BRICK FABRICATED FROM WASTE FRP

Abstract

A brick fabricated from a waste fiber-reinforced polymer (FRP) includes a main body. The main body is formed of a composite. The composition of the composite includes, in parts by weight, 1.0 part by weight of a plurality of furnace slag powders, 0.35 to 0.5 parts by weight of a plurality of glass fiber/polymer particles, 0.02 to 0.5 parts by weight of a plurality of glass powders, and 0.65 to 0.75 parts by weight of an alkali solution. The glass fibers/polymer particles are obtained by crushing the waste FRP. The glass powders are obtained by crushing a waste glass. The furnace slag powders, the glass fiber/polymer particles, the glass powders and the alkali solution are uniformly mixed into a mixture. The mixture is poured into a mold, and then generates a polymerization reaction to form the main body.

Claims

1. A brick fabricated from a waste fiber-reinforced polymer (FRP), comprising: a main body, formed of a composite, the composite, in parts by weight, comprising: 1.0 part by weight of a plurality of furnace slag powders, 0.35 to 0.5 parts by weight of a plurality of glass fiber/polymer particles, wherein the glass fibers/polymer particles are obtained by crushing the waste FRP, 0.02 to 0.5 parts by weight of a plurality of glass powders, wherein the glass powders are obtained by crushing a waste glass, and 0.65 to 0.75 parts by weight of an alkali solution, wherein a concentration of the alkali solution ranges from 3.0M to 12M, the furnace slag powders, the glass fiber/polymer particles, the glass powders and the alkali solution are uniformly mixed into a mixture, the mixture is poured into a mold, and then generates a polymerization reaction to form the main body.

2. The brick of claim 1, wherein the main body has an average compressive strength equal to or larger than 40.0 MPa at 7 days of age.

3. The brick of claim 2, wherein the plurality of glass fiber/polymer particles comprise one selected from the group consisting of an epoxy resin, a phenolic resin and an unsaturated polyester resin.

4. The brick of claim 3, further comprising: a pattern layer, formed on a top surface of the main body by a transferring process.

5. A brick fabricated from a waste fiber-reinforced polymer (FRP), comprising: a main body, formed of a composite, the composite, in parts by weight, comprising: 1.0 part by weight of a plurality of cement, and 0.35 to 0.5 parts by weight of a plurality of glass fiber/polymer particles, wherein the glass fibers/polymer particles are obtained by crushing the waste FRP, the cement and the glass fiber/polymer particles are uniformly mixed into a mixture with a water-cement ratio, the mixture is poured into a mold, and then generates a solidification and hardening reaction to form the main body, the water-cement ratio is equal to or less than 0.6.

6. The brick of claim 5, further comprising: a pattern layer, formed on a top surface of the main body by a transferring process.

Description

BRIEF DESCRIPTION OF THE APPENDED DRAWINGS

[0019] FIG. 1 is a cross-sectional view of a brick fabricated from a waste FRP according to the preferred embodiment of the invention.

[0020] FIG. 2 is a photograph of the appearance of one example of the brick of the invention as the example of grass planting brick.

[0021] FIG. 3 is a photograph of the appearance of one example of the brick of the invention as a wall brick without a pattern layer.

[0022] FIG. 4 is a photograph of the appearance of one example of the brick according of the invention as a wall brick having a pattern layer presenting a quasi-marble pattern.

[0023] FIG. 5 is an appearance photograph of one example of the brick according of the invention as a wall brick having a pattern layer presenting a pseudo-granite pattern.

DETAILED DESCRIPTION OF THE INVENTION

[0024] Some preferred embodiments and practical applications of this present invention would be explained in the following paragraph, describing the characteristics, spirit, and advantages of the invention.

[0025] Referring to FIG. 1, FIG. 1 is a cross-sectional view of a brick 1 fabricated from a waste FRP according to the preferred embodiment of the invention.

[0026] As shown in FIG. 1, the brick 1, fabricated from the waste FRP, according to the preferred embodiment includes a main body 10. The main body 10 is formed of a composite.

[0027] The composition of the composite, in parts by weight, includes 1.0 part by weight of a plurality of furnace slag powders, 0.35 to 0.5 parts by weight of a plurality of glass fiber/polymer particles, 0.02 to 0.5 parts by weight of a plurality of glass powders, and 0.65 to 0.75 parts by weight of an alkali solution. The glass powders are obtained by crushing a waste glass.

[0028] The glass fibers/polymer particles are obtained by crushing the waste FRP. Taking printed circuit boards as an example, manufacturers generally use an insulating prepreg material composed of non-woven fabrics made from glass fibers and an epoxy resin, and then press it with copper foil to form a copper foil substrate for use. The rough composition of printed circuit boards includes 28 wt. % of resin, 42 wt. % of glass fiber and 30 wt. % of metal. According to the invention, if the waste of fiber-reinforced polymer products is a printed circuit board, the printed circuit board will be crushed first to recover valuable metals, and the remaining residue will be used as the raw material for the main body 10 of the brick 1 according to the invention—a plurality of glass fiber/polymer particles. It should be noted that the proportions of glass fiber and polymer in different waste FRP products are different, but the plurality of glass fibers/polymer particles obtained by crushing different waste FRP products can be used as raw materials for the main body 10 of the brick 1 according to the invention.

[0029] A concentration of the alkali solution ranges from 3.0M to 12M. In one embodiment, the alkali solution can be NaOH, KOH, or other alkali solution.

[0030] The furnace slag powders, the glass fiber/polymer particles, the glass powders and the alkali solution are uniformly mixed into a mixture. The mixture is poured into a mold, and then generates a polymerization reaction to form the main body 10 of the brick 1 according to the invention.

[0031] In practical applications, the brick 1 according to the invention can be used as a grass planting brick, a wall brick, a floor brick, an interlocking brick, or other common brick on the market.

[0032] In one embodiment, the main body 10 of the brick 1 according to the invention has an average compressive strength equal to or larger than 40.0 MPa at 7 days of age.

[0033] In one embodiment, the plurality of glass fiber/polymer particles can include an epoxy resin, a phenolic resin or an unsaturated polyester resin.

[0034] Also as shown in FIG. 1, a brick 1, fabricated from a waste FRP, according to another preferred embodiment includes a main body 10. The main body 10 is formed of a composite.

[0035] Different from the preferred embodiment aforesaid, in another preferred embodiment of the invention, the composition of the composite, in parts by weight, includes 1.0 part by weight of a plurality of cement and 0.35 to 0.5 parts by weight of a plurality of glass fiber/polymer particles. Similarly, the glass fibers/polymer particles are obtained by crushing the waste FRP. The cement and the glass fiber/polymer particles are uniformly mixed into a mixture with a water-cement ratio. The mixture is poured into a mold, and then generates a solidification and hardening reaction to form the main body 10 of the brick 1 according to the invention. The water-cement ratio is equal to or less than 0.6.

[0036] Also as shown in FIG. 1, further, the brick 1 according to the preferred embodiment of the invention also includes a pattern layer 12. The pattern layer 12 is formed on a top surface 100 of the main body 10by a transferring process. In one embodiment, the pattern layer 12 includes an inorganic pigment and a glaze base. The glaze base is sintered to form a glazed layer, and the sintering temperature of the glaze base is lower than the ignition point of the polymer in the plurality of glass fibers/polymer particles. The pattern layer 12 with the glazing layer has high Mohs hardness, and is fire resistant.

[0037] Referring to FIG. 2 to FIG. 5, FIG. 2 is a photograph of the appearance of one example of the brick 1 of the invention as the example of grass planting brick. FIG. 3 is a photograph of the appearance of one example of the brick 1 of the invention as a wall brick without a pattern layer 12. FIG. 4 is a photograph of the appearance of one example of the brick 1 according of the invention as a wall brick having a pattern layer 12 presenting a quasi-marble pattern. FIG. 5 is an appearance photograph of one example of the brick 1 according of the invention as a wall brick having a pattern layer 12 presenting a pseudo-granite pattern. Obviously, the brick 1 according to the invention can replace bricks made of natural stone.

[0038] The composite used to manufacture the main body of the brick according to the invention is poured in different compositional proportions into several test bodies with a diameter of 100 mm×a height of 200 mm in accordance with the CNS 1230 test standard. These test bodies are subjected to a compressive strength test.

[0039] These test bodies made of different compositional proportions of composites are all based on 1.0 part by weight of a plurality of furnace slag powders, are fixedly added with 0.7 parts by weight of an alkali solution and 0.03 parts by weight of a plurality of glass powders, and there are three added glass fiber/polymer particle ratios: 0.35 parts by weight, 0.4 parts by weight, and 0.5 parts by weight. The weight of the furnace slag powders, the weight of the glass fiber/polymer particles, and the concentration of the alkali solution of the above-mentioned test bodies are listed in Table 1. The above-mentioned test bodies at the age of 7 days are taken to carry out the compressive strength test, and the average compressive strengths of these test bodies obtained by the compressive strength test are also listed in Table 1. In contrast, other test bodies are respectively made of the weight of furnace slag powder: the weight of glass fiber/polymer particle as 1:1, and the weight of furnace slag powder: the weight of glass fiber/polymer particle: the weight of metakaolin as 1:0.85:0.5, and the average compressive strengths of these test bodies are also listed in Table 1.

[0040] The test results listed in Table 1 confirm that in contrast, the average compressive strengths of the test bodies, respectively made of the weight of furnace slag powder: the weight of glass fiber/polymer particle as 1:1, and the weight of furnace slag powder: the weight of glass fiber/polymer particle: the weight of metakaolin as 1:0.85:0.5, both are lower than 25 MPa.

[0041] The average compressive strengths of the test bodies made of different compositional proportions of composites capable of fabricating the main body of the brick according to the invention all are higher than 40.0 MPa.

[0042] It should be emphasized that according to the compressive strength specified in the floor tile standard CNS13295, the compressive strength of Class A floor brick is higher than 32 MPa. Obviously, the average compressive strengths of the test bodies made of different compositional proportions of composites capable of fabricating the main body of the brick according to the invention all exceeds the compressive strength of Class A floor brick specified in the floor tile standard CNS13295.

TABLE-US-00001 TABLE 1 average weight of the furnace slag concentration compressive powders:weight of the glass of alkali strength fiber/polymer particles solution (MPa) 1:0.35 4M 53.64 1:0.4 4M 50.41 1:0.5 4M 47.61 1:0.35 6M 56.53 1:0.4 6M 55.74 1:0.5 6M 53.27 1:1 6M 15.82 1:0.85:0.5 (metakaolin) 6M 23.80

[0043] Even, the brick according to the invention can replace the brick made of natural stone.

[0044] With the example and explanations above, the features and spirits of the invention will be hopefully well described. Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teaching of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.