Construction materials made of recycled material

Abstract

A panel-shaped or block-shaped construction element which is partially made of recycled plastic and is reinforced with bamboo.

Description

[0001] Title: Building materials made from recycled material

[0002] The invention relates to the use of waste materials as building materials.

[0003] Too many new building materials are currently being manufactured from valuable raw materials. Materials that have already been used are difficult to recycle and reintegrate into the material cycle due to the way they are produced.

[0004] The applicant and inventor of this document deals with the design of cities, gardens, sports stadiums, and landscapes. He sees great potential in existing and partially discarded waste materials for cost-effective environmental design.

[0005] The object of the present invention is therefore to provide a building material that is as cost-effective as possible.

[0006] This task is accomplished by a plate-shaped building material consisting partly of recycled plastic, which is reinforced with a stabilizing additive made of bamboo.

[0007] This bamboo additive can consist of a bamboo tube, but also of bamboo shoots or bamboo pulp.

[0008] The granules used for this process are made from recycled plastic and can be reinforced by embedding bamboo. Different grades of recycled plastic sheets are used for this purpose; the recycled plastic made from (plastic) bottles is particularly durable. The recycled PET (polyethylene terephthalate) from plastic bottles is known for its strength, resistance to weathering, and its ability to hold colors and prints well. It is well-suited for applications requiring high strength and durability. For example, it is used in roofing materials and is very suitable for our intended use.

[0009] Recycled HDPE (High Density Polyethylene): HDPE is a versatile plastic often made from recycled milk cans, shampoo bottles, and other containers. It is characterized by its durability, chemical resistance, and weather resistance, making it well-suited for outdoor use.

[0010] Polycarbonate and acrylic glass (Plexiglas) are transparent plastic materials. However, the recycling process for polycarbonate and acrylic glass from waste plastic is somewhat more complicated and time-consuming.

[0011] Recycled polyvinyl chloride (PVC) also presents a good option, particularly for applications requiring flexibility and water resistance. It is robust, weatherproof, and can be manufactured in various colors and styles. This is interesting because the aesthetic aspect is also essential for the present invention and its accessories.

[0012] These recyclable plastics offer a good combination of quality, foldability, and environmental friendliness, making them well-suited for high-quality applications such as the roofing material of a tent-like structure. However, it is important to ensure that the recycled material comes from trusted sources and meets the relevant quality standards to guarantee the desired performance.

[0013] The basic principles of producing the granules from the aforementioned (waste) plastic are already known in the prior art.

[0014] The procedure basically works as follows:

[0015] 1. Collection and Sorting: The waste plastic is first collected and then sorted by type. This step is crucial because different types of plastic have different properties and are not always compatible with each other. Furthermore, the recycled material must meet specific requirements. Collecting the material reduces the environmental impact, at least to some extent. Ideally, the waste plastic is delivered pre-sorted from industry, households, and commercial establishments. This prevents the plastic from entering the waste stream. However, it should also be retrieved from landfills and the ocean.

[0016] 2. Shredding: the sorted waste plastic must now be shredded and ground.

[0017] 3. Cleaning: After shredding, the waste plastic is often cleaned to remove contaminants such as dirt, labels, adhesive residue, or other debris. This can be done by washing, sieving, or other cleaning methods.

[0018] 4. Melting and extrusion: The cleaned and shredded waste plastic is then melted in a melt extrusion process and forced through an extrusion die to form continuous strands or blocks.

[0019] 5. Granulation: The extruded strands or blocks are then cut into smaller granules. This can be done either by cutting with knives or by using special granulating machines. 6. Cooling and drying: The manufactured granules may need to be cooled and dried to remove moisture and ensure they are stable and do not stick together.

[0020] 7. Quality control and sorting: The finished granules are checked for quality and purity. They can also be sorted by plastic type to ensure they are suitable for specific applications.

[0021] Although this is only a rough overview of the process of manufacturing granules from recycled plastic, and it should also be noted that specific procedures and technologies may vary depending on the properties of the recycled plastic and the requirements of the final product, it is surprising to see that the manufacturing costs of recycled material do not differ significantly from those of "new" material.

[0022] The block- or plate-shaped components are produced, for example, by compression molding or injection molding of the plastic granules.

[0023] The compression molding process for manufacturing plastic sheets is a process in which plastic granules are pressed into a mold under heat and pressure to create a sheet with the desired shape and thickness.

[0024] The injection molding and extrusion processes are used to manufacture plastic parts with high precision and reproducibility.

[0025] Polyethylene can be used as a main component of the building element. It is one of the most frequently recycled plastics.

[0026] There are two main types of polyethylene: high-density polyethylene (HDPE) and low-density polyethylene (LDPE). Polyethylene is typically recycled through mechanical recycling, in which used plastic products are collected, cleaned, shredded, and melted to produce new polyethylene products. These recycled polyethylene materials are then reused for a wide variety of applications, including the manufacture of sheets, plastic containers, bottles, pipes, films, and other products.

[0027] Recycling polyethylene helps reduce landfill waste and enables the reuse of plastics, thereby conserving resources and reducing environmental impact. It is important to support recycled plastic products and to properly separate and recycle plastic waste to promote sustainability.

[0028] High-density polyethylene (HDPE): The density of HDPE is typically about 0.95 g / cm³. 3 up to 0.97 g / cm³ 3 HDPE has a higher density compared to other types of polyethylene, which gives it greater strength and stiffness. Low-density polyethylene (LDPE): The density of LDPE is typically between 0.91 g / cm³. 3 and 0.93 g / cm³ 3 LDPE has a lower density and is more flexible and less rigid than HDPE.

[0029] In a particularly specific embodiment of the present invention, the building material is configured as a wall and / or a door, optionally with windows. The windows can be made of glass or transparent plastic as a glass substitute.

[0030] In a further embodiment of the present building material, it also includes paper, cardboard and glass as additional building material components.

[0031] The resulting paper-plastic composite material consists of a mixture of (recycled) paper and plastic. The advantage of such composite materials lies in the combination of the positive properties of both materials, such as:

[0032] 1. Environmental friendliness: By using recycled paper and plastic waste, the material contributes to reducing the amount of waste and promotes sustainability.

[0033] 2. Weight and lightness: Compared to pure plastic, composite materials made of plastic and paper can be lighter, which makes transport and handling easier.

[0034] 3. Versatile applications: These materials are versatile and can be used for various applications in the construction industry, including roofing and wall coverings, flooring, insulation, and furniture. The sheet-like building material can be provided with recesses, channels, slots, and similar features, allowing the paper to be inserted (introduced) loosely or compacted.

[0035] 4. Durability: The combination of plastic and paper can result in a durable material that resists moisture, mold, and pests. The choice of plastics used and the processing methods of the composite material are crucial here. For example, in an extrusion process, molten plastics and shredded paper are forced through a die and then cooled and hardened. In injection molding, molten plastic is injected into a mold to which paper fibers or other fillers have been previously added. After cooling and hardening, a solid composite material is formed. Similarly, in suitable pressing processes, paper fibers and plastics are placed in a mold and pressed together under high pressure and temperature. The pressing process bonds the materials together and forms them into a solid composite material.The two materials can also be layered. The structure of the composite material can be designed to offer an optimal combination of strength and flexibility. By correctly arranging the layers and using reinforcements, certain properties such as tensile strength, flexural strength, and impact resistance can be improved. Certain binders also act as stabilizing agents. Physical treatment methods, such as heat treatment, compression strengthening, or chemical impregnation, should also be considered. In specific cases, additional reinforcements such as fiberglass, glass, carbon fiber, and similar materials can also be incorporated into the composite material.

[0036] 5. Easy processing: Composite materials made of plastic and paper can often be easily processed and shaped, which simplifies manufacturing and installation.

[0037] 6. Cost reasons: When using fully recycled materials, composite materials made of plastic and paper are more cost-effective than traditional building materials.

[0038] 7. Not to be forgotten is the aesthetics: depending on the design and manufacturing process, these materials can have a natural aesthetic that makes them attractive for various architectural applications.

[0039] In a particularly interesting embodiment of the inventive building material, the panels are designed to be water-impermeable and to form or have cavities in which water can be stored. Thus, the building elements can serve as water reservoirs and are also cooled. A mechanism that releases the water in a metered manner, allowing it to wet the walls and surrounding surfaces, cools the building element as it evaporates and creates a pleasant microclimate.

[0040] In a completely different embodiment of the present invention, the building material is designed as an interlocking system, whereby, for example, bamboo canes can serve as connecting pieces between the blocks and the panels. The blocks and panels are also stackable and can be easily transported. Constructing a beach soccer stadium, including seating, from the blocks using the building material according to the invention is easily possible and has already been realized by the inventor as a prototype.

[0041] In another version of the building material, the panels or blocks are not only permeated with a stabilizing grid, but also feature cardboard or paper struts, cardboard or paper panels, or glass panels or shards for reinforcement. The stabilizing grids can form square or diamond-shaped meshes with their struts. Several grids can also be twisted and stacked on top of each other to increase the stability of the building element.

[0042] The building material can be produced via a conveyor belt production line:

[0043] In addition to or as a replacement for the processes mentioned above, after delivery, cleaning, and sorting of the "raw" building material (e.g., waste plastic, waste glass, waste paper, etc.), the material is automatically placed onto individual conveyor belts using a robot. Differentiation must then be made for raw materials with varying qualities. For example, load-bearing capacity, hardness, softness, and flexibility must be considered. This separation process forms the basis for the quality and properties of the product. The subsequent steps described above are mostly computer-controlled, thus ensuring consistent quality. Additional features, such as holes for connectors, are added immediately after production, while the material is still "warm." If sheathing is necessary for the building material components, this is done in the following step. All these processes are carried out in accordance with the inventor's intentions and are therefore environmentally friendly and sustainable.Water is purified and reused. Where possible, work that could affect workers' health should be carried out using automation or without human intervention. Where possible, the energy required for this should be generated from alternative sources.

Claims

Patent claims 1. Plate- or block-shaped building element partially consisting of recycled plastic, which is reinforced with bamboo.

2. Plate- or block-shaped building element according to claim 1, characterized in that it is reinforced with at least one lattice made of bamboo.

3. Plate- or block-shaped component according to one of the preceding claims, characterized in that it consists of one or more plastic materials of the following group, namely polyethylene, polyvinyl chloride, polycarbonate, acrylic glass and polyethylene terephthalate.

4. Plate- or block-shaped building element according to one of the preceding claims, characterized in that it is designed as a wall and / or door.

5. Plate- or block-shaped building element according to one of the preceding claims, characterized in that it is designed as a wall with a window.

6. Plate- or block-shaped component according to one of the preceding claims, characterized in that it also comprises paper and / or glass in addition to the plastic.

7. Plate- or block-shaped component according to one of the preceding claims, characterized in that it is arranged such that the plates are water-impermeable and form cavities or have cavities in which water can be stored.

8. Plate- or block-shaped component according to one of the preceding claims, characterized in that the grid has diamond-shaped meshes.

9. Plate- or block-shaped component according to one of the preceding claims, characterized in that several grids are arranged twisted one above the other.

10. Method for manufacturing the component according to any one of claims 1 to 9.