume percentage of said hemp feedstock,
wherein said mixed extrudate comprises at least 50% of said total volume percentage of binder material,
wherein said hemp feedstock is substantially encapsulated by said binder material within said mixed extrudate,
wherein said mixed extrudate is substantially oriented within said binder material in a single output direction of an extruder due to a shear force acting on said mixed extrudate as it was ejected from a manifold, and
a first locking feature located on said first edge and a second locking feature on said second edge,
wherein said first edge of said rigid composite board is located opposite said second edge of said rigid composite board,
wherein said first locking feature extends from said upper edge to said lower edge,
wherein said second locking feature extends from said upper edge to said lower edge,
wherein said first locking feature is rounded and comprises a diameter that is greater than a thickness of said rigid composite board,
wherein said second locking feature of said second edge comprises a hook configured to interlock with said first locking feature.

17 more elements

A coextruded hemp board (CHB) comprising:

at least one flexible, substrate layer configured to accept a mixed extrudate on at least one surface,
wherein said at least one flexible, substrate layer forms a first layer of a rigid composite board,
wherein said rigid composite board comprises a bottom surface, top surface, first edge, second edge, upper edge, and lower edge,
at least one mixed extrudate layer comprising said mixed extrudate,
wherein said at least one mixed extrudate layer forms one or more additional layers of said rigid composite board,
wherein said at least one mixed extrudate layer forms said bottom surface, wherein said mixed extrudate comprises a binder material and a hemp feedstock that is not coated in a coupling agent,
wherein each layer of said at least one mixed extrudate layer has a density that is consistent throughout and a concentration of said hemp feedstock that is consistent throughout,
wherein components of said hemp feedstock comprise hemp hurd and hemp bast fiber,
wherein said hemp hurd and said hemp bast fiber are separate components of a hemp biomass,
wherein said hemp hurd is separated from said hemp bast fiber prior to creation of said mixed extrudate,
wherein said mixed extrudate comprises at least 5% of a total volume percentage of a hemp feedstock and up to 50% of said total volume percentage of said hemp feedstock,
wherein said mixed extrudate comprises at least 50% of said total volume percentage of binder material,
wherein said hemp feedstock is substantially encapsulated by said binder material within said mixed extrudate,
wherein said mixed extrudate is substantially oriented within said binder material in a single output direction of an extruder due to a shear force acting on said mixed extrudate as it was ejected from a manifold, and
a “score and ball” pattern formed on at least one of said top surface or said bottom surface and aligned parallel to said first edge.

12 more elements

Dependencies are inferred from the claim text.

Facts

Application: 18/278,984Filed 26 May 2023 · us provisional application
Priority: 7 Sep 2022
Published: US 2025/0196394 A119 Jun 2025
Granted: 16 Jun 2026
Term ends: Not estimatedThe source records don’t support an estimate.

Classification37 codes

B27N 3/04
Manufacture of substantially flat articles, e.g. boards, from particles or fibres: from fibres
B27N 3/28
Moulding or pressing: characterised by using extrusion presses
B27N 1/00
Pretreatment of moulding material
B27N 3/18
Moulding or pressing: auxiliary operations, e.g. preheating, humidifying, cutting-off