US20050165140A1 - Use of vegetative material as a filler in composite materials - Google Patents
Use of vegetative material as a filler in composite materials Download PDFInfo
- Publication number
- US20050165140A1 US20050165140A1 US11/082,585 US8258505A US2005165140A1 US 20050165140 A1 US20050165140 A1 US 20050165140A1 US 8258505 A US8258505 A US 8258505A US 2005165140 A1 US2005165140 A1 US 2005165140A1
- Authority
- US
- United States
- Prior art keywords
- rice husk
- rubber
- phr
- carbonised
- mesh
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000945 filler Substances 0.000 title abstract description 38
- 239000002131 composite material Substances 0.000 title abstract description 26
- 239000000463 material Substances 0.000 title abstract description 15
- 239000010903 husk Substances 0.000 claims abstract description 85
- 235000007164 Oryza sativa Nutrition 0.000 claims abstract description 76
- 235000009566 rice Nutrition 0.000 claims abstract description 76
- 238000000034 method Methods 0.000 claims abstract description 22
- 229920001971 elastomer Polymers 0.000 claims description 36
- 239000005060 rubber Substances 0.000 claims description 36
- 239000000203 mixture Substances 0.000 claims description 26
- 239000010426 asphalt Substances 0.000 claims description 18
- 229920001875 Ebonite Polymers 0.000 claims description 17
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 claims description 17
- 239000002245 particle Substances 0.000 claims description 16
- 238000007664 blowing Methods 0.000 claims description 12
- 238000002156 mixing Methods 0.000 claims description 8
- 229920005992 thermoplastic resin Polymers 0.000 claims description 5
- 235000019482 Palm oil Nutrition 0.000 claims description 3
- 239000002540 palm oil Substances 0.000 claims description 3
- 238000007906 compression Methods 0.000 claims description 2
- 230000006835 compression Effects 0.000 claims description 2
- 241000209094 Oryza Species 0.000 claims 20
- 240000007594 Oryza sativa Species 0.000 abstract description 56
- 238000004519 manufacturing process Methods 0.000 abstract description 7
- 230000008569 process Effects 0.000 abstract description 3
- 239000004604 Blowing Agent Substances 0.000 description 16
- 239000000126 substance Substances 0.000 description 16
- 229920003052 natural elastomer Polymers 0.000 description 14
- 229920001194 natural rubber Polymers 0.000 description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 13
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 11
- 244000043261 Hevea brasiliensis Species 0.000 description 11
- 239000003063 flame retardant Substances 0.000 description 11
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 10
- 239000005864 Sulphur Substances 0.000 description 10
- 239000000047 product Substances 0.000 description 10
- BFMKFCLXZSUVPI-UHFFFAOYSA-N ethyl but-3-enoate Chemical compound CCOC(=O)CC=C BFMKFCLXZSUVPI-UHFFFAOYSA-N 0.000 description 9
- 239000004033 plastic Substances 0.000 description 9
- 229920003023 plastic Polymers 0.000 description 9
- 229920005989 resin Polymers 0.000 description 9
- 239000011347 resin Substances 0.000 description 9
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 8
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 6
- 150000001875 compounds Chemical class 0.000 description 6
- 230000000694 effects Effects 0.000 description 6
- 239000000377 silicon dioxide Substances 0.000 description 6
- -1 accelerator Substances 0.000 description 5
- 239000003054 catalyst Substances 0.000 description 5
- 239000000428 dust Substances 0.000 description 5
- 238000009413 insulation Methods 0.000 description 5
- 239000000395 magnesium oxide Substances 0.000 description 5
- 238000003801 milling Methods 0.000 description 5
- 239000004014 plasticizer Substances 0.000 description 5
- 229920000642 polymer Polymers 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 101100202447 Drosophila melanogaster sav gene Proteins 0.000 description 4
- 235000021355 Stearic acid Nutrition 0.000 description 4
- 239000004411 aluminium Substances 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- 239000006229 carbon black Substances 0.000 description 4
- 238000009472 formulation Methods 0.000 description 4
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 4
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 4
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 239000008117 stearic acid Substances 0.000 description 4
- 229920001169 thermoplastic Polymers 0.000 description 4
- 239000004416 thermosoftening plastic Substances 0.000 description 4
- KUAZQDVKQLNFPE-UHFFFAOYSA-N thiram Chemical compound CN(C)C(=S)SSC(=S)N(C)C KUAZQDVKQLNFPE-UHFFFAOYSA-N 0.000 description 4
- 229960002447 thiram Drugs 0.000 description 4
- 239000011787 zinc oxide Substances 0.000 description 4
- 239000012190 activator Substances 0.000 description 3
- 235000021329 brown rice Nutrition 0.000 description 3
- 239000004202 carbamide Substances 0.000 description 3
- 239000007795 chemical reaction product Substances 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 230000003068 static effect Effects 0.000 description 3
- 229920003048 styrene butadiene rubber Polymers 0.000 description 3
- 229920003051 synthetic elastomer Polymers 0.000 description 3
- 239000005061 synthetic rubber Substances 0.000 description 3
- 239000004753 textile Substances 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 239000004634 thermosetting polymer Substances 0.000 description 3
- OWRCNXZUPFZXOS-UHFFFAOYSA-N 1,3-diphenylguanidine Chemical compound C=1C=CC=CC=1NC(=N)NC1=CC=CC=C1 OWRCNXZUPFZXOS-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 241001441571 Hiodontidae Species 0.000 description 2
- 229920000459 Nitrile rubber Polymers 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 235000013339 cereals Nutrition 0.000 description 2
- 238000013329 compounding Methods 0.000 description 2
- 239000004567 concrete Substances 0.000 description 2
- 239000011231 conductive filler Substances 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000012777 electrically insulating material Substances 0.000 description 2
- 238000004880 explosion Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000011152 fibreglass Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000002516 radical scavenger Substances 0.000 description 2
- GJBRNHKUVLOCEB-UHFFFAOYSA-N tert-butyl benzenecarboperoxoate Chemical compound CC(C)(C)OOC(=O)C1=CC=CC=C1 GJBRNHKUVLOCEB-UHFFFAOYSA-N 0.000 description 2
- 229920001567 vinyl ester resin Polymers 0.000 description 2
- 238000009736 wetting Methods 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 1
- 229920002209 Crumb rubber Polymers 0.000 description 1
- MWRWFPQBGSZWNV-UHFFFAOYSA-N Dinitrosopentamethylenetetramine Chemical compound C1N2CN(N=O)CN1CN(N=O)C2 MWRWFPQBGSZWNV-UHFFFAOYSA-N 0.000 description 1
- 240000003133 Elaeis guineensis Species 0.000 description 1
- 235000001950 Elaeis guineensis Nutrition 0.000 description 1
- 208000032365 Electromagnetic interference Diseases 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 241000276489 Merlangius merlangus Species 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 239000005662 Paraffin oil Substances 0.000 description 1
- 229920002535 Polyethylene Glycol 1500 Polymers 0.000 description 1
- 240000006394 Sorghum bicolor Species 0.000 description 1
- 235000011684 Sorghum saccharatum Nutrition 0.000 description 1
- 235000011941 Tilia x europaea Nutrition 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000002154 agricultural waste Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 150000001720 carbohydrates Chemical class 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000002817 coal dust Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229920001940 conductive polymer Polymers 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 235000019784 crude fat Nutrition 0.000 description 1
- 239000012933 diacyl peroxide Substances 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 150000002357 guanidines Chemical class 0.000 description 1
- 150000002366 halogen compounds Chemical class 0.000 description 1
- 239000000976 ink Substances 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 239000000944 linseed oil Substances 0.000 description 1
- 235000021388 linseed oil Nutrition 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 239000011419 magnesium lime Substances 0.000 description 1
- 239000012764 mineral filler Substances 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229940110728 nitrogen / oxygen Drugs 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000019612 pigmentation Effects 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 208000026438 poor feeding Diseases 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- DQWPFSLDHJDLRL-UHFFFAOYSA-N triethyl phosphate Chemical compound CCOP(=O)(OCC)OCC DQWPFSLDHJDLRL-UHFFFAOYSA-N 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
- C04B35/62213—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse using rice material, e.g. bran or hulls or husks
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L97/00—Compositions of lignin-containing materials
- C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
Definitions
- This invention relates to the use of a filler derived from cereal husk, more particularly rice husk, in composite materials to enhance the flame retardant, antistatic, accelerator, plasticiser and blowing characteristics in various composite materials.
- the invention has particular but not exclusive application to the following families of composites:—
- Composite materials are well known. Fillers are usually added to composite materials, including composite polymers, to save cost or to enhance a particular mechanical property or other characteristic of the materials. The usage of fillers is usually accompanied by coupling agents that enhance the polymer-filler and filler-filler interaction so that the expected properties are realised.
- the present invention is concerned with fillers which enhance the anti-static, flame retardant, accelerator, plasticiser, blowing characteristic and/or other physical or mechanical properties of composite materials and has particular application for use in composite polymers.
- fillers which enhance the anti-static, flame retardant, accelerator, plasticiser, blowing characteristic and/or other physical or mechanical properties of composite materials and has particular application for use in composite polymers.
- Such have wide application in the aeronautical, mining, computer, road building, textile, foot ware, rubber and polyurethane industries among others.
- More highly conductive composite polymers can also be used for Electro Magnetic Interference shielding, for example.
- Carbon black fillers, aluminium flakes and fibres, stainless steel fibres and chopped carbon fibres have all been used as fillers for the purpose of rendering composite plastic conductive.
- other chemicals such as Halogen compounds or triethyl phosphate have been used to achieve the flame retardant property.
- the known conductive fillers such as carbon black, aluminium, stainless steel and carbon fibres are expensive and furthermore some of these materials have other processing difficulties, eg. aluminium fibres and stainless steel fibres settle in liquid environments due to their high density. Further problems with known conductive fillers are that they often compromise other properties of composite plastics such as flame retardance and strength.
- Attraction between surfaces e.g. plastic films and textile yarns.
- the accumulation of electrostatic charges can be prevented by using materials of low resistance.
- the resistivity of natural rubber can be lowered by compounding with suitable ingredients.
- static electrification is a surface phenomenon, the product can be covered with a conducting surface layer.
- Low resistance rubber is required for a wide range of applications, such as rollers for textile machinery, conveyor belting, fuel hoses, flooring, footwear, antistatic gloves (electronic industry), cables, equipment used in hospital operating theatres, and aircraft components.
- antistatic and conductive are restricted here to rubber products rather than the rubber itself because the electrical resistance of the product depends not only on the resistivity of the rubber but also on the shape and most probable positions of charge generation and discharge.
- Natural rubber is normally considered to be an electrically insulating material but it can be an electrically insulating material but it can be compounded to give electrical resistivity lying anywhere between 1 ohm/cm. and 10 15 ohm/cm.
- the most common means of reducing resistance is to add a suitable carbon black (super conductive furnace). Resistance falls with a decrease in particle size, increase in black “structure” and increase in concentration.
- certain grades of aluminium ‘silicate may be used as antistatic fillers although these are usually less effective in reducing resistance than the super conductive furnace.
- antistatic agents that are available, such as ethylene oxide, but still these agents are less effective then the super conductive furnace.
- carbonised rice husk is particularly suited for use as a filler in plastics as it has been found to enhance the conductivity and flame retardant properties of the composite plastics.
- Honeycomb structure of a matrix is supposed to be one of the strongest structures that have been determined by Structural Engineers. The strength comes about from the full depth hexagons and half-depth trapezoids. This type of structures is presently used as designs for building bridge decks.
- the rice husk has a similar type of honeycomb design, which results in not only providing strength to the matrix, but also has sound and thermal insulation properties.
- the Sound insulation property is provided by the micro-cellular structures formed by the honeycomb structure in the brown rice husk. Thus the sound is trapped within the micro-cellular structure. This property is inherent to the brown (fresh) rice husk.
- the Thermal insulation property is provided by the honeycomb structure, which is strengthened by the silica and fibre which predominately present in brown rice husk and lesser in the carbonised (depend to the rate of carbonising) rice husk.
- the presence of appreciable quantities of oxygen on the surface of carbonised rice husk acts as insulation for each aggregate, thereby reducing the conductivity and also reducing the flammability.
- the presence of nitrogen and oxygen in the fresh husk not only enables the blowing effect but also nitrogen being inert reduces the flame spread.’
- the volume of gas (nitrogen/oxygen) evolution per gram of fresh rice husk is 240 ml/g.
- the husk's decomposition temperature is at about 280° C. and curing temperature of rubber and ethyl vinyl acetate is between 130° C.-180° C., thus when urea (dinitroso pentamethylene tetramine) is milled along the decomposition temperature is reduced within the curing temperatures.
- the presence of silica in the rice husk provides better mechanical strength.
- the filler is desirably cheap, environmentally friendly and replenishable and it does not compromise other characteristics of the composite material.
- the present invention in one aspect resides in the use of carbonised vegetative-based filler to provide improved antistatic, flame retardant, accelerator, plasticiser, blowing and/or other physical or mechanical characteristics in composite materials.
- the carbonised vegetative-based filler is carbonised rice husk.
- the carbonised rice husk is burnt at about 800° C. for about 4 seconds. Most preferably, the carbonised rice husk is burnt at 803-804° C. for 3-4 seconds.
- the invention resides in a composite material, more particularly a composite plastic including a vegetative-based filler when used as a conductive or flame retardant article.
- the carbonised vegetative-based filler is carbonised rice husk which has been burnt at 803-804° C. for 3-4 seconds.
- the present invention also exhibits the usage of fresh and carbonised rice husk as a blowing agent when used in combination with recycled (reclaimed), or virgin natural rubber or other suitable thermoplastic materials.
- recycled (reclaimed) or virgin natural rubber or other suitable thermoplastic materials.
- other conventional blowing agents have been used with natural or synthetic rubber to achieve the similar products but so far no blowing agents have been used with recycle (reclaim) rubber to produce similar products.
- the conventional blowing agents are expensive and dosages are higher as compared to the fresh rice husk. For example for the conventional blowing agent, the dosage is about 6.5-7 phr, whereas the fresh/carbonised rice husk, the dosage is between 1.5 to 3 phr. When rice husk is used at different dosages the blowing effect is different.
- the rice husk does not only work as a blowing agent, but also as a plasticizer and a filler.
- the properties achieved are comparable to conventional blowing agents, when using fresh or carbonised rice, has no difference to the conventional blowing agent other than the colour of the end product.
- Ebonite a hard, dark-coloured plastic-like material, is the reaction product of rubber and a large proportion of sulphur. Simple rubber/sulphur mixtures are seldom used in practice; they suffer from poor processability, require long cure times and lead to excessive shrinkage and heat evolution during cure. Accelerators, fillers, processing aids and other compounding ingredients are widely used in ebonite, as in soft rubber vulcanised rubber, to ease processing, shorten cure times and modify properties. The curing times for ebonite are generally up to ten (10) hours at 150° C., thus making ebonite products expensive. Ebonite can be made from synthetic, such as BR, NBR, SBR and Nitrile rubber and as well as from Natural rubber.
- the present invention exhibits the usage of fresh and carbonised rice as an accelerator when used in combination with recycled (devulcanised) or virgin natural rubber, and at the same time making ebonite a conductive product when carbonised rice husk is used.
- other conventional accelerators have been used with natural or synthetic rubber (virgin or recycled) to achieve the similar products but so far no accelerators like the rice husk material have been used with recycled (devulcanised) rubber to produce similar products. Further more the conventional accelerators and conductive carbon black are expensive and difficult to blend and process. When rice husk is used singularly at different dosages the activation effect is different to meet industrial requirements.
- the sulphur content should be in the range of 25-40 phr, but whereas when fresh rice husk between 25-30 phr is used the sulphur content could be reduced to 20-25 phr.
- Accelerators are less effective in ebonite than in soft rubber and large quantities are generally required.
- Basic accelerators such as guanidines and aldehyde-amines are preferred.
- Inorganic activators such as magnesium oxide, magnesium carbonate and lime are also effective when used with organic accelerators to reduce cure time without the risk of over heating.
- ebonite Common inorganic fillers used in ebonite are china clay, talc, silica, whiting and magnesium oxide. These also reduce shrinkage and heat evolution but loaded ebonite generally have weaker mechanical properties than unloaded ones. Carbon black does not reinforce ebonite and is normally only added for pigmentation, although conductive carbon black are sometimes used to prepare electrically conducting ebonite.
- the filler is carbonised rice husk (CRH) which has been burnt at 803-804° C. for 3-4 seconds. After this the CRH is obtained.
- CRH carbonised rice husk
- the manner in which the rice husk is burnt is believed to be important in achieving the desired surface area, surface structure and porosity necessary for conductivity and flame retardant and blowing properties in the composite plastics to be achieved.
- the importance of controlled burning in a prescribed time results in obtaining better surface area and porosity which in turn offers ideal properties emitting anti-static, flame retardant and enhancing physical properties of the material. In the absence of controlled burning, the surface area, surface structure and porosity would be distorted. While the present exemplification involves use of carbonised rice husk it is possible that the desired results may be achieved by use of other carbonised vegetative-based fillers.
- thermoset application called pulforming was used to manufacture fibre reinforced bolts.
- Fibre glass tows 36 tow of 8000 tex
- resin bath that contains:
- Polyester and Vinyl Ester combination ie. 60% Vinyl Ester (Derakane 411—Dow Chemical) and 40% Polyester (Everpol 3260 AR—P.T. Arinde).
- Zinc Stearate (mould releasing agent)—1.18% of the resin weight
- BYK 980 improves wetting and dispersing of fillers in glass fibre reinforcement compounds
- BYK 515 air releasing agent
- BYK 996 wetting and dispersing additive for mineral fillers in hot curing, glass fibre reinforced UP-resin systems—2% of the resin weight.
- the wet fibre glass tow is pulled into the mould and compressed at a pressure of 800 psi (5600 kPa) for 3.8 minutes at 130° C. Then the bolt is pulled out of the mould and left to cure.
- the rubber and the chemicals are mixed in a Banbury, for 5 minutes.
- the similar approach has been done for using SBR Rubber (100 g), silica (62 g), Peg 1500 (2.5 g), Paraffin oil (5 g), Zinc oxide (2.5 g), Wing stay (0.5 g), Wax (1 g), Mercadibenzothiazole disulphide (MBTS) (1.5 g), Tetramethylthiuram disulphide (TMTD) (0.2 g), Stearic acid (1.5 g) and Sulphur (2 g).
- the milling was done for ten (10) minutes and later cured in the oven for six (6) minutes at 150° C.
- This exercise was repeated by using fifty (50) percent of the virgin material compound and fifty (50) percent recycled (reclaimed) material compound, and cured in the oven at 150° C. for two (2) minutes.
- the blowing effect can be controlled to suit the industry's requirement.
- a conventional formula for ebonite was selected to compare.
- the rubber and the chemicals are mixed in a Banbury, for 5 minutes.
- the similar mixing as above was followed, using SBR 5 Rubber (10 g), ebonite dust (10 g), China clay (50 g), Magnesium oxide (5 g), Diphenylguanidine (3 g), Linseed oil (5 g) and Sulphur (45 g).
- the milling was done for ten (10) minutes and later cured in the oven for eight (8) hours at 150° C.
- the results are based on cure time, the formulation with rice husk cures faster than the formulation without rice husk, i.e. twelve minutes for with brown rice husk and about eight hour without rice husk.
- the temperature for curing could be from 145°-160° C. and the cure time may differ according to the mould size.
- EVA thermoplastic—Ethyl Vinyl Acetate
- the EVA and the chemicals are mixed in an Open Mill or Knider, for six (6) minutes.
- Ethyl Vinyl Acetate (EVA) is first milled with Stearic Acid (1%) and zinc oxide (5%) accelerator, which is followed with Rice Husk (Blowing agent) (2.5%).
- Rice Husk Blowing agent
- the mould was heated in the oven press to 160° C. then the sheeted EVA is placed in the mould and it is cured for twenty-two (22) minutes.
- the temperature for curing could be from 145°-160° C. and the cure time may differ according to the mould size.
- the rice husk is mixed by weight with tyre crumbs (35-40 mesh) and an effluent from the palm oil mill called Scavenger (which have a fatty acid content (C 8 C 18 ). From literature it has been reported that by using tyre crumb with the binder (bitumen) there is an improve df properties for the asphalt mixture. This invention not only uses tyre crumb along with rice husk and an oil palm effluent to further improve the properties. As well as the formulation address the recyclability of all agro waste by-products to be used in the road surfacing industries. The formulation of the rice husk mixture as follows: Rice husk 50% Tyre crumb 45% Scavenger 5%
- the rice husk mixture is added to the bitumen first in compliance to the SOCIETY OF HIGHWAY PROCEDURE (SHRP) to manufacture modified bitumen.
- SHRP SOCIETY OF HIGHWAY PROCEDURE
- the bitumen is first heated to about 160° C., then the rice husk mixture twenty percent 20% by weight of bitumen is mixed with the heated bitumen for about one hour.
- a modified bitumen is made. From here 5-7% by weight of this modified bitumen is added to the aggregate.
- the aggregate is first heated to about 200° C. and the modified bitumen is mixed for three to four minutes.
- the modified bitumen with rice husk mixture complies to all requirement of the SHRP.
- the rice husk mixture is added as a filler to the aggregate, by four (4%) by weight to the aggregate weight.
- the aggregate is first heated to 200° C., and is allowed to cool to about 160° C., then the rice husk mixture is added and mixed and lastly the bitumen 5-6% by weight of aggregate is added and mixed for 3-4 minutes.
- This blending with rice husk mixture complies to all requirement of the Marshall Properties.
Abstract
The present invention provides a filler for use in composite materials wherein said filler comprises a vegetative-based material and wherein said vegetative-based material can be fresh or carbonised. In one particularly preferred embodiment the present invention utilises carbonised rice husk. In a further aspect of the present invention there is provided a process for the production of a carbonised vegetative-based filler wherein said process comprises burning a fresh vegetative-based material at about 800° C. for about 4 seconds.
Description
- This application is a divisional application of U.S. application Ser. No. 09/889,610, entitled “Use of Vegetative Material as a Filler in Composite Materials”, filed Jan. 8, 2002, which is a continuation application of PCT/AU00/00018, filed Jan. 17, 2000 which published as WO 00/42116, which claims priority to AU PP 8198 filed Jan. 18, 1999, all of which are incorporated herein by reference in their entirety.
- This invention relates to the use of a filler derived from cereal husk, more particularly rice husk, in composite materials to enhance the flame retardant, antistatic, accelerator, plasticiser and blowing characteristics in various composite materials. The invention has particular but not exclusive application to the following families of composites:—
-
- 1. Thermoplastic Resins
- 2. Thermoset Plastics
- 3. Rubbers and Elastomeric Materials
- 4. Conductive Coatings and Printing Inks
- 5. Bitumen
- 6. Concrete
- Composite materials are well known. Fillers are usually added to composite materials, including composite polymers, to save cost or to enhance a particular mechanical property or other characteristic of the materials. The usage of fillers is usually accompanied by coupling agents that enhance the polymer-filler and filler-filler interaction so that the expected properties are realised.
- The present invention is concerned with fillers which enhance the anti-static, flame retardant, accelerator, plasticiser, blowing characteristic and/or other physical or mechanical properties of composite materials and has particular application for use in composite polymers. Such have wide application in the aeronautical, mining, computer, road building, textile, foot ware, rubber and polyurethane industries among others. For example, it is often desirable to prevent the build up of static charges which can cause sparks (and hence explosions or electrical damage) or production problems, eg. collection of dust and poor feeding of materials through machinery. More highly conductive composite polymers can also be used for Electro Magnetic Interference shielding, for example.
- Carbon black fillers, aluminium flakes and fibres, stainless steel fibres and chopped carbon fibres have all been used as fillers for the purpose of rendering composite plastic conductive. Likewise other chemicals such as Halogen compounds or triethyl phosphate have been used to achieve the flame retardant property.
- A number of theories have been proposed to explain how discreet particle fillers impart conductivity and flame retardant properties in composite plastics.
- In order for current to flow in a conductive polymer compound, electrons must travel along the filler as the plastic itself is an excellent insulator. To achieve this flow the discreet particles of the filler must be in contact or separate by a minimum distance which is probably less than 100 Angstroms. There are three properties of the filler particles which will effect the average inter-particle distance for a given filler loading in a polymer system. These are particle size, shape (structure), and porosity. Smaller size, irregular shape and high porosity all result in smaller inter-particle distances and hence higher conductivity. A fourth property of the particle which is relevant to conductivity and flame retardant properties in the composite plastics is surface chemistry, that is the presence of oxygen on the surface. The presence of appreciable quantities of oxygen on the surface (called volatile content) acts as insulation and hence reduces conductivity.
- The known conductive fillers such as carbon black, aluminium, stainless steel and carbon fibres are expensive and furthermore some of these materials have other processing difficulties, eg. aluminium fibres and stainless steel fibres settle in liquid environments due to their high density. Further problems with known conductive fillers are that they often compromise other properties of composite plastics such as flame retardance and strength.
- Static electrification of articles can lead to a number of undesirable effects including:
- Attraction of dust particles.
- Attraction between surfaces, e.g. plastic films and textile yarns.
- Risk of fire or explosion caused by sparking near inflammable liquids, gases, and explosive dusts, e.g. coal dust and flour.
- Risk of shock to persons handling equipment.
- The accumulation of electrostatic charges can be prevented by using materials of low resistance. The resistivity of natural rubber can be lowered by compounding with suitable ingredients. Alternatively, as static electrification is a surface phenomenon, the product can be covered with a conducting surface layer.
- Low resistance rubber is required for a wide range of applications, such as rollers for textile machinery, conveyor belting, fuel hoses, flooring, footwear, antistatic gloves (electronic industry), cables, equipment used in hospital operating theatres, and aircraft components.
- The terms “antistatic” and “conductive” are restricted here to rubber products rather than the rubber itself because the electrical resistance of the product depends not only on the resistivity of the rubber but also on the shape and most probable positions of charge generation and discharge.
- Natural rubber is normally considered to be an electrically insulating material but it can be an electrically insulating material but it can be compounded to give electrical resistivity lying anywhere between 1 ohm/cm. and 1015 ohm/cm. The most common means of reducing resistance is to add a suitable carbon black (super conductive furnace). Resistance falls with a decrease in particle size, increase in black “structure” and increase in concentration. For light coloured products certain grades of aluminium ‘silicate may be used as antistatic fillers although these are usually less effective in reducing resistance than the super conductive furnace. There are also other proprietary antistatic agents that are available, such as ethylene oxide, but still these agents are less effective then the super conductive furnace.
- The applicant has found that carbonised rice husk is particularly suited for use as a filler in plastics as it has been found to enhance the conductivity and flame retardant properties of the composite plastics.
- Honeycomb structure of a matrix is supposed to be one of the strongest structures that have been determined by Structural Engineers. The strength comes about from the full depth hexagons and half-depth trapezoids. This type of structures is presently used as designs for building bridge decks.
- The rice husk has a similar type of honeycomb design, which results in not only providing strength to the matrix, but also has sound and thermal insulation properties. The Sound insulation property is provided by the micro-cellular structures formed by the honeycomb structure in the brown rice husk. Thus the sound is trapped within the micro-cellular structure. This property is inherent to the brown (fresh) rice husk. The Thermal insulation property is provided by the honeycomb structure, which is strengthened by the silica and fibre which predominately present in brown rice husk and lesser in the carbonised (depend to the rate of carbonising) rice husk.
- The presence of appreciable quantities of oxygen on the surface of carbonised rice husk acts as insulation for each aggregate, thereby reducing the conductivity and also reducing the flammability. The presence of nitrogen and oxygen in the fresh husk not only enables the blowing effect but also nitrogen being inert reduces the flame spread.’ The volume of gas (nitrogen/oxygen) evolution per gram of fresh rice husk is 240 ml/g. The husk's decomposition temperature is at about 280° C. and curing temperature of rubber and ethyl vinyl acetate is between 130° C.-180° C., thus when urea (dinitroso pentamethylene tetramine) is milled along the decomposition temperature is reduced within the curing temperatures. The presence of silica in the rice husk provides better mechanical strength.
- Typical chemical and physical properties of fresh and carbonised rice husk are detailed as follows:
-
- consists of 20-23% of paddy
- husk burning: 20% ash by weight
- 90-95% is silica (amorphous and crystalline)
- physical characteristics: bulk density 96.12-112.14 kg/m3
- pH 7.14 (husk ash)
- moisture content 5.6-7.2%, dry basis
- ash 22.2%
Chemical Composition Moisture Content: 5.6-7.2%, dry basis Ash: 22.2% Protein 2.4% Crude fat 0.7% Carbohydrate 32.0%, Fresh RH Carbonised RH Al2O3 0.025% 0.023% CaO 0.36% 0.12% NaO 0.034% 0.018% Si02 96.2% 53.88% Fe203 0.041% 0.022% MgO 0.16% 0.078% K2O 0.69% 0.95% P2O5 0.57% 0.27% - It is an object according to one aspect of the present invention to provide an alternative filler which will enhance the antistatic, flame retardant, accelerator, plasticiser blowing and/or other physical or mechanical in composite materials. The filler is desirably cheap, environmentally friendly and replenishable and it does not compromise other characteristics of the composite material.
- The present invention in one aspect resides in the use of carbonised vegetative-based filler to provide improved antistatic, flame retardant, accelerator, plasticiser, blowing and/or other physical or mechanical characteristics in composite materials.
- Preferably, the carbonised vegetative-based filler is carbonised rice husk.
- Preferably, the carbonised rice husk is burnt at about 800° C. for about 4 seconds. Most preferably, the carbonised rice husk is burnt at 803-804° C. for 3-4 seconds.
- In another aspect the invention resides in a composite material, more particularly a composite plastic including a vegetative-based filler when used as a conductive or flame retardant article.
- Preferably, the carbonised vegetative-based filler is carbonised rice husk which has been burnt at 803-804° C. for 3-4 seconds.
- The present invention also exhibits the usage of fresh and carbonised rice husk as a blowing agent when used in combination with recycled (reclaimed), or virgin natural rubber or other suitable thermoplastic materials. Though other conventional blowing agents have been used with natural or synthetic rubber to achieve the similar products but so far no blowing agents have been used with recycle (reclaim) rubber to produce similar products. Furthermore the conventional blowing agents are expensive and dosages are higher as compared to the fresh rice husk. For example for the conventional blowing agent, the dosage is about 6.5-7 phr, whereas the fresh/carbonised rice husk, the dosage is between 1.5 to 3 phr. When rice husk is used at different dosages the blowing effect is different. It was also noted that the rice husk does not only work as a blowing agent, but also as a plasticizer and a filler. The properties achieved are comparable to conventional blowing agents, when using fresh or carbonised rice, has no difference to the conventional blowing agent other than the colour of the end product.
- Ebonite, a hard, dark-coloured plastic-like material, is the reaction product of rubber and a large proportion of sulphur. Simple rubber/sulphur mixtures are seldom used in practice; they suffer from poor processability, require long cure times and lead to excessive shrinkage and heat evolution during cure. Accelerators, fillers, processing aids and other compounding ingredients are widely used in ebonite, as in soft rubber vulcanised rubber, to ease processing, shorten cure times and modify properties. The curing times for ebonite are generally up to ten (10) hours at 150° C., thus making ebonite products expensive. Ebonite can be made from synthetic, such as BR, NBR, SBR and Nitrile rubber and as well as from Natural rubber. High strength, low thermal conductivity, chemical resistance and insulating properties of natural rubber make it a popular choice. Although it has been superseded in many applications by synthetic thermoplastic and thermosets, it is still used for outstanding chemical resistance and electrical properties coupled with high mechanical strength and ease of machining.
- The present invention exhibits the usage of fresh and carbonised rice as an accelerator when used in combination with recycled (devulcanised) or virgin natural rubber, and at the same time making ebonite a conductive product when carbonised rice husk is used. Though other conventional accelerators have been used with natural or synthetic rubber (virgin or recycled) to achieve the similar products but so far no accelerators like the rice husk material have been used with recycled (devulcanised) rubber to produce similar products. Further more the conventional accelerators and conductive carbon black are expensive and difficult to blend and process. When rice husk is used singularly at different dosages the activation effect is different to meet industrial requirements. Generally for ebonite production the sulphur content should be in the range of 25-40 phr, but whereas when fresh rice husk between 25-30 phr is used the sulphur content could be reduced to 20-25 phr. Accelerators are less effective in ebonite than in soft rubber and large quantities are generally required. Basic accelerators such as guanidines and aldehyde-amines are preferred. Inorganic activators such as magnesium oxide, magnesium carbonate and lime are also effective when used with organic accelerators to reduce cure time without the risk of over heating.
- Common inorganic fillers used in ebonite are china clay, talc, silica, whiting and magnesium oxide. These also reduce shrinkage and heat evolution but loaded ebonite generally have weaker mechanical properties than unloaded ones. Carbon black does not reinforce ebonite and is normally only added for pigmentation, although conductive carbon black are sometimes used to prepare electrically conducting ebonite.
- Best Mode
- Following is an example of the invention, in this example the filler is carbonised rice husk (CRH) which has been burnt at 803-804° C. for 3-4 seconds. After this the CRH is obtained.
- The manner in which the rice husk is burnt is believed to be important in achieving the desired surface area, surface structure and porosity necessary for conductivity and flame retardant and blowing properties in the composite plastics to be achieved. At this stage the range of temperature and the duration of the time of burning which achieves the desired result has not been fully explored, however it is predicted that the temperature range will be from about 100-950° C. and the time range will be from about 2=30 seconds, although these ranges may be much narrower. The importance of controlled burning in a prescribed time results in obtaining better surface area and porosity which in turn offers ideal properties emitting anti-static, flame retardant and enhancing physical properties of the material. In the absence of controlled burning, the surface area, surface structure and porosity would be distorted. While the present exemplification involves use of carbonised rice husk it is possible that the desired results may be achieved by use of other carbonised vegetative-based fillers.
- A thermoset application called pulforming was used to manufacture fibre reinforced bolts. Fibre glass tows (36 tow of 8000 tex) are pulled into a resin bath that contains:
- 1. Polyester and Vinyl Ester combination, ie. 60% Vinyl Ester (Derakane 411—Dow Chemical) and 40% Polyester (Everpol 3260 AR—P.T. Arinde).
- 2. Zinc Stearate (mould releasing agent)—1.18% of the resin weight BYK 980 (improves wetting and dispersing of fillers in glass fibre reinforcement compounds)—1.5% of the filler weight.
- 3. BYK 515 (air releasing agent)—0.5% of the total weight of the resin mixture.
- 4. BYK 996 (wetting and dispersing additive for mineral fillers in hot curing, glass fibre reinforced UP-resin systems)—2% of the resin weight.
- 5. Fillers (Ca2(CO)3 & Carbonised Rice Husk (mesh size 325) @ 55% & 12% of the resin weight).
- 6. Aluminium Trihydrate (2.4% of the resin weight).
- 7. Catalyst
-
- TBPH (Tertiary Butyl Peroxy-2-Ethyl Hexanoate)
- 2.12% of the resin weight.
- TBPB (Tertiary Butyl Perbenzoate)
- 0.53% of the resin weight.
- TBPH (Tertiary Butyl Peroxy-2-Ethyl Hexanoate)
- The wet fibre glass tow is pulled into the mould and compressed at a pressure of 800 psi (5600 kPa) for 3.8 minutes at 130° C. Then the bolt is pulled out of the mould and left to cure.
- The following day tests were carried out on the bolt with the following results:
-
- Tensile strength at the thread—50 kN
- Torque—45 ft/lb
- Bond strength—BS 1610:Part 1, Grade 1.0
- Fire rating—BS 5865:1980—Persistence flame shall be less than 10 seconds
- Electrical conductivity—less than 10 to the power of 9 Ohms.
- All chemicals used are taken by percentage of weight of rubber. The rubber and the chemicals are mixed in a Banbury, for 5 minutes. Recycled rubber (reclaim) (220 g) is first milled with zinc oxide (4.5%)—accelerator, which is followed with stearic acid (1.8%)—activator, Mercadibenzothiazole disulphide (MBTS)(0.5%), Tetramethylthiuram disulphide (TMTD)(0.2%)—accelerator, fresh rice husk (27%)—blowing agent and filler and sulphur (2.7%)—vulcanisate. Then the mixed compound is milled for five (5) minutes to form a sheet that is ready for curing. Then a piece of the sheet weighing about 32 g is placed in a mould that it is to be cured for two (2) minutes in a oven at 150° C. temperature. The conventional curing time is six (6) minutes at the same temperature of 150° C.
- The rubber and the chemicals are mixed in a Banbury, for 5 minutes. The similar approach has been done for using SBR Rubber (100 g), silica (62 g), Peg 1500 (2.5 g), Paraffin oil (5 g), Zinc oxide (2.5 g), Wing stay (0.5 g), Wax (1 g), Mercadibenzothiazole disulphide (MBTS) (1.5 g), Tetramethylthiuram disulphide (TMTD) (0.2 g), Stearic acid (1.5 g) and Sulphur (2 g). The milling was done for ten (10) minutes and later cured in the oven for six (6) minutes at 150° C.
- This exercise was repeated by using fifty (50) percent of the virgin material compound and fifty (50) percent recycled (reclaimed) material compound, and cured in the oven at 150° C. for two (2) minutes.
- With the level, of rice husk dosage, the blowing effect can be controlled to suit the industry's requirement.
- Machine Operating Conditions
- Virgin Rubber:
TYRE DUST EXAMPLE 1 EXAMPLE 1 TYRE WITH BROWN WITH BROWN WITHOUT PROPERTIES SMR-10 DUST RICE HUSK RICK HUSK BROWN Mooney 60 36.6 31.8 24 30 Viscosity MLI + 3, 100° C. Monsanto Rheometer, 150° C. Scorch time 1.4 3.8 1.2 2 2.5 Cure time 7.4 3.5 3.25 4 4
By using rice husk the Mooney viscosity was lower than the conventional filler, thus lowering scotch time (time taken by the rubber compound to flow into the mould) and curing time (time taken to cure rubber compound) respectively. As such this leads to a cheaper production system. Presently various fillers and blowing agents are being used in the production of soft/spongy rubber that would produce different types of cell structures for an end product, but the cost determines the market. - All chemicals used are taken by percentage of weight of rubber. The rubber and the chemicals are mixed in a Banbury, for six (6) minutes. The recycle (devulcanised) rubber is first milled with magnesium oxide (2%)—accelerator, which is followed with Diphenylguanidine (2%)—accelerator, fresh rice husk (30%)—accelerator and filler and sulphur (30%)—vulcanisate. After the milling at the Banbury for ten (10) minutes, it is then milled into a sheet. The mould was heated in the oven press to 150° C. then the sheeted rubber is placed in the mould and it is cured for twelve (12) minutes. The conventional curing time is between eight to ten hours at the same temperature of 150° C.
- A conventional formula for ebonite was selected to compare. The rubber and the chemicals are mixed in a Banbury, for 5 minutes. The similar mixing as above was followed, using SBR 5 Rubber (10 g), ebonite dust (10 g), China clay (50 g), Magnesium oxide (5 g), Diphenylguanidine (3 g), Linseed oil (5 g) and Sulphur (45 g). The milling was done for ten (10) minutes and later cured in the oven for eight (8) hours at 150° C.
- Mix Properties; Rice Husk Filled Mix
Mooney viscosity, MLI + 3, 100° C. 24 Mooney viscosity, MLI + 3, 120° C. 18.5 Mooney scorch, t5, MLI + 3, 120° C. min. 5.8 Monsanto Rheometer, 160° C. 110 time to 95% cross-linking, s - By using rice husk the curing time is reduced tremendously twelve minutes as compared to eight to ten hours. The sulphur content in the rubber polymer is reduced by fifteen percent.
- The results are based on cure time, the formulation with rice husk cures faster than the formulation without rice husk, i.e. twelve minutes for with brown rice husk and about eight hour without rice husk.
- All chemicals used are taken by percentage of weight of natural rubber (NR). The natural rubber and the chemicals are mixed in an open mill or kinder, for six (6) minutes. Natural rubber is first milled with stearic acid (1%) and zinc oxide (5%) activator, which is followed with rice husk (blowing agent) (2.5-3.5%), calcium carbonate—(40%), promoter—urea based (2.5-3.5%), silica (10%), accelerator dibenzthiazyldisulphide (MBTS) (0.05%) and catalyst sulphur (1.5%). After the milling at the open mill or kinder for ten (10) minutes, it is then milled into a sheet. The mould was heated in the oven press to 160° C. then the sheeted natural rubber is placed in the mould and it is cured for twenty-two (22) minutes.
- The temperature for curing could be from 145°-160° C. and the cure time may differ according to the mould size.
- Cured properties; rice husk filled blowed mix—micro-cellular cells.
1. Hardness Askar C 35 2. Shrinkage % 5 3. Specific Gravity g/cc 0.3-0.35 - By using rice husk as a blowing agent the catalyst percentage could be reduced and as well as the percentage of blowing agent used.
- Thermoplastic (EVA)
- All chemicals used are taken by percentage of weight of thermoplastic—Ethyl Vinyl Acetate (EVA). The EVA and the chemicals are mixed in an Open Mill or Knider, for six (6) minutes. Ethyl Vinyl Acetate (EVA) is first milled with Stearic Acid (1%) and zinc oxide (5%) accelerator, which is followed with Rice Husk (Blowing agent) (2.5%). Magnesium carbonate—(10%), Promoter-urea based (5%) and catalyst Diacyl Peroxide (1%). After the milling at the Open mill or Knider for ten (10) minutes, it is then milled into a sheet. The mould was heated in the oven press to 160° C. then the sheeted EVA is placed in the mould and it is cured for twenty-two (22) minutes.
- The temperature for curing could be from 145°-160° C. and the cure time may differ according to the mould size.
- Cured properties: Rice Husk filled blowed mix—micro-cellular cells
1. HARDNESS Askar C 29-35 2. SHRINKAGE % 2 3. SPECIFIC GRAVITY g/cc 0.200 4. COMPRESSION SET % 80 - By using rice husk as a blowing agent the catalyst percentage could be reduced and as well as the percentage of blowing agent used.
- The rice husk is mixed by weight with tyre crumbs (35-40 mesh) and an effluent from the palm oil mill called Scavenger (which have a fatty acid content (C8 C18). From literature it has been reported that by using tyre crumb with the binder (bitumen) there is an improve df properties for the asphalt mixture. This invention not only uses tyre crumb along with rice husk and an oil palm effluent to further improve the properties. As well as the formulation address the recyclability of all agro waste by-products to be used in the road surfacing industries. The formulation of the rice husk mixture as follows:
Rice husk 50% Tyre crumb 45% Scavenger 5% - In this particular example the usage of rice husk mixture is divided into two categories:
-
- A. RICE HUSK MIXTURE USED IN MODIFIED BINDER
- B. RICE HUSK MIXTURE USED IN AS FILLER
- A. The rice husk mixture is added to the bitumen first in compliance to the SOCIETY OF HIGHWAY PROCEDURE (SHRP) to manufacture modified bitumen. The bitumen is first heated to about 160° C., then the rice husk mixture twenty percent 20% by weight of bitumen is mixed with the heated bitumen for about one hour. As a result of this reaction a modified bitumen is made. From here 5-7% by weight of this modified bitumen is added to the aggregate. The aggregate is first heated to about 200° C. and the modified bitumen is mixed for three to four minutes. The modified bitumen with rice husk mixture complies to all requirement of the SHRP.
- B. The rice husk mixture is added as a filler to the aggregate, by four (4%) by weight to the aggregate weight. The aggregate is first heated to 200° C., and is allowed to cool to about 160° C., then the rice husk mixture is added and mixed and lastly the bitumen 5-6% by weight of aggregate is added and mixed for 3-4 minutes. This blending with rice husk mixture complies to all requirement of the Marshall Properties.
TABLE 1 PROPERTIES OF RICE HUSK MODIFIED BINDER - SHRP RICE SHRP 80/100 HUSK MIXTURE FLASH POINT TEMP. ° C. 230 240 SOFTENING POINT, ° C. 44-50 55-70 PENETRATION @ ° C. 25, dmm 80-100 60-100 BROOKFIELD VISCOSITY @ <500 >1500 135° C., MPaS DYNAMIC SHEAR RHEOMETER PG 70 ORIGINAL G*(Pa) <1000 >1200 δ(°) >80 >80 G*/Sin δ <1000 >1200 AFTER RTFOT G*(Pa) <1000 >3800 δ(°) >80 >70 G*/Sin δ <1000 >3800 AFTER PAV G*(Pa) <1000 >230 δ(°) >80 >50 G*/Sin δ <1000 >260 PG76 ORIGINAL G*(Pa) <1000 >1800 δ(°) >80 >70 G*/Sin δ <1000 >1800 AFTER RTFOT G*(Pa) <1000 >2400 δ(°) >80 >70 G*/Sin δ <1000 >2600, AFTER PAV G*(Pa) <1000 >230 δ(°) >80 >50 G*/Sin δ <1000 >280 -
TABLE 2 MIXED PROPERTIES OF RICE HUSK MODIFIED BINDER PROPERTIES 80/100 RICE HUSK MIXTURE MARSHALL STABILITY (kN) 5-10 >13 FLOW (mm) 2-4 2-4 QUOTIENT (kN/mm) 1-3.5 3-4 RESILIENT MODULUS @ 25° >2000 >2800 -
TABLE 3 MIXED PROPERTIES OF RICE HUSK MIXTURE AS FILLER PROPERTIES 80/100 RICE HUSK MIXTURE MARSHALL STABILITY (kN) 6-10 >12 FLOW (mm) 2-4 2-4 QUOTIENT (kN/mm) 1-3.5 3-4 RESILIENT MODULUS @ 25° >2000 >2800 -
TABLE 4 PREFERRED PARTICLE SIZE AND DOSAGE OF FRESH AND/OR CARBONISED RICE HUSK FOR PARTICULAR COMPOSITE MATERIALS COMPOSITE MATERIAL FRESH/DOSAGE CARBONISED/DOSAGE BITUMEN (MECHANICAL 100 MESH - 40-60 phr — PROPERTY THERMOPLASTIC (EVA) 325-400 MESH - 1.5-2.5 phr 325-400 MESH - 1.5-2.6 phr BLOWING CHARACTER THERMOPLASTIC (EVA) 325-400 MESH - 1.5-5 phr 325-400 MESH - 1.5-2.5 phr MECHANICAL PROPERTY RUBBER (N.R./S.R.) 325-400 MESH - 1.5-27 phr 325-400 MESH - 1.5-27 phr BLOWING CHARACTER EBONITE N.R. 100-200 MESH 18-30 phr — (REDUCE CURE TIME) RUBBER (N.R./S.R.) 100-200 MESH 5-10 phr 100-200 MESH 5-10 phr SCOTCH TIME THERMOSET RESIN — 325 MESH 10-15 phr (FLAME PROPERTY) THERMOSET RESIN 100-200 MESH 10-15 phr 100-200 MESH 10-15 phr (MECHANICAL PROPERTY) THERMOSET RESIN — 325 MESH 10-15 phr (ANTISTATIC) RUBBER-LATEX (N.R./S.R.) — 325-400 MESH 5-15 phr ANTISTATIC RUBBER (N.R./S.R.) — 325-400 MESH 5-15 phr ANTISTATIC CONCRETE 100-200 MESH 10-15 phr 100-200 MESH 10-15 phr (MECHANICAL PROPERTY)
N.R.—NATURAL RUBBER
S.R.—SYNTHETIC RUBBER
- It will of course be realised that whilst the above has been given by way of illustrative examples of this invention, all such and other modifications and variations hereto, as would be apparent to persons skilled in the art, are deemed to fall within the broad scope and ambit of this invention as herein set forth. For instance, while the preceding examples relate to the use of fresh and/or carbonised rice husk it would be apparent to a person skilled in the art that other cereal husks such as sorghum husk may be suitable.
- Throughout the description and claims of the specification where reference is made to the dosage of fresh and/or carbonised rice husk, this dosage is expressed in terms of “phr” (parts per hundred) based on the weight of the composite material into which the rice husk is being introduced.
- Throughout the description and claims of the specification the word “comprise” and variations of the word, such as “comprising” and “comprises”, is not intended to exclude other additives, components, integers or steps.
- The claims are:
Claims (12)
1. A method for improving the mechanical properties of bitumen, said method comprising blending fresh and/or carbonised rice husk together with tyre crumb into said bitumen.
2. A method according to claim 1 wherein the rice husk has a particle size of from 100 to 200 mesh and the dosage of rice husk is between 40 to 60 phr.
3. A method according to claim 1 wherein the rice husk and tyre crumb is mixed in composition with a palm oil effluent prior to it being added to the bitumen.
4. A method according to claim 3 wherein the composition comprises about 50% tyre crumb, about 45% rice husk and about 5% palm oil effluent.
5. A method according to claim 3 wherein the composition is added in a dosage amount of about 20% by weight of the said bitumen.
6. A method for improving the blowing character of a thermoplastic resin this method comprising blending fresh and/or carbonised rice husk into said thermoplastic resin. wherein the rice husk has a particle size of between 325 to 400 mesh and the dosage of the rice husk is between 1.5 to 2.5 phr.
7. A method for improving the mechanical properties of thermoplastic resin including compression strength, said method comprising blending rice husk into said thermoplastic resin wherein said rice husk has a particle size of between 325 to 400 mesh and the dosage of the rice husk is between 1.5 and 2.5 phr.
8. A method for improving the blowing character of rubber said method comprising blending fresh and/or carbonised rice husk into said rubber.
9. A method according to claim 8 wherein the rice husk has a particle size of between 325 to 400 mesh and the dosage of the rice husk is between 1.5 and 27 phr.
10. A method for reducing the cure time of ebonite NR wherein said method comprises blending fresh rice husk into said ebonite NR. wherein the rice husk has a particle size of between 100 to 200 mesh and the dosage of the rice husk is between 16 to 30 phr.
11. A method for improving the scotch time of rubber said method comprising blending fresh and/or carbonised rice husk into said rubber.
12. A method according to claim 11 wherein the rice husk has a particle size of between 100 to 200 mesh and the dosage of rice husk is between 5 to 10 phr.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/082,585 US20050165140A1 (en) | 1999-01-18 | 2005-03-17 | Use of vegetative material as a filler in composite materials |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPP8198 | 1999-01-18 | ||
AUPP8198A AUPP819899A0 (en) | 1999-01-18 | 1999-01-18 | Conductive and flame retardant plastic fillers |
PCT/AU2000/000018 WO2000042116A2 (en) | 1999-01-18 | 2000-01-17 | Use of vegetative material as a filler in composite materials |
US09/889,610 US6875263B1 (en) | 1999-01-18 | 2000-01-17 | Use of vegetative material as a filler in composite materials |
US11/082,585 US20050165140A1 (en) | 1999-01-18 | 2005-03-17 | Use of vegetative material as a filler in composite materials |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2000/000018 Division WO2000042116A2 (en) | 1999-01-18 | 2000-01-17 | Use of vegetative material as a filler in composite materials |
US09/889,610 Division US6875263B1 (en) | 1999-01-18 | 2000-01-17 | Use of vegetative material as a filler in composite materials |
Publications (1)
Publication Number | Publication Date |
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US20050165140A1 true US20050165140A1 (en) | 2005-07-28 |
Family
ID=3812403
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/889,610 Expired - Fee Related US6875263B1 (en) | 1999-01-18 | 2000-01-17 | Use of vegetative material as a filler in composite materials |
US11/082,582 Abandoned US20050165137A1 (en) | 1999-01-18 | 2005-03-17 | Use of vegetative material as a filler in composite materials |
US11/082,585 Abandoned US20050165140A1 (en) | 1999-01-18 | 2005-03-17 | Use of vegetative material as a filler in composite materials |
Family Applications Before (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/889,610 Expired - Fee Related US6875263B1 (en) | 1999-01-18 | 2000-01-17 | Use of vegetative material as a filler in composite materials |
US11/082,582 Abandoned US20050165137A1 (en) | 1999-01-18 | 2005-03-17 | Use of vegetative material as a filler in composite materials |
Country Status (7)
Country | Link |
---|---|
US (3) | US6875263B1 (en) |
EP (1) | EP1257608A4 (en) |
KR (1) | KR20010101569A (en) |
CN (1) | CN1636045A (en) |
AU (1) | AUPP819899A0 (en) |
CA (1) | CA2359085A1 (en) |
WO (1) | WO2000042116A2 (en) |
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US20090084287A1 (en) * | 2007-09-28 | 2009-04-02 | Sierra Process Systems, Inc., A Corporation Of The State Of California | Incorporation of heat-treated recycled tire rubber in asphalt compositions |
US20090104458A1 (en) * | 2005-12-13 | 2009-04-23 | Ryu Hai-Il | Functional cornstalk board and preparation method thereof |
US20090118396A1 (en) * | 2007-11-01 | 2009-05-07 | American Wood Fibers | Process to manufacture wood flour and natural fibers to enhance cellulosic plastic composites |
JP2009114255A (en) * | 2007-11-02 | 2009-05-28 | Toyo Tire & Rubber Co Ltd | Rubber composition for tire sidewall |
US20100024337A1 (en) * | 2008-08-04 | 2010-02-04 | Eco*Centric, LLC | Materials, Methods and Compositions for a Composite Building Material |
US20140213675A1 (en) * | 2013-01-31 | 2014-07-31 | Feng Chia University | Biopolymeric material including modified natural fibres and the method for manufacturing the same |
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- 2000-01-17 CA CA002359085A patent/CA2359085A1/en not_active Abandoned
- 2000-01-17 CN CNA008028664A patent/CN1636045A/en active Pending
- 2000-01-17 US US09/889,610 patent/US6875263B1/en not_active Expired - Fee Related
- 2000-01-17 EP EP00902495A patent/EP1257608A4/en not_active Withdrawn
- 2000-01-17 KR KR1020017009017A patent/KR20010101569A/en not_active Application Discontinuation
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2005
- 2005-03-17 US US11/082,582 patent/US20050165137A1/en not_active Abandoned
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---|---|---|---|---|
US20090104458A1 (en) * | 2005-12-13 | 2009-04-23 | Ryu Hai-Il | Functional cornstalk board and preparation method thereof |
US7838578B2 (en) * | 2005-12-13 | 2010-11-23 | Hail-Il Ryu | Functional cornstalk board and preparation method thereof |
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US20100024337A1 (en) * | 2008-08-04 | 2010-02-04 | Eco*Centric, LLC | Materials, Methods and Compositions for a Composite Building Material |
US20140213675A1 (en) * | 2013-01-31 | 2014-07-31 | Feng Chia University | Biopolymeric material including modified natural fibres and the method for manufacturing the same |
Also Published As
Publication number | Publication date |
---|---|
US20050165137A1 (en) | 2005-07-28 |
US6875263B1 (en) | 2005-04-05 |
KR20010101569A (en) | 2001-11-14 |
WO2000042116A3 (en) | 2002-09-12 |
WO2000042116A2 (en) | 2000-07-20 |
CN1636045A (en) | 2005-07-06 |
EP1257608A1 (en) | 2002-11-20 |
AUPP819899A0 (en) | 1999-02-11 |
EP1257608A4 (en) | 2004-12-29 |
CA2359085A1 (en) | 2000-07-20 |
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