TECHNICAL FIELD OF THE INVENTION

The present invention relates to a system and process for manufacturing tiles/blocks materials for construction purposes.

BACKGROUND OF THE INVENTION

Cement bricks, fly ash bricks, pavement blocks of cement, mud bricks are available in the market which are normally manufactured by mixing sand, cement, water and other ingredients followed by pouring in different moulds of required shapes and sizes. Blocks manufactured by such processes are costly and easily breakable.

There are several drawbacks of manufacturing tiles or blocks by above mentioned processes and raw materials. Raw materials such as stone, sand, clay, etc are obtained by digging the earth that causes soil erosion. Large quantity of water is needed for manufacturing, construction and utilization of the cement. Further, the kiln process may cause air pollution. Thus, soil, water, air, vegetation and human health are adversely affected by using the conventional processes for manufacturing bricks or tiles.

The current state of art includes the bricks or tiles manufactured by using specific waste plastics as additives to stone or asphalt or any solid waste like raw materials. It is required to have specific collection of the individual material or sort the desired material from the generally collected plastic waste. The process of collecting specific plastic or sorting the desired type from collected plastic adds to cost. Furthermore, also such efforts do little to solve the problem of utilization of vast unsorted, unsortable or unclassified bulk mixtures of plastic waste. Accordingly, there is a need of a process for manufacturing tiles or blocks using the waste material that overcomes above mentioned drawbacks. SUMMARY OF THE INVENTION

The present invention relates to a system and a process for manufacturing of tiles/blocks from waste plastics. The system includes a first conveyor, a second conveyor line, a mixing unit, a hot stock chute and a moulding station. The first conveyor line is used for conveying and processing of a first raw material. The first conveyor line includes a first feeder for delivering the processed first raw material. The second conveyor line is used for conveying and processing of a second raw material. The second conveyor line includes a second feeder for delivering the processed second raw material. The mixing unit is used for heating the processing of raw materials received from the first feeder and the second feeder thereby forming a hot mix stock. The mixing unit includes a burner for mixing and heating the processed raw materials from about 180 degrees to about 200 degrees. The hot stock chute is used for transferring the hot mix stock received from the mixing unit, the hot stock chute having a vibrating unit attached thereto. The molding station form converting hot mix stock to tiles/ blocks by application of pressure, wherein the pressure ranges from about 40 tones to about 50 tones. The present invention provides a process for manufacturing of tiles/blocks from waste plastics comprises. Initially, the first raw material is processed through a first conveyor line and the second raw material is processed through a second conveyor line. In next step, the first and second raw materials are mixed and heated with each other and other additives and fillers in a mixing unit at a predefined temperature thereby obtaining a hot mix stock. In the next step, the hot mix stock is transferred to a multi station hydraulic moulding machine through a hot stock chute using the vibrating unit. In the next step, the hot mix stock is molded in the multi station hydraulic moulding machine under a predefined hydraulic pressure thereby forming blocks/tiles BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a system and process for manufacturing tiles/blocks from stone aggregates and waste plastics in accordance with a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiments.

All materials used herein were commercially purchased as described herein or prepared from commercially purchased materials as described herein.

Although specific terms are used in the following description for sake of clarity, these terms are intended to refer only to particular structure of the invention selected for illustration in the drawings and are not intended to define or limit the scope of the invention.

References in the specification to "preferred embodiment" means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.

In general aspect, the present invention provides a process and a system for manufacturing tiles/blocks from stone aggregates and waste plastics.

The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers in brackets indicate corresponding parts in the various figures. Referring to FIG. 1 a system for manufacturing tiles/blocks from waste plastic (herein after "the system (100)") in accordance with an embodiment of the present invention is shown. The system (100) includes a plurality of conveyor lines, a mixing unit (138), a hot stock chute (140), a moulding machine (142), mould ejector (148), delivery conveyor (144), a pallet stacker (150) and a packing area (152).

In accordance with this one embodiment, the plurality of conveyor lines include a first conveyor line (I) and a second conveyor line (II). However, it is understood here that the number of conveyor lines may vary in alternative embodiments of the present invention. The first conveyor line (I) includes a bucket elevator (104) connected to a rotary sieve (106). The rotary sieve (106) includes a first conveyor (108) attached thereto at first end of the first conveyor (108). Second end of the first conveyor (108) connected to a first storage yard (110). The first storage yard (110) includes a bucket elevator (112) that conveys material from the first storage yard (110) to a heating unit (116). The heating unit (116) includes at least one burner (114) positioned therein. The heating unit (116) has a first feeder (118) attached thereto. In accordance with an embodiment of the present invention, the first conveyor line (I) is used for conveying and processing of a first raw material i.e. stone aggregates (102). However it is understood here that any other raw material may be conveyed and processed through the second conveyor line (II) in alternative embodiment of the present invention.

In this one embodiment, the stone aggregates (102) are passed through the bucket elevator (104) to a rotary sieve (106) for sieving. The rotary sieve (106) converts stone aggregates (102) into dust fine particle (DF). In this one embodiment, the size of the obtained clean stone aggregates ranges from 4 mm to 13.5 mm. The sieved stones are moved through the first conveyor (108) to the storage yard (110). The sieved stones are further conveyed to the rotary heating unit input hopper (116) for heating. In this one embodiment, the heating unit (116) includes a burner (114) that heats the sieved stones by an open flame thereby converting dust particles into hot clean stone aggregates (102). The hot clean stone aggregates are then transferred to the first feeder (118).

In accordance with this one embodiment of the present invention, the second conveyor line (II) includes a second conveyor (122) that passes sequentially through a rotary washer (124), a rotary dryer (126), a second storage yard (128), a feed shredder (130) and a third storage yard (132). The third storage yard (132) includes a bucket elevator (134) that carries a material from the third storage yard to a second feeder (136).

In accordance with this one embodiment, the second conveyor line (II) conveys and processes a second raw material i. e. waste plastic (120). However it is understood here that any other raw material may be conveyed and processed through the second conveyor line (II) in alternative embodiment of the present invention.

The waste plastic (120) includes waste plastic bottles or other plastic goods such as carry bags, cups, thermocoles, multi and mono layered waste plastics, plastic film packaging materials of thickness ranges from 2 mm to 4mm. The waste plastics used in present invention works a binder. PET bottles are used as filler that are added at the mixing stage of two raw materials in the mixing unit (138).

The waste plastic (120) is sorted and passed through the second conveyor (122) to the rotary washer (124). The rotary washer is equipped with water flushed in (WI) in the rotary for washing and cleaning of the sorted waste plastics (120) and excess water is flushed out (WO). The cleaned waste plastic is transferred into the rotary dryer (126) through the second conveyor (122) for drying. In this one embodiment, the washed plastic is dried by air drying technique. The air dried sorted waste plastic is further transferred to the second storage yard (128) and then send to a feed shredder (130) through the second conveyor (122) for shredding of the air dried sorted waste plastic. In this one embodiment, the feed shredder includes three rotary knives and two stationery knives placed in a predefined configuration. The shredded sorted waste plastic is further send to the third storage yard (132) and further transfer to the second feeder (136) through the bucket elevator (134).

In this one embodiment, the first feeder (118) and the second feeder (136) are connected to the mixing unit (138). The hot clean stone aggregates and the shredded plastic are fed into the mixing unit (138) through the first feeder (118) and the second feeder (136) respectively. In this one embodiment, a proportion of mixture second raw material is 40% to the weight of the first raw material. The hot stone aggregates and the obtained shredded waste plastics are mixed together along with fillers and other additives in the mixing unit (138) under a predefined temperature to obtain a hot mix stock. The hot mix stock is transferred to the molding machine (142) through a hot stock chute (140). The hot mix stock is subjected to a predefined pressure by using prefixed hydraulic pressure thereby forming mould of blocks/tiles (146) of a predefined size. The mould of blocks/tiles (146) are transferred are ejected to a delivery conveyor (144) for curing and settling of the blocks/tiles. The mould of blocks/tiles (146) are further delivered to the mould ejector (148), stacked on the pallet stacker (150) and are transported to a packing area (152) thereafter.

In this one embodiment, molding of the hot mix stock is carried out in the multi station hydraulic moulding machine (142). The multi station hydraulic machine (142) includes a plurality of moulds of predefined size placed in a rotary table (Not Shown). The hot mix stock is poured from the hot stock chute (140) into the moulds (146) of desired shape and size with a vibrating unit. In next step, the hot mix stock is subjected to a predefined hydraulic pressure forming pressed blocks/tiles. In this one embodiment, the hydraulic pressure used for pressing the hot mix stock into the moulds ranges from 40 to about 80 tones. In the last step, the pressed blocks/tiles are allowed to get dried and cool and further subjected to forced air cooling for a predefined time. In this one embodiment, the tiles/ blocks are allowed to cool from about 15 minutes to about 30 minutes. It is understood here that the cooling techniques and time required for cooling and drying may vary in alternative embodiments of the present invention. It is understood here that the blocks/tiles may be dipped into a suitable color, to produce a colored block/or polished smoothly using a granite polishing machine.

The present invention provides a process for manufacturing tiles/blocks from waste plastics comprises. Initially, the first raw material is processed through a first conveyor line (I) and the second raw material is processed through a second conveyor line (II). In next step, the first and second raw materials are mixed and heated with each other and other additives and fillers in a mixing unit (138) at a predefined temperature thereby obtaining a hot mix stock. The maximum temperature of the mixing unit is 250 °C. In the next step, the hot mix stock is transferred to a molding machine (142) through a hot stock chute (140) using the vibrating unit (Not Shown). In the next step, the hot mix stock is molded in the multi station hydraulic molding machine (142) under a predefined hydraulic pressure thereby forming blocks/tiles (146). In this one embodiment of the present invention, processing of the second raw material includes the steps of: In first step, the waste plastic materials are sorted and passed to the rotary washer (124) through the second conveyor (122). In the next step, the sorted waste plastic raw material is washed in the rotary washer (124). The washed and cleaned sorted waste plastic is transferred to the rotary dryer (126) through the second conveyor (122). In this step, the washed sorted waste plastic is air dried in the rotary dryer (126). In this one embodiment, the plastic is washed by water. However, it is understood here that some cleansing agent may added to the water as per the requirement. In the next step, the air dried sorted waste plastic is transferred to the feed shredder (130) through the second conveyor (122) to obtain shredded clean and sorted waste plastic of a predefined size. In this one embodiment, the size of shredded plastic ranges from about 2 mm to about 4 mm.

The blocks/tiles as manufactured using the method in accordance with an embodiment of the present invention have high compression strength, flexural strength malleability and ductility. In accordance with the present invention, the conveyors belts, mixing units, elevators are driven by geared motors. However, it is understood here that some other power mechanism may be used in alternative embodiments of the present invention. EXAMPLES

Only a few examples and implementations are disclosed. Variations, modifications, and enhancements to the described examples and implementations and other implementations can be made based on what is disclosed.

Examples are set forth herein below and are illustrative of different amounts and types of reactants and reaction conditions that can be utilized in practicing the disclosure. It will be apparent, however, that the disclosure can be practiced with other amounts and types of reactants and reaction conditions than those used in the examples, and the resulting devices various different properties and uses in accordance with the disclosure above and as pointed out hereinafter.

During mixing step the predefined quantity of obtained hot clean stone aggregates used is approximately 4 kg and the predefined quantity of shredded clean and sorted waste plastics used is 1.2 kg to 1.6 kg. The quantity depends upon the size of the obtained tile/block. For l x l foot block requires 4 kg of stone aggregate and 1.2 kg to 1.6 kg of shredded waste plastics.

The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching.

The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the present invention.