CLEAN PRODUCTION METHOD FOR BAMBOO FIBRES
Disclosed is a dean production method for bamboo fibres, comprising the following steps: bamboo pieces are separated into filaments, and the filaments are twisted into ropes to obtain rope-shaped bamboo filaments; the rope-shaped bamboo filaments are refined by means of multiple alternating cold-hot treatments and rolling and rubbing to obtain coarse rope-shaped bamboo fibres (wherein same can be directly put into a drying device and then made into coarse bamboo fibres for a composite material); the coarse rope-shaped bamboo fibres are subjected to continuous biological degumming to obtain the rope-shaped bamboo fibres; the rope-shaped bamboo fibres are fed into a cleaning device for repeated cleaning, rolling and drying are performed, and then spraying-type oiling is performed to obtain thin rope-shaped bamboo fibres; finally, the thin rope-shaped bamboo fibres are subjected to opening and carding to make bamboo fibres for a textile material.
The invention relates to dean production of natural bamboo fibres and relates particularly to a method for producing natural bamboo fibres that is executed by continuous production line, alternating cold-hot physical processing treatments and biological degumming parameters automatic control treatments, and capable of achieving no chemicals, no pollution, cleanness, environmental protection, energy saving and high efficiency.
2. Description of the Related ArtBamboo fibres which are natural bamboo fibres and also known as bamboo fibrils belong to plant stem wood fibres. Its celluloses are wrapped in lignin and hemicellulose. However, a length of a single fibre is only about 2 mm that causes a complete degumming treatment cannot be adopted when producing bamboo fibres for a textile material, but a semi-degumming treatment is applied to process and obtain natural bamboo fibres in a state of fibre bundles.
Most degumming treatments of natural bamboo fibres are chemical degumming treatments, but they will cause environmental pollution. Therefore, industry has turned to explore biological degumming treatment. Existing techniques still need to use chemicals, in other words, degumming by a combination of biological treatment and chemical treatment cannot achieve clean production. A preparation process mostly starts with processes of chemical softening and degumming bamboo pieces and that is unreasonable in use of bamboo resources. It not only adds production links, increases energy consumption and environmental pollution, but also increases conversion cost of bamboo fibres.
In addition, in a production process, no matter how bamboo filaments are produced, the bamboo filaments have a finite length as other plant fibres do. This makes automatic and continuous processing treatment of bamboo fibres a difficult problem.
SUMMARY OF THE INVENTIONThe technical problem to be solved by the invention is to provide a clean production method for bamboo fibres capable of achieving automatic and continuous processing of same, wherein same uses no chemicals, is clean, saves energy and is environmentally friendly.
The invention is implemented as follows:
Technical Solution 1A clean production method for bamboo fibres comprising:
step 1, a step of separating into filaments and forming into ropes: dividing a fresh bamboo material into equal bamboo strips, removing outer skins, inner skins and nodes from the bamboo strips to make bamboo pieces, and using a bamboo filament processing device to separate the bamboo pieces into filaments and twist the filaments into rope-shaped bamboo filaments; and
step 2, a step of microwave refining feeding the rope-shaped bamboo filaments into a multiple refinement device by an automated delivery and buffer device to refine the bamboo filaments by an alternation of cold and hot treatments and processes of rolling and rubbing, and then feeding the bamboo filaments into a drying device, thereby obtaining coarse rope-shaped bamboo fibres for a composite material.
Preferably, the step 1 includes using a filament separation device to separate the bamboo pieces into non-entangled filaments and using a rope forming device to twist the filaments into continuous rope-shaped bamboo filaments.
Preferably, in the step 2, the multiple refinement device includes ten to twenty pairs of grooved rollers and also includes a microwave heating device and a cold water spraying device alternating between every two pairs of the grooved rollers.
Technical Solution 2A clean production method for bamboo fibres comprising:
step 1, a step of separating into filaments and forming into ropes: dividing a fresh bamboo material into equal bamboo strips, removing outer skins, inner skins and nodes from the bamboo strips to make bamboo pieces, and using a bamboo filament processing device to separate the bamboo pieces into filaments and twist the filaments into rope-shaped bamboo filaments;
step 2, a step of microwave refining feeding the rope-shaped bamboo filaments into a multiple refinement device by an automated delivery and buffer device to refine the bamboo filaments by an alternation of cold and hot treatments and processes of rolling and rubbing, and then outputting coarse rope-shaped bamboo fibres;
step 3, a step of biological degumming: feeding the coarse rope-shaped bamboo fibres to a strip-shaped constant-temperature bio-enzyme fermentation pool by the automated delivery and buffer device and then outputting rope-shaped bamboo fibres after fermenting;
step 4, a step of cleaning and spraying oil: feeding the rope-shaped bamboo fibres to a cleaning device by the automated delivery and buffer device for repeated cleaning, rolling, and drying, with the cleaning device including a plurality of grooved rollers and a water spraying device, feeding the rope-shaped bamboo fibres to a drying device for a drying operation, then executing a process of spraying-type oiling after the drying operation, and thence outputting thin rope-shaped bamboo fibres; and
step 5, a step of opening and carding: feeding the thin rope-shaped bamboo fibres to an opening and carding device by the automated delivery and buffer device for smoothening and carding, thereby making bamboo fibres for a textile material.
Preferably, the step 1 includes using a filament separation device to separate the bamboo pieces into non-entangled filaments and using a rope forming device to twist the filaments into continuous rope-shaped bamboo filaments.
Preferably, in the step 2, the multiple refinement device includes ten to twenty pairs of grooved rollers and also includes a microwave heating device and a cold water spraying device alternating between every two pairs of the grooved rollers.
Preferably, in the step 3, a bio-enzyme in the strip-shaped constant-temperature fermentation pool is a complex bio-enzyme composed of laccase and xylanase, having a ratio between 1:0.5 and 1:1, parameters applied to the fermentation pool being controlled by: an enzyme concentration of bio-enzyme broth being between 2 g and 4 g per liter of water, a temperature of the bio-enzyme broth being between 45° C. and 65° C., a pH value of the bio-enzyme broth being between 4 and 6, and a dissolved oxygen concentration of the bio-enzyme broth being between 5.4 mg/L and 4.8 mg/L, any section of the rope-shaped bamboo fibres being fermented in the fermentation pool for 2 to 4 hours.
Preferably, a conveyor belt is disposed in the strip-shaped constant-temperature fermentation pool and passes through an entire length of the fermentation pool for delivering the coarse rope-shaped bamboo fibres, the conveyor belt being submerged in fermentation broth and having an operation speed set according to a formula defined by v=l/t in which v represents a conveying speed, l represents an entire length of the fermentation pool, and t represents time required for fermentation, a liquid level detector being disposed in the fermentation pool, and a plurality of detecting signal stations being disposed along a length direction for detecting temperatures, pH values and dissolved oxygen concentrations respectively, thereby controlling and adjusting each parameter instantly.
Preferably, the dissolved oxygen concentration is detected and controlled by a formula defined by DOf=(p/p0)*(477.8/(T+32.6)) in which p represents a local measured atmospheric pressure, p0 represents a standard atmospheric pressure, and T represents a temperature(° C.).
Preferably, the automated delivery and buffer device includes a plurality of pairs of grooved rollers and a buffer container.
The advantages of the invention are:
The invention fully utilizes natural and physical properties of the bamboo material, follows a physical rule, adopts a mechanical processing treatment, and uses a principle of thermal expansion and cold shrinkage and a biological degumming treatment to achieve a clean and continuous production of the bamboo fibres.
The invention is a clean production method for bamboo fibres, which is different from the prior art, has characteristics of continuous automation, no chemicals, no pollution, and clean production, and adopts unique techniques of transmission of forming the bamboo filaments into ropes, alternating cold-hot treatments, filaments separating and refining treatments, automatic control and continuous biological degumming treatments. It is a processing method of high efficiency, energy saving, full automation and pipeline production.
The invention which firstly separates the bamboo pieces into filaments and forms into ropes, and thence executes uninterrupted automatic and continuous treatments is favorable for greatly reducing labor cost and significantly increasing a production rate and production efficiency of the bamboo fibres.
The invention produces the bamboo fibres by using no chemicals and adopting the mechanical processing treatment and the material principle of thermal expansion and cold shrinkage to proceed the alternating cold-hot and biological degumming treatments. In particular the continuous processing art of forming the bamboo filaments into ropes turns a finite length of the bamboo (filaments) fibres into an infinite length theoretically that provides pre-conditions for achieving an automatic and continuous production.
Meanwhile, time required for an entire production process can be controlled within 12 hours, thereby solving industrialization problems of fast, low cost and large-scale production of the bamboo fibres.
The continuous biological degumming treatment of the invention not only breaks a conventional gap fermentation treatment, but also solves problems that main parameters of fermentation condition (environment), namely an enzyme concentration, a temperature, a pH value, and a dissolved oxygen concentration, variate at any time, and maintains the preferable fermentation condition by adopting instant detection and automatic control.
A first embodiment: processing coarse bamboo fibres for a composite material.
Step 1, a step of dividing a fresh bamboo material into equal bamboo strips, removing outer skins, inner skins and nodes from the bamboo strips to make bamboo pieces, and using a filament separation device to separate the bamboo pieces into non-entangled filaments and using a rope forming device to twist the filaments into continuous rope-shaped bamboo filaments. An equivalent diameter of a main body of the bamboo filaments is 0.5 mm
Step 2, a step of feeding the rope-shaped bamboo filaments into a multiple refinement device which includes ten pairs of grooved rollers and also includes a microwave heating device and a cold water spraying device alternating between every two pairs of the grooved rollers by an automated delivery and buffer device to roll, heat, roll and cool repeatedly, namely an alternation of cold and hot treatments and a rolling process. A conveying speed is controlled based on that processing time of any section of the rope-shaped bamboo filaments is 30 minutes. Finally, the bamboo filaments are fed into a drying device for a drying operation to obtain coarse rope-shaped bamboo fibres whose equivalent diameter of a main body is 0.3 mm for a composite material and packaged into a warehouse.
The automated delivery and buffer device includes a plurality of pairs of grooved rollers and a buffer container.
A second embodiment: as shown in
Step 1, a step of dividing a fresh bamboo material into equal bamboo strips, removing outer skins, inner skins and nodes from the bamboo strips to make bamboo pieces, and using a filament separation device to separate the bamboo pieces into non-entangled filaments and using a rope forming device to twist the filaments into continuous rope-shaped bamboo filaments. An equivalent diameter of a main body of the bamboo filaments is 0.5 mm
Step 2, a step of feeding the rope-shaped bamboo filaments into a multiple refinement device which includes fifteen pairs of grooved rollers and also includes a microwave heating device and a cold water spraying device alternating between every two pairs of the grooved rollers by an automated delivery and buffer device to roll, heat, roll and cool repeatedly, namely an alternation of cold and hot treatments and a rolling process. A conveying speed is controlled based on that processing time of any section of the rope-shaped bamboo filaments is 45 minutes. Coarse rope-shaped bamboo fibres are obtained and an equivalent diameter of a main body of the fibres is 0.28 mm
The automated delivery and buffer device includes a plurality of pairs of grooved rollers and a buffer container.
Step 3, a step of feeding the coarse rope-shaped bamboo fibres to a strip-shaped constant-temperature fermentation pool by the automated delivery and buffer device and then outputting from another side of the fermentation pool by the automated delivery and buffer device. A bio-enzyme in the strip-shaped constant-temperature fermentation pool is a complex bio-enzyme composed of laccase and xylanase and has a ratio of 1:0.5. Parameters applied to the fermentation pool are controlled by: an enzyme concentration of bio-enzyme broth is 2 g per liter of water, a temperature of the bio-enzyme broth is 45° C., a pH value of the bio-enzyme broth is 4, and a dissolved oxygen concentration of the bio-enzyme broth is 5.4 mg/L. Any section of the rope-shaped bamboo fibres is fermented in the fermentation pool for 2 hours.
A conveyor belt is disposed in the strip-shaped constant-temperature fermentation pool and passes through an entire length of the fermentation pool for delivering the coarse rope-shaped bamboo fibres. The conveyor belt is submerged in fermentation broth and having an operation speed set according to a formula defined by v=l/t in which v represents a conveying speed, l represents an entire length of the fermentation pool, and t represents time required for fermentation. A liquid level detector is disposed in the fermentation pool. A plurality of detecting signal stations are disposed along a length direction for detecting temperatures, pH values and dissolved oxygen concentrations respectively, thereby controlling and adjusting each parameter instantly. The bio-enzyme broth should be replenished timely in order to keep a liquid level of the fermentation pool constant. The dissolved oxygen concentration is detected and controlled by a formula defined by DOf=(p/p0)*(477.8/(T+32.6)) in which p represents a local measured atmospheric pressure, p0 represents a standard atmospheric pressure, and T represents a temperature(° C).
Rope-shaped bamboo fibres are obtained and an equivalent diameter of a main body of the fibres is 0.20 mm.
Step 4, a step of feeding the rope-shaped bamboo fibres to a cleaning device by the automated delivery and buffer device, with the cleaning device including ten pairs of grooved rollers and a water spraying device disposed between every two pairs of the grooved rollers for repeated rolling, rubbing and cleaning to remove residual bio-enzyme and colloid adhered to the fibres and further refine, feeding the rope-shaped bamboo fibres to a drying device for a drying operation after rolling, then executing a process of spraying-type oiling after the drying operation. A conveying speed is controlled based on that processing time of any section of the rope-shaped bamboo fibres is 60 minutes. Rope-shaped bamboo fine fibres are obtained and an equivalent diameter of a main body of the fibres is 0.15 mm
Step 5, a step of feeding the thin rope-shaped bamboo fibres to an opening and carding device by the automated delivery and buffer device for smoothening and carding, thereby making bamboo fibres whose equivalent diameter of a main body is 0.08 mm for a textile unweaving material and packaging into a warehouse.
A third embodiment: processing bamboo fibres for a textile weaving material. Step 1, a step of dividing a fresh bamboo material into equal bamboo strips, removing outer skins, inner skins and nodes from the bamboo strips to make bamboo pieces, and using a filament separation device to separate the bamboo pieces into non-entangled filaments and using a rope forming device to twist the filaments into continuous rope-shaped bamboo filaments. An equivalent diameter of a main body of the bamboo filaments is 0.5 mm
Step 2, a step of feeding the rope-shaped bamboo filaments into a multiple refinement device which includes twenty pairs of grooved rollers and also includes a microwave heating device and a cold water spraying device alternating between every two pairs of the grooved rollers by an automated delivery and buffer device to roll, heat, roll and cool repeatedly, namely an alternation of cold and hot treatments and a rolling process. A conveying speed is controlled based on that processing time of any section of the rope-shaped bamboo filaments is 60 minutes. Coarse rope-shaped bamboo fibres are obtained and an equivalent diameter of a main body of the fibres is 0.25 mm.
The automated delivery and buffer device includes a plurality of pairs of grooved rollers and a buffer container.
Step 3, a step of feeding the coarse rope-shaped bamboo fibres to a strip-shaped constant-temperature fermentation pool by the automated delivery and buffer device and then outputting from another side of the fermentation pool by the automated delivery and buffer device. A bio-enzyme in the strip-shaped constant-temperature fermentation pool is a complex bio-enzyme composed of laccase and xylanase and has a ratio of 1:1. Parameters applied to the fermentation pool are controlled by an enzyme concentration of bio-enzyme broth is 4 g per liter of water, a temperature of the bio-enzyme broth is 65° C., a pH value of the bio-enzyme broth is 6, and a dissolved oxygen concentration of the bio-enzyme broth is 4.8 mg/L. Any section of the rope-shaped bamboo fibres is fermented in the fermentation pool for 4 hours.
A conveyor belt is disposed in the strip-shaped constant-temperature fermentation pool and passes through an entire length of the fermentation pool for delivering the coarse rope-shaped bamboo fibres. The conveyor belt is submerged in fermentation broth and having an operation speed set according to a formula defined by v=l/t in which v represents a conveying speed, l represents an entire length of the fermentation pool, and t represents time required for fermentation. A liquid level detector is disposed in the fermentation pool. A plurality of detecting signal stations are disposed along a length direction for detecting temperatures, pH values and dissolved oxygen concentrations respectively, thereby controlling and adjusting each parameter instantly. The bio-enzyme broth should be replenished timely in order to keep a liquid level of the fermentation pool constant. The dissolved oxygen concentration is detected and controlled by a formula defined by DOf=(p/p0)*(477.8/(T+32.6)) in which p represents a local measured atmospheric pressure, p0 represents a standard atmospheric pressure, and T represents a temperature(t).
Rope-shaped bamboo fibres are obtained and an equivalent diameter of a main body of the fibres is 0.18 mm.
Step 4, a step of feeding the rope-shaped bamboo fibres to a cleaning device by the automated delivery and buffer device, with the cleaning device including twenty pairs of grooved rollers and a water spraying device disposed between every two pairs of the grooved rollers for repeated rolling, rubbing and cleaning to remove residual bio-enzyme and colloid adhered to the fibres and further refine, feeding the rope-shaped bamboo fibres to a drying device for a drying operation after rolling, then executing a process of spraying-type oiling after the drying operation. A conveying speed is controlled based on that processing time of any section of the rope-shaped bamboo fibres is 90 minutes. Rope-shaped bamboo fine fibres are obtained and an equivalent diameter of a main body of the fibres is 0.12 mm.
Step 5, a step of feeding the thin rope-shaped bamboo fibres to an opening and carding device by the automated delivery and buffer device for smoothening and carding, thereby making bamboo fibres whose equivalent diameter of a main body is 0.06 mm for a textile weaving material and packaging into a warehouse.
The above are only the preferred embodiments of the invention and are not intended to limit a protection scope of the invention. Any modifications, equivalent substitutions, and improvements made within spirit and principle of the invention should be included within the protection scope of the invention.
Claims
1. A clean production method for bamboo fibres, comprising:
- step 1, a step of separating into filaments and fouling into ropes: dividing a fresh bamboo material into equal bamboo strips, removing outer skins, inner skins and nodes from said bamboo strips to make bamboo pieces, and using a bamboo filament processing device to separate said bamboo pieces into filaments and twist said filaments into rope-shaped bamboo filaments; and
- step 2, a step of microwave refining: feeding said rope-shaped bamboo filaments into a multiple refinement device by an automated delivery and buffer device to refine said bamboo filaments by an alternation of cold and hot treatments and processes of rolling and rubbing, and then feeding said bamboo filaments into a drying device, thereby obtaining coarse rope-shaped bamboo fibres for a composite material.
2. The method as claimed in claim 1, wherein said step 1 includes using a filament separation device to separate said bamboo pieces into non-entangled filaments and using a rope fouling device to twist said filaments into continuous rope-shaped bamboo filaments.
3. The method as claimed in claim 1, wherein in said step 2, said multiple refinement device includes ten to twenty pairs of grooved rollers and also includes a microwave heating device and a cold water spraying device alternating between every two pairs of said grooved rollers.
4. A clean production method for bamboo fibres, comprising:
- step 1, a step of separating into filaments and forming into ropes: dividing a fresh bamboo material into equal bamboo strips, removing outer skins, inner skins and nodes from said bamboo strips to make bamboo pieces, and using a bamboo filament processing device to separate said bamboo pieces into filaments and twist said filaments into rope-shaped bamboo filaments;
- step 2, a step of microwave refining: feeding said rope-shaped bamboo filaments into a multiple refinement device by an automated delivery and buffer device to refine said bamboo filaments by an alternation of cold and hot treatments and processes of rolling and rubbing, and then outputting coarse rope-shaped bamboo fibres;
- step 3, a step of biological degumming: feeding said coarse rope-shaped bamboo fibres to a strip-shaped constant-temperature bio-enzyme fermentation pool by said automated delivery and buffer device and then outputting rope-shaped bamboo fibres after fomenting;
- step 4, a step of cleaning and spraying oil: feeding said rope-shaped bamboo fibres to a cleaning device by said automated delivery and buffer device for repeated cleaning, rolling, and drying, with said cleaning device including a plurality of grooved rollers and a water spraying device, feeding said rope-shaped bamboo fibres to a drying device for a drying operation, then executing a process of spraying-type oiling after said drying operation, and thence outputting thin rope-shaped bamboo fibres; and
- step 5, a step of opening and carding: feeding said thin rope-shaped bamboo fibres to an opening and carding device by said automated delivery and buffer device for smoothening and carding, thereby making bamboo fibres for a textile material.
5. The method as claimed in claim 4, wherein said step 1 includes using a filament separation device to separate said bamboo pieces into non-entangled filaments and using a rope forming device to twist said filaments into continuous rope-shaped bamboo filaments.
6. The method as claimed in claim 4, wherein in said step 2, said multiple refinement device includes ten to twenty pairs of grooved rollers and also includes a microwave heating device and a cold water spraying device alternating between every two pairs of said grooved rollers.
7. The method as claimed in claim 4, wherein in said step 3, a bio-enzyme in said strip-shaped constant-temperature fermentation pool is a complex bio-enzyme composed of laccase and xylanase, having a ratio between 1:0.5 and 1:1, parameters applied to said fermentation pool being controlled by an enzyme concentration of bio-enzyme broth being between 2 g and 4 g per liter of water, a temperature of said bio-enzyme broth being between 45° C. and 65° C., a pH value of said bio-enzyme broth being between 4 and 6, and a dissolved oxygen concentration of said bio-enzyme broth being between 5.4 mg/L and 4.8 mg/L, any section of said rope-shaped bamboo fibres being fermented in said fomentation pool for 2 to 4 hours.
8. The method as claimed in claim 4, wherein a conveyor belt is disposed in said strip-shaped constant-temperature fermentation pool and passes through an entire length of said fermentation pool for delivering said coarse rope-shaped bamboo fibres, said conveyor belt being submerged in fermentation broth and having an operation speed set according to a formula defined by v=l/t in which v represents a conveying speed, l represents an entire length of said fermentation pool, and t represents time required for fermentation, a liquid level detector being disposed in said fomentation pool, and a plurality of detecting signal stations being disposed along a length direction for detecting temperatures, pH values and dissolved oxygen concentrations respectively, thereby controlling and adjusting each parameter instantly.
9. The method as claimed in claim 8, wherein said dissolved oxygen concentration is detected and controlled by a formula defined by DOf=(p/p0)*(477.8/(T+32.6)) in which p represents a local measured atmospheric pressure, p0 represents a standard atmospheric pressure, and T represents a temperature.
10. The method as claimed in claim 4, wherein said automated delivery and buffer device includes a plurality of pairs of grooved rollers and a buffer container.
Type: Application
Filed: Dec 29, 2016
Publication Date: Aug 29, 2019
Inventor: Yi Zhang (Fuzhou, Fujian)
Application Number: 16/348,500
