A water channel produced from GRP cutting waste

Abstract

The invention relates to a water channel made of Glass Fiber Reinforced Polyester Matrix Composite (GRP) pipe-cutting waste.

Description

[0001] A WATER CHANNEL PRODUCED FROM GRP CUTTING WASTE

[0002] Technical Field of the Invention

[0003] The invention relates to a water channel made of Glass Fiber Reinforced Polyester Matrix Composite (GRP) pipe-cutting waste.

[0004] Background of the Art (Prior Art)

[0005] Plastics are widely used in many application areas such as packaging, aircraft, automotive, health, electronics and sports equipment thanks to their lightweight, easy-to-shape, user- friendly designs, long life, chemical resistance and low costs. Plastics contribute to an increased volume in the solid waste stream. Some plastic products, such as food packaging, are discarded shortly after purchase, while others have been reused repeatedly. Therefore, resource and environmental considerations have been integrated into the industrial planning and decision-making processes of governments, leading to the efficient use of resources, the reduction of environmental impacts of products through the reduction of solid waste and energy consumption, and the promotion of recycling. As is known, significant progress has been made in the recycling of polymers in recent years. However, recycling of composite materials remains difficult from an industrial point of view. Currently, there is limited commercial recycling for polymer matrix composites due to technological and economic constraints.

[0006] Glass fiber-reinforced polymers are mainly known as "Glass Fiber Reinforced Polyester (GRP)" because they are reinforced in polyester matrices. Due to its properties such as high strength, heat resistance, lightweight, corrosion resistance and electrical insulation, it is preferred in the aviation, railway, marine, electrical electronics, automotive and construction sectors.

[0007] Recycling of thermoset composites is inherently difficult due to their complex structure; in fact, thermoset resins are cross-linked and their combination with other materials causes problems. Therefore, most of the recycling activities to date are related to recycling as energy or fuel recovery and the use of recycled materials as fillers in the construction industry (e.g. as concrete admixtures). Today, polymer-based composites dominate the composites market, and among them, thermosets are more than two-thirds, but the use of thermoplastic composites is increasing rapidly. This is because fiber-reinforced polymer thermoplastic composites can be used efficiently as innovative materials for structural and semi-structural components such as door panels, seat backs, headliners, package trays, front panels and other car interiors. In particular, glass fiber reinforced thermoplastic composites are recyclable as well as their advantages such as high tensile and impact strength, high toughness, hardness and unlimited shelf life. In particular, polypropylene matrix composites are used for a large number of applications because they are inexpensive, can be recycled several times, have very good mechanical and thermal properties and have the lowest environmental impact among all other polymer composites. Fiberglass is made from glass fiber reinforcements added into thermosetting resin. In addition, aggregate, granular or lamella fillers can be used as auxiliary materials in production. By choosing the appropriate combination of resin, glass fiber, fillers and design, the manufacturer can produce a product that offers a wide range of features. These include reinforced thermoset resin pipe (RTRP), reinforced polymer mortar pipe (RPMP), glass fiber reinforced epoxy (GFRE), glass reinforced plastic (GRP) and glass fiber reinforced plastic (GFRP). Special production processes such as filament winding or spinning casting are used in the production of fiberglass pipes. Often, special resins such as epoxy, polyester or vinyl ester are used to produce fiberglass pipes.

[0008] Fiberglass pipe is used in many industries and in numerous applications including: • Chemical Processes, • Desalination, • Channel and Ventilation Pipes, • Geothermal, • Industrial Wastes, • Irrigation, • Oil Beds, • Drinking Water, • Power Plant Cooling and Raw Water, • Sanitary Sewerage, • Sea Water Inlet and Outlet, • Water Distribution, • Water Transmission applications.

[0009] Fiberglass pipe is a composite material system produced from glass fiber reinforcements, thermoset resins and additives. By choosing the right combination and amount of materials and the special production process, the designer can produce a product that will meet the most demanding requirements. Common characteristics of fiberglass composite pipe are:

[0010] Corrosion resistance: Fiberglass pipe systems are corrosion-resistant in a wide range of applications. Consequently, there is no need for internal linings and external coatings.

[0011] Power-to-weight ratio: Fiberglass composite pipe systems have excellent strength-to-weight characteristics. The strength ratio of fiberglass composites per unit of weight is higher than that of iron, carbon and stainless steel.

[0012] Lightweight: Fiberglass composites are mild. Fiberglass pipes are about one-sixth the weight of similar steel products and one-tenth the weight of similar concrete products.

[0013] Electrical characteristics: Standard fiberglass pipes are not conductive. Some manufacturers produce conductive fiberglass pipes for applications that require the distribution of static electricity that accumulates when transporting certain liquids, such as jet fuel. Dimensional stability: Fiberglass composites can maintain the critical tolerances required by the most demanding structural and pipework applications. The material meets the criteria of hardness, dimensional tolerance, weight and cost.

[0014] Low maintenance cost: Fiberglass pipes are easy to maintain because they do not rust, are easily cleaned and require minimum protection from the environment.

[0015] Physical Properties: The physical properties of the fiberglass pipe vary depending on the materials used in production and its design.

[0016] Chemical Resistance: All fiberglass pipes provide excellent resistance to water and natural ground conditions. General corrosion, galvanic corrosion, aerobic corrosion, pitting, and intergranular corrosion types are not valid for fiberglass pipes.

[0017] Abrasion Resistance: Fiberglass pipe has good abrasion resistance in general. In addition, flexible primer materials such as silica sand, silicon carbide, ceramic particles or polyurethanes can be coated on pipe surfaces and special designs can be made for highly corrosive environments.

[0018] UV Resistance: The structural integrity of the fiberglass pipe is not affected by UV light exposure. The use of pigments, paints, fillers or UV stabilizers in the resin system or painting of exposed surfaces can significantly reduce surface degradation by UV rays.

[0019] Resistance to Biologic Attack: Fiberglass pipe is in a content that will not deteriorate or break down under the attack of bacteria or other microorganisms and will not serve as food for microorganisms, macroorganisms or fungi. There is no known example of fiberglass pipe products being subjected to degradation or deterioration due to biological impact. No special treatment is required to protect the fiberglass pipe from biological attacks. Some elastomers used in gaskets may be susceptible to such attacks.

[0020] Temperature Resistance: The temperature resistance of the fiberglass pipe also depends largely on the matrix used. The permissible upper limit of service temperature will also be affected by the chemical environment and the voltage status of the pipe system. In general, chemicals are more aggressive at higher concentrations and higher temperatures. However, from the temperatures encountered in water supply systems [~1°C to ~30°C], the fiberglass pipe is not affected. Shipping and storage procedures can be used at temperatures below zero. However, users and installers of fiberglass pipes should be aware that the thermal expansion coefficient of fiberglass pipes is generally higher than that of metal pipes.

[0021] During the shortening of the pipe produced during the pipe production stages, the opening of the gasket channel and the shaping of the fittings, cutting waste occurs from the Glass Fiber Reinforced (GRP) composite pipe. The grain size of the waste is about 40 microns and below, and it is collected as sludge since it is cut with water.

[0022] The collected sludge is passed through the fdter system (filter press) and its water is partially removed. These wastes are taken by licensed disposal companies and buried in suitable lands and similarly removed from the environment. When compared with the production capacities of GRP pipe producers, for example, it is seen that approximately 2000 tons of similar waste is disposed of to nature every year in Ttirkiye. Cutting waste comes out of GRP pipe production during aqueous cutting and includes sand, glass fiber and polyester resin. Processes are applied to pulverize these wastes. The waste taken from the filter press machine is in a pellet.

[0023] First, these lumps are lumped. Then, these wastes are placed in the oven and moisture is removed. After removing from the oven, the crushed and sieved material becomes GRP waste powder.

[0024] The water channel of the invention is made of recycled GRP waste.

[0025] Descriptions of the Figures

[0026] Figure 1 : Exploded view of water channel

[0027] Figure 2: Water channel grid image

[0028] Figure 3: Water channel dimensions

[0029] Figure 4: Thermoset Matrix GRP Cutting Waste Additive Composite Water Channel Production Flow Chart

[0030] 1. Water Channel,

[0031] 2. Water Channel Grid

[0032] 3. Channel Cover

[0033] 4. Grid opening

[0034] 5. Legs

[0035] A=Body width

[0036] B=Ellipse horizontal diameter

[0037] C=Grid thickness

[0038] D=Ellipse vertical radius

[0039] Rf= Comer radius

[0040] E=Drain height

[0041] G=Body length

[0042] H=Support thickness J=K=L=M=Leg spacing

[0043] 6. N=Grid width

[0044] O=Hole initial grid start distance

[0045] P= Distance between grid openings

[0046] Detailed Description of the Invention

[0047] The water channel of the invention is a channel produced from the cutting waste of Glass Fiber-Reinforced Polymer (GRP) composite materials. This composite material contains 0.1% to 90% GRP cutting waste by weight in the composition of the thermoset matrix material (polyester, epoxy, vinyl ester, etc.).

[0048] As shown in Figure 1, the modular water channel comprises a U-shaped body (1), a grid (2) to cover the body, and channel covers (3) to secure the body and cover by locating at one or both ends of the body. The grid (2) comprises at least one grid opening (4). There are legs (5) at the bottom of the body (1) to keep it above the floor where the body is placed. In a preferred embodiment, the multiple bodies (1) can be mounted to each other from both ends without placing the channel covers (3), so that the desired length of the channel is obtained.

[0049] In an exemplary application of the invention, the Body length (G) can vary between 500- 6000mm. The distance (J, K, L, M) between the legs (5) is preferably between 90-400 mm. The width (A) of the U-shaped body (1) is preferably between 100-400 mm and the height (ellipse vertical radius) (D) is between 60-300 mm. The spacing of the grid openings (P) in the grid (2) is preferably between 50-300 mm.

[0050] The production method of the channel subject to the invention is as follows.

[0051] 1. GRP Cutting Waste Drying: Drying the waste from the fdter press

[0052] 2. Crushing: Size reduction in the crusher

[0053] 3. Sieving: Classification in different sizes

[0054] 4. Formulation and Mixing: Grain size selection and mixing with matrix material (polyester, epoxy, Vinyl ester, etc.)

[0055] 5. Forming and Curing: Forming and / or heating hardening with hot press and similar methods in different shaped molds

[0056] 6. Demolding and Finishing: Removing the solidified products in the mold, and surface treatments (edge correction, deburring, etc.)

[0057] 7. Product: Production of the water channel and fittings. Using the same composition, (U), (T) and Plus (+) shaped joint fittings with similar measurement ratios of the water channel can also be produced.

Claims

CLAIMS1. A channel made of Glass Fiber Reinforced Polyester Matrix Composite (GRP) pipecutting waste, characterized comprising a U-shaped body (1), a grid (2) structured to cover the body, and channel covers (3) located at both ends of the body, to fix the body and the grid.

2. The channel according to Claim 1, characterized in further comprising legs (5) to keep the body (1) above floor where the body (1) is placed.

3. The channel according to Claim 1, characterized in that the grid (2) further comprises at least one grid opening (4).

4. The channel according to Claim 1, characterized in that the length (G) of the body (1) is between 500-6000 mm, the width (A) is between 100-400 mm and the ellipse vertical radius (D) is between 60-300 mm.

5. The channel according to Claim 1, characterized in that the distance (J, K, L, M) between the legs (5) is preferably between 90-400 mm.

6. The channel according to Claim 1, characterized in that the spacing (P) between the grid openings (4) in grid (2) is between 50-300 mm.

7. The channel according to Claim 1, characterized in that it is made of thermoset matrix material containing 0. 1% to 90% by weight of glass fiber reinforced pipe cutting waste.

8. The channel according to Claim 7, characterized in that the thermoset matrix material is polyester, epoxy, or vinylester.

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