CA2578768A1

CA2578768A1 - Improved method for the manufacture of a composition for producing partitions based on different materials, composition and partition thus obtained

Info

Publication number: CA2578768A1
Application number: CA002578768A
Authority: CA
Inventors: Jorge Antonio Hernandez-Escobedo
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-09-01
Filing date: 2005-09-01
Publication date: 2006-03-09
Also published as: RU2007106781A; CN101102973A; WO2006025720A1; KR20070048268A; MXPA04008452A; JP2008511436A

Abstract

The invention relates to a composition which is used to produce partitions, blocks, panels, etc. of any type and size, based on different materials such as, for example, recycled paper and card. The invention also relates to the partition produced and to the method used to produce the composition.
According to the invention, the partition obtained comprises an alternative low-cost construction material having the following characteristics, namely:
non combustibility, thermal and acoustic insulation, easy workability and rapid installation. In addition, the composition is highly resistant to compression stresses and can be used for walls and slabs in the construction of low-cost dwellings. The invention further relates to the method of manufacturing said composition and to the partition thus produced.

Description

IMPROVED METHOD FOR THE MANUFACTURE OF A COMPOSITION FOR
PRODUCING PARTITIONS BASED ON DIFFERENT MATERIALS, COMPOSITION AND PARTITION THUS OBTAINED

BACKGROUND OF THE INVENTION

This invention refers to a composition used to fabricate bricks from several materials, such as recycled paper and cardboard, bricks and the procedure to manufacture the compositions, the brick obtained is an alternative construction material of low cost, non-flammable, thermal insulator and acoustic, easy to handle and quickly installed, in addition to high resistance to compression stress and that may be used in walls and slabs in building low-cost housing and the procedure to manufacture this composition; to date the procedures followed to manufacture compositions to fabricate bricks or blocks use a basic material and have included the use of diverse inorganic matters such as sand, clay, pea gravel, fine gravel, cement, that through several compression processes, high temperatures or vibrations, are poured into various molds to obtain the desired form; currently, there is no known composition and a procedure to manufacture or fabricate compositions based on recycled paper and cardboard to fabricate light and heavy bricks for the construction of walls in building low-cost housing and the procedure to manufacture this composition that exclusively consists of a synergist combination of organic material based on recycled paper and cardboard, such as carbon paper, newspaper, cardboard, bristol board and all kind of bond paper.

DESCRIPTION OF THE INVENTION

This invention refers to a composition used to fabricate bricks based on recycled paper and cardboard, bricks and the procedure followed to produce the composition, bricks used in building walls and construction of low-cost housing, the composition of this invention exclusively consists of all kind of paper found in trash dumps as waste, as for example, carbon paper, newspaper, cardboard, bristol board and all kind of bond paper, combined with clay and cements this combination surprisingly provides a cohesive effect with improved resistance and a low cost, the paper and cardboard used are one of the existing contaminants, because once placed in open-air trash dumps, to date there has been no manner of adequately recycling them, the composition of this invention is formed by all kind of paper and cardboard in a percentage of 10% to 95%, preferably 93%, clay in a proportion of 0.1% to 4%
preferably 1.4%, cement in a percentage of 2% to 10%, preferably 5.6%, all of which must be adjusted up to 100%, the cement is selected among those available in the market, preferably gray cement; additionally, the clay used is clay available in the market, preferably white clay or any kind of activated carbon and a procedure for the manufacture or fabrication of compositions based on recycled paper and cardboard, that consists of the following steps: A) collect the raw material which consists of all kind of paper found in trash dumps, selected from carbon paper, newspaper, cardboard, bristol board and all kind of bond paper in a percentage of 10% to 95%, preferably 93%; B) once the raw material has been collected, it is cut up in a same size, varying from 0.5 to 3 inches (1.27 cm to 7.62 cm), preferably 1 inch (2.54 cm), in such manner that it can be easily handled; C) the raw material cut up is placed in a container with water and left for about 2 to 3 hours in order that the raw material release the cellulose until it forms a thick viscous consistency; D) pass the thick and viscous raw material through some rollers to withdraw the maximum amount of water and dampness; E) place the raw material in a mixer rotating slowly for about 7 to 15 minutes, the mixing process must continue until a damp sandy consistency is obtained; F) then clay is added in a proportion of 0.1%

to 4%, preferably 1.4%, and cement in a percentage of 2%

to 10%, preferably 5.6%, according to resistance requirements of the brick and how it will be used, these components must be mixed slowly to avoid that clots form because of disintegration of the raw material; G) once everything has been mixed, the material obtained is transported on a band to a bin from which it is poured into the molds to form the brick; H) on every brick mold apply compacting pressure of approximately 15 to 40 tons, preferably 15 to 20 tons for about 20 minutes to one hour 30 minutes, according to the kind of brick required, light or heavy, during this pressing process empty spaces will be eliminated that may contain air; in addition, this elimination of air enables the brick to be more resistant to fire; I) dry and cure the brick with air or steam.

In the composition, the clay works as a purifier and retardant for a good mix of all the components, the mixing process of all the components must be low to avoid that clots and bubbles form caused by disintegration of the raw material.

Once the bricks have been compacted, the product obtained is placed on a wood platform to be transported to a drying area, which is a roofed space to avoid direct rays of the sun, helping the brick mixture to cure and set, avoiding rapid loss of dampness, which deteriorates the resistance properties of the brick, the drying process may also be carried out by directly applying steam to the brick, which causes it to cure or set faster.

Each brick obtained through this composition and procedure has the following characteristics:

- Easy transportation - Is quickly placed - Resistant to concentrated sulfuric acid - Resistance to the impact of a 45 caliber bullet - Does not require skilled hand labor - Reduces the cost of the structure, foundations, walls and slabs up to 50%

- Increases productivity of hand labor - Does not require false work - Low weight per brick (1.0 Kg per piece) - Specific 951 to 960 Kg/m (3) weight - 30% waterproof - Non-combustible type (B), when exposed to direct fire, does not burn easily, it carbonizes without letting off flames and avoids that fire be transmitted to the next rooms of the construction because of its compression (15 to 40 tons, preferably 15 to 20 tons) - High acoustic insulation (15% decibels) - High thermal insulation (11.7 Kcal/Hr/degrees C
- In outside walls it supports support winds of up to 400 Km/hr - Waterproof (50 - 60%) - Is lighter in inside walls (up to 1:200 Kgs) - Good resistance to flexion (3.32 Kg/cm (2) - There is no limitation to the architectural project, as even a saw may be used to cut the walls.

- The bricks may be assembled because of their structure.

EXAMPLES.
Example 1 The following composition is prepared following the procedure described above, the composition includes 300 grams of cement, 5 kilograms of raw material consisting of all kind of paper found in trash dumps, such as carbon paper, newspaper, cardboard, bristol board and all kind of bond paper, 75 grams of clay, a light brick is formed measuring 7x-14x28 centimeters, with a weight of 1.2 Kg, the preferably ratio for a light brick is 1:1:1.

Example 2 The same procedure as in the previous example, but using a composition that includes 600 300 grams of cement, 5 kilograms of raw material consisting of all kind of paper available in trash dumps, as for example, carbon paper, newspaper, cardboard, bristol board and all kind of bond paper, 75 grams of clay, a heavy brick is formed measuring 7x14x28 centimeters with a weight of 1.2 to 3 Kg., the preferable ratio of the components for weight is 1:2:3, once the mixing process has been completed, the composition is deposited in the mold with the desired form and is compacted at a 35 ton pressure;
additionally, once outside the molds, the fresh brick will pass on to the drying process, either outside or by steam.

Table 1 below shows several materials based on which the brick can be manufactured. Some of these materials correspond to patent applications that are being filed simultaneously to this one.

Table 1 Sample Materials Used to Produce the Bricks.

1 Wood shavings, granulated styrene, clay, sand and type 1 cement.

2 Plastic, granulated styrene, clay, sand and type 1 cement.

3 Plastic sand, granulated styrene, wood shavings and type 1 cement.

4 Silica, granulated styrene and sawdust.

5 Newspaper, cardboard, clay, sand, wood shavings and type 1 cement.

6 Styrene, gasoline, clay and sand.

7 Granulated styrene, clay, wood shavings, type 1 cement.

8 Newspaper.

9 Lampblack, clay, sand, plastic sand, type 1 cement.

10 Sugarcane molasses, plastic sand, clay, sand and type 1 cement.

11 Sawdust, small white seashells and white cement.

Table 2 below shows the results obtained from tests applied to various bricks fabricated with materials from table 1 above.

Table 2 Sampl Width Thickne Length Area Weigh Load Stres Weigh e cro s s Cm cm2 t Kg s t No cm Kg Kg/cm Gr/cm 1 14.0 7.3 30.2 422. 2.491 5200 12.3 1.45 2 13.5 6.7 28.8 388. 2.685 6650 17.1 1.29 3 13.7 5.3 28.0 383. 2.077 1430 37.3 0.96 4 10.4 6.4 20.6 214. 1.537 8050 37.6 1.21 10.4 6.2 20.8 216. 1.960 2572 118.9 1.46 6 10.3 3.9 20.4 210. 1.119 1480 70.4 1.41 7 10.4 5.1 20.5 213. 1.209 1172 55.0 1.16 8 8.2 11.9 18.8 154. 0.414 2700 17.5 0.63 9 10.4 6.0 20.5 213. 1.426 1067 50.1 1.13 10.4 6.2 20.5 213. 1.905 6650 31.2 1-45 11 Irregul Irregul Irregul 477. 6.583 2680 56.1 2.17 ar ar ar 5 0 Note: Stress obtained through compression tests.
This invention must not be considered limited to the particular examples described above, but must be understood to cover all aspects of the invention, clearly as observed in the attached claims. Several modifications, equivalent processes, as also, numerous compositions and procedures to which this invention may be applicable and shall be easy and clear for experts in the art toward which this invention is focused, when revising the specification.

I record evidence that to date, the best method which the applicant knows in order to put into practice the above-mentioned invention, is the one that results clear from this description of the invention.

Having described the above invention, the content of the following claims are claimed as property:

Claims

1. A procedure to prepare a composition based on recycled paper and cardboard used to fabricate bricks, features for comprising the following steps:

A) collect the raw material consisting of all kind of paper found in trash dumps, selected from carbon paper, newspaper, cardboard, bristol board and all kind of bond paper in a 10% to 9% percentage, preferably 93%;
B) once the raw material has been collected, it is cut up in a same size, varying from 0.5 to 3 inches (1.27 cm to 7.62 cm), preferably 1 inch (2.54 cm), so that it may be easily handled; C) the raw material cut up is placed in a container with water and left for about 2 to 3 hours in order that the raw material release the cellulose until it forms a thick viscous consistency; D) pass the thick and viscous raw material through some rollers to withdraw the maximum amount of water and dampness; E) place the raw material in a mixer rotating slowly for about 7 to 15 minutes, the mixing process must continue until a damp sandy consistency is obtained; F) then clay is added in a proportion of 0.1%
to 4%, preferably 1.4%, and cement in a percentage of 2%
to 10%, preferably 5.6%, according to the resistance requirements of the brick and how it will be used, these components must be mixed slowly to avoid that clots form because of disintegration of the raw material; G) once everything has been mixed, the material obtained is transported on a band to a bin from which it is poured into the molds to form the brick; H) on every brick mold apply a compacting pressure of approximately 15 to 40 tons, preferably 15 to 20 tons for about 20 minutes to one hour 30 minutes, according to the kind of brick required, light or heavy, during this pressing process empty spaces will be eliminated that may contain air; in addition, this elimination of air enables the brick to be more resistant to fire; I) dry and cure the brick with air or steam.

2. The method according to claim 1, featured because the clement is selected from among those available in the market, preferably gray cement.

3. The method according to claim 1, featured because the clay is selected from that available in the market, preferably white clay or any kind of activated carbon.

4. The method according to claim 1, because the brick may be light or heavy measuring 7×-1-×-28 centimeters, compacted at pressure of 35 tons.

5. A composition based on recycled paper and cardboard in order to fabricate bricks, featured because it includes all kind of recycled paper and cardboard in a percentage of 10% to 95%, preferably 93%, clay in a 0.1% to 4% proportion, preferably 1.4%, cement in a percentage of 2% to 10%, preferably 5.6%, all of this must be adjusted up to 100%.

6. A composition based on paper and cardboard according to claim 5, featured because the cement is selected from those available in the market, preferably gray cement.

7. A composition based on paper and cardboard according to claim 5, featured because the paper is selected from all kind of paper from trash dumps, as for example, carbon paper, newspaper, cardboard, bristol wood, and all kind of bond paper.

8. The use of a composition based on recycled paper and cardboard of claim 5 in order to fabricate light and heavy bricks for building walls.