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Title:
A METHOD FOR SYNTHESIZING A BUILDING MATERIAL
Document Type and Number:
WIPO Patent Application WO/2023/148533
Kind Code:
A1
Abstract:
A method (100) for synthesizing a building material is provided. The method includes melting, by a melting unit, a first material to obtain a first molten material. The first material includes at least one of low density polyethylene, high density polyethylene, and polyethylene terephthalate. The low density polyethylene, the high density polyethylene, and the polyethylene terephthalate are adapted to be melted in temperature less than 125° celsius, 125° celsius, and 260° celsius respectively. The method also includes crushing, by a crusher, a second material to obtain a crushed material. The second material comprises textile industry sludge. The method further includes mixing, by a mixer, the first molten material and the crushed material in a predefined ratio to obtain a building material.

Inventors:
T RAGHUNATHAN (IN)
S SARAVANA PRIYA (IN)
Application Number:
PCT/IB2022/052698
Publication Date:
August 10, 2023
Filing Date:
March 24, 2022
Export Citation:
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Assignee:
T RAGHUNATHAN (IN)
S SARAVANA PRIYA (IN)
International Classes:
C08L23/06; B29B17/00; C08J11/00
Domestic Patent References:
WO1996002373A11996-02-01
WO2001032405A12001-05-10
WO2015044894A12015-04-02
Other References:
SHIRI NOEL DEEPAK, KAJAVA P VARUN, PAIS LLOYD, NAIK VIKHYAT M: "Processing of Waste Plastics into Building Materials Using a Plastic Extruder and Compression Testing of Plastic Bricks", JOURNAL OF MECHANICAL ENGINEERING AND AUTOMATION, vol. 5, no. 3B, 1 January 2015 (2015-01-01), pages 39 - 42, XP093084523, DOI: 10.5923/c.jmea.201502.08
Attorney, Agent or Firm:
SINGH NANDIYAL, Vidya Bhaskar (IN)
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Claims:
WE CLAIM: 1. A method (100) for synthesizing a building material comprising: melting, by a melting unit, a first material to obtain a first molten material, wherein the first material comprises at least one of low density polyethylene, high density polyethylene, and polyethylene terephthalate, wherein the low density polyethylene, the high density polyethylene, and the polyethylene terephthalate are adapted to be melted in temperature less than 125ocelsius, 125ocelsius, and 260ocelsius respectively; (110) crushing, by a crusher, a second material to obtain a crushed material, wherein the second material comprises textile industry sludge; (120) and mixing, by a mixer, the first molten material and the crushed material in a predefined ratio to obtain a building material. (130) 2. The method (100) as claimed in claim 1, wherein crushing the second material comprises crushing the second material to obtain particle size less than 4.75 milli meters. 3. The method (100) as claimed in claim 1, wherein mixing the first molten material and the crushed material to obtain the building material comprises mixing the first molten material and the crushed material by the predefined ratio comprising 20:80 or 30: 80. 4. The method (100) as claimed in claim 1, wherein controlling the temperature provided to the first material to prevent charring of the first material comprises controlling the temperature provided to the first material to prevent charring of the first material by a temperature controller. 5. The method (100) as claimed in claim 1, wherein molding the building materials into one or more structures comprises molding the building materials into one or more structures by one or more molds. 6. The method (100) as claimed in claim 1, wherein providing color to the building material comprises providing color to the building material by the masterbatch.

7. The method (100) as claimed in claim 1, wherein mixing the first molten material and the crushed material in the predefined ratio to obtain the building material comprises mixing the first molten material and the crushed material in the predefined ratio to obtain the building material by a solar powered mixer. 8. The method (100) as claimed in claim 1, wherein melting the first material to obtain the first molten material comprises melting the first material to obtain the first molten material by the melting unit comprising, a solar powered melting unit, a kerosene based melting unit, liquid petroleum gas based melting unit, and induction melting unit.

Description:
A METHOD FOR SYNTHESIZING A BUILDING MATERIAL EARLIEST PRIORITY DATE This Application claims priority from a Complete patent application filed in India having Patent Application No. 202241006122, filed on February 04, 2022, and titled “A METHOD FOR SYNTHESIZING A BUILDING MATERIAL”. FIELD OF INVENTION Embodiments of the present disclosure relate to the field of polymer compositions and more particularly to a method for synthesizing a building material. BACKGROUND Plastic is composed of polymers. The polymers may be formed from chains of carbon atoms, with or without attachment of oxygen, nitrogen, or sulphur atoms. The chains of the carbon atoms may be composed of repeating units such as monomers. Presence of strong molecular bonds between the monomers makes the plastic non-biodegradable. The non-biodegradable nature of the plastic is contributing to a menace of plastic pollution. Plastic pollution may be defined as an accumulation of objects and particles which made up of the plastic in earth. The plastic pollution may have several harmful effects. The harmful effects may include a threat to living beings, upsetting food chains, ground water pollution, land pollution and the like. Also, burning the plastic may produce toxic gases which may further cause air pollution. Moreover, by product obtained after burning the plastic is also non-biodegradable. Another waste material which is causing pollution is textile sludge. During dyeing process one quarter of the dye is being released into environment as textile sludge. The textile sludge may include heavy metals such as iron, copper, cadmium, zinc, chromium and the like. The heavy metals are capable of creating environmental pollution by circulating in the environment. Similar to the plastic, the sludge may produce toxic gases upon burning. Also, the textile sludge is not bio-degradable. Repurposing the plastic and the textile sludge maybe a possible solution to reduce harmful effects of the plastic and the textile sludge. Currently existing technologies are inefficient in repurposing the plastic and the textile sludge into a building material. Mixing of the plastic and the textile sludge with concrete may reduce strength of the cement concrete. Also, sulphates and chlorides present in the textile sludge may reduce binding and durability of the cement. Hence, there is a need for an improved method for synthesizing a building material to address the aforementioned issue(s). BRIEF DESCRIPTION In accordance with another embodiment of the present disclosure, a method for synthesizing a building material is provided. The method includes melting, by a melting unit, a first material to obtain a first molten material. The first material includes at least one of low density polyethylene, high density polyethylene, and polyethylene terephthalate. The low density polyethylene, the high density polyethylene, and the polyethylene terephthalate are adapted to be melted in temperature less than 125 o celsius, 125 o celsius, and 260 o celsius respectively. The method also includes crushing, by a crusher, a second material to obtain a crushed material. The second material comprises textile industry sludge. The method further includes mixing, by a mixer, the first molten material and the crushed material in a predefined ratio to obtain a building material. To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures. BRIEF DESCRIPTION OF THE DRAWINGS The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which: FIG.1 is a flow chart representing the steps involved in a method for synthesizing a building material in accordance with an embodiment of the present disclosure; and FIG.2 is a schematic representation of another embodiment of the method of FIG.1, depicting operational arrangement of a mixer in accordance with an embodiment of the present disclosure. Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein. DETAILED DESCRIPTION For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure. The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures, or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting. In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Embodiments of the present disclosure relate to a method for synthesizing a building material is provided. The method includes melting, by a melting unit, a first material to obtain a first molten material. The first material includes at least one of low density polyethylene, high density polyethylene, and polyethylene terephthalate. The low density polyethylene, the high density polyethylene, and the polyethylene terephthalate are adapted to be melted in temperature less than 125 o celsius, 125 o celsius, and 260 o celsius respectively. The method also includes crushing, by a crusher, a second material to obtain a crushed material. The second material comprises textile industry sludge. The method further includes mixing, by a mixer, the first molten material and the crushed material in a predefined ratio to obtain a building material. FIG. 1 is a flow chart representing the steps involved in a method (100) for synthesizing a building material in accordance with an embodiment of the present disclosure. The method (100) includes melting a first material to obtain a first molten material in step 110. In one embodiment, melting a first material to obtain a first molten material includes melting a first material to obtain a first molten material by a melting unit. The first material includes at least one of low density polyethylene, high density polyethylene, and polyethylene terephthalate. The low density polyethylene, the high density polyethylene, and the polyethylene terephthalate are adapted to be melted in temperature less than 125 o celsius, 125 o celsius, and 260 o celsius respectively. In some embodiments, controlling the temperature provided to the first material to prevent charring of the first material may include controlling the temperature provided to the first material to prevent charring of the first material by a temperature controller. In one embodiment, the temperature controller may include a thermostat. The method (100) also includes crushing a second material to obtain a crushed material. In one embodiment, crushing a second material to obtain a crushed material includes crushing a second material to obtain a crushed material by a crusher in step 120. The second material includes textile industry sludge. In some embodiments, the crusher may include, but not limited to, gyratory crushers, jaw crushers, hammermills, horizontal shaft impact crushers, sizers, roll crushers, cone crushers, feeder-breakers, and the like. In one embodiment, crushing the second material may include crushing the second material to obtain particle size less than 4.75 milli meters. In one embodiment, the crusher may include a sieve to filter out particles based on a predefined size. The method (100) further includes mixing the first molten material and the crushed material in a predefined ratio to obtain a building material in step 130. In a specific embodiment, the building material maybe a semi solid material which solidifies after a predefined time. In one embodiment, mixing the first molten material and the crushed material in a predefined ratio to obtain a building material includes mixing the first molten material and the crushed material in a predefined ratio to obtain a building material by a mixer. In one embodiment, mixing the first molten material and the crushed material to obtain the building material may include mixing the first molten material and the crushed material by the predefined ratio including 20:80 or 30: 80. Further, in some embodiments, molding the building materials into one or more structures may include molding the building materials into one or more structures by one or more molds. In a specific embodiment, providing color to the building material may include providing color to the building material by the masterbatch. In one embodiment, mixing the first molten material and the crushed material in the predefined ratio to obtain the building material may include mixing the first molten material and the crushed material in the predefined ratio to obtain the building material by a solar powered mixer. In some embodiments, melting the first material to obtain the first molten material may include melting the first material to obtain the first molten material by the melting unit comprising, a solar powered melting unit, a kerosene based melting unit, liquid petroleum gas based melting unit, and induction melting unit. FIG. 2 is a schematic representation of another embodiment of the method (100) of FIG.1, depicting operational arrangement of a mixer (130) in accordance with an embodiment of the present disclosure. In one embodiment, the melter or mixer (130) may include a container (140) for holding the first material and the second material. In such an embodiment, the container (140) may be composed of aluminum. In one embodiment, the container (140) may be heated by an oil bath (280) in a larger container (290) which is insulated by one or more materials (150). In such an embodiment, the one or more materials (150) may include glass wool, aluminum rock wool, mineral wool, natural wool, cotton, straw, cellulose, paper, polyurethane foam, polystyrene foam, polyester, soy foam foil, fiber glass and the like. Further, in some embodiments, the mixer (130) may include one or more mixer blades (160) coupled to a vertical shaft (170) of a prime mover (180) to mix the first material and the second material. In one embodiment, the prime mover (180) may include, but not limited to, an ac motor, a dc motor, an induction motor, a universal motor and the like. In such an embodiment, the prime mover (180) may be adapted to operate in low rotations per minute. In one embodiment, the prime mover (180) may be powered by one or more solar panels (190). In one embodiment, a heat transfer fluid (200) may be circulating around the container (140) through conduits (210) for imparting heat energy to the container (140) to melt the first material. Furthermore, in a specific embodiment, the heat transfer fluid (200) may include, at least one of a molten salt, liquid metal, oil, air, water and the like. In some embodiments, a solar thermal panel (220) may be providing heat energy to the heat transfer fluid (200). In detail, the heat transfer fluid (200) may receive energy from the solar thermal panel (220), when the heat transfer fluid (200) is circulating around the one or more solar thermal panel (220). In one embodiment, a storage tank (230) may be associated with the solar thermal panel (220) to act as a reservoir for the heat transfer fluid (200). A pump (240) may circulate the heat transfer fluid (200) to the container (140) through conduits (210) to provide heat to the container (140). In one embodiment, the pump (240) may be powered from the one or more solar panel (190). In one embodiment, the one or more solar panel (190) may include, mono crystalline solar panel, poly crystalline solar panel, amorphous solar panel and the like. Also, in some embodiments, the one or more solar (190) panel may be associated with a charge controller (250) to provide constant power to the prime mover (180) and the pump (240). In one embodiment, the mixer (130) may be associated with a temperature sensor (260) to provide control signals to the pump (240) to maintain temperature of the container (140) in a predefined limit. In such an embodiment, the temperature sensor (260) may include, but not limited to, a thermostat. In one embodiment, the conduit (210) may include an inlet for replenishing the heat transfer fluid. In some embodiments, the container (140) may include an outlet (270) to collect the building material Various embodiments of the method for synthesizing a building material described above enable various advantages. Combination of the first material and the second material provides durability, compressive strength and binding strength to the building material. The first material and the second material are cheap and readily available thereby making the building material cost effective. The building material is capable of molded into any desired shape by respective molds. Moreover, synthesizing the building material provides a way for fighting environmental pollution by repurposing the first material and the second material. It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof. While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.