This invention relates to a composition of bio-composite blend of PVC, polystyrene with starch & fly-ash and degradation process thereof.
Background of the Invention
Polyvinylchloride (PVC), Polystyrene (PS) as such are non-biodegradable polymers. These vinyl polymers are very important vinyl polymers which are used in making different types of toys, household purpose materials etc, so when product made from these polymers are removed or scrapped then disposal of such items is a big problem in terms of our environment.
US8809425B2 Multifunctional bio composite additive compositions and methods discloses Bio composite compositions and compositions, which include dried distillers soluble, and which can be used in making bio composite compositions are described. Methods for preparing the compositions are also described.
Research Gap: In this reference, Copolymer is made by using isobutene and butyl rubber but in our invention vinyl polymers are being used with PLA in z blade mixer.
CA2802091A1 Floor covering composition containing renewable polymer discloses composition is described that includes at least one polyolefin, at least one thermoplastic bio-resin derived from starch or soy or both, and at least one compatibilizer having at least one polyolefin and at least one polar group. Surface coverings and floor coverings, such as laminated floor coverings, having the composition, are also described.
Research Gap: In this one olefin based polymer used with starch for composite, but in our invention two vinyl polymer ( PVC/PS) are being used with PLA to form composite which is given photolytic effect for biodegrdation
US6235815B1 Biodegradable polymeric mixtures based on thermoplastic starch discloses For converting native starch or starch derivatives into thermoplastic starch, added to the starch is at least one hydrophobic biodegradable polymer. This hydrophobic biodegradable polymer, which serves as a plasticizer or swelling agent, may be a polymer selected from the following list: an aliphatic polyester, a copolyester with aliphatic and aromatic blocks, a polyester amide, a polyester urethane, a polyethylene oxide polymer and/or a polyglycol, and/or mixtures of these. When the starch, such as in particular native starch or derivatives thereof, is mixed in the melt with the hydrophobic biodegradable polymer as a plasticizer or swelling agent, to homogenize the mixture, the water content is reduced to <1% by weight based on the weight of the mixture
Research Gap: In this US patent, biodegrdable polymer mixture prepared with starch and its derivatives. While in our more than one non-biodegrdable polymer like PVC, PS are being used in blend blend with starch, which become degradable by photolytic effect later.
None of the prior art indicate above either alone or in combination with one another disclose what the present invention has disclosed. In this invention, Polyvinylchloride (PVC), Polystyrene (PS) non-biodegradable polymers have been used in making bio composite blend with use of starch( from agri waste or plant material) and industrial waste like fly ash along with PLA ( Poly-lactic acid) in appropriate conditions then such composite shows good stability and can be used in place of PVC or PS in making toys or other household purpose materials which after use can also be degraded by using photolytic and microbial exposure.
Polyvinylchloride (PVC), Polystyrene (PS) as such are non-biodegradable polymers but when PVC/PS is modified by preparing composite blend with selected plasticizer like glycerol, Industrial waste fly ash and starch from agricultural waste like straw or husk then such blend has good scope of biodegradation. Glycerol or sorbitol can be used from 2 to 10 % as plasticizer and fly-ash which works as filler like kaolin clay, it is used 5 to 10% in composite preparation. starch of Agri-waste like rice husk or straw can be added from 5 to15%. Such composite is prepared by taking all components in granules form and PVC is added in DMF, fly-ash and straw mixed with plasticizer (glycerol) and then all mixed taken in z- blade mixer at 160 to 180°C and heated for 30-40 mins. Such composite developed also has good strength to use by high degree of biodegradability. This composite is also thermally stable upto 90 to 105°C.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
Discloses herein a composition comprises non-biodegradable vinyl polymers like Polyvinylchloride (PVC), Polystyrene (PS) or PVP or any other vinyl polymer is converted in to bio composite by mixing in the ratio of 10 to 90% and mixing PLA from 5 to 20%; wherein PLA or any other plasticizer like glycerol is added; and Glycerol or sorbitol is used from 2 to 10 % as plasticizer; wherein Industrial waste fly ash from 2 to 10% is used; and Starch (2 to 10%) from agricultural waste like straw or husk is used then such blend has good scope of biodegradation. Present invention further discloses a method of manufacturing the composition as claimed in claim 1-3, wherein said method comprising the steps of : 1- 2g PVC taken in 250 ml beaker and added 5- ml DMF with constant staring on magnetic stirrer(400rpm) at 400C for 45 minutes followed by 0.5 to 1 g PS and PLA ( 5 to 20% ) added , 1-2 ml of Glycerol with constant staring on magnetic stirrer at 400C for further 30 minutes., starch from agri-waste or corn starch ( 5-10%) , fillers like fly ash or clay ( 2-5%) were added in different proportions. Then films were casted in petri-dish.
In this invention, non-biodegradable vinyl polymers like Polyvinylchloride (PVC), Polystyrene (PS) or PVP or any other vinyl polymer can be converted in to bio composite by mixing in the ratio of 10 to 90% and mixing PLA from 5 to 20%.
PLA or any other plasticizer like glycerol can be added. Glycerol or sorbitol can also be used from 2 to 10 % as plasticizer. Industrial waste fly ash from 2 to 10% can be used. Starch (2 to 10%) from agricultural waste like straw or husk can be used then such blend has good scope of biodegradation. PVC/PS/PLA are mixed and taken in zblade mixer or hydrothermal reactor at 140 to 180°C for appropriate blending/composite. Such prepared composite is exposed to photolytic effect /UV exposure from 1 days to 10 days followed by microbial exposure for getting better degradation.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
Fig-1(a & b) FT-IR image of PVC and best composite
Fig-2 (a& b) SEM images of composites
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
As it is well known fact that plastics specially PVC or PE or Polystyrene or polypropylene products are not biodegradable. Many efforts have been made by many researchers for creating biodegradability in PVC or PS/polythene products. Nanotechnology has helped in producing and developing new composite material which may have similar physical properties like PE but degradability may vary. By nanocomposite preparation variety of product with desired properties is being achieved. Major Lookup is currently proceeding to improve serials with higher biodegradability and extra surroundings pleasant nature. Biodegradable polymers are designed so that degradation takes place with the aid of the enzymatic motion of dwelling micro-organisms such as bacteria or fungi to produce carbon dioxide, water and nontoxic biomass. Polymer blends and composites with natural polymers as one of the elements have been developed through many researchers. These kinds of structures are effortlessly processable and can be commercialized. One of the predominant risks of blending or reinforcing natural polymers with artificial polymer is their incompatibility with the matrix, which is brought about by means of the immiscibility of the hydrophilic natural polymers with the hydrophobic artificial polymers.
Process-
Methods- Preparation of composite Film along with Plasticizer and Additives
1- 2g PVC taken in 250 ml beaker and added 5- ml DMF with constant staring on magnetic stirrer(400rpm) at 400C for 45 minutes followed by 0.5 to 1 g PS and PLA ( 5 to 20% ) added , 1-2 ml of Glycerol with constant staring on magnetic stirrer at 400C for further 30 minutes., starch from agri-waste or corn starch ( 5-10%) , fillers like fly ash or clay ( 2-5%) were added in different proportions. Then films were casted in petri-dish.
Characterization-
Physical strength- Physical property like tensile strength was tested for analysis of strength properties. Biodegradability of film was determined by soil burial test. Strength of polymer film was determined by using tearing strength tester as per ASTM D638 from Central Pulp and Paper Research Institute (CPPRI), Saharanpur (UP). The value of tearing strength values are shown in table-1. From the table it can be observed that composite of PVC with PS, PLA and fly ash have shown better physical strength and it can be used in place of alone PVC or single PS.
Thermal Stability- Thermal stability of different polymer composite samples were determined in IPT –IIT Saharanpur campus (IIT- Roorkee) lab by using thermal Analyzer. From the thermal study different Tg (glass transition temperatures) were determined as per ASTM E 1356 method. Thermal stability of different polymer and composites (/Starch/glycerol/flyash/Chitosan) are shown in figure2. Polymer composites have shown Tg up to 107°C. so such composites can be used upto 100 °C easily.
Photolytic (UV exposure) & Microbial degradation -
Thin films of polymer blend after taking their weights were exposed to UV radiation by using UV-B lamp (280-315 nm) for about 30 days and their FT-IR study as well as strength properties were also determined. Biodegradation study was done by applying soil burial test in a 8 cubic ft soil box. After UV exposure all types of polymer blends were buried in soil box with optimum conditions for microorganism growth for 3 to 6 months. microbes (bacteria/ fungi) were allowed through sewage water sample.
All PVC/PS composite films were also characterized by using FT-IR and SEM. FT-IR is used for confirmation about formation and breaking of atomic bonds in polymer composites Such methods have been suggested by many researchers for biodegradation. (After 3 months loss in weight was calculated which are given in table-1 and strength properties are shown in table-2. While FT-IR and sem images are given in fig-1 and 2., which confirm the formation of bio composite in the invention.
Conclusion
Microbial activities are actual significant for the renewal of our environment and preservation of the global carbon cycle. These accomplishments are included in the term biodegradation. From this study it can be concluded that if composite of PVC is prepared with some biodegradable polymer like PVA or starch or other agri-waste, suitable filler ( flyash/ clay ) and plasticizer ( glycerol) then such developed product may be used in place of traditional plastics as they may have considerable physical strength and these will be biodegradable also in photolytic and microbial environment. Plasticizer can be blended from 2 to 10 % ( w/w) while filler not more than 10% can be added to get stable composite. As such if more filler(clay) is added then its strength may decrease.
Table – 1 – Weight loss study of PVC blends/composites in soil environment
Sr. No. Sample Blend with % Degradation Duration
Polymer Plasticizer Filler
1. PVC - - - 0 3 months
2. PVC PS ( 25%) Starch (10%) 10 3 months
3. PVC PS ( 25%) PLA (5%) Flyash ( 5%) 18 3 months
4. PVC PS ( 50%) PLA (10%) Flyash ( 5%) 27 3 months
5. PVC PS ( 50%) PLA (10%) Flyash ( 5%) 35 3 months
6. PVC PS ( 50%) _ husk(10%) PLA (10%),Glycerol (5%) Flyash ( 5%) 48 3 months
7. PVC PS ( 25%) _ husk/starch(-20%) PLA (10%)+Glycerol (5%) Flyash ( 5%) 58 6 months

Table-2 Strength Properties (Tensile strength, Pa) and % biodegradation (Wt. Loss)
S.No Film /Composite Film
Strength After UV exposure(30d) After UV+ micro expos.(90days) % Max strength
Reduction.
1. PVC 3.84 3.50 3.38 10%
2. PVC+PS composite strach 3.35 2.82 2.30 30.9
3. PVC composite PS/PLA(5)+gly
3.21 2.92 1.90 40.8
4. PVC composite+PS(50)
Str+PLA(10)+flyash(5) 3.36 2.80 1.72 48.8
5. PVC composite
Str+PLA(10)+flyash(5) 3.52 2.70 1.54 56.2
6. PVC composite+PS(50%)
Starch+PLA(10)+flyash(5) 3.65 2.65 1.50 59
7. PVC composite+PS(25)
Str+PLA(10)+flyash(5) 3.75 2.55 1.40 62.6

Table-3 ( Tg) Glass Transition temp of polymer composites)
S. No Polymer composite name Sample stability (Tg) temp
1. PVC 800C
2. PVC+PS composite strach 820C
3. PVC composite PS/PLA (5)+ gly 850C
4. 4 PVC composite+PS(50)
Str+PLA(10)+flyash(5) 900C
5. PVC composite
Str+PLA(10)+flyash(5) 970C
6. PVC composite+PS(50%)
Starch+PLA(10)+flyash(5) 1020C
7. PVC composite+PS(25)
Str+PLA(10)+flyash(5) 1050C

ADVANTAGES OF THE INVENTION:
By this invention, polymer plastics (in which more than 75% used polymers are PVC and PS) can be converted into new polymer composite blend along with PLA , starch and fly ash by which new polymer can be used in making toys or other household materials and after use of these materials, these can be disposed of without creating problem in environment because the new developed polymers have biodegradability after exposure to photolytic effect and microbial exposure.
Example:
1. In this invention, non-biodegradable vinyl polymers like Polyvinylchloride (PVC), Polystyrene (PS) or PVP or any other vinyl polymer can be converted in to bio composite by mixing in the ratio of 10 to 90% and mixing PLA from 5 to 20%.
2. PLA or any other plasticizer like glycerol can be added. Glycerol or sorbitol can also be used from 2 to 10 % as plasticizer
3. Industrial waste fly ash from 2 to 10% can be used
4. Starch (2 to 10%) from agricultural waste like straw or husk can be used then such blend has good scope of biodegradation.
5. PVC/PS/PLA are mixed and taken in zblade mixer or hydrothermal reactor at 140 to 180°C for appropriate blending/composite.
6. Such prepared composite is exposed to photolytic effect /UV exposure from 1 days to 10 days followed by microbial exposure for getting better degradation.

We Claims:

1. A composition of bio-composite blend of PVC, polystyrene with starch & fly-ash comprises non-biodegradable vinyl polymers like Polyvinylchloride (PVC), Polystyrene (PS) or PVP or any other vinyl polymer is converted in to bio composite by mixing in the ratio of 10 to 90% and mixing PLA from 5 to 20%; wherein PLA or any other plasticizer like glycerol is added; and Glycerol or sorbitol is used from 2 to 10 % as plasticizer; wherein Industrial waste fly ash from 2 to 10% is used; and Starch (2 to 10%) from agricultural waste like straw or husk is used then such blend has good scope of biodegradation.
2. The composition as claimed in claim 1, wherein PVC/PS/PLA are mixed and taken in zblade mixer or hydrothermal reactor at 140 to 180°C for appropriate blending/composite.
3. The composition as claimed in claim 1, wherein prepared composite is exposed to photolytic effect /UV exposure from 1 days to 10 days followed by microbial exposure for getting better degradation.
4. A method of manufacturing the composition as claimed in claim 1-3, wherein said method comprising the steps of : 1- 2g PVC taken in 250 ml beaker and added 5- ml DMF with constant staring on magnetic stirrer(400rpm) at 400C for 45 minutes followed by 0.5 to 1 g PS and PLA (5 to 20% ) added , 1-2 ml of Glycerol with constant staring on magnetic stirrer at 400C for further 30 minutes., starch from agri-waste or corn starch ( 5-10%) , fillers like fly ash or clay ( 2-5%) were added in different proportions. Then films were casted in petri-dish.
5. The composition as claimed in claim 1, wherein thin films of polymer blend after taking their weights are exposed to UV radiation by using UV-B lamp (280-315 nm) for about 30 days and their FT-IR study as well as strength properties are also determined.
6. The composition as claimed in claim 1, wherein Biodegradation study is done by applying soil burial test in 8 cubic ft soil box; after UV exposure all types of polymer blends were buried in soil box with optimum conditions for microorganism growth for 3 to 6 months; and microbes (bacteria/ fungi) were allowed through sewage water sample.
7. The composition as claimed in claim 1, wherein all PVC/PS composite films are also characterized by using FT-IR and SEM; and FT-IR is used for confirmation about formation and breaking of atomic bonds in polymer composites.