Description:FIELD OF THE INVENTION
[0001] The present disclosure relates to eco-friendly reinforced pipes. Particularly, but not exclusively, the present disclosure is directed towards a method and system for manufacturing bio-composite pipes utilizing engineered bamboo.
BACKGROUND OF THE INVENTION
[0002] Plastic pipes, while widely used for their affordability and lightweight nature, have several disadvantages that raise environmental and functional concerns. The plastic pipes, commonly used in industries such as plumbing and irrigation, are derived from petroleum-based materials. Such pipes are non-biodegradable. Thus, the plastic pipes do not decompose easily, leading to long-lasting waste in landfills and oceans. Over time, the plastics break down into microplastics, contaminating ecosystems and entering the food chain, harming wildlife and human health.
[0003] Numerous measures have been taken by various Governments, and United Nations for achieving sustainable development goals. To attain such sustainable development goals, it is the foremost requirement to minimize the usage of plastic-based products. Plastic pipes are one of the largely plastic-based products used worldwide for plumbing, irrigation, etc. However, to reduce the usage of plastic pipes, there is a requirement to manufacture biodegradable, stable, durable products.
[0004] Bamboo is recognized for its fast growth and considerable tensile strength, rendering it an environmentally sustainable substitute for conventional materials such as plastic and steel. Nevertheless, raw bamboo possesses constraints, such as quality variability, moisture vulnerability, and variable durability. Current techniques for converting bamboo into functional items have not completely maximized its structural capabilities, particularly for high-stress applications such as piping.
[0005] Bamboo pipes are made from natural, renewable resources and decompose harmlessly when discarded, leaving no toxic residues. By replacing plastic pipes with bamboo-based options, it can be possible to significantly reduce plastic waste, mitigate pollution, and move towards a circular economy that prioritizes renewable materials and environmental preservation. However, the primary challenge lies in strength, durability, and structural quality, of the bamboo-based pipes which may hinder long-term usage for plumbing, irrigation, and other structural applications.
[0006] Therefore, there is a need for a method and system for method and system for manufacturing bio-composite pipes utilizing engineered bamboo. The present disclosure is directed to overcome one or more limitations stated above, and any other limitation associated with the conventional arts.
SUMMARY OF THE INVENTION
[0007] One or more shortcomings of the prior art are overcome, and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
[0008] The present disclosure relates to a method for manufacturing bio-composite pipes utilizing engineered bamboo. The method comprises harvesting bamboo stalks from a sustainable source. Further, the method comprises extracting bamboo fibers by processing the harvested bamboo stalks through one or more mechanical procedures. Furthermore, the method comprises treating the extracted bamboo fibers with moisture resistance technique, strengthening, and chemical treatment to enhance resistance against moisture, strength, and durability. Thereby, the method comprises fabricating a bio-composite material by processing the treated bamboo fibers with a binding agent. Subsequently, the method comprises extruding or molding the bio-composite material into pipes of specified shape and dimensions. Upon extruding or molding the bio-composite material, the method comprises manufacturing bio-composite pipes by curing the formed pipes to enhance structural integrity and performance.
[0009] The present disclosure relates to a system for manufacturing bio-composite pipes using engineered bamboo. The system comprises a bamboo processing unit, a treatment unit, a composite formation unit, an extrusion and molding unit, and a curing unit. The bamboo processing unit is used to extract bamboo fibers from harvested bamboo stalks. Further, the treatment unit is used for applying chemical or mechanical treatments on the extracted bamboo fibers to enhance resistance against moisture, strength, and durability. Furthermore, the composite formation unit is used for fabricating a bio-composite material by processing the treated bamboo fibers with a binding agent. The extrusion and molding unit is used for shaping the bio-composite material into pipes of specified shape and dimensions. Also, the curing unit is used for hardening and strengthening the material to manufacture bio-composite pipes.
[0010] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
A BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
Figure 1 illustrates a schematic block diagram of a system for manufacturing bio-composite pipes, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a flow chart of a method of manufacturing bio-composite pipes utilizing engineered bamboo, in accordance with an embodiment of the present disclosure; and
Figure 3 illustrates pictorial representation of the method of manufacturing the bio-composite pipes, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0012] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
[0013] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and the scope of the disclosure.
[0014] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device, or process that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or process. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
[0015] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
[0016] The present invention proposes a method and system for producing bio-composite pipes with engineered bamboo, responding to the increasing need for sustainable and durable materials in construction and fluid transport systems. The method and system improve strength and durability of bamboo fibres by amalgamating them with binding non-toxic chemicals to produce a bio-composite material. Such bio-composite material is used to manufacture bio-composite pipes. The bio-composite pipes are environmentally sustainable and exhibit enhanced resistance to environmental elements like moisture and decay, rendering them suitable for plumbing, irrigation, and other structural applications where conventional materials may be less efficient or more resource-demanding.
[0017] Figure 1 illustrates a schematic block diagram of a system for manufacturing bio-composite pipes, in accordance with an embodiment of the present disclosure.
[0018] As shown in Figure 1, the system 100 comprises a plurality of integrated components, such as a bamboo processing unit 102, a treatment unit 104, a composite formation unit 106, an extrusion and molding unit 108, a curing unit 110, and a cutting and finishing unit 112. For producing bio-composite pipes, the system 100 comprises the plurality of integrated components, each having a specific function to manufacture the bio-composite pipes. The plurality of integrated components operates in concert to provide efficient manufacturing and high-quality output.
[0019] According to an embodiment, the bamboo processing unit 102 is responsible for cutting, drying, and shredding upon harvesting bamboo stalks from a sustainable source. The bamboo processing unit 102 unit is adapted to handle multiple stages of processing the bamboo, starting with cutting raw bamboo stalks into manageable sizes. The raw bamboo stalks are thereby being facilitated with uniform processing and efficient handling. The bamboo processing unit 102 incorporates drying chambers, mechanical shredders, and sieve devices to assure uniform fiber extraction.
[0020] In the drying chambers, the bamboo stalks undergo drying to reduce moisture content in order to ensure enhanced durability and resistance to decay during subsequent steps. Thereby, the dried bamboo is then fed into the mechanical shredders that break the dried bamboo down into smaller fragments or strips, making it easier to extract the fibers. Further, the sieve devices are used to separate and classify the fibers based on size and uniformity. Thus, the bamboo processing unit 102 ensures a streamlined and efficient method for obtaining high-quality bamboo fibers from harvested bamboo stalks that meet specific industrial standards for strength, texture, and uniformity.
[0021] According to an embodiment, the treatment unit 104 is used for applying chemical or mechanical treatments on the extracted bamboo fibers to enhance resistance against moisture, strength, and durability. The treatment unit 104 administers chemical and thermal treatments to the bamboo fibers. The treatment unit 104 consists of soaking tanks for chemical treatments and heat chambers for thermal strengthening. The treatment unit 104 is designed to handle enormous amounts of bamboo fibers in a continuous operation.
[0022] More particularly, the treatment unit 104 utilizes moisture resistance technique, strengthening, and chemical treatment by the soaking tanks and the heat chambers. The moisture resistance technique corresponds to treating the bamboo fibers with a chemical solution. A commonly used chemical is borax (sodium borate) or boric acid. These substances are frequently utilized in soaking tanks for bamboo treatment because they offer effective protection against decay, termites, and environmental damage. Furthermore, copper-based preservatives such as copper-chrome-arsenate (CCA) or copper azole (CA) are also widely used in bamboo treatment to enhance resistance to fungal rot and insect attacks. in the soaking tanks to improve resistance to decay, termites, and environmental deterioration. Further, the strengthening corresponds to thermal treatment of the bamboo fibers in the heat chambers to improve tensile strength and overall durability. The chemical treatment relates to treating the bamboo fibers with chemicals to protect from pests and prevent degradation. The chemicals used for the chemical treatment relate to at least one of borates or silicates.
[0023] According to an embodiment, the composite formation unit 106 is used for fabricating the bio-composite material by processing the treated bamboo fibers with a binding agent. The composite formation unit 106 unit mixes the treated bamboo fibers with the binding agent or binding chemicals to generate the bio-composite material. The binding agent comprises a polymer resin selected from the group comprising epoxy resin, polyurethane resin, and biodegradable polymers. The composite formation unit 106 comprises automatic mixers and temperature-controlled tanks to ensure constant blending to generate the bio-composite material. The automatic mixers ensure consistent and homogeneous mixture of the binding agent with the treated bamboo fibers. Further, the temperature-controlled tanks make sure to keep desired temperature for permanent blending of the binding agent on the treated bamboo fibers to generate bio-composite material.
[0024] The bio-composite material refers to a composite material formed by combining treated bamboo fibers with the binding agent. The bamboo fibers serve as the reinforcement, providing structural strength and flexibility, while the binding agent acts as a medium for holding the fibers together and giving the material its final shape and durability. The bio-composite material is prepared for either molding or extrusion process afterwards.
[0025] According to an embodiment, the extrusion and molding unit 108 is used for shaping the bio-composite material into pipes of specified shape and dimensions. The extrusion and molding unit 108 comprises an extrusion section that forces the bio-composite material through a die to make pipes, and a molding section utilizes multi-part molds for more complex designs. The extrusion and molding unit 108 is designed to create pipes having varying diameters and wall thicknesses, depending on the intended application of the pipes.
[0026] More particularly, the extrusion section extrudes the bio-composite material at temperatures ranging from 150°C to 200°C to form pipes with homogeneous diameters. Such temperature ensures the bio-composite material reaches a pliable state for forming. The heated bio-composite material is then pushed or drawn through a specially designed die, which precisely defines the pipe’s diameter, ensuring uniformity and consistency across the product. Further, the molding section molds the bio-composite material in a multi-part mold. The multi-part mold shapes the bio-composite material into more intricate or specific designs of pipes that extrusion alone cannot achieve. Upon molding into the pipes, the system 100 cures at controlled temperatures to solidify the material of the pipes.
[0027] According to an embodiment, the curing unit 110 performs a controlled curing procedure for hardening and strengthening the formed pipes to manufacture bio-composite pipes. The curing unit 110 comprises curing chambers with adjustable heat and humidity settings. The finishing section cuts, smooths, and inspects the pipes to assure product quality. The curing unit 110 exposes the formed pipe in a controlled temperature over a specific duration to solidify and harden. Curing enhances the structural integrity, strength, and durability of the pipes, ensuring they meet the required performance standards for their intended applications.
[0028] According to an embodiment, the cutting and finishing unit 112 is used for trimming and smoothing the edges of the bio-composite pipes post-extrusion or molding, and curing. The cutting and finishing unit 112 may include, but not limited to, trimming machines, edge polishing tools, laser cutters, and deburring tools for trimming and smoothing the edges. The cutting and finishing unit 112 cuts, smooths, and inspects the pipes to assure product quality.
[0029] Figure 2 illustrates a flow chart of a method of manufacturing bio-composite pipes utilizing engineered bamboo, in accordance with an embodiment of the present disclosure.
[0030] Figure 3 illustrates a pictorial representation of the method of manufacturing the bio-composite pipes, in accordance with an embodiment of the present disclosure.
[0031] As depicted in Figure 2, the method 200 includes a series of steps 202 through 212 manufacturing bio-composite pipes utilizing engineered bamboo. The details of the method 200 have been explained below in forthcoming paragraphs. The order in which the method steps are described below is not intended to be construed as a limitation, and any number of the described method steps can be combined in any appropriate order to execute the method or an alternative method. The method 200 begins from a start block and starts execution of operations at step 202, as shown in Figure 2. The method 200 mixes bamboo’s natural strength with advanced treatment procedures and bio-composite materials to make environmentally friendly, durable pipes ideal for many uses.
[0032] At step 202, the method 200 comprises harvesting bamboo stalks from a sustainable source. The bamboo stalks are picked based on quality, maturity, and fiber density. The collected bamboo stalks are split into smaller sections and then exposed to preliminary drying to eliminate excess moisture. The step 202 ensures that the bamboo is in optimal condition for fiber extraction. Such step is pictorially represented as a bamboo from sustainable source 302 in Figure 3 of the present disclosure. The flow of the method 200 now proceeds to step 204.
[0033] At step 204, the method 200 comprises extracting bamboo fibers by processing the harvested bamboo stalks by one or more mechanical procedures. The one or more mechanical procedures relate to at least one of shredding, peeling, splitting, and decortication, which are used to extract bamboo fibers. The bamboo processing unit 102 is used to extract bamboo fibers by processing the harvested bamboo stalks. Further, the fibers are then separated by length and thickness, assuring consistency in the final product. Also, Figure 3 illustrates the pictorial representation of extracted bamboo fibers 304 by processing the harvested bamboo stalks. The flow of the method 200 now proceeds to step 206.
[0034] At step 206, the method 200 comprises treating the extracted bamboo fibers with moisture resistance technique, strengthening, and chemical treatment to enhance resistance against moisture, strength, and durability. The treatment unit 104 is used to treat the extracted bamboo fibers. In the moisture resistance technique, the treatment unit 104 treats the bamboo fibers with the chemical solution to strengthen their resistance to moisture, minimizing the danger of rot or degradation when exposed to water. Further, in the strengthening, the bamboo fibers undergo the mechanical or thermal treatment to boost their tensile strength and overall durability. Furthermore, in the chemical treatment, the treatment unit 104 treats the bamboo fibers with chemicals like borates or silicates to protect the fibers from pests such as termites and prevent degradation. The flow of the method 200 now proceeds to step 208.
[0035] At step 208, the method 200 comprises fabricating the bio-composite material by processing the treated bamboo fibers with the binding agent. The binding agent comprises a polymer resin selected from the group comprising of epoxy resin, polyurethane resin, and biodegradable polymers. According to another embodiment, the bio-composite material is fabricated by processing the treated bamboo fibers with a reinforcing agent. The reinforcing agent may relate to, but not limited to, natural fibers like jute or synthetic fibers like fiberglass. Such reinforcing agents may be added to the composite for greater tensile strength, depending on the application requirements.
[0036] At step 208, the method 200 further comprises reinforcing the bio-composite material with natural or synthetic fibers for enhanced tensile strength. The composite formation unit 106 fabricates the bio-composite material by processing the treated bamboo fibers and thereby reinforces the bio-composite material. A mixture of bio-composite material is created in a controlled environment where temperature and pressure are regulated to enable full adhesion between the fibers and the resin. Pictorial representation of fabricating the bio-composite material is shown as bio-composite bamboo sheet 306 in Figure 3 of the present disclosure.
[0037] A ratio of treated bamboo fibers to the binding agent is adjusted to balance strength and flexibility in the final pipe product being made by the bio-composite material. For example, a higher proportion of bamboo fibers enhances the pipe's tensile strength, making it more durable and resistant to pressure or impact. Conversely, increasing the binding agent improves flexibility, allowing the pipe to bend or withstand deformation without cracking. By carefully adjusting this ratio, manufacturers can customize the properties of the bio-composite material to meet specific performance requirements. The flow of the method 200 now proceeds to step 210.
[0038] At step 210, the method 200 comprises extruding or molding the bio-composite material into pipes of specified shape and dimensions. The extrusion and molding unit 108 is used for extruding or molding the bio-composite material into pipes. In the extrusion process, the bio-composite material is pressed through the die to generate pipes of the specified diameter and thickness. For specific applications, molding can also be used to make pipes with more complex shapes or to insert fittings directly into the pipe construction. The flow of the method 200 now proceeds to step 212.
[0039] At step 212, the method 200 comprises manufacturing bio-composite pipes by curing the formed pipes to enhance structural integrity and performance. The curing unit 110 is used to manufacture bio-composite pipes. The curing unit 110 treats the pipes in a controlled heat and humidity to ensure that the binding agent fully hardens, giving the pipes their final strength and longevity. The curing process normally lasts between 24 and 48 hours, depending on the materials utilized and the thickness of the pipes. Pictorial representation of the final pipe is shown as bio-composite bamboo pipes 308 in Figure 3 of the present disclosure.
[0040] After curing, the pipes are inspected for quality and, if necessary, cut or smoothed to guarantee uniform edges and surface polish. The cutting and finishing unit 112 is used for cutting or smoothening to guarantee uniform edges and surface polish. Additional protective coatings may be placed on the exterior surface of the pipes for further protection against external effects, such as Ultraviolet (UV) radiation or abrasion. Protective coatings may be applied by way of manual brushing or other methods, such as spraying or dipping, depending on operational efficiency and product needs.
[0041] While the above-discussed steps in Figure 2 are shown and described in a particular sequence, the steps may occur in variations to the sequence in accordance with various embodiments. Further, a detailed description related to the various steps of Figure 2 is already covered in the description related to Figure 1 and is omitted herein for the sake of brevity.
[0042] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the disclosure of the embodiments of the invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
[0043] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[0044] While various aspects and embodiments have been disclosed herein, other aspects and embodiment will be apparent to those skilled in the art.
Advantages of the present disclosure:
[0045] The method 200 and system 100 disclose manufacturing bio-composite pipes utilizing engineered bamboo. The method 200 and system 100 have several advantages over conventional disclosures. These are:
• Sustainability: Bamboo is a fast-growing, renewable resource, making these bio-composite pipes an environmentally responsible alternative to plastic and metal pipes.
• Durability: The treated bamboo fibers offer greater strength, moisture resistance, and lifespan, making the pipes suited for a wide range of applications, including high-stress conditions.
• Versatility: The system may be customized to generate pipes of variable diameters and thicknesses, ideal for different industries, such as plumbing, irrigation, and construction.
• Cost-Effectiveness: The technology enables for efficient, scalable production of pipes, decreasing material costs while maintaining good product quality.
[0046] The bio-composite pipes of the present disclosure may be utilized in plumbing systems to transmit water in residential and commercial structures because of their strength and moisture resistance. The pipes are appropriate for agricultural irrigation due to their eco-friendliness and resistance to environmental conditions. Additionally, the pipes can be utilized in construction as load-bearing elements or as part of scaffolding systems
[0047] In the detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The description is, therefore, not to be taken in a limiting sense.
, Claims:We claim:
1) A method (200) for manufacturing bio-composite pipes utilizing engineered bamboo, the method comprising:
harvesting (202) bamboo stalks from a sustainable source;
extracting (204) bamboo fibers by processing the harvested bamboo stalks through one or more mechanical procedures;
treating (206) the extracted bamboo fibers by moisture resistance technique, strengthening, and chemical treatment to enhance resistance against moisture, strength, and durability;
fabricating (208) a bio-composite material by processing the treated bamboo fibers with a binding agent;
extruding or molding (210) the bio-composite material into pipes of specified shape and dimensions; and
manufacturing (212) bio-composite pipes by curing the formed pipes to enhance structural integrity and performance.
2) The method (200) as claimed in claim 1, wherein one or more mechanical procedures relate to at least one of shredding, peeling, splitting, and decortication, which are used to extract bamboo fibers.
3) The method (200) as claimed in claim 1, wherein:
the moisture resistance technique corresponds to treating the bamboo fibers with a chemical solution to improve resistance to decay, termites, and environmental deterioration,
the strengthening corresponds to a mechanical or thermal treatment of the bamboo fibers to improve tensile strength and overall durability, and
the chemical treatment relates to treating the bamboo fibers with chemicals to protect from pests and prevent degradation, wherein the chemicals relate to at least one of borates or silicates.
4) The method (200) as claimed in claim 1, wherein the binding agent comprises a polymer resin selected from a group comprising epoxy resin, polyurethane resin, and biodegradable polymers.
5) The method (200) as claimed in claim 1, wherein fabricating (208) the bio-composite material further comprises:
reinforcing the bio-composite material with natural or synthetic fibers for enhanced tensile strength.
6) The method (200) as claimed in claim 1, wherein extruding the bio-composite material at temperatures ranging from 150°C to 200°C to form pipes with homogeneous diameters, and
molding the bio-composite material in a multi-part mold, which is then cured at controlled temperatures to solidify the material.
7) A system (100) for manufacturing bio-composite pipes using engineered bamboo, the system comprising:
a bamboo processing unit (102) to extract bamboo fibers from harvested bamboo stalks;
a treatment unit (104) for applying chemical and mechanical treatments on the extracted bamboo fibers to enhance resistance against moisture, strength, and durability;
a composite formation unit (106) for fabricating a bio-composite material by processing the treated bamboo fibers with a binding agent;
an extrusion and molding unit (108) for shaping the bio-composite material into pipes of specified shape and dimensions; and
a curing unit (110) for hardening and strengthening the material to manufacture bio-composite pipes.
8) The system (100) as claimed in claim 7, wherein the treatment unit (104) comprises an apparatus for providing at least one of thermal, and chemical treatments to the bamboo fibers to improve their mechanical properties.
9) The system (100) as claimed in claim 7, wherein the composite formation unit (106) comprises automatic mixers and temperature-controlled tanks for treating the bamboo fibers with the binding agent to generate the bio-composite material.
10) The system (100) as claimed in claim 7, wherein the extrusion and molding unit (108) comprises an extrusion section that forces the bio-composite material through a die to make pipes, and a molding section utilizes multi-part molds for more complex designs,
wherein the extrusion and molding unit (108) is designed to create pipes having varying diameters and wall thicknesses, depending on the intended application of the pipes.
11) The system as claimed in claim 7, further comprising a cutting or finishing unit (112) for trimming and smoothing the edges of the bio-composite pipes post-extrusion or molding, and curing.