Oyster shell-based material
A bio-based material made from oyster shells addresses inefficient recycling and environmental impacts by creating a durable, fire-resistant substitute for natural stones, enhancing sustainability and waste recovery.
Patent Information
- Application Number
- FR2024000685
- Authority / Receiving Office
- FR · FR
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2024-01-24
- Publication Date
- 2025-12-26
- Estimated Expiration
- 2034-01-24
AI Technical Summary
Current recycling methods for oyster shells are inefficient, and the extraction of rocks like granite and marble have a significant environmental impact, necessitating a sustainable alternative.
A bio-based material is created by mixing water-based acrylic resin, mineral powder, and oyster shell flakes to form a solid, non-toxic, fire-resistant, and durable material that can be molded into various forms and finishes, using oyster shells as a substitute for natural stones.
The material reduces the carbon footprint and effectively recycles inert waste, providing a sustainable alternative to traditional materials while maintaining mechanical strength and aesthetic versatility.
Abstract
Description
Title of the invention: Oyster shell-based material
[0001] The present invention relates to the creation of a sustainable bio-based material made from oyster shells from the Arcachon basin.
[0002] Today, 3,000 tons of oyster shells are collected annually in the Arcachon Basin. Recycling alternatives exist, such as processing them into powder for poultry feed, fertilizing agricultural land, or using them in the composition of innovative mortars; however, only 15% of these shells are currently recycled. Furthermore, the industrial extraction of rocks such as granite or marble has a significant environmental impact. Consequently, the material presented here is a substitute for these alternatives.
[0003] The device according to the invention makes it possible to reduce the carbon footprint and contributes to the recovery of these inert non-incinerable wastes.
[0004] The material is obtained by mixing water-based, solvent-free acrylic casting resin, mineral powder, and oyster shell flakes with a particle size ranging from 0 to 6 millimeters. These bind together to create a solid material. The material is non-toxic, has good mechanical properties, and is also fire-resistant and durable.
[0005] According to particular embodiments:
[0006] The material obtained by molding can be in various forms. It can be produced in the form of sheets whose dimensions can vary according to the intended purpose and use, or in free form.
[0007] The color of the material can vary from white to creamy white or even ivory white. It can be colored using natural liquid or powder pigments. The color of the oyster shell flakes can also vary from white to eggshell by cooking the oyster shell before or after crushing. The appearance can also vary depending on whether the surface of the material is successively sanded using abrasive papers of different grits. For example, to obtain a mirror finish, a final sanding with a 2000-grit abrasive disc or the application of a polish is possible.
[0008] Water-based impregnating agents can be used to make the product waterproof, allowing it to be protected from dirt or ultraviolet radiation.
[0009] The attached photo illustrates the invention:
[0010] Figure 1 shows the result obtained by mixing acrylic resin and oyster shell flakes with a particle size ranging from 0 to 4 millimeters. (Ivory white)
[0011] With reference to [Fig. 1], the product is produced by molding the material in a mold measuring 200 x 170 x 28 mm. The mold is carefully coated with a release agent, allowing the molded part to be removed after complete drying.
[0012] The mixture is made using a mixer and obtained by combining water-based, solvent-free acrylic casting resin, mineral powder and crushed oyster flakes with a particle size ranging from 0 to 4 mm.
[0013] The oyster shells were cleaned beforehand, soaked in a chlorinated water bath for several days, dried, crushed, and then sieved before use.
[0014] Dosage: The proportions are calculated based on the weight of each product used. The crushed oyster shells constitute the casting mix in a proportion equal to the weight of the mineral powder. Example: To create this 1.67 kg sample of material, we used 330 grams of acrylic resin + 670 grams of mineral powder and 670 grams of 0 / 4 mm oyster shell flakes.
[0015] The mixture was thus poured into the mold or formwork and then vibrated so as to avoid any formation of air bubbles which could reduce the mechanical properties of the material created.
[0016] The demolded sample [Fig. 1] was mechanically sanded using abrasive discs of 500 grains, then 1500 grains and finally 2000 grains.
[0017] The material according to the invention is particularly intended for the production of worktops, furniture and indoor and outdoor equipment as a substitute for natural stones (granite / marble).
Claims
Demands
1. Bio-based material substitute for natural stones characterized in that it is composed of water-based, solvent-free acrylic resin, mineral powder and crushed oyster shells.
2. Bio-based material according to claim 1 characterized in that the charge of crushed oyster shells constitutes the casting mixture in a proportion equal to the weight of mineral powder.
3. Material according to claim 1 or 2 characterized in that the particle size of the oyster flakes varies from 0 to a maximum of 6 mm.