Formulation and procedure for the manufacturing of polymeric rectangular and quadrangular prisms

Abstract

The present invention is related to the area of construction, specifically to the formulation and procedure for the manufacturing of polymeric rectangular and quadrangular prisms for the construction of walls, slabs and roofs. The polymeric rectangular and quadrangular prisms consist in independent structures that produce defined structural formations and easy assembly in construction. The polymer modular structures of the present invention are conformed by a continuous phase, which is constituted by a polymeric matrix based in the mixture of virgin and / or recycled thermofusible plastics, obtained of polyolefin (homopolymer, copolymer and terpolymer) polyesters, polyalkylarenes, polycarbonate and their mixtures, as well as soluble additives in the same matrix; and by a discontinuous phase based in organic and inorganic loads.

Description

FORMULATION AND PROCEDURE FOR THE MANUFACTURING OF POLYMERIC RECTANGULAR AND QUADRANGULAR PRISMS.Field of Invention

[0001] The present invention is related to the area of construction, specifically to the formulation and procedure for the manufacturing of polymeric rectangular and quadrangular prisms for the construction of walls, slabs and roofs. Said polymeric prisms are internally conformed by continuous and discontinuous phases; also, agents of compatibility in-situ are used that promote the interaction of phases with a consequent improvement in the mechanical, physical, chemical and functional properties of interest for the area of construction. Additionally, by applying this invention, a reduction in the emission of unpleasant odors during the manufacturing and useful life of the polymeric prisms is obtained.Background of the Invention

[0002] In general, the construction of walls follows the traditional method of masonry, where geometric forms of polygonal prisms are employed through their manual placement and joining them through liquid materials that solidify, obtaining with this the union between pieces. It is preferable the use of rectangular prisms built of stone compounds such as clay, lime mortar and concrete, amongst others.

[0003] Recently, the stone compounds that compose the geometric forms are being replaced by plastic materials, whether in total or partial manner. There are numerous companies that have emerged, where they market a variety of designs in geometric forms and coin the generic name of blocks.

[0004] The plastic blocks are manufactured by conventional processes of molding by injection, employing thermoplastic compounds, virgin or recycled, based in polyolefin, PET, PC amongst other; as well as mineral and pigmented charges. Casan, C.A., in the patent of Spain No. 2277518B1 makes the combination of plastic structures of polyurethane expanded formed by injection, to which they join brick structures for the application of roofs and walls, but requires of silica based sealant to realize the union amongst the pieces and does not mention any formulation. They do not also mention about some of the additives that promotes the resistance to the environmental conditions.

[0005] Other patents exist where they only address the conformation of the plastic block, without offering more information over the formulation or nature of the plastic material as in the case of the patent of EE.UU. No.3668832 realized by Harman, J.D., where he described a plastic block to manufacture walls. Alvarez-Moysen, A.R., in the patent WO 2010 / 013991A1 mentions a system of blocks for the construction of walls, but only indicated the geometric form of the block and does not address the nature of the same and its formulation.

[0006] Other authors mention the manufacturing of blocks with plastic materials for the construction of walls with high transparency, for example, Sandor, FJ. in his patent of EE.UU. No 5261205 mentions methods and apparatus to manufacture panels of plastic blocks; where polycarbonate is used with the commercial name LEXAN to manufacture the blocks and does not mention the use of any type of additive to improve the properties of resistance to the environment. Kline, J.R. in his patent of EE.UU. No 5033245, described a block of architectonic construction formed by a plastic material that transmits light and looks like a block of glass; for the manufacturing, polycarbonate or acrylic or a plastic resin is used, without offering major information of the nature of the plastic resin and also does not mention the formulation or additives used to promote the stability to the environment.

[0007] Shieberl, D., in his application of patent in EE.UU. No. US2024 / 0003132 Al, mentions plastic blocks for the modular construction, where recycled plastic is used for the manufacturing, but does not offer more information over the nature of said plastic or the use of additives to promote some property of the block. The inventor Perez-Gonzalez, A.G. in his world patent WO 2017 / 155381 Al, describes a block for the construction of walls in an easy and fast manner, pointing out that the material of construction of a plastic block consist in PET and recycled PET, and another plastic with similar properties. But does not mention any formulation or composition to manufacture such block and also does not indicate any additive to promote stability of the blocks to the environment.

[0008] Knudson et al., in his patent of EE.UU. No. 6571529 B2, mentions a block of load-bearing wall resistant to the environment and method of use of the same. The block consists in a polymer material, rubber, glass fiber, plastic, silicon, vinyl or a combination of them, but does not offer any proportion of components and does not mention any use of an additive to promote the resistance to the environment. So that the block fulfills the functionality, he indicates that the retaining wall requires of a filling material such as sand, gravel, rocks and other similar materials.

[0009] Nunez-Vargas, M., in his patent of EE.UU. No. 8297012 B2, indicates a construction module made of multiple layers of hollow plastic blocks, said blocks are manufactured of recycled PET. He does not mention anything about the formulation or use of additives that permit its stability to the environment.

[0010] Wong et al., in his application of the patent in EE.UU. No. 2020 / 0038772 Al, mentions a block that is built based on acrylonitrile-butadiene-styrene-terpolymer (ABS), polycarbonate or another plastic that has a high degree of strength and rigidity. He also indicates that the block can be made of clay, ceramic, concrete or another rigid material, as well as wood and metal for example aluminum and alloys. To connect said blocks, a glue, cement or mortar must be used. He does notmention anything about the formation or use of additives that permit the improvement of any physical or functional property as stability to the environment.

[0011] Whitaker, J., in the application of the patent of England Ni. 2420453 A, provides a plastic block of construction that incorporates a drainage channel. The block is constituted by PVC and can incorporate fillers, dyes, pigments and fire retardant; he also mentions that the blocks are hollow to promote the thermal isolation, but does not indicate proportion of components or the properties of resistance to ultraviolet light or the use of promoters of stability or aids to the process during its manufacturing.

[0012] Bouchillon, J.L, in his patent of EE.UU. No. 2593480, mentions a block of construction of plastic shell, where the block has a high resistance in construction, excellent resistance to the transmission of humidity, gas and sound, as well as resistance to the environment, putrefaction, insects and is fireproof. The block is based in the use of thermoplastics as polyolefin, polyvinyl, polyesters and cellulosic; it also includes thermoset plastics as polyesters and polyvinyl, formable elastomers type phenol-formaldehyde, melamine, etc. The inventor mentions that the formulation can contain stabilizers, loads, pigments, dyes, fire retardants, fungicides and insect repellent. Also, the use of an adhesive is necessary to join said blocks and the nature of the adhesive comprehends elastomeric cements such as PU, epoxy, ketones and esters, either in water emulsion or in a solution. This patent does not contemplate the use of organic loads of natural origin nor of compatible agents that promote the interaction of polar and non-polar components in the formulation of the block, it does not also address the use of aids of process for the manufacturing of the same.

[0013] Currently, the plastic blocks are manufactured through the molding process by injection, where the raw material is treated and conditioned to then mix it and so integrate its different components. It then passes to an extruder to melt and homogenize the components; being thispoint of process critical, because usually the deterioration of the polymers occurs by effect of the temperature and high efforts of the cut. Large smoke emissions are also generated with unpleasant smell that can remain a long time in the block, even after its fabrication. Finally, it passes the process of injection to form a block, where commonly flow problems of the melted material occur in the mold, deformations in the product caused by mixes or deficient melting, as well as overheating of the product. An important aspect to highlight is the energy consumed in these processes that comes influenced by the temperatures used, which are supplied by resistances arranged along the extruder or injector, and also by the effort of the motor to move the melted mix realized. In cases where the melted mixes have viscosities or lack the sufficient homogeneity, problems can arise during the injection and generate products with deficient quality. The problems of manufacturing enunciated in the previous paragraph come by formulations and non-controlled processes, which can be remedied with the present invention.Summary of the Invention

[0014] An objective of the invention is to provide a formulation for the manufacturing of polymeric rectangular and quadrangular prisms; consisting of a continuous phase integrated by the mixing of thermofusible plastics, virgin or recycled, obtained of polyolefin (homopolymers, copolymers or terpolymers) polyesters, polyalkylarenes, polycarbonates and their mixes; as well as one or various soluble additives in said phase, that confers properties of physical and chemical resistance. Additionally, the polymeric rectangular and quadrangular prisms have a discontinued phase based in organic and inorganic loads. On the other hand, in this invention, in-situ compatibility agents are used, which promote the interaction of components between the phases of the polymeric prisms, improving the mechanical-structural properties, as well as the resistance to humidity, ultravioletlight, the microbiological attack and the fire retardant; also the stability of color and the absence of unpleasant odors during the fabrication and useful life is promoted; which is to say, the mechanical, physical and chemical stability of the modular arrangement under environmental conditions is promoted.

[0015] Another objective of the invention is to provide a formulation for the manufacturing of the polymeric rectangular and quadrangular prisms that is friendly to the environment by taking advantage of post-industrial waste or other wastes of organic origin categorized as problematic to the environment for its elevated generation or its low use.

[0016] An additional objective is to provide a method of manufacturing of polymeric rectangular and quadrangular prisms for the industry of the construction, where the emission of unpleasant odors and quality failures in the final product are prevented.Detailed description of the invention

[0017] The present invention is related with the formulation of polymeric rectangular and quadrangular prisms, which novelty lies in the use of a continuous phase that is constituted by a polymer or a mix of thermoplastic polymers pure o recycled, selected of homopolymers, copolymers or terpolymers of polyolefin, polyesters, polyalkylarenes, polycarbonates and their mixes; as well as compatible additives with said polymer matrix. The discontinuous phase is formed by organic and inorganic loads that form small particles distributed uniformly in the polymer matrix. Additionally, compatible agents are used that promote the integration of components between both phases.

[0018] The balance of components in the formulation of polymeric rectangular and quadrangular prisms, permits to take place the manufacturing process controlled in temperatures of residence, pressure, viscosity of injection and processing times. As consequence the processing equipmentwear is reduced, the burr generation at the moment of molding diminishes, the thermic stability during the processing and its useful life is promoted, also the emission of smoke that generate unpleasant odors is eliminated. With the above, the cost of process is reduced and when the polymeric prisms are used in the construction of walls, slabs and roofs, there is a savings in raw material and time of construction.

[0019] In the present invention, the polymer matrix is constituted by one or a mix of thermoplastic polymers pure or recycled, including homopolymers or copolymers of the family of polyolefin; some examples include in a nonexclusive manner the polyethylene of high density (HDPE), low density (LDPE) and lineal of low density (LLDPE); polypropylenes with isotactic, syndiotactic and atactic molecular structure are included; copolymers of ethylene such as ethylene vinyl acetate (EVA), ethylene propylene diene methylene (EPDM), ethylene propylene methylene (EPM), copolymers of ethylene propylene. In the present invention the use of one or a mix of polyethylene of high density, low density, lineal of low density or polypropylene with the structures before described are preferred; the amount of such polymers is of 0.1% in weight to 98% in weight, in a preferred manner 1% in weight to 90% in weight, and in a more preferred manner of 5% in weight to 80% in weight of the total amount of components.

[0020] The polymer matrix can also be conformed of a mix of polyesters, for example the polyethylene terephthalate (PET) with diverse molecular weights and linear or branched conformation to some degree. Also polycarbonate can be used in the formulation. The use of both families of polymers is of 0.0% in weight to 98% in weight, in a preferred manner of 0.1% in weight to 80% in weight and in a more preferred manner of 0.5% in weight to 70% in weight of the total amount of components.

[0021] The polymer matrix is also formed by one or a mix of homopolymers or copolymers of alkylarene and its derivatives; as examples are polystyrene, poly (alpha-methyl styrene), poly (ortho-methyl styrene), poly (para-terbutyl styrene) or a mix of the same. In this invention the polystyrene in an amount of 0.1% in weight to 90% in weight, in a preferred manner of 0.1% in weight to 50% in weight and in a most preferred manner of 0.1 to 15% in weight of the total amount of components.

[0022] The polymer matrix is also constituted of thermoplastic recycled polymer coming from the industrial waste of printed packaging, clothes whose origin is polyester, etc. The present invention makes use of these recycled materials, whether alone or combined with thermoplastic polymer virgin or recycled; the amount used is of 0.1% in weight to 98%, in a preferred manner of 0.1% in weight to 90% in weight and in a most preferred manner 0.5% in weight to 80% in weight of the total amount of components.

[0023] The industrial processes for the preparation of the homopolymers, copolymers or terpolymers described in the present invention, use processes of classic polymerization for free radicals, anionic, condensation and Ziegler Nata. The polymers obtained have defined composition, molecular weight and microstructure controlled. So that the polymers maintain their structural and functional integrity, normally additives are used that confer special properties of physical or chemical resistance, depending on the application in which the product is directed.

[0024] Within the additives considered in this invention the plasticizers are found, which are organic compounds that are incorporated to the homopolymers, copolymers and terpolymers to increase their flexibility and facilitate their transformation. The plasticizers reduce the glass transition temperature (Tg), conducing to a reduction in the elastic module of the mix and reducing the viscosity of the same in melted state. The efficiency of a plasticizer is directly influenced by the amount used to achieve the property of interest.

[0025] The plasticizers used in this invention, whether it's in a pure o mixed manner, comprehend organic compounds of paraffinic, naphthenic origin, organic phosphates, monoester, diester, triester of organic acids, anhydrides, glycerol and mono di and polyalkyl glycols, all of them witharomatic, aliphatic or epoxy structures. The comparability of the plasticizers in the polymer matrix is based in the polarity similarity that directly influences in the property of permanence (no migration). For example, of plasticizers based in phosphate are in triphenyl phosphate (TFF); another group of metallic salts of organic acids comprehends the octyl epoxy stearate and calcium stearate. In this invention the diester and trimester plasticizers of organic acids pure or mixed with other plasticizers of different chemical nature are preferred, amongst the preferred plasticizers are the dioctyl adipate (DOA) or mixes of esters of glycol di-benzoate esters. It is also preferred the use of plasticizers based in esterified glycerol with mono, di or polyunsaturated organic acids; as example of them the epoxidase soybean oil (ESBO), epoxidase linseed oil (ELO), Castor oil, palm oil, corn oil, but is not limited to use other types of oils or plasticizers of vegetable or animal origin or derived of petroleum. The use of plasticizers based on esters of aromatic organic acids such as dioctyl phthalate (DOP) and derived are prohibited in this invention for the regulatory restrictions that exist.

[0026] In the present invention it is preferred the use of epozidized soybean oil, dyoctyl adipose or mixes in an amount of 0.01% in weight to 25% in weight, in a preferred manner 0.05% in weight to 15% in weight and in a most preferred manner 0.05% in weight to 10% in weight of the total amount of components.

[0027] Another group of additives used in the present invention, comprehend the aids in process. Such compounds are used to diminish the friction forces and reduce the wear of bodies in friction, as it happens with the polymer matrix, the organic and inorganic loads with the walls of the mixing equipment, extruders, injectors and molds. When an excessive friction occurs, the compounds of the machinery tends to wear and eventually a permanent damage occurs by the elevated abrasion or torque force. Another additional problem is the deficiency in melting, caused by the lack of homogeneity in the mixing and undesirable defects in the quality of the finished product. The aids in process have low compatibility with the polymer matrix, therefore, they tend to form a boundarylayer between the material to mix and the metallic surface of the mixing equipment. The aids of process are based in metallic salts of organic acids, paraffin waxes, polyolefin of low molecular weight and dialkyl amides. In the present invention the use of stearate acid, stearate of calcium, calcium palmitate, stearate of zinc, zinc palmitate or stylene bis streamside (EBS) or a mix of them is preferred, in an amount of 0.01% in weight of 20$ in weight, in a preferred manner 0.1% in weight to 15% in weight and in a most preferred manner 0.5% in weight to 10% in weight of the total amount of components.

[0028] All the polymers during their processing are submitted to high temperatures, high shear stresses and exposure to oxidizing compounds that promote their degradation. To avoid such undesirable effects, in the present invention antioxidant systems are used that protect the polymer matrix of the thermal degradation during the different stages of the procedure. With this, the thermal stability is promoted during the life time of the use of the product and prevents the emission of unpleasant smoke caused by the degradation of the polymer. An important aspect of the present invention is the elimination of carbonization points in the final product.

[0029] The antioxidants are organic compounds based in different chemical structures amongst which the phenol hindered by alkyl radicals are found, organic compounds of phosphate, phosphonate and thioesters. The polymers that present tertiary carbons are susceptible to the thermal degradation by oxidation, forming free radicals that in the presence of oxygen form peroxides that cut the polymer chains, fragmenting the polymer. The phenolic antioxidants work capturing the free radical and forming an inert species for the polymer; examples of these antioxidants are Pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxiphenyl) propionate) under the commercial name of Irganox 1010 or Dovernox 10, Octadecyl-3(3,5 -di-tert-butyl-4- hydrophenyl)-propionates with the commercial name of Irganox 1076 or Dovernox 76. The dialkyl ester of thiodipropionic acid comprehend another group of antioxidants that contain the elementof sulfur, the advantage of which lies in that the products of degradation do not produce coloration in the polymers; two examples of these types of antioxidants are Didodecil-3, 3'-thiodipropionic under the commercial name of Irganox PS 800 and the acid 3, 3'-thiodipropionic dioctadecylester with the commercial name of Irganox PS 802.

[0030] Some antioxidants based in hindered phenol tend to form coloration of yellow to pink, when a large degradation has occurred on the same. In the present invention, the use of the antioxidants based in thioester is preferred, whether alone or mixed when the polymer matrix gives origin to rectangular prisms of light colors; for example, these compounds are found in Irganox PS 800 and Irganox PS802, used in an amount of 0.01% in weight to 10% in weight, in a preferred manner 0.01% in weight of 0.01% in weight to 5% in weight and in a most preferred manner 0.01% in weight to 3.0% in weight of the total amount of components.

[0031] Another group of antioxidants are the organic compounds alkyl and aryl (phosphide and phosphonate) which offer greater or lesser thermal stability depending in the chemical structure and conditions of reaction. All the phosphides and phosphonates are secondary antioxidants that decompose peroxides generated during the thermal degradation; some examples of antioxidants based in phosphide or phosphonate are Bis-(2,4-di-tert-butyilphenol) pentaerythritol diphosphate under the brand Irgafos 126 and the reis(2,4-di-ter-butylphenol) phosphide with the commercial name of Irgafos 168 or Doverphos 480. In the present invention, antioxidants are used based in phosphides Irgafos 126, Irgafos 168, Dystearyl Pentaerythritol Diphosphate with commercial name of Doverphos S-680, as well as other base phosphide antioxidants of alkyl phenol as are Doverphos L GP-11 and Doverphos LGP-12, whether alone or in combination, used in the amount of 0.01% in weight of 15% in weight, in a preferred manner 0.01% in weight to 10% in weight and in a most preferred manner 0.01% in weight to 7% in weight of the total amount of components.

[0032] In the present invention the mixture of hindered phenol antioxidants or thioester, together with phosphides or phosphonate is used to take advantage of the synergy existent amongst both. The proportion of hindered phenol or thioester: phosphide or phosphonate is in the interval of 0.001:1.0 until 1.0:0.001, respecting the amount of the total of components described in the previous paragraphs.

[0033] A family of additives of great importance added in the polymer matrix of this invention are the stabilizers of light, also called protectors of ultraviolet light. The ultraviolet rays that come to the earth surface have sufficient energy to cause the rupture of covalent bonds of diverse polymers, generating yellowing and loss of mechanical properties. Change of color also occurs in pigmented surfaces. The stabilizers of light absorb the ultraviolet light and emit their energy in another wavelength that does not result prejudicial for the polymers, for example in the form of heat. Amongst the stabilizing compounds of light, the alkoxybenzophenones, benzotriazoles, acrylonitriles substituted and derived of hindered amine called Stabilizers of Light by hindered Amine (HALS).

[0034] The stabilizers of light known as absorbers of UV light comprehend the alkoxybenzophenones and benzotriazoles. The compounds HALS are in charge of sequestering the formed radicals, generating a compound that is active to react with peroxide and finally releases the molecule HALS active, along with harmless compounds for the polymer.

[0035] In the present invention the use of absorbers of light are preferred alone or mixed with sequesters of radicals. The relation of UV absorbers and sequesters between 0.001:1.0 to 1.0:0.001. Examples of absorbers of UV light are Phenol, 2(5-chlorine-2H-benzotriazol-2-yl)-6-)l,l- dimethylethly)-4-methyl known with the commercial name of Tinuvin 326; the Methadone, 2- hydroxy-4-(octyloxy)-phenyl under commercial name of Chimassorb 81 of BASAF o LA-1413 of Amfine Chemical Corp.; the 2phenol, 2-(2H-benxotriazol-2-il)-4-(l,l,3,3,-tetrametibutyl) withcommercial name of Tinuvin 329; the Phenol, 2(2H-benzotriazol-2-yl)-4,6-bis(l-methyl-l- phenilethyl) with commercial name of Tinuvin 326 of BASF o LA-36 of Amfine Chemical Corp., hydroxiphenylbenzotriazol with commercial name of Tinuvin 329 of BASF o LA-29 of Amfine Chemical Corp, and Tinuvin 234 in an amount of 0.001% in weight to 15% in weight, in a preferred manner 0.01% in weight to 10% in weight and in a most preferred manner 0.01% in weight to 7.0% in weight of the total amount of components. Examples of sequesters type HALS are found 1,6- hexanediamina, N-N'-bis (2,2,6,6-tertramethyl-4-piperidin-il),2,4,6-trichloride-l,3,5-triazina, N- butyl-l-butylamina and N-butyl-2,2,6,6- tertramethyl-4-piperidineamina known as Chimassorb 2020; mix of HALS high molecular weight along with zinc oxide and octadecanoate which commercial name is Tinuvin 494; commercial mix Chimassorb 119 and Tinuvin 622 which commercial name is Tinuvin 111; commercial mix of Chimassorb 944 and Tinuvin 622 also known as Tinuvin 783; the Poly((6-((l,l,3,3-tetramethylbutyl) amino) =l,3,5-triazan-2,4-di) ((2, 2, 6, 6- tetramethyl-4-piperidynl)amino)-l,6-hexadenyl((2,2,6,6-tetramethly-4-piperidinyl)amino)) commercially known as Chimassorb 944; one hindered amine derived of triazine which commercial name is Tinuvin NOR 371 and one hindered amine with the commercial name of Tinuvin XT200.

[0036] In the present invention the use of one or a mix of the stabilizers of light mentioned in the above paragraph is preferred in an amount of 0.001% in weight to 20% in weight, in a preferred manner 0.01% in weight to 15% in weight and in a most preferred manner 0.01% in weight to 10.0% in weight of the total amount of components.

[0037] Other additives used in the invention correspond to the flame retardants (RF) or intumescent. The use of these materials increase the resistance of the polymer matrix to the ignition; which is to say, the rate of heat release is delayed and the rate of flame propagation is reduced, which leads to stopping or delaying a fire and let the people trapped manage to escape.When a polymer burns, thermo-oxidative reactions occur that reduce the hydrocarbon chains tomonomers or oligomers that because of the effect of high temperatures are oxidized to CO2, water and other products of the degradation.

[0038] When a non-protected polymer is exposed to a source of ignition, high temperature or fire, this tends to break down, generating gases of combustion and in the presence of oxygen with temperature, a flame is originated that increases in intensity, provoking more degradation of the polymer and so encourages a cycle of degradation thermos oxidized.

[0039] The mechanisms to delay the fire spread consists in using halogenated or phosphorous organic compounds; another method uses the physical barriers generated during the process of combustion where the passage of heat and the emission of fuel gases is difficult. The current regulations restrict the use of flame retardants of halogenated compounds. In the present invention, halogenated compounds are not used for the formulation and manufacturing of polymer rectangular and quadrangular prisms.

[0040] Other flame retardant compounds are red phosphorus, but has little use since it can form toxic gases of phosphine in presence of humidity. The compounds based in ammonium phosphate are polar materials, having the inconvenience of being soluble in water.

[0041] The flame retardants bases in phosphate or synergistic combinations with nitrogen derivatives generate intumescent mixtures, which is to say, compounds that when burned they swell and form layers or scabs that prevents the exchange of gases and serve as a thermic barrier. The ammonium polyphosphates have limited solubility in water and normally are used in combination with pentaerythritol or a derivative of pentaerythritol as carbon agent and melamine as foaming agent. Some preferred compounds in the present invention contemplate commercial intumescent products such as Aflammit PPN903, Aflammit PPN 967, Aflammit PPN 978, ADK-STABPP-2100JC and ADK STAB FP-2500S.

[0042] Another family of flame retardants are compounds based on nitrogen. The advantages are low toxicity, they don't generate dioxins or acidic substances and the emission of smoke is less. An example of these type of products is a derivative of triazina N-alcoxi hindered amine with commercial name FLAMESTAB NOR 116.

[0043] In the present invention, the use of flame retardant products or intumescent described in previous paragraphs is preferred, whether alone or forming mixtures, being used in amounts of 0.01% in weight to 30% in weight, in a preferred manner 0.1% in weight to 25% in weight, in a most preferred manner 0.1% to 15% in weight of the total amount of components.

[0044] Another group of flame retardants are inorganic compounds based in metal hydroxides, hydrates and carbonates with different degrees of fineness or particle size; for example, the aluminum hydroxide, aluminum tri hydrate and magnesium hydroxide. A disadvantage in using this type of materials is that a great amount is used in the formulation to achieve the effects of flame retardant and this leads to a drastic drop of mechanical properties of the polymer, affecting the process and rheology of the mixtures. Other inorganic compounds of interest are magnesium carbonate, Nesqueonite, hydro magnesia, calcium hydroxide, bohemite, magnesium phosphate heptahydrate, calcium sulphate dehydrate (plaster), calcium hydroxide and lime (calcium oxide that when hydrated forms calcium hydroxide). The flame retardants considered in the present invention contemplate the inorganic compounds described previously, whether alone or forming mixtures and are found in the amounts of 1% in weight to 50% in weight, in a preferred manner 1% in weight to 40% in weight and in a most preferred manner 5% in weight to 30% in weight of the total amount of components.

[0045] In the present invention compatible agents are used that favor the interaction between the continuous and discontinuous phases of the polymeric prisms, in addition to promoting the adherence between its components, the dispersion between mineral loads and the polymers isimproved, improving the stability of the system. For such effect, they use compounds from the organosilane family, which generic formula is Rl-Si- (R2)3, where R1 is an alkyl group whether alone or united in epoxy, vinyl, amino, carboxylic or thio groups, and R2 is an alkyl or alkoxide group (-OR). Amongst the silanes, mono, di, tri and multifunctional silanes can be used.

[0046] The silanes react with themselves or with inorganic substances that have hydroxyl groups in their chemical structure, for example, minerals, glass and organic compounds with hydroxyl groups. On the other hand, the same molecule can react with organic substances only if it has reactive groups and in absence of them, the interaction will only be physical. For example, silanes with epoxy groups will react with substances that contain amino groups, hydroxyl, acids and water; mentioning the discontinued phase constituted by fragments of vegetable fibers, will contain protein, cellulose, hemicellulose, lignin and starches, all of them reactive to the functional epoxy group.

[0047] Some silanes used in the present invention whether alone or in mixtures of them are the following: vinyltrietoxisilane whose commercial name is Silquest A-151NT of Momentive or Z-6518 of Dow Corning; vinyltrimetoxisilane with commercial name of Silquest A-171 of Momentive or Z- 6300 of Dow Corning; gamma-aminopropiltrietoxisilane with commercial name of Silquest A-1100, octiltrietoxisilane with commercial name of Silquest A-137 of Momentive or Z-6341 of Dow Corning, gamma-glicidoxipropiltrimetoxisilane with commercial name of Silquest A-187, hexadeciltrimetoxisilane with commercial name of Silquest HDTMS. These examples are only a fraction of the diverse structures of silanes that can be used in this invention, but is not limited to the use of them depending on the physical-chemical property desired. In this invention the use of silanes is used in a pure o mixed manner in an amount of 0.01% in weight to 20% in weight, in a preferred manner 0.1% in weight to 10% in weight and in a most preferred manner 0.1% in weight to 7% in weight of the total amount of components.

[0048] One of the aspects of the invention is that the formulation of the rectangular and quadrangular prisms is based in a polymeric matrix that constitutes a continuous phase; and in addition one discontinuous phase composed by organic and inorganic loads. A load is defined as a material that is added to the formulations to reduce cost, without substantial affectation of the mechanical and rheological properties and of color of the polymer matrix. When the loads have very low densities such as organic loads, a weight loss of the final product is achieved and with it, a reduction of price.

[0049] The inorganic loads used in the modification of plastics are the calcium carbonate, alkaline earth metal sulfates, silicates, silicas and other oxides. The inorganic loads of this invention contemplate the use of one or mixture of compounds before described, amongst which are found calcium carbonate, hydrated magnesium silicate (talcum), lime (calcium oxide), calcium sulfate dehydrate (cast), zinc oxide, zinc sulfide, barium sulfate, glass microspheres and mica; the amounts considered in this invention are 1% in weight to 50% in weight, in a preferred manner 5% in weight to 35% in weight and in a most preferred manner 5% in weight to 25% in weight of the total amount of components.

[0050] An important point of the invention is that the polymeric prism has resistance to the microbiological attack, given that some components of the same act as loads and inhibitors of the growth of microorganisms, such is the case of the Lime (calcium oxide) and zinc oxide. The amounts used for the effects of the inhibition of microbiological growth is found included in the interval described in the above paragraph.

[0051] Other compounds that form the discontinuous phase of the polymeric rectangular and quadrangular prisms are the organic loads, which modify and influence in the following aspects: 1) Reduce the total density of the block, 2) reduce cost and 3) depending of the nature of the organic material, it will provide properties of mechanical resistance. On the other hand, when organicY1particles of reduced size are introduced, they will be mixed in the polymeric matrix in a uniform manner, obtaining mixtures with controlled mechanical properties.

[0052] When organic loads are used with a tubular conformation or in fibers, an increase in mechanical properties are obtained; in such cases, the loads are reinforcing. The reinforcing loads used in this invention are of natural origin, amongst which are wheat, rice and oat husks, almond shell, sugar cane fiber, agave fiber, cranberry fiber, corn husks, sawdust and in general, all organic material that contain a mixture of cellulose, hemicellulose, starch, lignin or their derivatives. For its use in the invention, they must be grinded to a fiber length of 0.1mm to 30mm and in a preferred manner 0.1mm to 15mm and in a most preferred manner of 0.1mm to 5mm. An important point to consider is the humidity contained in the organic loads, since a lower amount leads to a better process and less quality defects in the final product; the maximum humidity is 15% in weight and the most preferred less than 10% in total weight of the organic fiber. The amount used in the organic load in the present invention is of 1% in weight to 80% in weight, in a preferred manner 1% in weight to 50% in weight and in a most preferred manner 1% in weight to 30% in weight of the total amount of components.

[0053] Another aspect of the invention consists in the use of organic and inorganic pigments, which give color to the polymeric rectangular and quadrangular prisms. The pigments have the size of a very fine particle, which promotes an adequate dispersion in the polymeric matrix or continuous phase. An example of organic pigment is the black in smoke (pure carbon).

[0054] The inorganic pigments are used with more frequency for their thermic stability and ease of obtaining them; examples of these pigments are titanium dioxide for white, different metal oxides as iron for ochers, browns and reds; chromates like the one based in lead for yellow, zinc for green, etc. The ultramarine pigments are complex combinations of silica, alumina, NaOH and sulfur; the amount of inorganic pigments used in the present invention are of 0.01% in weight to 50% in weight,in a preferred manner 0.1% in weight to 20% in weight and in a most preferred manner 0.1% in weight to 10% in weight of the total amount of components.

[0055] The method of manufacturing the polymeric rectangular and quadrangular prisms of the present invention where the emission of unpleasant odors and quality failures in the final product is prevented, consist of 3 steps: 1) Conditioning of raw material, 2) Mixture of components and 3) Molding by injection or intrusion.

[0056] In the first step, the thermoplastics coming from industrial waste are selected and grinded to a size between 0.01mm to 30mm, in a preferred manner 0.1mm to 15mm and in a most preferred manner 0.1mm to 5mm. In the case of organic loads coming from natural fibers, they are grinded to a size of a fiber described beforehand, then they go to a dryer to remove the excess moisture so to not interfere during the process of melting and injection. The rest of the raw materials described in this invention, do not require an additional conditioning and are used just like they are given by the supplier.

[0057] The second step consists in weighing the components in accordance to each formulation and after mixing them, using the conventional mixer. The virgin or recycled thermoplastics, organic and inorganic loads, compatible agents, antioxidants, flame retardants, stabilizers of UV light, aids of process, plasticizers and pigments are added. Subsequently, the mixture is passed to an extruder and cutter where the pellets are obtained. The control of temperature prevents the degradation of the polymeric matrix and organic components, avoiding the generation of unpleasant smoke; this control is fundamental, being between 80 C to 250 C, in a preferred manner of 100 C to 220 C, in a most preferred manner of 120 C to 200 C.

[0058] The third step consist in realizing the molding by injection or intrusion, where the pellets coming from the second step are introduced with an equipment of conventional injection. The temperatures of process are found between 80 C and 250 C, in a preferred manner of 100 C to 220C, in a most preferred manner of 120 C to 200 C. The pieces so formed are rectified in dimensions to comply with the requirements defined in the specifications of quality.

[0059] The invention for the formulation and manufacturing of the polymeric rectangular and quadrangular prisms are obtained of the mixture of pure and recycled thermoplastics consisting in polyolefin (homopolymer, copolymer and terpolymer) of polypropylene, polyethylene (HDPE, LDPE and LLDPE), Ethylene vinyl acetate (EVA), polyesters such as PET, polyalkylarenes such as polystyrene, polycarbonates and their mixtures in an amount of 0.1% in weight to 98% in total weight of the components. Additionally, the use of the monoester, diester and triester plasticizers of organic acids, anhydrides, glycerol and mono, di and polyalkyl glycols, all of them aromatics, aliphatic and epoxidase, which are present in amounts of 0.05% in weight to 15%, in a preferred manner of 0.01% in weight to 25% in weight and in a most preferred manner 0.05% in weight to 10%. Also included aids in process based in salts of organic acids, polyolefin and dialkylamides present in an amount of 0.01% in weight to 20% in weight, in a preferred manner 0.1 % in weight to 15% in weight and in a most preferred manner 0.5% in weight to 10% in weight of the total amount of components.

[0060] As a thermic stabilizing system the antioxidants base hindered phenol or thiols are included and are present in amounts of 0.01% in weight to 10% in weight, in a preferred manner 0.01% in weight to 5% in weight and in a most preferred manner 0.01% to 3.0% in weight of the total amount of components. Also included the antioxidants base phosphide, being present in an amount of 0.01% in weight to 15% in weight, in a preferred manner 0.01% in weight to 10% in weight and in a most preferred manner 0.01% in weight to 7.0% in weight of the total amount of components. As stabilizers of ultraviolet light, the absorbers of benzophenones and benzotriazoles or their mixtures are included, present in the amount of 0.01% in weight to 15% in weight, in a preferred manner 0.01% in weight to 10% in weight and in a most preferred manner 0.01% in weight to 7.0% in weightof the total amount of components. Additionally, sequesters of radicals type HALS are included in an amount of 0.001% in weight to 20% in weight, in a preferred manner 0.01% in weight to 15% in weight and in a most preferred manner 0.01% in weight to 10.0% in weight of the total amount of components.

[0061] Other additives used in the invention are fire retardants and / or intumescent, organic or inorganic, being present in an amount of 0.01% in weight to 50% in weight, in a preferred manner 0.1% in weight to 40% in weight, in a most preferred manner 0.1% to 30% in weight of the total amount of components. Additionally, in-situ compatible agents are found in the organsilanes with generic formula is Rl-Si- (R2)3, where R1 is an alkyl group whether alone or united in epoxy, vinyl, amino, carboxylic or thio groups, and R2 is an alkyl or alkoxide group (-OR). Amongst the silanes, mono, di, tri and multifunctional silanes can be used; being present in an amount of 0.01% in weight to 20% in weight, in a preferred manner 0.1% in weight to 10% in weight and in a most preferred manner 0.1% in weight to 7% in weight of the total amount of components.

[0062] As inorganic loads, carbonates and sulfates of alkaline earth metals, silicates, silicas and other oxides are found, in amounts of 1% in weight to 50% in weight, in a preferred manner 5% in weight to 35% in weight and in a most preferred manner 5% in weight to 25% in weight of the total amount of components. As organic loads we find wheat, rice and oat husks, almond shell, sugar cane fiber, agave fiber, cranberry fiber, corn husks, sawdust and in general, all organic material that contain a mixture of cellulose, hemicellulose, starch, lignin or their derivatives, being present in the invention in amounts of 1% in weight to 80% in weight, in a preferred manner 1% in weight to 50% in weight, and in a most preferred manner 1% in weight to 30% in weight of the total amount of components. Finally, the organic and inorganic pigments are included in an amount of 0.01% in weight to 50% in weight, in a preferred manner 0.1% in weight to 20% in weight and in the most preferred manner 0.1% in weight to 10% in weight of the total amount of components.

[0063] The formulation and process for the manufacturing of rectangular and quadrangular prisms described above, can be used to prevent the emission of unpleasant odors and quality failures of the final product.

[0064] As it is comprehended by an expert in art, for anyone and for the totality of the purposes, in terms of providing a written description, the percentages described in the present invention also cover any possible sub-interval or combinations of sub-intervals. This notation also applies to the terms "less than" and similar that can be broken down in sub-intervals.

[0065] The invention is not restricted to the particular formulations described, but cover all of its modified forms that enter within the reach of the following claims.

Claims

Claims1.- One formulation for the manufacturing of polymeric rectangular and quadrangular prisms, characterized because it consists of a polymeric matrix constituted of one continuous and one discontinuous phase; the continuous phase composed by: a mixture of thermoplastics pure or recycled, plasticizers, aids in process, thermic stabilizers or antioxidants, protectors of ultraviolet light, fire retardants and / or organic and inorganic intumescent and compatible agents; the discontinuous phase by: organic and inorganic loads, as well as organic and inorganic pigments.2.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the mixture of thermoplastics consists in polyolefin (homopolymer, copolymer and terpolymer) of polypropylene, polyethylene (HDPE, LDPE and LLDPE), Ethylene vinyl acetate (EVA), polyesters such as PET, polyalkylarenes such as polystyrene, polycarbonates and their mixtures in an amount of 0.1% in weight to 98% in total weight of the components.3.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the plasticizers comprehend: monoester, diester and triester of organic acids, anhydrides, glycerol, di and polyalkyl glycols, all of them aromatic, aliphatic and epoxidase, which are present in amounts of 0.05% in weight to 25%, in a preferred manner of 0.01% in weight to 15% in weight and in a most preferred manner 0.05% in weight to 10%.4.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim1, characterized also because of the aids of process with salts of organic acids, polyolefin and dialquilamidas present in an amount of 0.01% in weight to 20% in weight, in a preferred manner 0.1 % in weight to 15% in weight and in a most preferred manner 0.5% in weight to 10% in weight of the total amount of components.5.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the thermic stabilizers comprehend antioxidants base hindered phenol or thiols, being present in the amount of 0.01% in weight to 10% in weight, in a preferred manner 0.01% in weight to 5% in weight, and in a most preferred manner 0.01% in weight to 3.0% in weight of the total amount of components.6.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the antioxidants base phosphide is present in an amount of 0.01% in weight to 15%, in a preferred manner 0.01% in weight to 10% in weight and in a most preferred manner 0.01% in weight to 7.0% in weight of the total amount of components.7.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the protectors of UV light comprehend benzophenones and benzotriazoles or their mixtures, present in the amount of 0.001% in weight to 15% in weight, in a preferred manner 0.01% in weight to 10% in weight and in a most preferred manner 0.01% in weight to 7.0% in weight of the total amount of components; as well as sequesters of radicals type HALS in an amount of 0.001% in weight to 20% in weight, in a preferred manner 0.1 % in weight to 15% inweight and in a most preferred manner 0.01% in weight to 10% in weight of the total amount of components.8.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because of the fire retardants and / or organic and inorganic intumescent based in phosphorus and nitrogen, being present in an amount of 0.01% in weight to 50% in weight, in a preferred manner 0.1% in weight to 40% in weight, in a most preferred manner 0.1% to 30% in weight of the total amount of components.9.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 8, characterized also because the fire retardant and / or preferred intumescent are Aflammit PPN903, Aflammit PPN 967, Aflammit PPN 978, ADK-STAB PP-2100JC, ADK STAB FP-2500S and FLAMESTAB NOR 116.10.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the compatible agents are organosilanes with generic formula is Rl-Si- (R2)3, where R1 is an alkyl group whether alone or united in epoxy, vinyl, amino, carboxylic or thio groups, and R2 is an alkyl or alkoxide group (-OR). Amongst the silanes, mono, di, tri and multifunctional silanes can be used; being present in an amount of 0.01% in weight to 20% in weight, in a preferred manner 0.1% in weight to 10% in weight and in a most preferred manner 0.1% in weight to 7% in weight of the total amount of components.11.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the inorganic loads comprehend carbonates and sulfates ofalkaline earth metals, silicates, silicas and other oxides, in amounts of 1% in weight to 50% in weight, in a preferred manner 5% in weight to 35% in weight and in a most preferred manner 5% in weight to 25% in weight of the total amount of components.12.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the organic loads comprehend wheat, rice and oat husks, almond shell, sugar cane fiber, agave fiber, cranberry fiber, corn husks, sawdust and in general, all organic material that contain a mixture of cellulose, hemicellulose, starch, lignin or their derivatives, being present in the invention in amounts of 1% in weight to 80% in weight, in a preferred manner 1% in weight to 50% in weight, and in a most preferred manner 1% in weight to 30% in weight of the total amount of components.13.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because of the organic and inorganic pigments are included in an amount of 0.01% in weight to 50% in weight, in a preferred manner 0.1% in weight to 20% in weight and in the most preferred manner 0.1% in weight to 10% in weight of the total amount of components.14.- The manufacturing of rectangular and quadrangular prisms in accordance with the claim 1, characterized also because the post-industrial waste of organic origin is taken advantage of.15.- A method of manufacturing polymeric rectangular and quadrangular prisms in accordance with the claim 1, characterized because it consists of:A first step, selecting and conditioning the raw material;A second step, mixing the components and extruding them to form pellets; andA third step, molding by injection or intrusion.16.- The method of conformity with the claim 15, characterized also because the temperatures of process in the extruder are between 80 C to 250 C, in a preferred manner from 100 C to 220 C in a most preferred manner of 120 C to 200 C.17.- The method of conformity with the claim 15, characterized also because the temperatures of process of molding for injection or intrusion are between 80 C to 250 C, in a preferred manner from 100 C to 220 C, in a most preferred manner from 120 C to 200 C.18.- The method of conformity with the claim 15, characterized also because unpleasant odors are eliminated.19.- The method of conformity with the claim 17, characterized also because the problems of quality associated by lack of homogeneity and lack of control of temperature are eliminated.20.- Polymeric rectangular and quadrangular prisms formulated in conformity with claim 1.21.- Polymeric rectangular and quadrangular prisms manufactured in conformity with claim 14.22.- Polymeric rectangular and quadrangular prisms manufactured in conformity with claim23.- Polymeric rectangular and quadrangular prisms manufactured in conformity with claim for the construction of walls, slabs and roofs.24.- Polymeric rectangular and quadrangular prisms manufactured in conformity with claim for the construction of walls, slabs and roofs.

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