Protein based biopolymer foam product manufacture involves foaming aqueous suspension of protein based biopolymers and fine particle additives, mixing with fibers, forming and heating

摘要

An aqueous suspension is produced from protein-containing biopolymers and fine particle additives. The suspension is then foamed(3) and natural fibers mixed(4) into the foam. The mixture is then continuously shaped(10) and heat treated(13). The entire process runs continuously. Additional fluids miscible with water and having a boiling point not less than150[deg]C may be added to the suspension. Fine and coarse particle additives may be mixed into the suspension, the latter including elastomers. The aqueous suspension is foamed(3) under pressure. Heat treatment may be followed by additional processing of the foamed product, e.g. grinding(14) or scattering of seed onto the surface. An underlayer such as a woven fabric can be added to the underside of the shaped product and moved with the latter. Natural fibers are metered into the foam in a loose, individual condition and without destroying the foam structure. Heat treatment may be performed in either a conveyer belt drying unit at 110-240[deg]C for 1.5-3.5 hours or in an air flow dryer at similar temperatures for 15-50 minutes. The heat treatment occurs in a moist atmosphere with a slightly turbulent air flow. An independent claim is included for plant for manufacturing the shaped biopolymer foam product with a foaming unit comprising a suspension container(1), suspension pump(2) and foaming unit(3) and a fiber feeding system with metering unit(7) connected to a mixer(4). A foam shaping unit(10) forms material emerging from the mixer and is followed by drying(13) and post processing(20) units through which a conveyer(19) moves.