A NOVEL COMPOSITION FOR MANUFACTURING PLASTIC COMPOSITES AND A PROCESS THEREOF

Abstract

The present invention provides particular a novel composition for manufacturing plastic composites and a process thereof. Said invention provides a composition and a process utilizes any or all kind of plastic waste in manufacturing composites and thereby is economical and environment friendly. It utilizes any or all kind of plastic wastes includes road waste, soft & hard form of plastic waste. Moreover, it eliminates the use of cement and utilizes plastic wastes in manufacturing composites; therefore is environment friendly. Said present compositions utilizes plastic waste in manufacturing light weight composites that are highly stable with increased strength, shelf life and durability. Said composition is fire resistant with increased strength withstanding heavy load.

Claims

1-10. (canceled)

11. A fire resistant composition for manufacturing plastic composites, utilizing non segregated plastic waste and industrial wastes as raw materials, wherein said composition for medium load with the strength in the range of 33 N/mm.sup.2-45 N/mm.sup.2 comprises: Composite A, Composite B, Composite C, in the ratio of 0-90%:10-70%:0-80% respectively; wherein said composite A consists of sand or silica and aggregates or quarry dust, construction & demolition waste, said composite B consists of plastic wastes and copolymer; said composite C consists of fly ash, ceramic waste and additives.

12. The composition for manufacturing plastic composites according to claim 11, wherein said sand or silica in Composite A is in the range of 40 to 100% and said aggregates or quarry dust is in the range of 0 to 60%.

13. The composition for manufacturing plastic composites according to claim 11 wherein the particle size of said sand or silica in Composite A is in the range of 2 mm to 15 mm.

14. The composition for manufacturing plastic composites according to claim 11, wherein the particle size of said aggregates or quarry dust in Composite A is in range of 1 mm to 25 mm.

15. The composition for manufacturing plastic composites according to claim 11, wherein said plastic waste in Composite B is in the range of 85-100% and said copolymers is in the range of 0-15%.

16. The composition for manufacturing plastic composites according claim 11, wherein said fly ash in Composite C is in the range of 20 to 100%, said ceramic waste in the range of 0 to 80% and said additives is in the range of 0 to 15%.

17. A fire resistant composition for manufacturing plastic composites, utilizing non segregated plastic waste and industrial wastes as raw materials; wherein said composition for heavy load with the strength in the range of 50 N/mm.sup.2-75 N/mm.sup.2 comprises: Composite A, Composite B, Composite C, said composite A, composite B and composite C is in the ratio of 40-65%:57-30%:3.5-5% respectively.

18. A fire resistant composition for manufacturing plastic composites, utilizing non segregated plastic waste and industrial wastes as raw materials; wherein said composition for light load with the strength in the range of 25 N/mm.sup.2-31 N/mm.sup.2: Composite A, Composite B, Composite C, said composite A, composite B and composite C is in the ratio of 70-54%:28-40%:2-3%.

19. A process for manufacturing plastic composites according to claim 11, wherein said process reduces manufacturing time by 10 times comprises steps: collecting of said composites A, B and C in said range; cleaning and de moisturizing Composite A at 100° C. then mixing of Composite C; shredding composite B in ranging from 5 to 15 mm; preparing mixture and mixing all the composites; feeding the mixture to customized heater with temperature in ranging from 160°-300° C.; moulding of said processed mixture and extracting composites; ambient curing of composites.

20. The composition for manufacturing plastic composites according to claim 12 wherein, the particle size of said sand or silica in Composite A is in the range of 2 mm to 15 mm.

21. The composition for manufacturing plastic composites according to claim 12, wherein, the particle size of said aggregates or quarry dust in Composite A is in range of 1 mm to 25 mm.

22. The composition for manufacturing plastic composites according to claim 13, wherein, the particle size of said aggregates or quarry dust in Composite A is in range of 1 mm to 25 mm.

Description

DETAILED DESCRIPTION OF INVENTION

[0044] An embodiment of the present invention provides a novel composition for manufacturing the plastic composites and a process thereof. Said invention utilizes any or all kind of plastic waste in manufacturing composites and thereby is economical and environment friendly. Wherein any or all kind of plastic wastes includes road waste, soft & hard form of plastic waste. The present invention utilizes plastic waste in manufacturing light weight composites that are highly stable with increased strength, shelf life and durability. Said composition is fire resistant with increased strength withstanding heavy load. The present process for manufacturing said lightweight yet strengthened and durable composites from plastic wastes eliminates the process of segregating the plastic waste raw material in turn eliminating the need of heavy machinery required by the conventional processes to segregate plastic wastes. Present process is less time consuming and is energy as well as cost efficient. Also, said process eliminates the generation of effluent and carbon emission being environment friendly.

[0045] The present invention utilizes any or all kind of plastic & industrial wastes as raw materials to manufacture composites.

[0046] Wherein

[0047] Said novel composition for manufacturing the composites, comprises of: [0048] Composite A [0049] Composite B [0050] Composite C

[0051] Said composite A, composite B and composite C is in the ratio of 0-90%:10-70%:0-80% respectively.

[0052] Wherein;

[0053] Said composite A consists of sand or silica and aggregates or quarry dust wherein said sand or silica comprises of but does not limits to the use of fine grain, sand waste and foundry sand. Said sand or silica is in the range of 40 to 100%. The particle size of said sand or silica is in the range of 2 mm to 15 mm. Said aggregates or quarry dust is in the range of 0 to 60%. The particle size of said aggregates or quarry dust is in range of 1 mm to 25 mm.

[0054] Said composite B consist of plastic wastes and copolymers. The present invention eliminates the need of segregating the plastic wastes and thereby utilizing any or all kind of plastic waste raw material in the same form in which it is received. Wherein the plastic waste used in the present composition is the plastic waste that utilizes varied plastics not limiting to the use of PET (Polyethyleneterephthalate), HDPE (High density polyethylene), LDPE (Low density polyethylene), PP (polypropelyne), polystyrene, Water bottles, Bags, Jars, Drums, poly sack, Toys, PVC cooling sheets, HM bags, bottles, Industrial, plastic bags, Articles, Films, Articles (cup), MLP (Multi-layer plastic) laminated, Aluminium content plastic, Soft plastics and mixture of them. The plastic waste in the present composition is therefore non segregated plastic waste saving the time, energy and cost of the entire process. Said plastic waste is in the range of 85-100%. Said copolymers utilizes varied polymers not limiting to the use of ethylene and propylene. Said copolymers is in the range of 0-15%.

[0055] Said composite C consist of fly ash, ceramic waste and additives. Said fly ash is in the range of 20 to 100%. Said ceramic waste consists of but does not limiting to the use of ceramic waste; wherein said ceramic waste is in the range of 0 to 80%. Said additives consists of but does not limiting to the use of Aluminum hydroxide, polyester, PVC, Huntite (Mg.sub.3Ca(Co.sub.3).sub.4), magnesium hydroxide, ethyl-vinyl acetate ((C.sub.2H.sub.4)n(C.sub.4H.sub.6O.sub.2)n) and combination of thereof. Said additives in the range of 0 to 15%.

[0056] Another embodiment of the present invention provides a novel composition to manufacture plastic composites that varies in accordance with its strength, durability, thickness and usage. Wherein in order to withstand the heavy load the strength of the manufactured composite is in the range of 50 N/mm.sup.2 to 75 N/mm.sup.2; whereas the thickness of the composite varies in the range Of 45 mm to 60 mm. Said composite withstanding the heavy load comprises of: [0057] Composite A [0058] Composite B [0059] Composite C

[0060] Said composite A, composite B and composite C is in the ratio of 40-65%:57-30%:3.5-5% respectively.

[0061] Yet further embodiment of the present invention provides the composition to withstand the light load. Wherein in order to withstand the light load the strength of the manufactured composite is in the range of 25 N/mm.sup.2-31 N/mm.sup.2; whereas the thickness of the composite varies in the range of 20 mm to 30 mm. Said composite withstanding the light load comprises of: [0062] Composite A [0063] Composite B [0064] Composite C

[0065] Said composite A, composite B and composite C is in the ratio of 70-54%:28-40%:2-3%.

[0066] The process for manufacturing the novel plastic composites eliminating the effluent generation, hazardous chemicals generation and carbon emission involves the steps described herein below:

Step. 1: Collecting of Composites:

[0067] Collecting of said composites A, B and C, which includes sand or silica, aggregates or quarry dust, plastic wastes, copolymer, fly ash, ceramic waste and various additives.

Step 2: Cleaning and De Moisturizing Composite A:

[0068] Cleaning of composite a utilizing sand mesh wire and employing the sand granules of size ranging from 1 to 5 mm for use in the present composition. Followed by de moisturizing the cleaned sand by heating in upto 100° C. removing the moisture content. Mixing of fly ash of Composite C in the dried sand.

Step 3: Shredding, Washing and Drying Composite B:

[0069] Shredding of said composite B into the flakes ranging from 5 to 15 mm utilizing shredder machine. Said flakes are washed in order to remove impurities and other contaminants and are dried. Mixing of said plastic flakes and co polymers in a mixer.

Step 4: Preparing Mixture and Mixing all the Composites.

[0070] Mixing and blending of composite A, B and C within said ratio into the blender

Step. 5: Feeding the Mixture to Customized Heater

[0071] The mixture obtained in step 4 is feed and processed into the customized heater with temperature ranging 160°-300° centigrade keeping it in continuous drive at 10-30 RPM mixture which prepares and homogenize the material. Said mixture prepare the bonding between particles or resins which provide semi solid material.

Step 6: Moulding of Said Processed Mixture and Extracting Composites

[0072] The semi-solid mixture obtained from step 5 is subjected into the die casting mould extracting the composite applying hydraulic pressure.

Step. 7: Ambient Curing of Composites

[0073] Extracted composites are subjected to ambient curing for a period less than 1 hour. The step enables the present invention to cure the processed composite at ambient temperature eliminating the need of the employing the temperature to cure the composite, thus being energy efficient and environment friendly. Also the time required to cure the processed composite is substantially less as the range of various compositions in the said composites absorbs less water.

[0074] Present novel composition for manufacturing plastic composites and the process thereof is further utilized to manufacture varied plastic composites not limiting to, paving blocks, tiles, roof tiles and others by varying the composition in the given range. The composites manufactured by the present composition in the said specified range by the aforesaid process are resistance to freeze/thaw damage, shock, chemical damage, and thermal damage. It provides the composite with substantially increased shelf life, strength, substantially high strength to weight ratio and durability. Also the composite provided are resistant to external physical and chemical forces, ultraviolet radiation. Moreover the composites manufactured by the present composition and process are fire resistant, absorbs less water, are abrasive resistant, corrosion resistant. Said process for manufacturing composites eliminates the generation of effluent, hazardous gases and carbon emission which helps in pollution control at time of production and is therefore is highly efficient and environment friendly.

EXAMPLE

[0075] Said composite A, B and C are taken in said ratio with High strength, Medium strength and Low strength of the same. Said ratio indicates the compressive strength of material, water absorption, impact strength and flammability at different composition. Said below table illustrate and results in high compressive strength, minimum water absorption, pass the impact strength and provide resistance to fire as shown in below table:

TABLE-US-00001 Compressive Water Impact Composites Ratio % strength absorption strength Flammability High Composite A 57-30 50-75 0.2% Pass Non- strength Composite B 40-65 N/mm.sup.2 flammable Composite C 3.5-5   Medium Composite A 70-54 33-45 0.2% Pass Non- strength Composite B 28-40 N/mm.sup.2 flammable) Composite C 2-3 Low Composite A 20-27 25-31 0.25% Pass Non- strength Composite B 80-70 N/mm.sup.2 flammable Composite C 0-2

[0076] Therefore from above table, the present invention (P) provide composites manufactured by the present composition in the said specified range by the aforesaid process are resistance to freeze/thaw damage, shock, chemical damage, and thermal damage. It provides the composite with substantially increased shelf life, strength, substantially high strength to weight ratio and durability and therefore is highly efficient and environment friendly.

COMPARISON OF PRIOR ART AND PRESENT INVENTION

[0077] The typical prior art and the present invention are hereby compared in the below table to clearly bring out the technical differences between the prior art and the present invention.

[0078] A comparison is done between the prior art and of the present invention through the values of various parameters and its impact. This clearly depicts the disadvantages of the prior arts systems; thereby establishing the need for the present invention.

TABLE-US-00002 Description Prior Art Present composition Size 200 × 165 × 60 200 × 165 × 20 Weight 3.67 kilogram 1.5 kilogram Thickness 60 mm 20 mm Compressive Strength 30 MPa 30 MPa Heat resistance — Up to 150° C. Water absorption <6% 1.033% Stability — Deformation starts after 150° C. Compressive load 30 N/mm.sup.2 30 N/mm.sup.2 Melting temperature — Melting starts at 180° C. Curing time 3 to 15 days — Setting time 10 hours 1.5 hours Bonding material Cement Waste plastic Burning rate — Zero Flammability — No flames

[0079] From the above table, it is conclude that half weight and dimension of the present invention (P) provides equal compressive strength and the manufacturing time, and also reduces manufacturing time by 10 times which thereby decreases the manufacturing cost. Thus the present invention (P) provides the composite with substantially increased shelf life, strength, substantially high strength to weight ratio and durability and therefore is highly efficient and environment friendly.

Advantages of Present Invention

[0080] The present invention eliminates the use of harmful cement in manufacturing composites yet provides composites with increased strength and stability.

[0081] It utilizes the non-segregated plastic waste thereby eliminates the process of treating and segregating plastic waste that involves use of huge machinery that requires more energy input and man power. Therefore it is energy efficient, cost efficient, user friendly and environment friendly.

[0082] The manufacturing time required by the present process is substantially decreased.

[0083] Provides composites that are light in weight yet are highly stable. This further facilitates the transportation of the composites reducing the man power in handling said composites.

[0084] It substantially decreases the use of sand/minerals and therefore is environment friendly.

[0085] It provide the novel composition for manufacturing plastic composites and its process which provide the resistance to flammability and burning of the composites.

[0086] It uses industrial waste as a filler material therefore reduces their dumping into landfills and provides their afterlife use also.

[0087] It provides a novel composition for manufacturing plastic composite and process wherein the process use less water absorption rate.

[0088] It provides a novel composition for manufacturing plastic composite and process that is resistance to physical and chemical forces, corrosion resistance, chemical resistance and shock resistance.

[0089] Eliminates the generation of effluent during the process of manufacturing composites.

[0090] Eliminates the generation of hazardous gases during the process of manufacturing composites.

[0091] Unlike the conventional techniques the present invention does not require water for manufacturing the composites and thus saves water and is therefore efficient and environment friendly.