Binderless Composite Material for Recyclable Building Surfaces
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Solution Overview
Problem
Current sustainable composite materials for decorative building applications, such as Corian and Silestone, are not easily recyclable due to the presence of synthetic binders, leading to high recycling costs and often end up in landfills, while they also have limited waste content and require energy-intensive production processes.
Innovation Solution
A composite material comprising at least 75 wt % waste materials, with less than 5 wt % synthetic binding agents, made from a blended mixture of glass and non-glass mineral components, which can be heated to form a structurally robust and aesthetically unique product without the need for synthetic binders, allowing for easy recycling and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If synthetic binders are used to create sustainable composite materials, then the material achieves structural integrity and durability, but the material becomes difficult to recycle and requires expensive pre-treatment
Solution Approach 1:
The invention removes synthetic binders from the composite material system entirely. Instead of using acrylic resins or polyester resins to bind aggregates, the patent employs a binderless approach where aggregates are directly assembled and secured mechanically, eliminating the problematic binding agents that prevent recycling.
Solution Approach 2:
The invention replaces the chemical bonding mechanism (synthetic resin binders) with a mechanical assembly system. Aggregates are held together through mechanical means such as interlocking structures, friction, and physical assembly rather than chemical adhesion, enabling easy disassembly and recycling.
2Shape
If traditional materials like sheet stone and ceramic tiling are used, then aesthetic quality is achieved, but resource consumption increases due to long-distance transportation
Solution Approach 1:
The invention changes the material composition parameters by using locally available waste aggregates instead of importing finished decorative materials. This localizes the resource base and eliminates long-distance transportation while maintaining aesthetic quality through careful selection and arrangement of aggregate materials.
3Loss of substance
If Corian and Silestone composites incorporate waste materials, then environmental sustainability improves, but the waste content remains less than 75 wt % and recycling is still problematic
Solution Approach 1:
The invention extracts and eliminates synthetic binding agents from the composite system, achieving over 75 wt % waste content by using primarily waste aggregates. The removal of non-recyclable binders makes the entire material recyclable through simple mechanical separation without expensive chemical pre-treatment.
Solution Approach 2:
The invention enables full recovery and recycling of waste materials by eliminating the binding agents that would otherwise contaminate the recycling stream. Waste aggregates can be easily separated, cleaned, and reused in new composite materials without the need for binder removal processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of recyclable, durable, and aesthetically superior composite materials with high waste content, reducing landfill waste and energy usage, while maintaining structural integrity and offering diverse aesthetic and textural options.
Implementation Method 1
made from a blended mixture of glass and non-glass mineral components, which can be heated to form a structurally robust and aesthetically unique product
Implementation Method 2
The composite material may be formed from a blended mixture of the relevant components
Data Source
AI summary
The present invention relates to a composite material, particularly a composite material for ceramic tiles, stone cladding, surface tops (e.g. worktops), and the like. The composite materials are typically derived from waste products. The composite materials of the present invention are formed from a glass component and a non-glass mineral component (e.g. ceramics and/or glaze). Generally the composite materials do not require any binders (especially synthetic binders) to hold the materials together. Therefore, the composite materials and products made therefrom are typically recyclable.