A WALL TILE WITH POROUS COMPOSITE

FIELD OF THE INVENTION

The present invention provides porous composite for the manufacturing of wall tile. It also provides the process for making said porous composite.

BACKGROUND OF THE INVENTION

We spend majorly of our time living in spaces surrounded by bordering walls usually covered with chemical paint or tiles of various types. It is a minimum expectation that where we spend more time in the area it should be pollution free, heat-insulated to control the room temperature in all seasons as well as it should be sound insulated also. Most importantly opting to products that are produced through polluting process always contribute to degrading nature. Some products like chemical paints generate harmful and toxic fumes after usage for several weeks or rather months which affects the user at major level and the environment in micro level, however the aspect that across the world a large number of chemical paints being opted makes it a serious concern whether the fumes that exit a living space might possibly cause an after effect to the environment in near future.

As stated by Environmental Protection Agency (EPA), the effects of evaporating paint are far stronger indoors than out. The (EPA) estimates that indoor volatile organic compounds (VOCs) are normally two to five times higher than outdoor levels. During activities like stripping paint, indoor levels can be 1,000 times the outdoor levels. Some VOCs are harmless, even in a confined space like a home. Others are potentially lethal carcinogens. Most of the off-gassing of interior paint takes place in the early days after painting but the paint can continue emitting VOCs for years, posing an ongoing threat to health. For someone who makes the mistake of applying an exterior paint to an interior surface, the potentially dangerous offgassing can continue for far longer. According to the EPA, some of the health dangers of VOC exposure include:

Irritation of the eyes, nose, and throat Headaches

» Organ damage

» Allergic skin reactions

" Fatigue

Nausea and/or vomiting

Visual disorders

» Impaired memory

» Some compounds are suspected or known to cause cancer

At present the products available in form of tile that apply or cover wall are such as foam-based tiles, ceramic, porcelain, stone, metal, or even glass material. The said tiles materials usually have some advantages and disadvantages. Advantages, having to be easy to maintain, water-resistant, and durable. Whereas, disadvantages having, not working as a heat insulator means being unable to maintain the room temperature constant in all seasons, and the manufacturing process contributes to air or water pollution directly or indirectly. The existing available alternates also require skilled labour to apply and needs time to install.

Living in a suburb with so many residents, always have complained about illness as stated in the list above and noise emanating from several sources. The disturbance has made it almost impossible to find total peace in our residence or our working area. Soundproofing of the working place can change the quality of life for the better. Reducing sound in leaving the area is the surest way to give maximum relaxation to the person who stays in that area. So, heat insulation and soundproofing working areas are being today’s utmost need.

The problem has motivated us to invent a solution that can replace polluting effect of chemical paints, Polyurethane, pvc foam-based tiles and is easier to install and replace than ceramic, glass tiles etc. The present porous composite is completely organic, recyclable, manufactured chemically free, is affordable and abundant, has very less or no effect on environment for production, application and maintenance, is easy to install and replace.

The present innovation comes up with a porous composite that can be shaped into desired form to function as furniture, indoor articles, flooring overlays or tiles that can be applied to cover new and existing wall surfaces that surround indoor spaces. The porous composite is made up of organic bio-friendly materials selected from bagasse, pulpwood, and wheat in combination with suitable filler(s) and binder that can absorb the sound to reduce reverb and is also able to dampen heat in the internal space of the working area.

The present invention is mitigating the above-mentioned problems. The present invention provides the porous composite for the manufacturing of wall tile to replace currently available said products that generate pollution, dampen heat transfer from external environment along with soundproofing advantageous.

SUMMARY OF THE INVENTION

Present invention, in first aspect provides a porous composite for a wall tile comprising, a) a base component selected from bagasse, pulpwood and wheat sheet; b) one or more filler component selected from a corn flour, a turmeric powder and a charcoal dust; and c) optionally a binder component.

In the second aspect, it provides a porous composite for a wall tile comprising bagasse and a binder component.

Various aspects of the present invention herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments herein will be better understood from the following detailed description with reference to the following drawings, Figure 1: shows wall tile A;

Figure 2: shows wall tile B;

Figure 3: shows wall tile C;

Figure 4: shows wall tile D;

Figure 5: shows wall tile E;

Figure 6: shows wall tile F

Figure 7: illustrating the setup of sound testing trials with and without applying the present wall tile(s)

Bill of material (BOM)

Figure 8: illustrating cross sectional view of testing wall applied with the present wall tile(s) Bill of material (BOM)

Figure 9: illustrating cross sectional view of thermal heat transfer test with and without applying the present wall tile(s)

Bill of material (BOM)

Figure 10: illustrating cube specimen made from five cement sheets and one side is kept open Bill of material (BOM)

Figure 11: illustrating one of the samples (DISC SA) made ready for testing; and

Figure 12: illustrating setup for particulate matter absorption test Bill of material (BOM)

DETAILED DESCRIPTION

The present invention provides pollution free, heat and sound insulating, cost- effective and environment friendly porous composite for the manufacturing of wall tile. It also provides the process for making said porous composite.

The present invention, in first aspect discloses a porous composite for a wall tile that comprises, a) a base component selected from bagasse, pulpwood and wheat sheet; b) one or more filler component selected from a corn flour, a turmeric powder and a charcoal dust; and c) optionally a binder component.

In the second aspect, it provides a porous composite of wall tile comprising bagasse and a binder component.

Preferably, the base component is selected from bagasse, pulpwood, and wheat sheet. The amount of the base component used in the composite is present in the range of 75 % to 97.5 % of the total composite weight of the wall tile.

The base component is present in the form of standard size of A3 sheet. These sheets are readily available in market to direct use. The sheets are made up from the residue of respective items. Bagasse sheet is made from sugarcane residue, the wheat sheets made from straws residue of wheat crops consisting whereas the pulpwood sheets are made up from mixed woods from forest. The chemical composition of each A3 sheet used in experiment is as follows.

The purpose of base component in porous composite is to act as the base mass that takes form of the desired shape and have the ability to generate porous structure to & conduct filler elements. The abilities of base component are such that it can be easily available in market, can be grinder easily along with water, binder and filler elements to develop a pulp. And as water evaporates, the base material shall not completely contract in-order to undergo generation of pores due to generation of vapour induced voids at micro dimension. The filler(s) components are suitable for use in the current invention. The filler that can be employed in this invention is one or more selected from com flour, a turmeric powder, and charcoal dust. The amount of said filler(s) used in the composite is present in the range of 0% to 25% of the total composite weight of the wall tile. The purpose of filler(s) component in porous composite is to smoothen the surface defects and fill larger voids, to add aesthetic value through color and colored patterns. Any element in solid state and of particle size between 10 - 500 micro meters can be ideally used as filler element. Some filler elements as well as certain proportioned combination of filler element can provide further functional value like silver nano particle that may be combined with an activated isotope of certain element that may absorb SO2 from air and create an oxidation layer thereby helping to reduce SO2 in air. Due to technological limitation the combination has not been experimented, however such an element specifically defined for absorbing other air pollutants can be used in form of filler in the proposed porous material in order to be applied in desire applications. The percentage of filler can be extended up to 25% by weight.

The binder component is suitable for use in the current invention. The amount of said binder used in the composite is present in the range of 0% to 5% of the total composite weight of the wall tile. The purpose of binder component in porous composite is to improve stiffness of final product and to improve binding of filler elements with base component. The type of binder used in making the material is casein glue which is a milk derived nontoxic glue organic in nature and produced chemical free. The criteria for selecting binder is a material with binding/ gluing property. An element which possesses such property must be produced without toxic process or chemical byproduct, shall be colourless and shall effect no change after mixing with pulp.

The binder component that can be suitably employed in this invention is casein glue. In a preferred embodiment of the present invention, the porous composite for a wall tile comprises, a) the base component is wheat sheet and is in the quantity ranging from 85% to 90% with respect to the total weight of said porous composite; and b) the filler component is com flour and is in the quantity ranging from 5% to 10% with respect to the total weight of said porous composite.

Preferably, the porous composite for a wall tile comprising wheat sheet as a base component is further coated with moisture resistant material.

The moisture resistant material is suitable for use in the current invention. The moisture resistant material is used in the quantity ranging from 3% to 7% with respect to the total weight of said porous composite for coating.

The moisture resistant material that can be suitably employed in this invention is liquid paraffin wax.

In one preferred embodiment of the present invention, the porous composite for a wall tile comprises, a) the base component is wheat sheet and is in the quantity ranging from 75% to 80% with respect to the total weight of said porous composite; b) the filler component is corn flour and turmeric powder and they are in the quantities of from 5% to 7% and from 3% to 5% respectively with respect to the total weight of said porous composite; and c) the binder component is casein glue and is in the quantity ranging from 4% to 5% with respect to the total weight of said porous composite.

Preferably, the porous composite for a wall tile comprising wheat sheet as a base component is further coated with moisture resistant material.

The moisture resistant material is suitable for use in the current invention. The moisture resistant material is used in the quantity ranging from 3% to 7% with respect to the total weight of said porous composite for coating.

The moisture resistant material that can be suitably employed in this invention is liquid paraffin wax.

In another preferred embodiment, the porous composite for a wall tile comprises, a) the base component is bagasse sheet and is in the quantity ranging from 80% to 85% with respect to the total weight of said porous composite; and b) the filler component is com flour and turmeric powder and they are in the quantities of from 5% to 7% and from 10% to 12% respectively with respect to the total weight of said porous composite.

In another preferred embodiment, the porous composite for a wall tile comprises, a) the base component is bagasse and is in the quantity ranging from 80% to 85% with respect to the total weight of said porous composite; b) the filler component is corn flour and charcoal dust and they are in the quantities of from 5% to 10% and from 10% to 15% respectively with respect to the total weight of said porous composite; and c) the binder component is casein glue and is in the quantity ranging from 2% to 5% with respect to the total weight of said porous composite.

In another preferred embodiment, the porous composite for a wall tile comprises, a) the base component is pulpwood and is in the quantity ranging from 80% to 85% with respect to the total weight of said porous composite; and b) the filler component is corn flour and charcoal dust and they are in the quantities of from 5% to 10% and from 10% to 15% respectively with respect to the total weight of said porous composite.

In another preferred embodiment, the process for preparation of porous composite for a wall tile comprises following steps: a) adding the base component to the water and boiling the obtained mixture for 30 minutes; b) draining the water from said boiled mixture to get the soft wet pulp of base component; c) grinding said soft wet pulp of base component to obtain a paste; d) adding one or more filler component and optionally the binder component to said paste and re-grinding them together to obtain a consistent mixture; e) compressing said consistent mixture till it is reduced to 50-60% of its volume; and f) drying said compressed consistent mixture to remove the water completely and obtain the porous composite for a wall tile.

Preferably, in step c) grinding of the soft wet pulp of base component to obtain a paste can be made by 750- watt mixer grinder with around 18000RPM for 20-25 minutes till it converts into the smooth paste; in step e) compressing of the consistent mixture obtained from step d) is can be made by pressure equivalent to 400-500KPA applied through a weight-force of 1500Kg evenly across the surface of dye plate gradually using screw press assembly to compress both male and female plates causing the pulp to compress; and

In step f) drying of the compressed consistent mixture obtain from step e) can be made by using the preheated oven at 140°C for 15 minutes to remove the water completely to obtain the dry porous composite for a wall tile.

The porous composite for a wall tile comprising wheat sheet as a base component is further coated with moisture resistant material.

The moisture resistant material is suitable for use in the current invention. The moisture resistant material is used in the quantity ranging from 3% to 7% with respect to the total weight of said porous composite for coating. The moisture resistant material that can be suitably employed in this invention is liquid paraffin wax.

According to the second aspect of the invention a porous composite for a wall tile comprising bagasse and a binder component. The said porous composite of wall tile comprises bagasse in the quantity ranging from 95 % to 97.5 % with respect to the total weight of said porous composite and the binder component being the casein glue in the quantity ranging from 2% to 5% with respect to the total weight of the said porous composite.

In a preferred embodiment, the process for preparation of porous composite for a wall tile comprises following steps: a) adding the base component to the water and boiling the obtained mixture for 30 minutes; b) draining the water from said boiled mixture to get the soft wet pulp of said base component; c) grinding died soft wet pulp of base component to obtain a paste; d) adding the binder component to said paste and re-grinding them together to obtain a consistent mixture; e) compressing said consistent mixture till it is reduced to 50-60% of its volume; and f) drying said compressed consistent mixture to remove the water completely and obtain the porous composite for a wall tile.

Preferably, in step c) grinding of the soft wet pulp of base component to obtain a paste can be made by 750- watt mixer grinder with around 18000RPM for 20-25 minutes till it converts into the smooth paste; in step e) compressing of the consistent mixture obtained from step d) is can be made by pressure equivalent to 400-500 KPA applied through a weight-force of 1500Kg evenly across the surface of dye plate gradually using screw press assembly to compress both male and female plates causing the pulp to compress; and

In step f) drying of the compressed consistent mixture obtain from step e) can be made by using the preheated oven at 140°C for 15 minutes to remove the water completely to obtain the dry porous composite for a wall tile. The porous composite for a wall tile comprising wheat sheet as a base component is further coated with moisture resistant material.

The base component and binder that can be suitably employed in this invention is bagasse and casein glue respectively.

The ingredients for use in this composition are judiciously selected and plays very important role to make suitable porous composite for making wall tile which gives sound and heat insulation effect in the close room wherein the presently invented wall tile(s) are installed.

Below is the table elaborating the sound insulation results achieved after installation of presently invented wall tile(s) with porous composite in the closed room.

Sound test experiment: for proving noise dampening in the room by use of proposed material in form of tiles

Location of tests - Virar India

Temperature of room before experiment = 30°C

Relative Humidity RH of room before experiment = 80%

Absolute Humidity 0 of room before experiment = 21 gm/kg of dry air

Specification of tiles used in the experiment:

Surface area of each Tile is 0.01951m Dimensions of Samples

For carrying out the tests, a vacant room of dimension 5feet L x 5feet W x 7feet H was chosen as space for carrying out trials.

The boundary walls are made of single brick line 4 inches width and covered with l/2inche construction cement plaster on both sides. The roof is made of standard cement sheet evenly layered over surface with thickness 10mm.

The floor made of 8 inches layer of concrete.

This testing space has one door of dimension 6ft x 2ft made of teak wood of 2 inches thickness. As shown in Figure 7 and 8, where side M is the wall side with door,

A sound generating device (portable speaker bluetooth operated 48 Watts Zebronics make) was kept on the surface O, at 2.5 feet distance from wall J and 2.5 feets from wall L and 1 feet away from wall K. It was placed in a direction to throw the sound on wall K.

A sound detecting device with sound level meter (Measurement range: 3O~13OdB, Resolution: 0.1 dB, Accuracy: ±1.5dB) was kept in line with the sound generating device, outside the room 1 feet away from wall K.

A trial was carried out to test the sound dampening effect of tile materials by first throwing the sound of 95db on uncovered wall K through said sound generator and measuring the sound received at sound detecting device. Then the same activity was repeated after applying Samples A, B, C, D, E, F tiles one by one. The tiles were glued on surface K using casein glue, inside the room. The results obtained for with and without tile coat are as below: Conclusion: Above data shows the porous composite(s) has ability to absorb the sound energy by at least 18.34% to 24.63%. Concluding that the inventive material helps in dampening the sound energy.

Heat transfer rate trials

To conduct the test, a cement fibre sheet (CS) of dimension Ifeet xl feet and 9mm thickness is mounted vertically on floor. The Operating space indicated as OS represents indoor space. The CS is placed between heat source (HA) and OS. The HA used in test is 2000W Room Fan Heater, HC-812T model which is directioned to blow hot air towards the CS as shown in figure 9, the HA is kept on floor 15 inches away from CS. The temperature sensor namely TS1 being positioned between CS and HA, installed on CS surface at center. Another temperature sensor TS2 is placed to measure the temperature of air in indoor space. The TS2 is positioned between OS and CS mounted on surface of CS at the center. The temperature sensors used are PT- 1000 RTD sensor, accurate up to 0.2Deg C and range of measurement being -40 to 300Deg C. Both the sensors TS1 and TS2 were mounted inline, where TS1 is placed near the CS surface facing the HA and TS2 is placed near the CS surface facing the OS. TS 1 and TS2 were placed at the center of the surfaces of CS.

The inventive material samples A, B, C, D, E, F were simultaneously applied on the CS by gluing them using Casein glue, on the surface facing the OS to check their heat dampening effect one by one.

Figure 9 depicts the setup of thermal heat transfer testing trials before applying the material (Top image) after applying the material (Bottom image)

The HA was switched on at 2000W mode to blow hot air over the CS surface. The hot air exiting the HA was blowed over the surface of CS where TS1 is installed. TS1 outputs signals of temperature reading and is tabulated below. The heat from hot air transfers across the CS where TS2 sensor outputs temperature signals, this data is tabulated below under two sections defined as with and without applying inventive material Samples A, B, C, D, E, F respectively (MS). The difference in

TS1 and TS2 when no sample material (MS) is applied shall indicate the ability of CS to dampen heat, this value is defined as Fl. Whereas difference of TS1 and TS2 when sample material MS is applied, shall indicate the ability of both CS and MS to dampen heat together, this value is defined as F2. The overall temperature reduction ability of the inventive sample(s) MS shall be F2 - (Average Fl).

Before starting the experiment, the ambient temperature during the tests was 30Deg

C and relative humidity was 85% RH

Following data was captured

Conclusion: In reference to data observed, we conclude that the porous composite(s) serve as temperature dampener and reduce heat transfer to result temperature reduction effect by 14.37-24.17%.

The porous composite has ability to dampening the temperature and reduce heat transfer to result temperature reduction effect by 14.37-24.17%.

Tests for air pollutants emission, volatile organic compounds (VOC): Volatile organic compounds have lower boiling point and tend to create fumes easily. These fumes typically consist of n-Butanol, Styrene, (1 -Methylethyl) benzene, Propylbenzene, Benzaldehyde, Ethyl- 1 -hexanol, Ethylhexyl acetate, 2- Ethylhexyl acrylate, Octyl propionate etc. which cause harmful effects when human skin is exposed and or breathed.

The objective is to simulate a prototype indoor room/space and compare between painted and inventive material samples applied with respect to amount of VOC emitted by each sample specimen.

To conduct the tests, 40 pieces of cement sheet were taken to form the walls of testing cube, the size of each cement sheet is 12 inches x 12 inches x 9mm. The 40 pieces of cement sheet are separated in a group of 8 each group consisting 5 pieces of cement sheet.

The first group (group 1) of 5 sheets were painted with single coat of “solar half’ shade plastic paint, the paint was applied on one side of each sheet.

The second group (group 2) of 5 sheets were painted with single coat of “orange spark” shade plastic paint, the paint was applied on one side of each sheet.

Group 3, group 4, group 5, group 6, group 7, group 8 were coated with single layer inventive sample material A, B, C, D, E, F respectively by gluing over one side of every sheet using casein glue.

After drying, the first group of paint coated sheets was assembled by joining edge to edge using silicon glue such that each sheet is perpendicular to adjoining sheet in order to form a cube with one side open. While assembling the cube, the coated surface of each group is chosen to form the internal surface and non-coated surface form the external surface. The cube now includes a bottom side SC5, three perpendicular sides SC2, SC3, SC4, one top side SCI and one side CSO. This open side represents window(s) and door(s) that cause air exchange across the room. Refer figure 10, illustrating cube specimen made from five cement sheets and one side is kept open. The first group of sheets (group 1) assembled into a cube with one side open is hereafter called as cube Pl. Similarly, the group 2, group 3, group 4, group 5, group 6, group 7, group 8 are assembled into cube P2, cube U, cube V, cube W, cube X, cube Y, cube Z.

The cube specimens with respect to samples applied are stated as follows

To determine the VOC content, a portable Total VOC measuring meter OC-904 PID Sensor (MVOC) is used. The figure 10 illustrates the setup arrangement of the tests Testing data

Each cube was placed over a bench of height 3 feet from ground, the cube samples were rested on bottom side defined as SC5. The test started on 17th January 2021 in the outdoor, the ambient temperature was measured 27 Deg C and Relative humidity was 80% RH during the test. The reading from MVOC was recorded every day at 12pm noon for continuous 11 days to understand the variance in VOC peak and saturation level. The MVOC meter was pre calibrated before collecting the data. The measuring tip of handheld MVOC meter was holded at center of cube through the open side of cube CSO.

Conclusion: As observed from data, VOCs evolved from chemical paint are found to be up to 1344PPB. Whereas as per the standards of OSHA occupational safety and health administration and EPA the safe limits are 0-300ppb. Referring to the trials the paint samples space A and space B emit up to 4.5 times the values indicated as safe limit and continues to be out of safe limit for 11 days. Whereas the test was carried for only single coat of sample 1 and sample 2 over surface area equivalent to 5*12*12 = 720sqin eq to 0.4645sqm only.

Referring to the tests it can be concluded that application of material can reduce pollution effect on indoor space if chemical-based paint is replaced by proposed inventive material. Also, the material in the form of tile is equally aesthetic when compared with chemical paint-based wall surface. The material can thus be concluded as a viable and pollution free alternative for chemical paints.

The porous composite for a wall tile wherein the porous composite(s) has ability to reduce the pollution effect on indoor space by replacing the chemical-based paint.

Testing of particulate matter absorption:

The test is carried out to compare inventive material with ceramic tiles & painted samples to determine the ability to arrest particulate matter contents from air. For carrying out tests, a cylindrical glass beaker of 100mm internal diameter and 200mm height 2mm thickness is used as enclosure. Within the enclosure the sample, particulate matter generating source and particulate monitoring sensor is placed. The source of particulate matter selected is an incense stick Loban Dhoop (10 grams incense) each of the incense burned for 2 hours continuously. A weighing device used was Glass enclosed MS Semi-Micro Balances of MT make with measuring capacity of 220gm and measurability of O.Olmg change in weight.

The testing enclosure included PM2.5 and PM10 micro analyser to measure amount of respective air pollutants. The analyser model is a OCMD BAM2000 model that measures PM2.5 & PM10 with maximum range of 3000pg/m3min and an accuracy of 1%. The weight change before and after particulate matter exposure would determine the amount of particulate matter absorbed or adsorbed.

To perform the tests, a disc of 100mm is cut out from a ceramic tile (DISC CT) of 4mm thickness as well as from each inventive material sample A, B, C, D, E, F to form 6 disc samples namely DISC SA, DISC SB, DISC SC, DISC SD, DISC SE, DISC SF. Sample of painted surface is obtained by cutting out a disc of 100mm diameter from a cement sheet of 9mm thickness and applying plastic paint of Shade solar half over all surfaces this sample is named as DISC SP. After drying, the painted sample DISC SP was cleansed from any dust or debris and pre-weighted in a glass enclosed digital scientific weighing scale. Similarly, disc samples DISC SA, DISC SB, DISC SC, DISC SD, DISC SE, DISC SF & DISC CT were brushed to remove any dust particles and were pre weighted.

Refer figure 11, illustrating one of the samples (DISC SA) made ready for testing.

The arrangement of testing setup requires the beaker to be positioned upside down over a bench surface (as per the figure 12). The particulate matter sensor is sticked to the cylinder wall inside the beaker using glue tape, the one used in setup was electrical insulation tape of 12mm width. The sensor is positioned at height of 150mm from the open end edge of the beaker. To perform the tests Following steps were performed and the testing samples was started with DISC SP and carried out in following sequence DISC CT, DISC SA, DISC SB, DISC SC, DISC SD, DISC SE, DISC SF. aa. The sample was glued inside the beaker on the flat glass surface with the help of a double sided tape. bb. The incense is ignited and mounted vertically on the bench. cc. The beaker attached with respective sample and particulate matter sensor was then immediately placed concentric over the burning incense stick. dd. After the burning is complete, the respective sample was removed out of the beaker and carefully detached from the cylinder and placed in the glass enclosed digital scientific weighing scale and the data was captured. ee. The process from aa to dd was repeated after cleaning the burnout ash residue over bench, by placing a fresh incense and gluing the next sample material in sequence. The tests were repeated until all samples were tested one by one.

The difference of weight shall be the amount of Particulate matter adsorbed or absorbed by respective specimen

Testing data

Location of tests - Virar India

Ambient Temperature= 29 °C

Relative Humidity RH = 85%

Absolute Humidity 0 = 21 gm/kg of dry air

Sample dimension 0.1m Diameter Refer figure no. 12, illustrating arrangement of setup required for particulate matter absorption test.

Test data table

Conclusion: As observed from test data, the Ceramic tile sample as well as Paint sample specimen depict very negligible change in weight when exposed to particulate matter contents, whereas the inventive material specimens depict considerable change in weight. Referring the data from table above, DISC SA & DISC SB show minimum and maximum change in weight after exposure to particulate matter.

If the peak sensor value of PM2.5 and PM10 for DISC SA & DISC SB is considered to evaluate total amount of particulate matter emitted for 2 hours, an amount equivalent to approximately 204mg of PM2.5 & 193mg of PM10 i.e 397mg mass of combined particulate matter is emitted. Whereas in comparison to the weight change data, Sample A & Sample B has been able to conduct up to 16% and 22% of the particulate matter mass respectively. Arresting the particulate matter within inventive material shall avoid particulate matter to suspend in the respective indoor space and thus shall avoid particulate matter from entering respiratory system of humans in respective space.

The porous composite for a wall tile, wherein the porous composite (s) has ability to arrest the particulate matter within themselves to avoid particulate matter to suspend in the respective indoor space and avoid particulate matter from entering respiratory system of humans in respective space.

Testing of recyclability of invented material (additional test)

The objective of this test is to check the recyclability aspect of proposed inventive material. The test Sample C is selected in this test. Following steps are performed

1. The sample C is cut into 1 inch pieces and put into a grinder along with 100ml water. The aim is to grind the paper mass for 20-25 minutes until a smooth paste is obtained.

2. The pulp once ready is transferred to a tray out from the grinding vessel.

3. The pulp mass is made to evenly lay over female press area and the male dye piece is placed over the pulp content. A pressure equivalent to 280-290 KPA was applied through a Weight-force of 1500Kg evenly across the surface of dye plate gradually using screw press assembly to compress both male and female plates causing the pulp to compress. The force is continually added until a point arrives where the pulp has compressed upto 50-60% of its volume. This compression rate can be tracked by simply marking the initial and final displacement of female plate before and after compression. The temperature during this compression process is constant, ambient initially and after the process.

4. After compression of pulp, let the free water completely drain from release pores of mold. At this point of time, the compressed tile still has 25-30% moisture and the tile is delicate

5. For complete drying, an oven is preheated at 140Deg C, the sample is kept inside the oven for 15 minutes at 140Deg C.

6. After complete drying, the tile acoustic resonance makes wood like resemblance when knocked on indicating that it is fairly dry enough to be used for.

7. The re-processed tile depicts physical properties exactly similar to actual sample C tile

Testing of re-processed tile in comparison of original tile

Conclusion: The test depicts the ability of proposed inventive material to be easily recycled. Due to limitations in access to machinery that involve recyclability test of comparative materials we have not performed the tests, however currently available products like Chemical paint, Ceramic wall tiles, PVC foam tiles no-where state recyclability of respective materials.

The porous composite for a wall tile wherein the porous composite(s) is recyclable.

The present wall tile(s) consist majority of a base material that can also support growth of genetically designed plants. Due to its porous nature, roots can well develop across the material and hence it can be possible to achieve vertical plantation in indoors with replaceable section tiles. Due to technological limitation, it is difficult to develop the end result but plants/creepers that survive in low ambient light, able to transpire, have surface ability to generate wax or hairy structures like silver birch, can emit illuminating effect through bioluminescence. These features when achieved in future can allow us to have a breathing wall material that naturally absorb CO2 and emit oxygen, the surface structures can enhance that ability of settling particulate matter, the illuminating bioluminescence can add lighting to the indoors.

The inventive material is proposed to be alternative to laminates, veneers etc. which are applied over wooden furniture for aesthetic purpose.

Example 1:

Wall tile A

The base component that is wheat A3 sheet (120gm) was added to the water (2 liter) and boiled the obtained mixture for 30 minutes. Drained the water from said boiled mixture to get the soft wet pulp of base component. The said soft wet pulp of base component grinded by 750 watt mixer grinder with around 18000RPM for 20-25 minutes to obtain a paste. The filler components that are corn flour (lOgm) and Turmeric (6gm) was added to the paste. The binder component casein glue (6gm) is also added to the said paste and re-grinding them together for 5mins. to obtain a consistent mixture. Compressed the said consistent mixture till it is reduced to 50-60% of its total initial volume by applying pressure equivalent to 400-500 KPA through a weight-force of 1500Kg evenly across the surface of dye plate using screw press assembly to compress both male and female plates to compressed the pulp. The said compressed pulp dried by using preheated oven at 140°C for 15 minutes to remove the water completely and obtained the dry porous composite for a wall tile A. The complete dried wall tile A coated with paraffin wax (lOgm) by standard spray gun.

Weight of wall tile A = 152gm

Length (L) X Width (W) X Thick (T) (in mm) = 130 x 130 x 8

Range of porosity 31-35%

Example 2:

Wall tile B

The base component that is bagasse A3 sheet (160gm) was added to the water (2 liter) and boiled the obtained mixture for 30 minutes. Drained the water from said boiled mixture to get the soft wet pulp of base component. The said soft wet pulp of base component grinded by 750 watt mixer grinder with around 18000RPM for 20-25 minutes to obtain a paste. The filler components that are corn flour (lOgm) and Turmeric (6gm) was added to the paste and re-grinding them together for 5 mins, to obtain a consistent mixture. Compressed the said consistent mixture till it is reduced to 50-60% of its total initial volume by applying pressure equivalent to 400-500 KPA through a weight-force of 1500Kg evenly across the surface of dye plate using screw press assembly to compress both male and female plates to compressed the pulp. The said compressed pulp dried by using preheated oven at 140°C for 15 minutes to remove the water completely and obtained the dry porous composite for a wall tile B.

Weight of wall tile B = 190gm

Length (L) X Width (W) X Thick (T) (in mm) = 130 xl30 x 15

Range of porosity = 27-28% Example 3:

Wall tile C

The base component that is pulpwood A3 sheet (120gm) was added to the water (2 liter) and boiled the obtained mixture for 30 minutes. Drained the water from said boiled mixture to get the soft wet pulp of base component. The said soft wet pulp of base component grinded by 750 watt mixer grinder with around 18000RPM for 20-25 minutes to obtain a paste. The filler components that are corn flour (lOgm) and charcoal dust (15gm) was added to the paste and re-grinding them together for 5 mins, to obtain a consistent mixture. Compressed the said consistent mixture till it is reduced to 50-60% of its total initial volume by applying pressure equivalent to 400-500 KPA through a weight-force of 1500Kg evenly across the surface of dye plate using screw press assembly to compress both male and female plates to compressed the pulp. The said compressed pulp dried by using preheated oven at 140°C for 15 minutes to remove the water completely and obtained the dry porous composite for a wall tile C.

Weight of wall tile C = 145gm

Length (L) X Width (W) X Thick (T) (in mm) = 130 xl30 x 8

Range of porosity = 28-30%

Example 4:

Wall tile D

The base component that is Bagasse A3 sheet (120gm) was added to the water (2 liter) and boiled the obtained mixture for 30 minutes. Drained the water from said boiled mixture to get the soft wet pulp of base component. The said soft wet pulp of base component grinded by 750 watt mixer grinder with around 18000RPM for 20-25 minutes to obtain a paste. The filler components that are corn flour (lOgm) and charcoal dust (15gm) was added to the paste. The binder component casein glue (3gm) is also added to the said paste and re-grinding them together for 5 mins, to obtain a consistent mixture Compressed the said consistent mixture till it is reduced to 50-70% of its total initial volume by applying pressure equivalent to 400-500 KPA through a weight-force of 1500Kg evenly across the surface of dye plate using screw press assembly to compress both male and female plates to compressed the pulp. The said compressed pulp dried by using preheated oven at 140°C for 15 minutes to remove the water completely and obtained the dry porous composite for a wall tile D.

Weight of wall tile D = 148gm

Length (L) X Width (W) X Thick (T) (in mm) = 130 xl30 x 8

Range of porosity = 23-25%

Example 5:

Wall tile E

The base component that is wheat A3 sheet (lOOgm) was added to the water (2 liter) and boiled the obtained mixture for 30 minutes. Drained the water from said boiled mixture to get the soft wet pulp of base component. The said soft wet pulp of base component grinded by 750 watt mixer grinder with around 18000RPM for 20-25 minutes to obtain a paste. The filler component that is com flour (lOgm) was added to the paste and re-grinding them together for 5mins. to obtained a consistent mixture. Compressed the said consistent mixture till it is reduced to 50- 70% of its total initial volume by applying pressure equivalent to 400-500 KPA through a weight-force of 1500Kg evenly across the surface of dye plate using screw press assembly to compress both male and female plates to compressed the pulp. The said compressed pulp dried by using preheated oven at 140°C for 15 minutes to remove the water completely and obtained the dry porous composite for a wall tile E. The complete dried wall tile E coated with paraffin wax (5gm) by standard spray gun.

Weight of wall tile E = 115gm

Length (L) X Width (W) X Thick (T) (in mm) = 130 xl30 x 6

Range of porosity = 29-31%

Example 6:

Wall tile F

The base component that is bagasse A3 sheet (120gm) was added to the water (2 liter) and boiled the obtained mixture for 30 minutes. Drained the water from said boiled mixture to get the soft wet pulp of base component. The said soft wet pulp of base component grinded by 750 watt mixer grinder with around 18000RPM for 20-25 minutes to obtain a paste. The binder component that is PVA (3gm) was added to the paste and re-grinding them together for 5 mins, to obtained a consistent mixture. Compressed the said consistent mixture till it is reduced to 50- 70% of its total initial volume by applying pressure equivalent to 400-500 KPA through a weight-force of 1500Kg evenly across the surface of dye plate using screw press assembly to compress both male and female plates to compressed the pulp. The said compressed pulp dried by using preheated oven at 140°C for 15 minutes to remove the water completely and obtained the dry porous composite for a wall tile F.

Weight of wall tile F = 123gm

Length (L) X Width (W) X Thick (T) (in mm) = 130 xl30 x 6

Range of porosity = 26-28%

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope.