Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
  • C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J11/00—Recovery or working-up of waste materials
  • C08J11/04—Recovery or working-up of waste materials of polymers
  • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
• • 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
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L89/00—Compositions of proteins; Compositions of derivatives thereof
  • C08L89/04—Products derived from waste materials, e.g. horn, hoof or hair
  • C08L89/06—Products derived from waste materials, e.g. horn, hoof or hair derived from leather or skin, e.g. gelatin
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

• the present invention is concerning a composite containing vegetal fibers, industrial residues and mineral loads associated to thermoplastic resins and manufacturing process. More specifically, it encompasses a composite that allows the utilization of fibers and residues, not requiring the fibers and residues previous treatment nor the inclusion of oils or cerumens.
• INVENTION ANTECEDENT The use of vegetal fibers, in an isolated way or in a mixture with other materials, comes from long ago. In order to reduce the presence of cracks in bricks burnt in the sun, and also to make them lighter, various peoples turned to the vegetal fibers.
• the composites manufactured with vegetal fibers demonstrate physical and mechanical characteristics that make them useful for a number of applications, from roofs covering to storage tanks.
• the vegetal fibers show low cost, lightness, abundance, come from raw-material renewable sources, are biodegradable, do not pollute the environment, show high specific resistance and, in a generic way, a good set of mechanical properties.
• Various vegetal fibers as sisal, jute, coconut, cotton and banana pulp are being used as reinforcement in polymeric or matrices made of cement, partially or totally substituting synthetic fibers as nylon, glass or carbon, of higher cost.
• the utilization of the vegetal fibers and residues is a higher and higher need in the modern industry.
• the residues originating from the sawmills, furniture and transformation industry do not find adequate use, being usually destined for energy generation, for the recovering of chicken yard floors and for horticultural purposes. Part of the residues is simply burnt or laid in public places, deeply aggravating the environment issue.
• the technique state describes products and processes that use residues and/or vegetal fibers for the production of a compressed wood destined for industrial use.
• the patent JP31007334 presents a process for the production of an aggregate that has cellulosic material, such as rice husk, impregnated in a treatment solution that contains monoethanolamine, triethanolamine, aluminum sulfate and urea, in such a way to allow the efficient elimination of the acetic acid contained in the cellulosic materials and permitting the subsequent molding of the resin. Moreover, the process encompasses the thermal treatment stages between 100 and 250°C and the grinding. In a different way, the process object of the present invention uses cellulosic material without previous treatment.
• the patent US5939192 presents a process to provide a molding material that contains vegetal fiber particles, preferably wood or cellulose, impregnated in a solution that contains between 2 to 15% in weight/volume of the composition of acid resin, 10% in weight/volume of the composition of an oily fraction, among fats, oil and cerumen, and between 0,5 and 12% of polyois and salts.
• the process consists in heating the vegetal fiber and to soak it with the liquid solution, added by the thermal treatment stages and milling. Similar to the previous patent, it is expected previous treatment of the vegetal fiber particles, stage not necessary in the process object of the present invention.
• the patent BR9703918 presents a manufacturing process of synthetic compressed wood board produced from industrial and vegetal residues and an agglutinating element from these residues which, after the adequate combination by heating, undergoes calender, pressing and cooling, becoming boards commercially accepted.
• the synthetic compressed wood board characterizes itself for being composed from fibered materials rich in lignin, as rice husk, in natural state and previously dried, mixed with a synthetic element, such as polyethylene, polypropylene and other similar ones, in the adequate volume proportion.
• the patent request BR9603850 presents a compressed wood production process using a mixture of cashew nut liquid resin and various agricultural residues such as rice husk, coconut husk, wood scrapes, chestnuts skins, banana tree straw, for compressed wood production.
• These products present various applications in the construction business as well as in the furniture manufacturing, with humidity resistance characteristics, resistance to chemical agents decay and to the attacks of termites and other insects.
• the process object of the present invention does not foresee the addition of oil to the cellulosic material.
• patent BR0100419 presents a rice husk preparation process to be used with resins that comprises the stages of milling and drying the rice husk, with 2% to 10% adding of mineral and/or vegetal oil and/or fat of dry rice husk, plasticizers, pigments, among others, undergoing heating and the final stage of conformation.
• this process it is solely used rice husk with addition of mineral, vegetal oil and/or fats.
• different cellulosic material is used which does not require the addition of oils or cerumen, since one of the stages of the process involves the intrusion of the mixture.
• the processes described in the technique state incorporate a cellulosic material to a linking element as to form a homogeneous material proper to be formed, foreseeing stages of previous treatment of the cellulosic material and extrusion of the mixture for the boards formation. Nevertheless, there is still the need of simplifying the process and promote the association of vegetal fibers, industrial residues and mineral load in order to acquire composites with good mechanical properties, without the need of the fibers and residues previous treatment stage and including the intrusion stage in the boards production process.
• the open literature does not describe nor suggest a composite with vegetal fibers, industrial residues and mineral loads associated to thermoplastic resins that do not demand previous treatment of the fibers and residues nor the inclusion of oils and cerumens, such product and process being described and vindicated in the present request.
• the present invention regards a composite having vegetal fibers and/or industrial residues and/or mineral loads associated to a thermoplastic resin, providing a high resistance material.
• a composite manufacturing process that includes the vegetal fibers grinding stages or industrial residues milling, the thermoplastic resin mixture, the insertion of the mixture in the intruder in a temperature betweeri 80 and 300°C and the forming of the mixture in a chamber in a pressure between 05 to 1 ,500 kg/cm 2 . It is characteristic of the invention a manufacturing process of a composite having vegetal fibers, industrial residues and thermoplastic resins which does not require the stage of metric granulation treatment and specific hydroscopic. It is characteristic of the invention a process that does not need a previous stage of treatment of the fibers and residues nor the inclusion of oils or cerumens. It is characteristic of the invention the mixture processing capability, preferably, in closed molds.
• the composite, object of the present invention contains vegetal fibers combined with thermoplastic resins and/or industrial residues and a mineral load, in such a way to provide a product of high mechanical resistance.
• the composite contains vegetal fibers and industrial residues associated to a thermoplastic resin.
• the composite contains from 1.0 to 40.0% in weight/volume of the composition of vegetal fibers, from 1.0 to 40.0% in weight/volume of the composition of industrial residues and thermoplastic resins and a concentration between 20.0% to 98.0% in weight/volume of the composition.
• the composite contains industrial residues associated to a thermoplastic resin, cited composite that comprises between 1.0 to 80.0% in weight/volume of the composition of milled industrial residues and thermoplastic resins in a concentration between 20.0 to 99.0% w/v.
• the composite contains vegetal fibers associated to a thermoplastic resin, cited composite that comprises between 1.0 to 80.0% in weight/volume of the composition of vegetal fibers and from 20 to 99% in w/v of pure plastic resins or milled plastic residues.
• the composite contains industrial residues and a mineral load associated to a thermoplastic resin, cited composite that comprises between 1.0 to weight volume of the composition of a mineral load and from 20.0 to 98.0% w/v of thermoplastic resins.
• the composite contains vegetal fibers, industrial residues and mineral loads associated to a thermoplastic resin, cited composite that comprises between 1.0 to 23.0% in weight/volume of the composition of vegetal fibers, 1.0 to 23.0% in weight/volume of the composition of milled industrial residues, 1.0 to 24.0% in weight/volume of the composition of a mineral load and from 30.0 to 97.0% w/v of thermoplastic resins.
• the milled industrial residues incorporated to the mixture can be varied and multiples, in compliance with the composition proportion.
• All of the compositions proposed by the present invention have dyes and coalescing agents.
• the dye can be used in a concentration around 2.0% in weight volume of the composition and the coalescing agents around 2.0% w/v.
• the vegetal fibers can be selected among sawdust, compressed wood residues, rice husks, peanut, coffee, cocoa, cashew, cotton, fruits and cereals, corn straw, rice, wheat, soybeans, beans, sugarcane pulp, corncob, coconut fiber, ramee, jute, sisal, pineapple leaves, banana tree straw.
• the industrial residues can be selected among leather residues, natural and/or synthetic rubber, synthetic and natural textile.
• the mineral load can be selected among fiberglass, calcium carbonate and alike.
• thermoplastic resins can be used, solely or in combination: polypropylene, polystyrene, polyethylene, Acrylonitrile Butadiene Styrene (ABS), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyacetal, polymethyl methacrylate (PMMA), polycarbonate (PC), polymer anionic (PA), polyurethane (PU), ethylene vinyl polyacetate (EVA) and alike.
• the manufacturing process of the composite containing vegetal fibers combined with thermoplastic resins and/or industrial residues and mineral loads includes the stages of: a) Grind the vegetal fibers to a maximum metric granulation of 10 mm; b) Mill the industrial residues to a metric granulation less or equal to 10 mm.
• the industrial residues are micro sized; c) Blend the vegetal fibers and/or industrial residues and/or mineral loads with the thermoplastic resins; d) Make the mixture dense in a thermic line between 20 to 150°C; e) Insert the mixture in the intruder in a temperature between 80 to 300°C; f) Insert the plasticised mixture in a chamber with pressure level between 05 to 1,500 kg/cm 2 , cited mixture that shall be controlled by molecular fixation. Examples shall be presented next which must be considered only as illustrative of the present invention, thus, the purpose of the invention is not delimited by the same. EXAMPLES OF PREFERRED COMPOSITES: COMPONENT QUANTITY (% W/V)
• COMPONENT Leather scrapes Plastic resins The product acquired from the mixture of vegetal fibers, industrial residues and mineral loads associated to thermoplastic resins, object of the present invention, has its use indicated for the construction business as paving blocks, roofs covering, pallets, profiles, among others.

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• Chemical & Material Sciences (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Wood Science & Technology (AREA)
• Sustainable Development (AREA)
• Compositions Of Macromolecular Compounds (AREA)

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Cited By (14)

Citations (1)

• 2004
  • 2004-06-18 BR BRPI0402485 patent/BRPI0402485B1/pt active IP Right Grant
• 2005
  • 2005-06-15 WO PCT/BR2005/000113 patent/WO2005123840A1/en active Application Filing

Patent Citations (1)

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