ES2364059B1 - PROCEDURE FOR THE MANUFACTURE OF PLATES FOR CONSTRUCTIONS MADE FROM WASTE, AS WELL AS PLATES MADE. - Google Patents

Abstract

Procedure for the manufacture of plates for construction made from waste, as well as plates made. # Procedure of manufacture of plates for construction made from waste and which are likely to be used for thermal and acoustic insulation in the sectors of the construction and urban furniture, where non-hazardous waste is used as the main raw material, coming from various sectors, such as carpeting, foams, plastics, rubber, etc. and wherein said process basically comprises the steps of reception (1), storage (2) and adaptation (3) of the materials, mixing (5) with adhesives and other additives (6), pressing (7), demolding (8) , cooling and drying of the plates and final storage (10) for shipment.

Description

Procedure for the manufacture of construction plates made from waste, as well as plates made.

Technical sector

This invention generally concerns the field of manufacturing of plates for thermal and acoustic insulation in works and construction from recycled material, understood as such plates, panels, acoustic panels, insulating panels, quick boards, protective boards, flooring, ceilings, etc.

State of the art

Different types of acoustic plates are known to reduce the transmission of road sound, among which we cite the following patent numbers: US 3630310, from plastic foam, US 3656576 that uses fi bers and US 4094379 that uses a mixture of materials (plastic foam, fibers, rubber, etc.)

Also, processes for the manufacture of acoustic plates from recycled rubber tires are also known. These procedures are limiting in terms of the waste to be processed; These processes are only valid for a single type of very specific waste.

On the other hand, the processing of tires involves separating the steel and textile filaments present in the residual tire, which makes the process to purify the material to be processed more expensive.

On the other hand, the plates obtained with any of the procedures mentioned in the previous paragraphs propose to combine different raw materials: residual tires and cork, taking advantage of the properties that the latter material provides. This implies that the plates have been made using residual materials and new materials, which means an increase in manufacturing costs and the exploitation of new resources.

From the analysis of the state of the art it is concluded that there is currently no plate manufacturing process using waste mixtures as raw material.

On the other hand, the present invention patent has the particularity of using only as raw material, residual materials, and which are also waste that today has a low or no recycling potential, which would mean its disposal in landfill or incinerator.

Description of the invention

The invention relates to a plate manufacturing process for the construction and urban furniture sectors, in which non-hazardous waste is used as the main raw material, as well as the manufactured plates themselves.

The waste object of the process of invention, come from various sectors, therefore, they are very numerous and of various kinds, such as carpet, foams, plastics, rubber, etc.

They can be mixed and impure, but as a minimum requirement, the waste to be processed must meet the following conditions: constant production, homogeneity and absence of hazardous materials (toxic, corrosive, etc.).

Through the use of the techniques of this invention, acoustic panels with various applications can be manufactured, among others: acoustic screen in road infrastructure (roads, train tracks, etc.), industrial acoustics, acoustic insulation in buildings, etc.

On the other hand, the processing of tires involves separating the steel and textile filaments present in the residual tire, which makes the process to purify the material to be processed more expensive.

Brief description of the fi gures

To complete the description that is being made and in order to help a better understanding of the characteristics of the invention, a set of drawings is attached as an integral part thereof, with an illustrative character and not limiting the following has been represented:

Figure 1 represents a flow chart of the process of manufacturing plates for construction from waste.

Detailed description of a preferred mode of the invention

This Invention Patent, as expressed in the statement of this specification, refers to the process of manufacturing plates for construction made from waste. This process is basically composed of the following operations shown in Figure 1. -Reception of materials (1) -Storage in reception tank (2) -Primary disposal of materials (3) -Storage and reception of adhesives (4) - Mixed (5) -Adctivation of adhesives, flame retardants and catalysts (6) -Pressing -Vapor injection (7) -Demolition (8) -Transport and evacuation of plates (9) -Storage for expedition (10)

Next, these operations characteristic of the present invention patent are detailed in greater detail:

Reception of materials (1)

Waste to be processed may be disappointed in different ways; attending to their physical presentation, these can be presented; - crushed - in strips - whole pieces -etc. And according to their delivery method, they can be delivered: - in bullets - in compactor boxes - in bags. All of them are downloaded in the material reception area.

Storage in reception depot (2)

Depending on the presented form of the waste and its physical characteristics, they are stored in tanks, on pillars or in silos, for further processing.

Primary adaptation of materials (3)

The waste used as raw materials must be adapted in order to be able to use them in the process. This adaptation consists of:

-

selection and separation of materials by typology, with the purpose of separating those improper materials that could interfere in the final quality of the product or in the process.

-

Crushing and reduction of size, to allow a greater surface of contact with the binder.

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Cleaning and removal of impurities.

Storage and reception of adhesives (4)

Adhesives arrive at the plant in drums. These are placed in the area specifically for them. The tanks have taps and dosing valves that allow direct use.

Mixed

Mixtures of waste will be necessary when each of the waste brings a quality to the final product.

In any case, at this stage, the previously appropriate residue will be mixed.

Additivation of adhesives, flame retardants and catalysts (6)

In the same mixer, the adhesive binders are added allowing intimate contact with the surface of the particles. If necessary, additives (flame retardants, catalysts, etc.) are added at this time.

Pressing - Steam injection (7)

Once mixed, the material is introduced into the press plate, spread evenly and pressed with steam injection at the bottom to accelerate the crosslinking of the binders.

On the other hand, during this pressing operation, additional elements can be incorporated into the plate, either for decorative or aesthetic reasons, or to provide the plate with other final features and properties necessary for its subsequent use.

These additional elements may consist of:

-

flame retardant tissue sheet.

-

Decorative fabric.

-

Protective mesh (metal, plastic, etc.).

These elements are placed in the base of the press plate before it is filled by the material, or in the upper part once the material has been placed and extended. In both cases, these elements are firmly attached to the plate, forming part of it, and providing it with additional features.

Mold (8)

Once the time of pressing and "curing" with steam has elapsed, the plates are demoulded by means of 4 pistons that raise the plate above the mold.

Transport and evacuation of plates (9)

The plates are allowed to cool and dry to remove excess moisture due to steam injection.

Expedition storage (10)

Finally, the plates are palletized and stored for later shipment.

The plates may have the desired surface shape, for example, corrugated, squared, etc., and this will depend on the pressing elements of the plate that carry such motifs and which, upon pressing, leave said mark on the plate.

The main object of this invention is the use of waste materials for the manufacture of construction plates. With reference to the conventional plate manufacturing process, the installation and the procedure described in this Invention Patent presents a technological innovation associated with the use of waste products. This peculiarity allows to recover materials, and therefore, avoids the exploitation of resources.

The method of invention offers the possibility of manufacturing different products. Thus it is possible to manufacture rigid panels for partitions, enclosures, wall coverings, vehicle floors, suspended ceilings, carpets, drains for landfills, etc.

For a correct interpretation, a practical embodiment is described below, by way of example, not limitation, of the operation of the present Invention Patent, accompanied by the drawings, in which schematically represented, a process designed according to the present Patent of Invention

The plant, in addition to the reception and storage of the waste already mentioned, is composed of;

A circular flat blade shredder (blade versus blade), which has two interchangeable sieves that determine the final particle size. It has a metal detector in the mouth of the entrance to separate those improper materials and an aspiration system for fi lters to capture fines.

At the outlet of the crusher, the material is stored in metal tanks from which it passes to a scale to determine the dosing of the mixer load.

A horizontal mixer of blades of 150 Kg. Of capacity and 15 CV of power where the material (crushed waste) is intimately mixed with the binder, which falls from the upper mouth of the storage tank of adhesives by means of a dosing pump.

Subsequently, the material in process is led to a piston press lower injection of water vapor, 35 hp and 2 m2 of press plate. This special design team consists of a traditional press to which the steam injection subsystem has been incorporated from the base of the press plate and two interchangeable plates (while one is filled, the other press). The steam provides 150,000 kcal / h at 6-7 kg / cm2 of pressure applied at 150 ° C for 15 seconds.

Once the pressing and curing time has expired, the demolding system is started, which consists of a lower piston that pushes the shaped plate out of the mold by placing it on a conveyor belt that extracts it from the pressing unit, from where it is available on pallets for later shipment.

Claims (4)

one.

Procedure for the manufacture of plates for construction made from waste, characterized in that it comprises the following operational stages: -Reception of materials (1) -Storage in reception tank (2) -Primary disposal of materials (3) -Storage and reception of adhesives (4) -Mixing (5) -Adctivation of adhesives, flame retardants and catalysts (6) -Pressing -Vapor injection (7) -Demolition (8)

-Transport and evacuation of plates (9) -Storage for expedition (10).

2.

Manufacturing process of thermal and acoustic insulation plates, according to claim 1, characterized in that the waste used is chosen among textiles, rubbers, plastics or mixtures thereof.

3.

Construction plate made from waste by a method as described in claims 1 and 2.

SPANISH OFFICE OF THE PATENTS AND BRAND Application no .: 200930957 SPAIN Date of submission of the application: 05.11.2009 Priority Date: REPORT ON THE STATE OF THE TECHNIQUE 51 Int. Cl.: E01F8 / 00 (2006.01) E04B1 / 99 (2006.01) RELEVANT DOCUMENTS

Category

Documents cited Claims Affected

TO

US 5724783 A (MANDISH) 10.03.1998, the whole document. 1-3

TO

US 2006058404 A1 (MEYERS, III et al.) 16.03.2006, the whole document. 1-3

TO

US 5088253 A (CHRIST) 18.02.1992, the whole document. one

Category of the documents cited X: of particular relevance Y: of particular relevance combined with other / s of the same category A: reflects the state of the art O: refers to unwritten disclosure P: published between the priority date and the date of priority submission of the application E: previous document, but published after the date of submission of the application

This report has been prepared • for all claims • for claims no:

Date of realization of the report 09.08.2011

Examiner V. Anguiano Mañero Page 1/4

REPORT OF THE STATE OF THE TECHNIQUE Application number: 200930957 Minimum documentation searched (classification system followed by classification symbols) E01F, E04B Electronic databases consulted during the search (database name and, if possible, terms of search used) INVENES, EPODOC State of the Art Report Page 2/4  WRITTEN OPINION Application number: 200930957 Date of Completion of Written Opinion: 09.08.2011 Statement

Novelty (Art. 6.1 LP 11/1986)

Claims Claims 1-3 IF NOT

Inventive activity (Art. 8.1 LP11 / 1986)

Claims Claims 1-3 IF NOT

The application is considered to comply with the industrial application requirement. This requirement was evaluated during the formal and technical examination phase of the application (Article 31.2 Law 11/1986).  Opinion Base.- This opinion has been made on the basis of the patent application as published. State of the Art Report Page 3/4  WRITTEN OPINION Application number: 200930957 1. Documents considered.- The documents belonging to the state of the art taken into consideration for the realization of this opinion are listed below.

Document

Publication or Identification Number publication date

D01

US 5724783 A (MANDISH) 10.03.1998

D02

US 2006058404 A1 (MEYERS, III et al.) 03/16/2006

D03

US 5088253 A (CHRIST) 18.02.1992

2. Statement motivated according to articles 29.6 and 29.7 of the Regulations for the execution of Law 11/1986, of March 20, on Patents on novelty and inventive activity; quotes and explanations in support of this statement The patent application meets the requirements of novelty, inventive activity and industrial application indicated in the law of patents 11/1986 (articles 6,8 and 9). The problem posed by the applicant is how to make plates for thermal and acoustic insulation using As raw material waste mixtures. The solution proposed by the applicant consists of a procedure of manufacture for insulation plates that has the particularity of using only as raw material materials residual The first claim describes a process for the manufacture of plates from residues with the steps: -Reception; storage; adequacy. -Mixed; addiction; pressing; unmold -Transport. -Storage for expedition. US 5724783 A describes an insulating panel and manufacturing method, which consists of the steps of selecting material and reception, storage, mixing, aggregation of insulating and adhesive materials (fiberglass, polystyrene, rubber recycled tires) to be subsequently pressed by pressing. It differs from patent application document in which the step of catalyst addiction and pressing by means of steam injection In turn, document US 2006058404 A1 describes a method of manufacturing panels and insulating structures by recycled plastic, fiberglass, rubber, sand, etc., which differs from the patent application document in that it does not they indicate the addiction of catalysts and the pressing is done by mill or press. Document US 5088253 A indicated in the report on the state of the art only reflects the state of the art and does not question the patentability requirements indicated in the patent law. State of the Art Report Page 4/4