Fibrous plant stalk decorticator

Abstract

A fibrous pant stalk decorticator is disclosed. The decorticator includes a feeding device a breaker roll having a first plurality of blades, and a skutcher roll having a second plurality of blades. The skutcher is positioned such that the first and second pluralities of blades overlap. A plurality of air outlets pass through the blades and are configured to provided pressurized air to the fibrous plant stalk as it is passed through the decorticator.

What is claimed is: 
     
       1. A fibrous plant stalk decorticator comprising:
 a feeding device; 
 a breaker having a first plurality of blades; 
 a scutcher having a second plurality of blades, the scutcher positioned such that the first and second pluralities of blades overlap; and
 a plurality of air outlets passing through one or more blades and configured to provided pressurized air to a fibrous plant stalk as it is passed through the decorticator. 
 
 
     
     
       2. A decortication element for use in a fibrous plant stalk decorticator, the decortication element comprising:
 a wheel hub assembly comprising:
 an inner face, wherein the inner face is configured for attachment to a drive shaft; wherein the inner face comprises an interior air inlet for receiving a flow of air and directing the flow of air through the interior of the wheel hub assembly; 
 an outer face, wherein the outer face comprises an air outlet for receiving a flow of air from the interior of the wheel hub assembly and directing the flow of air out from the wheel hub assembly; and 
 one or more blades, wherein at least one blade is comprised of a blade air channel extending through the center of the blade and out through a top edge portion of the blade, wherein the blade air channel is configured to receive air from the wheel hub assembly and to direct it to a fibrous plant stalk as it is passed through the decorticator. 
 
 
     
     
       3. The system of claim 1, wherein the system further comprises:
 a feeding assembly, wherein the feeding assembly comprises an upper feed belt assembly and a lower feed belt assembly; wherein the upper feed belt assembly comprises an upper crushing roll; wherein the lower feed belt assembly comprises a lower crushing roll; wherein the upper and lower crushing rolls are vertically aligned and spaced to form a first intake gap; wherein the upper and lower crushing rolls are configured to rotate in opposite directions;   wherein the upper and lower crushing rolls are configured to compress plant material inserted into the first intake gap and to expel the plant material in the form of a fibrous mat of compressed material;   a feed table, wherein the feed table comprises a top surface and a feed table edge;   a gripping feed roll, wherein the gripping feed roll is configured to frictionally engage with the fibrous mat as it is expelled from the first intake gap; wherein the gripping feed roll is configured to propel the fibrous mat over the feed table edge; wherein the gripping feed roll is configured to rotate in the same direction as upper crushing roll;   an upper breaking roll, wherein the upper breaking roll comprises a first plurality of blades extending from an outer hub; wherein the upper breaking roll is mechanically engaged with an upper shaft; wherein the upper shaft is configured to rotate the upper breaking roll at a first speed in the same direction as the upper crushing roll;   a lower scutching roll, wherein the lower scutching roll comprises a second plurality of blades extending from an outer hub; wherein the lower scutching roll is mechanically engaged with a lower shaft; wherein the lower shaft is configured to rotate the lower scutching roll at a second speed in a second direction; wherein the second speed is faster than the first speed; and   a guide assembly, wherein the guide assembly extends between the upper crushing roll and the feed table edge; further wherein the guide assembly is positioned and configured to prevent lateral movement of the stalks past the ends of the upper crushing roll and the feed table;   wherein the orbital paths of the first and second plurality of blades intermesh during rotation;   wherein at least one of the air outlets comprises a blade air channel within at least a first surface of the at least one of the first or second plurality of blades.    
     
     
       4. The system of claim 3, wherein the feed table edge comprises a rounded edge with micro-combing grooves.  
     
     
       5. The system of claim 3, wherein the width of the scutching and breaking rolls exceeds the width of the feed element by more than 0.5 inches on either side.  
     
     
       6. The system of claim 5, wherein the upper breaking roll is configured to bend the fibrous mat down at a first location over the feed table edge in a first direction to an angle of between 60-120 degrees.  
     
     
       7. The system of claim 6, wherein the lower scutching roll is positioned so the fibrous mat is bent at a second location as the outer edge of a scutcher blade intermeshes into the space between the first breaker blade and the feed table edge.  
     
     
       8. The system of claim 7, wherein the feed table has an adjustable angle of inclination.  
     
     
       9. The system of claim 8, wherein the feed table edge is inversely contoured.  
     
     
       10. The system of claim 9, wherein the distance of clearance between the orbital circumference of the upper breaking roll and the edge of the feed table is adjustable within a range of 5-44 millimeters.  
     
     
       11. The system of claim 3, wherein the feed table comprises a conveyor.  
     
     
       12. The system of claim 1, wherein at least one of the air outlets comprises a blade air channel within at least a first surface of the at least one of the first or second plurality of blades.