Use of polymer composites in the manufacture of beams, pre-molded components, and interlocking floors, as well as manufacturing methods.

Abstract

The present invention relates to a polymer matrix composite comprising, as components, sand, organic or inorganic fillers, polyester resin, organic peroxide initiator, polymer structure phase matching additive or flexibility-imparting additive. Furthermore, the present invention relates to a method for manufacturing the composite, and further to the use of the composite for manufacturing construction industry products including beams, columns, pre-molded roof tiles, sleepers, cross, girders, pre-molded gutters, interlocking floors, pre-molded construction panels, supports, poles, artificial stone for countertops and floors, floor panels used in bridges, pre-molded slabs, clad panels, and / or lattices. The composite offers many times the advantages compared to materials currently used in the manufacture of these products because it contains an optimized composition that combines ideal physicochemical properties to perform its intended function.

Description

Technical Field

[0001] The present invention relates to polymer composites and their use in the manufacture of beams, preformed members, and interlocking floors having high resistance to compression and bending.

[0002] In addition, the present invention also relates to polymer composites and methods for manufacturing beams, preformed members, and interlocking floors.

[0003] The application area of the present invention relates to the field of the construction industry. More specifically, it is designed for use in large structures that support heavy loads and apply preformed members such as beams. Furthermore, it relates to paved areas that require high resistance for the passage and storage of heavy objects such as containers in ports, airports, and industrial sites.

Background Art

[0004] Today, various types of beams, preformed members, and interlocking floors are known, especially rectangular interlocking floors, sixteen-sided interlocking floors, braille blocks, directional braille blocks, warning blocks, hollow interlocking floors, etc. are prominent.

[0005] Beams, preformed members, and interlocking floors can be used, among other things, in road construction, sidewalks, paving, squares, bicycle paths, club common areas, parking lots, outdoor areas of shopping malls, industrial floors, airport patios, container terminal patios, etc.

[0006] Currently, the world's concrete production volume is estimated to be about 10 km per year 3 and this value is continuing to increase due to the rapid development of urban infrastructure around the world. Therefore, new materials are being created to offset the use of natural resources in construction and minimize the impact on the environment. Interlocking blocks for the same function, manufactured using new materials in addition to concrete, fall into this category.

[0007] Beams, pre-formed members, and interlocking paving are inherently environmentally friendly, more durable than other types, and offer high drainage, low-frequency and easy maintenance, and lower costs. In interlocking systems, the members fit together like a jigsaw puzzle, allowing for individualization and rapid modification of members, reduced drainage and water return to the soil due to joints, and material savings.

[0008] The construction industry is one of the activities with the greatest impact on the environment because it consumes a large amount of natural resources. This sector utilizes 40-75% of natural resources, generating a considerable amount of residue. In Brazil alone, approximately 25% of industrial residue comes from the construction industry. In addition, the cement industry, while not directly generating solid residue (as ash from fuel combustion in rotary furnaces is usually incorporated into the clinka itself), generates significant emissions of gaseous pollutants and particulate matter. Therefore, the main impact is caused by the emission of polluting gases from this combustion. One example is the high emissions of carbon dioxide (CO2), one of the main greenhouse gases. Cement plants account for approximately 5% of the world's annual carbon dioxide (CO2) emissions released into the atmosphere from human activity sources. This is equivalent to approximately 2.8 billion tons of CO2 being released into the atmosphere annually. It is estimated that 1 ton of CO2 is generated in the production of 1 ton of clinka, significantly contributing to the increase in the greenhouse effect. The cement manufacturing process can release sulfur oxides along with nitrogen oxides, carbon monoxide, and lead compounds, all of which are pollutants. In addition, cement plants are one of the largest sources of mercury (Hg) emissions from human activity, accounting for approximately 1.71 tons of untreated or uncontrolled mercury releases into the atmosphere annually.

[0009] Concrete polymers, which use polymer resins as a binder, are a good choice for the construction industry in applications requiring high mechanical performance, durability, and rapid curing—essential properties for materials aimed at building sustainability.

[0010] Beams, pre-formed members, and conventional interlocking paving are made from naturally derived raw materials—river sand, rock sand, rock powder, additives, pigments, gravel, and cement with high resistance and rapid hardening properties. The materials used in the manufacture of interlocking paving, also known as blocks or simply plain interlocks, must meet the parameters of Brazilian standards ABNT NBR 9781:2013 Concrete parts for paving—Specifications and Assay Methods and ABNT NBR 15953:2011 Pavement Interlocked with concrete parts—Execution.

[0011] An alternative to these conventional blocks is recycled interlocking blocks made from construction residue (RCC) and demolition residue (RCD).

[0012] In addition, as can be seen from current technology, various researchers are working on developing alternative beds.

[0013] The document in European Patent Application Publication No. 2758353(A1) protects a mixture for obtaining polymer concrete, which consists of a portion of its volume of filler or infill and the remaining portion of a resin mixture, the resin mixture may be a resin to which a curing agent and accelerator have been added. Examples of the claimed resins are the use of polyester resin or acrylic resin. However, the document does not envision the use of DCPD (dicyclopentadiene) or the use of chemical additives to improve mechanical properties.

[0014] U.S. Patent No. 9,885,157 describes a method for installing paving tiles on a concrete base that prevents future damage to the tiles due to vehicle traffic. To achieve this, a mixture (bonder) is used to fix the tiles to the concrete. This mixture may include polymer latex, cement, sand, and a wettable powder. This composition creates a permanent bond between the tile and the cement base.

[0015] Portland cement is a globally accepted name for a material commonly known as cement in the construction industry. Portland cement is a fine powder with cohesive, binding, or adhesive properties that solidifies upon contact with water. Once solidified, Portland cement does not decompose even when exposed to water.

[0016] Portland cement was created by the British builder Joseph Aspdin and patented in 1824. At the time, it was common in Britain to use stone from Portland, an island located in the southern part of the country. Aspdin's invention resulted in a cement that resembled the color and hardness of this Portland rock, so he registered the name in his patent. This is why the cement is called Portland cement.

[0017] Most types of Portland cement currently on the market are used for general purposes. However, some have certain characteristics and properties that make them more suitable for specific applications, which can result in concrete or mortar with desirable resistance and durability.

[0018] Portland cement consists of clinker and additives. Clinker has limestone and clay as raw materials. First, the limestone is crushed, then pulverized, and then mixed with the pulverized clay in appropriate proportions. This mixture is then processed to finally produce a powder.

[0019] Additives are other raw materials that, when mixed with clinker during the grinding stage, enable the production of various types of Portland cement currently available on the market. These other raw materials include plaster, blast furnace slag, pozzolanic materials, and carbon materials.

[0020] Clinker is the main component and is present in all types of Portland cement. Additives can vary depending on the type of cement, and these additives primarily determine the different types of cement.

[0021] Preformed beams are frequently used in the construction of bridges and viaducts, buildings, and commercial warehouses, aiming to reduce time and construction costs through a streamlined construction process. The prestressing of the members allows them to accommodate various span sizes, making them suitable for diverse designs. Another advantage is the reduction in concrete and steel consumption through the use of more durable materials.

[0022] Beams are fabricated either without segments (called staves) or as a single unit, depending on the construction method. Generally, the first option is recommended for bridges and designs with large spans. In contrast, integrated members are used for spans up to 40 meters. The design should follow the slab-beam-column order from the standpoint of transmitting normal stresses. In the case of rectangular shapes, beams can be manufactured in various cross-sections and sizes depending on the specific aspect of the construction. All of these pre-formed members have an internal metal frame and are often prestressed.

[0023] Reinforced concrete beams and columns offer numerous advantages to construction because concrete beams connect vertical columns, and, most importantly, because beams are robust. Concrete beams are frequently used in slab-beam-column systems to transmit vertical stresses from the slab to the column, or to transmit concentrated loads when acting as support for the column. Concrete beams transmit the weight of the slab and other elements to the column. The use of concrete beams allows for the use of the most diverse design shapes in construction, making it entirely possible to carry out well-planned construction using columns, concrete beams, and slabs. [Overview of the project] [Problems that the invention aims to solve]

[0024] In light of current technology scenarios and in search of a novel alternative material applicable to the manufacture of beams, pre-formed members, and high-durability interlocking paving with or without metal frames, comparable to conventional Portland cement, the researchers of the present invention have developed a polymer composite that can be used to manufacture beams, pre-formed members, and high-durability interlocking paving for heavy traffic use without metal frames. This polymer composite comprises, as materials, sand, inorganic or organic filler, at least one dicyclopentadiene (DCPD)-based polyester resin combined with or not combined with virgin terephthalic (PET) resin or neopentyl glycol (NPG) resin, and at least one phase-matching additive or flexibility agent. This allows for the production of beams and pre-formed members with mechanical properties achieved without the use of an internal frame in the workpiece, and interlocking paving with mechanical properties for high-durability floors (for heavy traffic) using floor dimensions for light traffic.

[0025] Therefore, no existing technology offers a solution equivalent to the one presented in this invention, combining the technical differences, economic advantages, safety, and reliability.

Means for Solving the Problem

[0026] The present invention relates to a polymer composite composed of sand, organic or inorganic fillers, sand, inorganic or organic fillers, a polyester resin, an organic peroxide initiator, and an additive or flexibility-imparting agent having a polymer structure.

[0027] The present invention also relates to the use of the polymer composite in the production of highly resistant beams, preformed members, and interlocking floors, whose mechanical properties such as resistance to axial compression, resistance to four-point bending, water absorption resistance, and abrasion resistance are equivalent to or improved compared to the same processed products made from Portland cement under the same conditions and of the same size.

[0028] The present invention also relates to a method for producing the polymer composite, as well as beams, preformed members, and interlocking floors.

[0029] Furthermore, the present invention provides the ability to obtain beams and preformed members without using an internal frame, and the beams and preformed members exhibit mechanical properties equivalent to or better than those obtained from these preformed processed products made of reinforced concrete from conventional Portland cement. In addition, in the case of an interlocking floor, it is possible to achieve the value of a highly resistant floor, i.e., a floor applicable to the storage of heavy objects such as in a heavy traffic zone or a container, using a floor with light traffic floor dimensions.

Modes for Carrying Out the Invention

[0030] The present invention relates to a polymer composite made from sand, organic or inorganic fillers, sand, inorganic or organic fillers, a polyester resin, an organic peroxide initiator, and an additive or flexibility-imparting agent having a polymer structure.

[0031] The present invention also relates to the use of the polymer composite in the production of highly resistant beams, preformed members, and interlocking floors that can be used in the construction industry.

[0032] More specifically, the present invention relates to beams, pre-formed members, and interlocking floors for use in the construction industry, which have equivalent or improved mechanical properties such as resistance to axial compression, resistance to four-point bending, water absorption resistance, and abrasion resistance when compared to the same processed product made from Portland cement and manufactured under the same conditions and size.

[0033] The present invention also relates to polymer composites, as well as methods for manufacturing beams, pre-molded members, and interlocking floors.

[0034] Another aspect of the present invention relates to obtaining beams and pre-formed members without using an internal frame, wherein the beams and pre-formed members exhibit mechanical properties equivalent to or better than those obtained from conventional pre-formed products made from reinforced concrete made from Portland cement.

[0035] The present invention also relates to obtaining a highly durable interlocking floor, i.e., a floor that can be applied to heavy traffic zones or the storage of heavy objects such as containers, using floor dimensions suitable for light traffic.

[0036] Furthermore, the present invention relates to products defined as beams, pre-formed members, and interlocking floors obtained using composite materials for use in the construction industry.

[0037] According to the present invention, the composite material used to obtain beams, pre-molded members, and interlocking floors comprises: (a) sand; (b) at least one inorganic or organic filler, or a mixture thereof; (c) at least one polyester resin; (d) at least one organic peroxide initiator; and (c) at least one additive.

[0038] In the first aspect, sand is understood to be all types of sand known in the current art, including sand defined as construction sand, washed sand (also known as natural sand), mine sand, and quarry sand. Washed sand may be defined as fine-grained, medium-grained, and coarse-grained.

[0039] According to the present invention, organic fillers are understood to be any residues that can be used to impart specific properties or to make a product less expensive, such as, but not limited to, fly ash, sugarcane bagasse, or eucalyptus root, and other plant or mineral residues.

[0040] According to the present invention, inorganic fillers are understood to be any residues that can be used to impart specific properties or to make a product less expensive, such as silica, alumina, limestone, smelting sand, talc, gravel powder, plaster, lime, dolomite, bentonite, barite, attapulgite, saprolite, vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, gilsonite, etc., but are not limited thereto.

[0041] Polyester resin is a synthetic resin formed by the reaction of a dibasic organic acid with a polyhydric alcohol. According to the present invention, it is selected from the group consisting of orthophthalic acid, isophthalic acid, and / or terephthalic acid unsaturated polyester resin and PET monomer, either associated with each other or with other components such as dicyclopentadiene (DCPD) or neopentyl glycol (NPG). Dicyclopentadiene (DCPD), PET monomer, neopentyl glycol (NPG), or combinations thereof are preferred.

[0042] The organic peroxide initiator is selected from the group consisting of benzoyl peroxide, methyl ethyl ketone peroxide, tert-butyl peroxide, tert-butyl benzoate peroxide, and ditert-butyl dicumyl peroxide, and is preferably a moderately reactive methyl ethyl ketone peroxide blunted with dimethyl phthalate.

[0043] Furthermore, additives are defined as phase matching agents or coupling agents, or softeners. Phase matching agents are selected from the group including vinyltrimethoxysilane, methacryltrimethoxysilane, methacryloxypropyltrimethoxysilane, vinyltriethoxysilane, calcium diacrylate, zinc diacrylate, and combinations thereof, while softeners are selected from butyl acrylate, butyl methyl acrylate, methyl methacrylate, triethylene glycol methacrylate, ethylhexyl methacrylate, acrylic acid, methacrylic acid, and combinations thereof.

[0044] As described above, the primary objective of the present invention is a polymer composite useful for obtaining products applicable to the construction industry, defined as beams, pre-molded members, and interlocking floors.

[0045] A second object of the present invention is to obtain products that can be used in the construction industry, defined as beams, pre-molded members, and interlocking floors, by using polymer composites in their manufacture.

[0046] The beams and pre-formed members are manufactured without the use of an internal frame and exhibit mechanical properties equivalent to or better than those obtained from these pre-formed products made of conventional Portland cement reinforced concrete. The interlocking floors, using floors with light-traffic dimensions, achieve high-durability floors, i.e., values ​​for mechanical properties, water absorption resistance, and abrasion resistance suitable for heavy-traffic zones or storage of heavy objects such as containers.

[0047] According to the present invention, composite materials used in the manufacture of beams, pre-molded members, and interlocking floors consist of sand, organic or inorganic fillers, polyester resin, organic peroxide indicators, and additives defined as phase matching agents or softeners.

[0048] The sand used in the manufacture of the composite has a composition mainly of silica particles, but may also contain other minerals such as feldspar, mica, zircon, magnetite, ilmenite, monazite, and castellite. Commercially available sand usually contains moisture. In terms of granule size, in the manufacture of one preferred composite material, an average sand granule size (0.2 mm to 0.6 mm) is used, which has been pre-washed to remove most organic impurities, and dried to a moisture content of less than 1% by mass.

[0049] The amount of sand used is 30% to 97% by mass, based on the total mass of the composite composition. Preferably, the ratio is 47% to 94% by mass, based on the total mass of the composite composition, and more preferably, 55% to 85% by mass, based on the total mass of the composite composition.

[0050] The composite materials used in the manufacture of the processed products of the present invention, including beams, pre-formed members, and interlocking floors, further include the use of at least one organic or inorganic filler that acts as a filler for any spaces that may occur between sand grains.

[0051] Organic fillers are selected from the group including fly ash, sugarcane bagasse, eucalyptus root, or other plant or mineral residues, and inorganic fillers are selected from the group including silica, alumina, limestone, smelting sand, gravel powder, plaster, lime, dolomite, bentonite, barite, attapulgite, saprolite, vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, gilsonite, or mixtures thereof.

[0052] Fly ash consists of solidified material from a suspension of burner exhaust gases and is collected by an electrostatic precipitator or extracted by mechanical filtration. Due to solidification in a suspension under gas flow, the resulting particles are preferably spherical, often hollow or highly porous, and have a particle size of 0.5 μm to 100 μm.

[0053] Depending on the type of mineral impurities present in the charcoal, ash is primarily composed of silicon dioxide (SiO2), aluminum oxide (Al2O3), and iron oxide (Fe2O3). Ash possesses pozzolanic activity, meaning that it can react with calcium hydroxide and alkali at room temperature and in the presence of water to form calcium silicate hydrate, a compound capable of holding Portland cement. In other words, these formed compounds maintain cohesive force between the particulate aggregate and the cementitious matrix.

[0054] In the floor of the present invention, pozzolanic activity is not important because the matrix contains a polymer resin rather than Portland cement, and its curing reaction is a crosslinking reaction of polymer chains, which does not involve the formation of calcium silicate hydrate.

[0055] Gypsum, also known as plasterstone, is a calcium mineral composed of calcium sulfate dihydrate, with the chemical composition corresponding to the formula Ca(SO4)·2H2O. Generally, this mineral varies in color from white to translucent, and in addition to its low hardness on the order of 2.0, it has a mica-like flaky appearance, a pearly luster, and a smooth (or fibrous) feel. It is the most abundant sulfate in the Earth's crust, existing in evaporites or in the form of intermediate strata of shale, limestone, and clay, and can also be found in meteorites. Through calcination, gypsum loses its water of crystallization, and if the water of crystallization is retained, it can be converted to plaster (CaSO4·1 / 2H2O), or if the water of crystallization is completely lost, it can be converted to calcium sulfate (anhydrous gypsum) (CaSO4).

[0056] The primary use of gypsum is in the manufacture of cement, but it is also used in the production of sulfuric acid, chalk, glass, nail polish, plaster, and beer. In addition, plaster or calcium sulfate is used as a mold material, dehydrator, binder, and soil conditioner (a source of calcium and sulfur), and also has metallurgical applications (slag formation).

[0057] The filler is present in a ratio of 4% to 38% by mass, preferably 6% to 30% by mass, and more preferably 7% to 25% by mass, based on the total mass of the composite composition.

[0058] More specifically, the composite of the present invention contains ash, gypsum, or plaster in an amount that may be within the range of 4% to 38% by mass, preferably 6% to 30% by mass, and more preferably 7% to 25% by mass, based on the total mass of the composite composition.

[0059] The polyester resin present in the composite of the present invention is selected from the group comprising unsaturated orthophthalic acid, isophthalic acid, and / or terephthalic acid polyester resins, polyethylene terephthalate (PET), and polyethylene terephthalate (PET), which are associated with each other or with other components such as dicyclopentadiene (DCPD) or neopentyl glycol.

[0060] The resin is present in a ratio of 4% to 44% by mass, preferably 6% to 38% by mass, and more preferably 8% to 32% by mass, based on the total mass of the composite composition.

[0061] The resins primarily used are unsaturated polyester resins, which are also used in paints and adhesives. In the processed products of the present invention, including beams, pre-molded members, and interlocking floors, DCPD is used in an amount that may be within the range of 4% to 44% by mass, preferably 6% to 38% by mass, and more preferably 8% to 32% by mass, based on the total mass of the composite material composition.

[0062] Polyethylene terephthalate (PET) is also used, which is a thermosetting polymer developed in 1941. This polymer is formed by the reaction of terephthalic acid and ethylene glycol. The main uses of this polymer are in the form of textile fibers and beverage packaging. Therefore, this polyester has functional ester groups in its main chain, exhibits thermosetting properties, and can be reprocessed in countless cycles.

[0063] The industrial production of polyethylene terephthalate (PET) is carried out in two steps: prepolymerization and subsequent polycondensation. Prepolymerization produces the bee-terephthalate oligomer (2-hydroxyethylene) (BHET), which can be obtained through two different chemical routes. The second step, polycondensation, is the reaction that yields PET. The first chemical route for obtaining BHET is carried out by the direct esterification of terephthalic acid with ethylene glycol. This route is characterized by its heterogeneity and autocatalytic nature, meaning that no catalyst is required. The reaction temperature in this route is in the range of 240-260°C. In the second chemical route for obtaining BHET, terephthalic acid is replaced with dimethylene terephthalate ester, a catalyst is used, and the temperature range is 170-210°C. During the polycondensation reaction, water and methanol are removed as byproducts. In the present invention, the PET resin is used in the production of composite materials in the form of virgin PET monomers, which have the function of crosslinking the polymer matrix and conferring mechanical resistance to the resulting floor.

[0064] There is little literature in the current art concerning the use of PET as a filler in concrete for manufacturing processed products. There are reports that mention the use of shredded bottles and filaments for this purpose. In such cases, neither the filaments nor the particles obtained from the shredded bottles function as fillers and do not act as a matrix in the final material as applied in the case of the objectives of the present invention. In addition, the PET used in both the form of filaments and particles from shredded bottles is a thermosetting version of this polymer, meaning they are sensitive to temperature changes and may result in warping and deformation when used to obtain the processed products (beams, pre-molded members, and interlocking floors) of the objectives of the present invention. In contrast, the PET resin used in the composites of the present invention is a thermosetting resin that undergoes crosslinking during polymerization, ensuring that the final processed product does not deform or warp due to temperature changes and maintains its shape for a long period of time. Thus, this is an entirely novel and inventive use of PET in composite materials for obtaining the processed products of the present invention and / or for multifaceted purposes.

[0065] The composite of the present invention, used in the manufacture of processed products including beams, pre-molded members, and interlocking floors, contains PET monomer in an amount that may be in the range of 4% to 44% by mass, preferably 6% to 38% by mass, and more preferably 8% to 32% by mass, based on the total mass of the composite material composition.

[0066] Neopentyl glycol (NPG) is used in the synthesis of polyesters, paints, lubricants, and plasticizers. In the case of polyesters, NPG enhances the polymer's stability against heat, light, and water. Because NPG tends to be less susceptible to hydrolysis or oxidation compared to natural esters, it is also used in the production of esters used in synthetic lubricants.

[0067] Industrially, NPG can be obtained by the aldol reaction of formaldehyde and isobutyraldehyde, which produces the intermediate hydroxypivaldehyde, which can then be converted to NPG by hydrogenation in the presence of excess formaldehyde or otherwise using a palladium-carbon catalyst. Among its many applications, NPG can be used in particular as a protecting group for ketones, for example, in the synthesis of gestene, or as an organoboronic acid ester of NPG for application in the Suzuki reaction, a cross-coupling reaction widely used in obtaining fully substituted polyolefins, polystyrenes, and biphenyls. In the composite of the present invention, NPG is used in conjunction with a crosslinked polyester resin so that the final composite material has high thermal and dimensional stability.

[0068] The composites of the present invention, used to obtain beams, pre-molded members, and interlocking floors, contain an NPG-containing polyester resin in an amount that may range from 4% to 44% by mass, preferably 6% to 38% by mass, and more preferably 8% to 32% by mass, based on the total mass of the composite material composition.

[0069] The peroxide initiator used in the complex composition is selected from the group including benzoyl peroxide, methyl ethyl ketone peroxide, tert-butyl peroxide, tert-butyl benzoate peroxide, and ditert-butyl dicumyl peroxide. Preferably, methyl ethyl ketone peroxide is moderately reactive and blunted with dimethyl phthalate, and is used in a ratio of 0.05% to 6.0% by mass based on the total mass of the complex, preferably 0.075% to 1.5% by mass based on the total mass of the complex composition, and more preferably 0.10% to 0.85% by mass relative to the compound complex.

[0070] Methyl ethyl ketone (MEKP) is an organic peroxide with explosive properties similar to butanone peroxide. In STP, while butanone peroxide is a white powder, MEKP is a colorless, oily liquid. MEKP is slightly less sensitive to shock and temperature, and is more stable during storage. Depending on the reaction conditions, various adducts or direct addition products different from methyl ethyl ketone and hydrogen peroxide may be obtained. The first reported adduct was a cyclic dimer, C8H, in 1906. 16 It was O4. Subsequent studies have shown that linear dimers are the most frequently obtained adducts in the mixture of products, and this is the form that is commonly available commercially. 30-40% diluted solutions of MEKP are used by a wide range of users, including those in industry and those skilled in the art, such as as a catalyst to initiate crosslinking of unsaturated polyester resins. In this application, MEKP is dissolved in dimethyl phthalate, cyclohexane peroxide, or diallyl phthalate to reduce its susceptibility to impact. Benzoyl peroxide may also be used for the same purpose. MEKP is a highly irritating substance to the skin and can cause progressive corrosive damage or blindness.

[0071] The composites of the present invention used to obtain beams, pre-formed members, and interlocking floors also include a methyl ethyl ketone peroxide blunted with dimethyl phthalate in an amount that may range from 0.05% to 6.0% by mass, preferably 0.075% to 1.50% by mass, and more preferably 0.10% to 0.85% by mass, based on the total mass of the composite composition.

[0072] Furthermore, the complex of the present invention also includes additives defined as phase matching agents or softeners, which are selected from the group including vinyltrimethoxysilane, methacryltrimethoxysilane, methacryloxypropyltrimethoxysilane, vinyltriethoxysilane, calcium diacrylate, zinc diacrylate, butyl acrylate, butyl methyl acrylate, methyl methacrylate, triethylene glycol methacrylate, ethylhexyl methacrylate, acrylic acid, methacrylic acid, or combinations thereof, and are present in a ratio of 0.01% to 1.1% by mass relative to the complex, and the additives may be partially or completely replaced by a polymer structure softener.

[0073] Vinyltrimethoxysilane is a vinyl-functionalized silane with a reactive methoxy group. Its primary uses are as a crosslinking and grafting agent for the manufacture of high-density polyethylene cables and tubes. However, vinyltrimethoxysilane can be grafted onto various polymers, including various polyethylenes and polyesters. Due to the presence of the methoxy group, vinyltrimethoxysilane acts as a dewatering agent in coatings and adhesives. Vinyltrimethoxysilane can also be used in conjunction with aminosilanes in the synthesis of polyethers. Furthermore, vinyltriethoxysilane is also a vinyl-functionalized silane, but its reactive group is a two-carbon ethoxy group. It is also used as a coupling agent for polyolefins, primarily in polypropylene composites containing glass fibers.

[0074] The composite of the present invention contains vinyltrimethoxysilane or vinyltriethoxysilane in an amount that may be in the range of 0.01% to 1.1% based on the total mass of the composite composition.

[0075] According to the present invention, the object of the present invention is a composite material used in the manufacture of beams, pre-molded members, and interlocking floors, (a) sand; (b) at least one organic or inorganic filler; (c) at least one type of polyester resin; (d) at least one organic peroxide initiator; and (e) at least one additive, It consists of.

[0076] More specifically, the object of the present invention is a composite material used in the manufacture of beams, pre-molded members, and interlocking floors, (a) sand; (b) At least one organic filler selected from the group consisting of fly ash, sugarcane bagasse, eucalyptus root, or other plant or mineral residues; or an inorganic filler selected from the group consisting of silica, alumina, limestone, smelting sand, gravel powder, plaster, lime, dolomite, bentonite, barite, attapulgite, saprolite, vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, gilsonite, or mixtures thereof; (c) At least one polyester resin selected from the group consisting of orthophthalic acid, isophthalic acid, and / or terephthalic acid unsaturated polyester resins that are associated with each other or with other components such as dicyclopentadiene (DCPD) or neopentyl glycol; (d) at least one organic peroxide initiator selected from the group consisting of benzoyl peroxide, methyl ethyl ketone peroxide, tert-butyl peroxide, tert-butyl benzoate peroxide, ditert-butyl peroxide, and dicumyl peroxide, with methyl ethyl ketone peroxide being preferred as a moderately reactive agent desensitized with dimethyl phthalate; and (e) At least one additive designated as a phase matching agent or softener, selected from the group consisting of vinyltrimethoxysilane, methacrylictrimethoxysilane, methacryloxypropyltrimethoxysilane, vinyltriethoxysilane, calcium diacrylate, zinc diacrylate, butyl acrylate, butyl methyl acrylate, methyl methacrylate, triethylene glycol methacrylate, ethylhexyl methacrylate, acrylic acid, methacrylic acid, or combinations thereof. It consists of.

[0077] In addition, the composite material that is the object of the present invention is useful for obtaining beams, pre-molded members, and interlocking floors, and may also contain reaction accelerators, crushed rubber, glass fibers or metal fibers, metal or polymer structures, and finishing agents.

[0078] The reaction accelerator system is determined from the group selected from cobalt naphthenate, cobalt octoate, dimethylaniline (DMA), or mixtures thereof.

[0079] The accelerator system is mixed into the resin in an amount that may range from 0.05% to 8.0% by mass, based on the total mass of the complex. A ratio of 0.1% to 3.5% by mass is preferably used, and more preferably, a ratio of 0.1% to 3.5% by mass of cobalt naphthenate or cobalt octoate is used alone or in combination with 0.002% to 0.150% by mass of dimethylaniline (DMA), based on the total mass of the complex.

[0080] The crushed rubber originates from the tire and may be present in an amount of 0% to 45% by mass based on the total mass of the composite. Preferably, crushed rubber is used in a ratio of 0% to 20% by mass based on the total mass of the composite.

[0081] The glass or metal fibers may be short and uniformly distributed in the matrix, or they may be long and aligned in a single direction. The amount of fibers may be in the range of 0% to 8% by mass, based on the total mass of the composite, and preferably the ratio of glass or metal fibers is 0% to 3.0% by mass, based on the total mass of the composite.

[0082] The metal or polymer structure may be a wire or mesh and may be present in an amount that is in the range of 0% to 30% by mass based on the total mass of the composite. A ratio of 0% to 20% by mass based on the total mass of the composite is preferred.

[0083] The finishing agents include staining, polishing, etc., depending on the installation location of the beams, pre-formed members, and interlocking floors, which are the products obtained as defined above, and are related to the aesthetic interest or marking needs for the specified use.

[0084] The composite materials described in this invention can replace all or part of conventional Portland concrete used in the construction industry, including in the manufacture of beams, pre-formed members, and interlocking floors.

[0085] Composite materials offer countless technical and economic advantages compared to current technologies.

[0086] Among its advantages, researchers highlight its immense potential for use in a wide range of applications, such as the manufacture of panels, supports, crosses, and poles, due to its high mechanical resistance, excellent dielectric properties, chemical resistance to corrosion, low porosity, low water absorption, and even its lightweight nature.

[0087] Another advantage is related to the fact that products manufactured with the composite of the present invention are not susceptible to fungal growth and the resulting insect infestations that occur with products obtained using Portland cement. This is because the main fungi that grow on Portland cement feed on calcium and phosphates released as the concrete ages, which are not present in the composite material of the present invention. Therefore, in addition to being able to maintain the aesthetic characteristics of products manufactured using Portland cement, the composite of the present invention can also protect the health of people in the environment in which these products are installed.

[0088] The composite material of the present invention is resistant to decay, insect infestation, and sunlight, and its potential water absorption does not result in loss of hardness or other mechanical properties because this absorption is due to the potential porosity of the material, which prevents chemical reactions with water. As a result, products (beams, pre-molded members, and interlocking floors) deteriorate less over time compared to products made with conventional Portland cement. Compared to reinforced concrete, it exhibits impermeability and electrical insulation, and does not produce toxic components after hardening.

[0089] Products obtained using the composite material of the present invention (beams, pre-formed members, and interlocking floors) do not require a metal frame in their structure, as is the case with reinforced concrete. Therefore, structural corrosion problems do not occur, and the resulting products are highly homogeneous members, which enhances the reliability of the products.

[0090] Furthermore, when ash is preferably used as a filler, the composite reduces environmental risks because residue is reduced by using waste from the steel, thermoelectric, agricultural, sugar, and ethanol industries, or from any industrial process that burns biomass in boilers, and because water is not used in the manufacture of the composite, eliminating the need to treat wastewater.

[0091] Composite materials are (i) A process of drying the sand until the moisture content reaches 1% or less. (ii) A process of weighing all components, (iii) A step of obtaining a dry mixture consisting of sand and filler and homogenizing these components for about 20 minutes. (iv) A step of obtaining a liquid mixture consisting of additives and resin, then adding a peroxide initiator to the liquid mixture and mixing until homogeneous, (vi) Add the liquid mixture to the mechanical mixer, which contains a mixture of dry aggregates, and mix immediately for about 1-2 minutes, or until a homogeneous appearance is obtained. (v) A process for obtaining composite materials for use in the manufacture of beams, pre-formed members, and interlocking floors, It is manufactured containing [the specified ingredient].

[0092] According to the present invention, the composite material comprises (a) 70-85% sand; (b) 8-20% resin; (c) 6-25% filler; (d) 0.1-0.85% peroxide initiator; and (e) 0.01-0.85% additive.

[0093] More specifically, the composite material of the object of the present invention comprises (a) 70-85% sand; (b) 8-20% resin; (c) 6-15% ash, gypsum, or plaster; (d) 0.1-0.6% peroxide initiator; (e) 0.1-0.85% additives; and (f) 4-8% marble powder. The pre-accelerated resin may contain a reaction accelerator, preferably 1% cobalt naphthenate.

[0094] The developed beams, pre-formed components, and interlocking floors are (i) A process for manufacturing a composite material comprising the following steps: (a) drying the sand until the moisture content reaches 1% or less, (b) weighing all the components, (c) obtaining a dry mixture, (d) obtaining a liquid mixture, (e) putting the liquid mixture into a mechanical mixer, since it contains a mixture of dry aggregates, and mixing immediately for about 1-2 minutes, or until a homogeneous appearance is obtained (as described above). (ii) A process of molding a beam, pre-molded member, or floor using a mold that has a predetermined form and has been prepared by applying a layer of release agent, (iii) For large members such as beams and pre-formed members, the process involves pressing with a pressure on the order of 20 tons, and for small members such as interlocking floors, the process involves pressing with a pressure of at least 4 tons. (iv) A pre-curing process in a hothouse under atmospheric pressure at a temperature of approximately 60°C for 120 minutes. (v) A curing process under pressure and at an ambient temperature of approximately 25°C for at least 7 days. It was manufactured containing [the specified ingredient].

[0095] The product is molded over a period of 12 minutes, using a pressure of 4 tons for small components (interlocking floors) and 20 tons for large components (beams and pre-molded components). The aggregate specifications stipulate that the moisture content must not exceed 1%, and the specific gravity of the sand must be 2.65 g / cm³. 3 It should be, and the specific gravity of fly ash is 2.16 g / cm³. 3 It should be, and the specific gravity of gypsum is 2.32 g / cm³. 3 It should be such that the specific gravity of the plaster is 1.80-2.60 g / cm³. 3 It may vary within this range.

[0096] Estimated elemental chemical composition and morphology

[0097] To determine the morphology and estimated elemental chemical composition of the products of the preferred embodiments described above, assays were performed using a scanning electron microscope (SEM) of a model Inspect S50 FEI equipped with EDS. The samples of the preferred embodiments used were coated with gold to a thickness of approximately 10–20 nm. Analysis was performed using a secondary electron beam for morphological analysis and X-rays emitted for estimated elemental chemical composition analysis by EDS.

[0098] Microscopic images show a material with low porosity, a uniformly distributed aggregate phase, and excellent adhesion of aggregate to the polymer matrix. This differs from the state seen in conventional Portland concrete, which exhibits many internal phases generated during its manufacturing process, both during the curing reaction and aggregate addition. In the manufacturing process of conventional Portland concrete, high porosity due to open and closed pores is achieved through gas release during curing. EDS analysis revealed that this preferred embodiment has an elemental chemical composition of 45.36% carbon atoms, 25.73% oxygen atoms, 21.79% silicon atoms, 5.35% aluminum atoms, and 1.77% potassium atoms.

[0099] Thermal properties of the composite

[0100] To clarify the thermal properties, composites obtained using dicyclopentadiene (DCPD) resin were tested for their thermal properties, with the aim of determining both their thermal stability and their degradation profile. Samples of the present invention were analyzed using differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) techniques performed at a Center for Characterization and Materials Development (CCDM / DEMA / UFSCar) accredited laboratory.

[0101] Differential scanning calorimetry (DSC) identifies temperature-dependent differences in the energy supplied to a substance (sample) and a reference substance (standard), both of which are simultaneously subjected to a controlled temperature change program. Considering that phase transitions in materials occur under heat flow, either through their release (exothermic events) or absorption (endothermic events), phenomena such as solidification, melting, glass transition, oxidation, and hardening can be monitored. DSC curves of the same preferred embodiment were obtained using a Netzsch trademarked apparatus, Model DSC 214 Polyma, with a nitrogen gas flow of 50 mL / min, in a sealed aluminum pan, according to the following heating / cooling program: (a) heating from 23°C to 300°C at a rate of 20°C / min; (b) isothermal maintenance at 300°C for 5 minutes; (c) cooling from 300°C to 23°C at a rate of 20°C / min; (c) isothermal maintenance at 23°C for 5 minutes; and (d) heating from 23°C to 300°C at a rate of 20°C / min.

[0102] Analysis of samples of preferred embodiments of the present invention obtained using dicyclopentadiene (DCPD) resin shows that after 14 days of curing, there is slight residual curing with two endothermic events of 10 J / g and 20 J / g at temperatures of 114°C and 230°C, respectively, but the curing of the material can be considered substantially complete during this period. Conventional Portland cement concrete has a more intense curing process in the first 7 days, and the curing process can be considered substantially complete after 28 days. However, the curing of conventional Portland cement concrete can take up to 2 years to be completely finished, depending on the application.

[0103] Thermogravimetric analysis is an analytical technique that monitors the mass change of a sample as a function of temperature. Thermogravimetric analysis of the same preferred embodiment was performed using a TA Instruments brand thermogravimetric analyzer, model TA Q500, with a heating rate of 20°C / min, alumina pan, and a temperature range of 30°C to 850°C. In the first stage of the analysis, an inert nitrogen gas atmosphere was used with a temperature range of 30°C to 550°C and a flow rate of 50 mL / min. In the second stage of the analysis, an oxidizing oxygen gas atmosphere was used with a temperature range of 550°C to 850°C and a flow rate of 50 mL / min.

[0104] Thermogravimetric analysis of a preferred embodiment using dicyclopentadiene (DCPD) resin showed that up to 230°C, there was a slight removal of residual monomers and water on the order of 0.79 mass%, due to residual curing of the material. From 230°C to 550°C, a mass loss of 8.11 mass% was recorded, which corresponds to decomposed organic matter derived from polymer chains with smaller molar masses. At 850°C, 90.44 mass% residual ash was obtained. These results indicate that the material derived from the preferred embodiment using DCPD resin exhibits high thermal stability.

[0105] Flammability test

[0106] Furthermore, considering the thermal properties and fire susceptibility characteristics of the material of the present invention, a flammability test was performed on the same preferred embodiment. The flammability test was conducted at a CCDM-accredited laboratory in accordance with the IEC 60695-11-20:2015 Fire Hazard Testing Part 11-20:Test Flames standard. The results demonstrated that the material manufactured by the preferred embodiment using DCPD resin was flame-retardant, no visible flames were observed on the side opposite the evidence body, and no holes larger than 3 mm were formed in the test specimen after cooling.

[0107] Mechanical properties

[0108] In test specimens obtained according to the present invention containing dicyclopentadiene (DCPD) resin, the mechanical properties of resistance to axial compression and resistance to tensile compression due to radial compression were determined at the Falcao Bauer (Technology Center for Quality Control) accredited laboratory, in accordance with technical standards ABNT NBR 7680-1 / 2015 (ASTM C39) and ABNT NBR 7222:2011 (ASTM C496 / C496M), respectively. The resistance to axial compression was (70.5 ± 0.2) MPa, and the resistance to tensile compression due to radial compression was (6.1 ± 0.1) MPa. In typical embodiments of Portland cement, the value of resistance to axial compression is in the range of 10 to 45 MPa, and the value of resistance to tensile compression due to radial compression is in the range of 2 to 7 MPa, depending on its properties or the water / cement ratio used. Therefore, embodiments of the present invention using DCPD resin have higher resistance to axial compression than typical embodiments of Portland cement. This same preferred embodiment further exhibits resistance to tensile force due to radial compression equivalent to that achieved in a typical embodiment of Portland cement.

[0109] In two preferred embodiments using dicyclopentadiene resin, beam load tests were conducted by a major construction company in its Large Structures Laboratory on beams measuring 50 cm × 30 cm × 2.87 m, in accordance with standard ABNT NBR 9607:2019 (similar to ACI-318:2002). A total load of 21.5 tons was applied to the beams of the two preferred embodiments, and the arrow shape formed by the load on the beams was measured. No arrow shape was measured, meaning that the deformation of both beams subjected to a 21.5-ton load was 0 mm.

[0110] In samples of interlocking floors of the same preferred embodiment using dicyclopentadiene (DCPD) resin, abrasion resistance was determined by abrasion testing at the Falcao Bauer Technology Center for Quality Control accredited laboratory, in accordance with standard ABNT NBR 9781-1 / 2013 (ASTM C936 / C936M 20). The abrasion value obtained for the material of the present invention was 19.5 mm, which, according to standard ABNT NBR 9781 (ASTM C936 / C936M 20), is less than 20.0 mm. Therefore, this material is classified as having high abrasion resistance for interlocking floors.

[0111] Given that sleepers are in fact inverted bi-supported beams, several evaluations performed for these applications may be relevant in this invention. The main evaluations to consider include, among others, positive and negative moments, resistance to repeated loads on the support, and overload on the rail support, in preferred embodiments using dicyclopentadiene (DCPD) resin.

[0112] In a preferred embodiment using dicyclopentadiene resin, positive and negative moments were evaluated for the support and center sections at a LAEDE (Laboratory of Acoustics and Dynamic and Static Tests) accredited testing laboratory, in accordance with standards ABNT NBR 11709:2015 and AREMA:2019, using loads of 108.93 kN for the negative moment to the support section, 143.21 kN for the positive moment to the support section, 39.66 kN for the negative moment to the center section, and 27.76 kN for the positive moment to the center section. No damage, cracks, or fractures were observed at any point in the tested sleepers that behaved like an inverted cantilever beam.

[0113] The evaluation of repeated loads on the support structure, which may also be called fatigue testing, was conducted at a LAEDE (Laboratory of Acoustics and Dynamic and Static Tests) accredited laboratory in accordance with standards ABNT NBR 11709:2015 and AREMA:2019, using loads in the range of 14.32kN to 157.53kN, corresponding to a variation of 10-110% of the positive moment load on the support structure. In addition, a frequency of 7Hz was used for a total of 3 million loading and unloading cycles. No damage, cracks, or fractures were observed at any point in the sleepers manufactured from the preferred embodiment using the dicyclopentadiene (DCPD) resin of the present invention.

[0114] The load-bearing capacity of the sleepers against overload was evaluated by applying a force of 250.62 kN to their support at a rate of 50 kN / min. This overload was applied for 5 minutes at a LAEDE (Laboratory of Acoustics and Dynamic and Static Tests) accredited testing laboratory in accordance with standards NBR 11709:2015 and AREMA:2019, followed by unloading at the same rate. No damage, cracks, or fractures were observed at any point in the sleepers manufactured using the same preferred embodiment with dicyclopentadiene (DCPD) resin. Immediately thereafter, the sleeper support was loaded again at the same rate to the point of fracture, reaching a load of 318.30 kN.

[0115] The modulus of elasticity (MOE) and modulus of fracture (MOR) of the same preferred embodiment using dicyclopentadiene (DCPD) resin were tested at a LAEDE (Laboratory of Acoustics and Dynamic and Static Tests) accredited laboratory at a displacement rate of 127 mm / min, according to standards NBR 11709:2015 and AREMA:2019. When a load of 30.8 kN was applied, due to the high rigidity of the sleeper, there was insufficient bending to measure the arrow shape in its center. Based on this result, the MOE is estimated to be greater than 15 GPa. The modulus of fracture (MOR) identified for the sleeper manufactured and tested according to the preferred embodiment was 21.59 MPa. The value recommended by AREMA:2019 is greater than 17.2 MPa. The modulus of elasticity (MOE) was also tested according to standard ABNT NBR 8522:2017 (ASTM C469) and identified as 15.7 GPa.

[0116] Another preferred embodiment using PET monomer resin was evaluated for its mechanical properties, specifically resistance to axial compression and abrasion resistance. In addition, its water absorption capacity was also evaluated. All assays were performed at the Falcao Bauer Technology Center for Quality Control accredited laboratory, in accordance with standard ABNT NBR 9781-1 / 2013 (ASTM C936 / C936M 20). The results showed axial compression resistance of (64.9±8.2) MPa, abrasion resistance of 20.5 mm, and water absorption capacity of (5.4±0.3)%.

[0117] While examples of preferred embodiments of the present invention have been described, it should be understood that the scope of the present invention encompasses other possible modifications of the concept of the invention described herein and is limited only by the content of the appended claims, including potential equivalents. [Examples]

[0118] Example 1: Method for manufacturing composite materials

[0119] To manufacture the composite material, the sand is first dried until its moisture content reaches less than 1%.

[0120] Next, the components are weighed in predetermined proportions, and in one example of a preferred embodiment, it consists of 81% sand; 8.35% filler, preferably gypsum; 9.65% resin, preferably derived from DCPC; 0.38% initiator, preferably MEKP; and 0.62% vinyltrimethoxysilane additive.

[0121] After weighing, the dry compound sand and filler are mixed in a conventional mixer (industrial mixer or cement mixer), or manually if the amount of compound being manufactured is small, under pressure and ambient temperature conditions for approximately 20 minutes until completely homogenized.

[0122] The next step is the formation of an organic liquid mixture (referred to as syrup), which consists of adding an additive (a phase matching agent or softener, selected from the group including vinyltrimethoxysilane, methacrylictrimethoxysilane, methacryloxypropyltrimethoxysilane, vinyltriethoxysilane, calcium diacrylate, zinc diacrylate, butyl acrylate, butyl methyl acrylate, methyl methacrylate, triethylene glycol methacrylate, ethylhexyl methacrylate, acrylic acid, methacrylic acid, or a combination thereof), an unsaturated polyester of orthophthalic acid, isophthalic acid, and / or terephthalic acid, either associated with each other or with other components such as dicyclopentadiene (DCPD), or / or mixing for about 20 seconds to ensure homogeneity of the liquid phase. Subsequently, the initiator is added in liquid mixture to a moderately reactive methyl ethyl ketone peroxide blunted with dimethyl phthalate and homogenized for about 20 seconds.

[0123] Finally, add the dry mixture to the mixer, then add the liquid mixture and mix immediately for 1-2 minutes until a homogeneous appearance is achieved.

[0124] Example 2: Method for manufacturing beams, members and pre-molded parts, and interlocking floors

[0125] Using the composite material obtained according to Example 1, beams, pre-molded members, or floors are molded in a mold having a pre-established form and prepared by applying a layer of release agent. The release agent may be petrolatum, mineral oil, paraffin derived from plants, animals, or petrochemicals, a polymer solution of a linear polymer (polyethylene, polypropylene, polyalcohol vinyl, polyvinyl chloride, polytetrafluoroethylene), a polymer film, silicone, or a combination thereof.

[0126] For the manufacture of large components such as beams and pre-formed members, a press with a force of approximately 20 tons for about 30 seconds is used, while for the manufacture of smaller components such as interlocking floors, a press with a force of approximately 4 tons for about 30 seconds is used. After pressing, the components are sent to a heating chamber for pre-curing at atmospheric pressure and a temperature of approximately 60°C for 120 minutes, followed by a curing process under pressure and at a temperature of 25°C for at least 7 days.

Claims

1. sand, At least one type of organic or inorganic filler, At least one type of polyester resin, At least one organic peroxide initiator, and At least one type of additive A polymer composite characterized by containing the following:

2. The composite according to claim 1, characterized in that the filler is selected from the group consisting of fly ash or sugarcane bagasse or eucalyptus root or other plant or mineral residues, silica, alumina, limestone, smelting sand, talc, gravel powder, plaster, lime, dolomite, bentonite, barite, attapulgite, saprolite, vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, gilsonite, and combinations thereof.

3. The composite according to claim 1, characterized in that the polyester resin is selected from the group consisting of orthophthalic acid, isophthalic acid and / or terephthalic acid unsaturated polyester resins associated with each other or with other components such as dicyclopentadiene (DCPD) or neopentyl glycol (NPG), a thermosetting resin polyethylene terephthalate (PET) monomer, and combinations thereof.

4. The complex according to claim 1, characterized in that the organic peroxide initiator is a moderately reactive methyl ethyl ketone peroxide desensitized with dimethyl phthalate.

5. The composite according to claim 1, characterized in that the additive is a phase matching additive or a flexibility-imparting additive.

6. The composite according to claim 5, characterized in that the phase matching additive is selected from the group consisting of vinyltrimethoxysilane, methacrylictrimethoxysilane, methacryloxypropyltrimethoxysilane, vinyltriethoxysilane, calcium diacrylate, zinc diacrylate, and combinations thereof, and the flexibility-imparting additive is selected from the group consisting of butyl acrylate, butyl methyl acrylate, methyl methacrylate, triethylene glycol methacrylate, ethylhexyl methacrylate, acrylic acid, methacrylic acid, and combinations thereof.

7. The composite according to claim 3, characterized in that the resin is dicyclopentadiene present in an amount ranging from 4% by mass to 44% by mass, based on the total mass of the composite.

8. The composite according to claim 3, characterized in that the resin is a PET monomer present in an amount within the range of 4% to 44% by mass, based on the total mass of the composite.

9. The composite according to claim 3, characterized in that the resin is an orthophthalic acid unsaturated polyester resin present in an amount within the range of 4% to 44% by mass, based on the total mass of the composite.

10. The composite according to claim 3, characterized in that the resin is an isophthalic acid unsaturated polyester resin present in an amount within the range of 4% to 44% by mass, based on the total mass of the composite.

11. The composite according to claim 3, characterized in that the resin is a terephthalic acid unsaturated polyester resin present in an amount within the range of 4% to 44% by mass, based on the total mass of the composite.

12. The composite according to claim 3, characterized in that the resin is neopentyl glycol present in an amount ranging from 4% by mass to 44% by mass based on the total mass of the composite.

13. The composite according to claim 1, characterized in that the sand is preferably sand of average particle size and is present in a ratio of 30% to 97% by mass based on the total mass of the composite.

14. The composite according to claim 1 or 2, characterized in that it contains at least one type of filler in a ratio of 4% to 38% by mass based on the total mass of the composite.

15. The composite according to claim 1, characterized by comprising a reaction accelerator system, pulverized rubber and / or glass fibers or metal fibers.

16. The composite according to claim 15, characterized in that the glass fibers or metal fibers are short and uniformly distributed in the matrix, or long and aligned in a single direction.

17. The composite according to claim 1, further comprising a mesh in the form of layers or structures and a metal frame or a polymer frame.

18. The composite according to claim 1 or 13, characterized in that the sand contains silica particles and may also contain other minerals such as feldspar, mica, zircon, magnetite, ilmenite, monazite, and castellite.

19. The composite according to claim 2, characterized in that the ash comprises silicon dioxide (silica), aluminum oxide (alumina), and iron oxide (hematite).

20. A method for producing a polymer composite according to any one of claims 1 to 19, (i) The process of drying the sand, (ii) A step of weighing the solid materials constituting the composite, (iii) A step of mixing sand and at least one type of dry solid material which is a filler for 20 minutes until it is sufficiently homogenized. (iv) A step of weighing the liquid materials constituting the composite, (v) A step of mixing at least one liquid additive, which is a matching agent or a flexibility imparting agent, with the resin and homogenizing it thoroughly for 1 to 2 minutes to obtain an organic mixture also called a syrup. (vi) Add an initiator to the organic mixture or syrup and homogenize it for 1 to 2 minutes. (vii) Adding the prepared organic mixture to the mixture of dry components, (viiii) A step of homogenizing the formed substance for 1 to 3 minutes. A method that includes this.

21. The use of the polymer composite according to any one of claims 1 to 19, characterized in that it is for the manufacture of processed products selected from beams, columns, pre-formed roof tiles, sleepers, cross, girders, pre-formed gutters, interlocking floors, pre-formed construction panels, supports, poles, artificial stone for countertops and floors, floor panels used in bridges, pre-formed slabs, clad panels and / or lattices.

22. Use of polymer composites manufactured by the method of 20, characterized in that it is for the manufacture of processed products selected from beams, columns, pre-formed roof tiles, sleepers, cross, girders, pre-formed gutters, interlocking floors, pre-formed construction panels, supports, poles, artificial stone for countertops and floors, floor panels used in bridges, pre-formed slabs, clad panels and / or lattices.

23. The use according to claim 21, characterized in that the processed product is a beam, a pre-molded member, or an interlocking floor.

24. A method for manufacturing beams, pre-molded members and interlocking floors, (i) The process of drying the sand, (ii) A process of weighing the solid materials that make up the composite, (iii) A step of mixing sand and at least one type of dry solid material which is a filler for 20 minutes until it is sufficiently homogenized. (iv) A step of weighing the liquid materials constituting the composite, (v) A step of mixing at least one liquid additive, which is a matching agent or a flexibility imparting agent, with the resin and homogenizing it thoroughly for 1 to 2 minutes to obtain an organic mixture also called a syrup. (vi) Add an initiator to the organic mixture or syrup and homogenize it for 1 to 2 minutes. (vii) Adding the prepared organic mixture to the mixture of dry components, (viiii) A step of homogenizing the formed substance for 1 to 3 minutes. (ix) A process of forming a beam, pre-molded member, or floor using a mold having a predetermined shape and prepared by applying a layer of release agent. (x) For large members such as beams and pre-formed members, the process involves pressing with a pressure on the order of 20 tons, and for smaller members such as interlocking floors, the process involves pressing with a pressure of at least 4 tons. (xi) A step of pre-curing in a heating chamber at atmospheric pressure and a temperature of approximately 60°C for 120 minutes. (xi) A curing process under pressure and at an ambient temperature of approximately 25°C for at least 7 days. A method that includes this.

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