Description:FORM 2

THE PATENTS ACT-1970
(39 of 1970)
&
The Patent Rules, 2006

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
1. TITLE OF THE INVENTION

Waterproof Polysand Bricks Using Non-Recyclable Plastic Waste And Method Of Preparation Thereof.

2. APPLICANTS

a) Name Pune Construction Engineering Research Foundation
b) Nationality Indian
c) Address 6, Srinivas Building, Patwardhan Baug
Erandwane
Pune-411004
Maharashtra India
3. PREAMBLE TO THE DESCRIPTION

The following specification particularly describes the invention and the manner in which it is to be performed.
 
Title of Invention:
Waterproof polysand bricks using non-recyclable plastic waste and method of preparation thereof.
Field of Invention:
The invention relates to Waterproof polysand bricks using non-recyclable plastic waste. The bricks provided by the present invention contain material like waste plastic and aggregate. The bricks are waterproof and weather resistance.
Background of invention:
Using plastic in construction sector is an upcoming new process and technology. In India plastic has been used for construction of roads & highways which increases the quality of road and its life. In recent time periods few companies in India as well as around the world have started manufacturing bricks and other products made from specific type of plastic waste and other material. Given below are the list of few companies and their products/ manufacturing materials.

Various companies in India prepare bricks using plastic waste. A company named Rhino Machines Pvt Ltd manufactures bricks made from waste plastic and sand foundry dust with small portion of coarse sand. They use 20% waste plastic and remaining 80% is foundry dust. These bricks have density of approximate 1600 kg/m3 and compression strength of average 10 N/mm2. These bricks are eco-friendly as they are made from all waste material but also have few disadvantages as follows:
• Since foundry dust is used as aggregate, it being toxic material which when comes in regular contact with any person can lead to transmit those toxic particles.
• As these bricks aren’t fire resistance, under any circumstances the bricks catch fire the fumes released from burning of plastic and foundry dust can be dangerous and toxic.
• These bricks also have low bonding quality with cement motor. Therefore, plastering these bricks is a difficult process. Rhino Machines Pvt Ltd manufactures bricks

Zerund manufactures lightweight eco-friendly fly-ash blocks which includes around 3 – 5% waste plastic (PET & HDPE). These blocks are very similar to fly-ash blocks. The advantages of these blocks are they have low density and can be used in residential projects. Since these bricks have low plastic ratio they have high fire resistance quality.
Gjenge is one of foreign company which uses waste plastic for manufacturing paver blocks in Kenya. The company uses single used plastic and sea sand as aggregate. The ratio of the mix design is unknown. The strength of these blocks is around 20 N/mm2. These blocks have good strength and can be designed according to requirement and colour.
Ramtsilo manufacturing & construction company makes bricks made from waste plastic in South Africa. There bricks contain 30% plastic and aggregate. The bricks have 7 – 15 Mpa strength with 2% water absorption. These bricks are used in single storey construction.
The increase in waste plastic in general is affecting humans, wildlife and our habitat and long decomposition period it is becoming difficult and hard to treat plastic waste. So, it can be used in construction sector which a rapidly growing field and the cost of material can be reduced making the project ecofriendly & economical with desired quality.
The main object of the present invention is to provide waterproof polysand bricks using non-recyclable plastic waste.
Another object is to provide bricks which are heat resistant up to ~120°C even with the plastic waste contents
Another object is to provide the said waterproof polysand bricks using all types of waste plastic which are non-recyclable e.g. TYPE 7 PLASTIC (OTHER)
Yet another object is to provide the and method of preparation of the polysand bricks provided by the present invention.
Summary of invention:
The present invention provides Waterproof polysand bricks using non-recyclable plastic waste and method of preparation thereof. The bricks of the present invention use the waste plastic material which is not recyclable. The ratio of the waste used in preparation of bricks is 40-60% as compared to traditional composition. Instead of adding separate binder, plastic itself is used as a binding material for those bricks. The process of preparation of the bricks comprises cleaning of waste plastic and separating it from other waste, shredding the plastic waste into small pieces preparing a mixture consisting 60% waste shredded plastic and 40% aggregate. The mixture of both the waste plastic and aggregate is mixed to obtain homogenous mixture, heating the mix of plastic-aggregate around 150 – 180°C, optionally adding desired colour in the melted mix and when the mixture is completely melt pouring the melted plastic-aggregate in the brick moulds of desired sizes, allowing the bricks obtained to cool in atmosphere or by sprinkling water, removing the bricks from the mould to obtained the polysand bricks. The product obtained by the present invention is heat resistant up to ~120°C even though it contains plastic waste. The product can be made of any required size and shape. For architect purpose it can also be given any type of design and colour. The density of product varies from 1400 kg/m3 to 1900 kg/m3.
Detailed description of the process (statement of invention)
Accordingly, the present invention provides Waterproof polysand bricks using non-recyclable plastic waste the said polysand bricks comprising a composition 40-60% of non-recyclable polymer material and 40-60% aggregate.
In one of the embodiments of the present invention the non-recyclable polymer waste consists of PET, HDPE, LDPE, PP, PS
In yet another embodiment the aggregate is Fine aggregate: 40% ( less than 3mm diameter), Coarse aggregate: 40% ( 8mm – 15mm diameter), C& D waste: 20% ( 3mm – 12 mm diameter)
The present invention also provides a process for the preparation of the poly sand bricks, the said process comprising cleaning of waste plastic and separating it from other waste, shredding the plastic waste into small pieces, preparing a mixture consisting of 40-60% waste shredded plastic and 40-60% aggregate, mixing both the waste plastic and aggregate to gather homogeneous mixture, heating the mixture of plastic-aggregate to 150 – 180°C, optionally adding the colour in the melted mixture, pouring the melted plastic-aggregate mixture in the brick moulds of sizes and shapes, allowing the bricks obtained to cool in atmosphere or by sprinkling water, removing the bricks from the mould to obtained the poly sand bricks.
In one of the embodiments of the present invention the melted mixture may be added with the colour to obtain the coloured bricks.
In yet another embodiment the moulds used for the preparation of bricks may be of any shape, size, contour.
In a feature of the invention the colour, size and shape of the bricks could be made to requirements of the final utilization thereof.
Working of the invention:
All types of plastic material should be collected from the factories waste, municipal town panchayath and industries waste and also food packages and plastic bottles this will come under the LDPE, PET bottles, Carry bags, HDPE plastic type. Aggregate like Coarse sand & crush can be collected from the nearest masonry shop.
BATCHING
Measurement of materials for making brick is called batching. After collection of materials, we separate the types of plastic based on their recycling properties and remove any other waste presented in the collected material. The separated waste plastic needs to be cleaned and dried. After cleaning the waste plastic needs to be shredded into small pieces around 10mm the sent for melting. In order to shred this plastic a shredding machine is required which can shred material like waste plastic.
MELTING
After completion batching the plastic waste were taken for burning in which the shredded plastic is drop one by one into the container and allowed to melt. These would be done in closed vessel because to prevent the toxic gases released into atmosphere. These will be at the temperature of 150-180 degrees centigrade. A melting machine is required which will help to melt the plastic at required temperature. This machine are available at industrial areas where plastic manufacture use them.
MIXING
Mixing of materials is essential for the production of uniform and strength for brick. It is to be ensured that the mass becomes homogeneous, uniform in colour and consistency. Generally, there are two types of mixing, Hand mixing and mechanical mixing. In this project, we adopted hand mixing. Until the entire plastic content required for making plastic brick of one mix proportion is added into it. Then these plastic liquids thoroughly mixed by using trowel before it hardens. For large production a machine mixer is required to mix the aggregate and the plastic in given proportion. Such types of mixers aren’t easily available in the market as the concept is new. A new mixer needs to be designed based on the requirement of manufacturing.
MOULDING
The mixture is then poured into the brick mould made from plywood and is compacted by using tamping rod or steel rod. The surface is finished by using trowel. Before placing the mixture into the mould, the sides of the mould are oiled to easy removal of bricks. Mould removed after 24 hours. The mould is used for preparing brick in uniform shape. The size of mould is 190X90X90 mm. The moulds were assembled and placed on the base plate. The faces must be thinly coated with mould oil to easily demould after casting. For large production a compressive moulding machine is required to achieve precision shape of the brick without any deformation. The moulded brick can then be cooled fast with the help of water.
Characteristics of poly sand bricks:
• Plastic bricks have high strength compared to other bricks.
• The product has good finishing and less wear & tear as plastic doesn’t break easily.
• Plastic bricks can also be given colour and texture to make it look aesthetic, does no additional outer plaster is required which helps in cost saving.
• The percentage of bricks getting damaged during transportation is less than 2% compared to other bricks.
• Plastic bricks are economical as waste plastic is been used in it as main ingredient.
• Plastic bricks have less water absorption percentage.
• The plastic bricks can be used multiple times even after demolishing the structure.
Advantages of the present invention:
• The invention provides poly sand bricks/plastic bricks Plastic bricks having high strength compared to other bricks.
• The product has good finishing and less wear & tear as plastic doesn’t break easily.
• Poly sand bricks can also be given colour and texture to make it look aesthetic, does no additional outer plaster is required which helps in cost saving.
• The percentage of bricks getting damaged during transportation is less than 2% compared to other bricks.
• Plastic bricks are economical and eco-friendly as waste plastic is been used in it as main ingredient.
• Plastic bricks have less water absorption percentage.
• The plastic bricks can be used multiple times even after demolishing the structure.
, C , Claims:We claim:

1. Waterproof poly sand bricks using non-recyclable plastic waste the said poly sand bricks comprising a composition 40-60% of non-recyclable polymer material and 40-60% aggregate.

2. The Poly sand bricks as claimed in claim 1 wherein the non-recyclable polymer waste consists of PET, HDPE, LDPE, PP , PS

3. The Poly sand bricks as claimed in claim 1 to 2 wherein the aggregate is Fine aggregate: 40% ( less than 3mm diameter), Coarse aggregate: 40% ( 8mm – 15mm diameter), C& D waste: 20% ( 3mm – 12 mm diameter.

4. The present invention also provides a process for the preparation of the poly sand bricks, the said process comprising cleaning of waste plastic and separating it from other waste, shredding the plastic waste into small pieces, preparing a mixture consisting of 40-60% waste shredded plastic and 40-60% aggregate, mixing both the waste plastic and aggregate to gather homogeneous mixture, heating the mixture of plastic-aggregate to 150 – 180°C, optionally adding the colour in the melted mixture, pouring the melted plastic-aggregate mixture in the brick moulds of sizes and shapes, allowing the bricks obtained to cool in atmosphere or by sprinkling water, removing the bricks from the mould to obtained the poly sand bricks.

5. The process for the preparation of the poly sand bricks as claimed in claim 4 wherein the melted mixture is added with the colour to obtain the coloured bricks.

6. The process for the preparation of the poly sand bricks as claimed in claims 4 to 5 wherein the moulds used for the preparation of bricks are of any shape, size, contour.

Dated this 23rd day of October 2024