1. A composite material comprising:
a. 80 to 90% (w/w) of at least one plastic waste;
b. 5 to 15% (w/w) of at least one reinforcer; and
5 c. 2 to 8% (w/w) of at least one promoter;
wherein the at least one plastic waste is selected from biaxially oriented
polypropylene (BOPP) waste, packaging waste, polypropylene waste, or
combinations thereof.
2. The composite material as claimed in claim 1, wherein the reinforcer is
10 selected from a primary reinforcer, a secondary reinforcer, or combinations
thereof.
3. The composite material as claimed in claim 2, wherein the primary
reinforcer is selected from Cocos nucifera husk, bamboo fibre, sisal fiber,
glass fiber, hemp fiber, ramie fiber, or combinations thereof; and wherein
15 the secondary reinforcer is selected from glass fiber mat, wire mesh,
bamboo mesh or combinations thereof.
4. The composite material as claimed in claim 1, wherein the promoter is
selected from the group of wax and oil.
5. The composite material as claimed in claim 1, wherein the composite
20 material further includes an additive in a weight range of 0.1 to 3% (w/w)
with respect to total weight of the composite material.
6. The composite material as claimed in claim 5, wherein the additive is
selected from bisphenol type epoxy resins, barium-zinc compounds,
calcium-zinc compounds, polypropylene, polyethylene, low-density
25 polyethylene, high-density polyethylene, silica, talc, calcium carbonate,
alumina silicate, kaolin, mica, halogen polymers, aluminium hydroxide,
magnesium hydroxide, red phosphorus, expanded graphite, ammonium
polyphosphate, linear low-density polyethylene, or combinations thereof.
7. The composite material as claimed in claim 1, wherein particle size of the
30 plastic waste is in a range of 1 mm to 15 cm.
24
8. The composite material as claimed in claim 1, wherein particle size of the
reinforcer is in a range of 1 mm to 15 cm.
9. The composite material as claimed in claim 1, wherein the composite
material is in the form of a sheet of thickness in a range of 5 to 25 mm.
5 10. A composite sheet comprising:
a top layer of at least one plastic waste;
a middle layer of the composite material as claimed in claims 1 to 9; and
a bottom layer of at least one plastic waste,
wherein the at least one plastic waste is selected from biaxially oriented
10 polypropylene (BOPP) waste, packaging waste, polypropylene waste, or
combinations thereof.
11. The composite sheet as claimed in claim 10, wherein the composite sheet
exhibits a flexural strength in a range of 20 to 45 MPa.
12. A process of preparing the composite sheet as claimed in the claim 10, said
15 process comprises:
a. mixing at least one plastic waste, at least one reinforcer, at least one
promoter and, optionally, an additive with a processing aid to obtain a
mixture;
b. compacting the mixture to obtain a material; and
20 c. sandwiching the material between two portions of at least one plastic
waste positioned on top and bottom of the material followed by
compressing to obtain the composite sheet.
13. The process as claimed in claim 12, wherein the plastic waste is subjected
to pre-treatment.
25 14. The process as claimed in claim 12, wherein the plastic waste and the
reinforcer are independently subjected to shredding, prior to mixing with at
least one promoter.
15. The process as claimed in claim 14, wherein the shredding is performed to
obtain the plastic waste and the reinforcer having a particle size in a range
30 of 1 mm to 15 cm.
25
16. The process as claimed in claim 12, wherein the processing aid is selected
from synthetic oil, silicone oil, thermic fluid oil, high temperature grease or
combinations thereof.
17. The process as claimed in claim 12, wherein the compressing is carried out
5 by hot compression molding and cold compression in the presence of a
metal sheet.
18. The process as claimed in claim 17, wherein the hot compression molding
is carried out by compressing at a temperature in a range of 150-250 °C at a
pressure in a range of 0.5-2 ton/sq. inch for a time period in a range of 20 –
10 60 min.
19. The process as claimed in claim 17, wherein the cold compression is carried
out at 10-25°C for a time period in a range of 5-15 min and at a pressure in
a range of 0.01-0.5 ton/sq. inch.
20. The process as claimed in claim 17, wherein the metal sheet is selected from
15 aluminium sheet, steel sheets, or combination of thereof.
21. A composite board comprising a plurality of composite sheets as claimed in
claim 10, and at least one secondary reinforcer positioned in between the
plurality of composite sheets.
22. An article comprising the composite material as claimed in claim 1, the
20 composite sheet as claimed in claim 10, or the composite board as claimed
in claim 21.
23. The article as claimed in claim 22, wherein the article is selected from
panels, boards, furniture, frames, pallets, formwork, insulation, false roof,
or partition wall.