Description:FIELD
The present disclosure relates to a composition for preparing wood-like material and a process for its preparation.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
The rapid changes and socio-economic transformations over the last few decades affected and caused severe stress mainly on climate, energy, environment, and most facets of the globe. Further, there is a need for the development of alternative materials/compositions to reduce the impact on climate, energy, and environment. Recently, it is reported novel applications of materials from thermoplastic resins loaded with fillers in lignocellulose fibers (composite) due to the added benefits that they provide to the materials in terms of lightness, low cost, mechanical resistance and the like.
The conventional composite having polyvinyl chloride (PVC) and a biofiller (biomass) which is difficult to process as it creates high torque during the extrusion process thereby decreasing the processibility of the composite.
There is, therefore, felt a need to provide a composition for preparing wood-like material and a process for its preparation that mitigates the drawbacks mentioned hereinabove or at least provide a useful alternative.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
Another object of the present disclosure is to provide a composition for preparing wood-like material.
Still another object of the present disclosure is to provide a composition for preparing wood-like material that has smooth surface quality.
Another object of the present disclosure is to provide a composition for preparing wood-like material that has comparatively better performance characteristics.
Yet another object of the present disclosure is to provide a composition for preparing wood-like material that has comparatively higher mechanical strength.
Another object of the present disclosure is to provide a simple, effective, and environment-friendly process for the preparation of a composition for preparing wood-like material.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a composition for preparing wood-like material.
The composition comprises polyvinyl chloride (PVC) resin in an amount in the range of 0 mass% to 50 mass% with respect to the total amount of the composition; internally plasticized polyvinyl chloride (IP- PVC) in an amount in the range of 3 mass% to 60 mass% with respect to the total amount of the composition; a biomass in an amount in the range of 25 mass% to 40 mass% with respect to the total amount of the composition; and an additive in an amount in the range of 10 mass% to 20 mass% with respect to the total amount of the composition.
The present disclosure further relates to a process for the preparation of a composition for preparing wood-like material.
The process comprises drying a biomass at a first predetermined temperature for a first predetermined time period to obtain a dried biomass. The dried biomass, a predetermined amount of at least one additive, and a predetermined amount of polyvinyl chloride (PVC) resin and IP-PVC resin are mixed at a predetermined speed for a time period in the range of 15 minutes to 60 minutes, followed by drying at a second predetermined temperature for a second predetermined time period to obtain a dried mixture. The dried mixture is melt mixed at a third predetermined temperature for a third predetermined time period followed by drying to obtain the composition.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a mechanism of PVC-cellulose matrix interaction, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a particle size distribution for a) sugarcane bagasse; and b) ground nut husk, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates scanning electron microscope (SEM) images of PVC/ sugarcane bagasse (SB) composition for a) 4.8 mass% of IP-PVC (used in example 1); b) 24.2 mass% of IP-PVC (used in example 3); and c) 48.5 mass% of IP-PVC (used in example 4); and
Figure 4 illustrates images of demo products made from composition of the present disclosure.
DETAILED DESCRIPTION
Embodiments of the present disclosure will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
As used herein, the term “and/or” includes any combination of one or more of the associated listed elements.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
The rapid changes and socio-economic transformations over the last few decades affected and caused severe stress mainly on climate, energy, environment, and most facets of the globe. Further, there is a need for the development of alternative materials/compositions to reduce the impact on climate, energy, and environment. Recently, it is reported novel applications of materials from thermoplastic resins loaded with fillers in lignocellulose fibers (composite) due to the added benefits that they provide to the materials in terms of lightness, low cost, mechanical resistance and the like.
The conventional composite having polyvinyl chloride (PVC) and a biofiller (biomass) which is difficult to process as it creates high torque during the extrusion process thereby decreasing the processibility of the composite.
The present disclosure relates to a composition for preparing wood-like material and a process for its preparation.
In an aspect, the present disclosure provides a composition for preparing wood-like material.
The composition comprises polyvinyl chloride (PVC) resin in an amount in the range of 0 mass% to 50 mass% with respect to the total amount of the composition; internally plasticized polyvinyl chloride (IP- PVC) in an amount in the range of 3 mass% to 60 mass% with respect to the total amount of the composition; a biomass in an amount in the range of 25 mass% to 40 mass% with respect to the total amount of the composition; and an additive in an amount in the range of 10 mass% to 20 mass% with respect to the total amount of the composition.
Interaction between PVC and cellulose molecule is higher due to van der waals and dipole-dipole moment interaction between H+ and Cl- as well as H+ & OH- (as shown in figure 1). Mechanical properties of W-PVC are higher as compared to W-PP &W-PE due to this interaction.
In accordance with an embodiment of the present disclosure, the internally plasticized polyvinyl chloride comprises diallyl phthalate in an amount in the range of 1 mass% to 35 mass% with respect to the total amount of the internally plasticized polyvinyl chloride, and polyvinyl chloride (PVC) in an amount in the range of 65 mass% to 99 mass% with respect to the total amount of the internally plasticized polyvinyl chloride. In an exemplary embodiment, the internally plasticized polyvinyl chloride comprises diallyl phthalate is in an amount of 33.3 mass% with respect to the total amount of the internally plasticized polyvinyl chloride, and polyvinyl chloride (PVC) is in an amount of 66.7 mass% with respect to the total amount of the internally plasticized polyvinyl chloride.
The internally plasticized polyvinyl chloride (IP- PVC) helps in lowering torque thereby leading to ease in processing.
In accordance with an embodiment of the present disclosure, the biomass is at least one selected from the group consisting of sugarcane bagasse, ground nut husk, rice husk, and bamboo fibers. In an exemplary embodiment, the biomass is sugarcane bagasse. In another exemplary embodiment, the biomass is ground nut husk.
In accordance with an embodiment of the present disclosure, the biomass has a particle size in the range of 20 microns to 150 microns. In an exemplary embodiment, the biomass has a particle size of 81 microns.
In accordance with an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a lubricating agent, a binder, an impact modifier, a thermal stabilizer and an inorganic filler.
In accordance with an embodiment of the present disclosure, the lubricating agent is selected from the group consisting of fatty acid salt, fatty acid ester, paraffin wax, and polyethylene wax.
In accordance with an embodiment of the present disclosure, the fatty acid salt is at least one selected from the group consisting of calcium stearate, tribasic lead stearate, dibasic lead stearate, glycerol mono stearate, and lead stearate. In an exemplary embodiment, the fatty acid salt is calcium stearate.
In accordance with an embodiment of the present disclosure, the fatty acid ester is at least one selected from the group consisting of ester of C8/C18 fatty acid.
In accordance with an embodiment of the present disclosure, the C8/C18 fatty acid is selected from stearic acid and sebacic acid. In an exemplary embodiment, the C8/C18 fatty acid is stearic acid.
In accordance with an embodiment of the present disclosure, the binder/impact modifier is at least one selected from the group consisting of poly(butyl methacrylate-co-methyl methacrylate), polymethyl methacrylate-co-methacrylic acid, poly(methyl methacrylate-co-methyl methacrylate), acrylates copolymers, diene based copolymers, and chlorinated polyethylene (CPE).
In accordance with an embodiment of the present disclosure, the thermal stabilizer is selected from the group consisting of methyl tin stabilizer and tribasic lead sulphate.
In accordance with an embodiment of the present disclosure, the inorganic filler is selected from calcium carbonate, talc, titanium dioxide, and silicon dioxide. In an exemplary embodiment, the inorganic filler is calcium carbonate.
The inorganic filler enhances the hardness, tensile properties and improves the impact properties of the composition.
In accordance with an embodiment of the present disclosure, the composition is characterized by having:
• tensile strength in the range of 2 MPa to 30 MPa;
• elongation at break in the range of 0.5% to 4%;
• izod impact in the range of 15 J/m to 45 J/m;
• flexural strength in the range of 5 MPa to 55 MPa; and
• hardness in the range of 45 D to 85 D.
The composition for preparing wood-like material of the present disclosure can be used for various applications such as graphic art, construction, furniture, and the like. The wood-like material prepared by using composition of the present disclosure has a comparatively smooth surface quality, relatively better performance characteristics, and comparatively higher mechanical properties.
The composition for preparing wood-like material of the present disclosure helps in avoiding the use of wood thereby helping to protect the environment.
In another aspect, the present disclosure provides a process for the preparation of a composition. The composition of the present disclosure is used for preparing wood-like material.
The process of the present disclosure is described in detail as given below:
In a first step, a biomass is dried at a first predetermined temperature for a first predetermined time period to obtain a dried biomass.
In accordance with an embodiment of the present disclosure, the biomass is at least one selected from the group consisting of sugarcane bagasse, ground nut husk, rice husk, and bamboo fiber. In an exemplary embodiment, the biomass is sugarcane bagasse. In another exemplary embodiment, the biomass is ground nut husk.
In accordance with an embodiment of the present disclosure, the biomass has a particle size in the range of 20 microns to 150 microns. In an exemplary embodiment, the biomass has a particle size of 81 microns.
In accordance with an embodiment of the present disclosure, an amount of the biomass is in the range of 25 mass% to 40 mass%. In an exemplary embodiment, an amount of the biomass is 32.3 mass%
In accordance with an embodiment of the present disclosure, the first predetermined temperature is in the range of 50 ºC to 120 ?. In an exemplary embodiment, the first predetermined temperature is 80 ºC.
In accordance with an embodiment of the present disclosure, the first predetermined time period is in the range of 5 hours to 10 hours. In an exemplary embodiment, the first predetermined time period is 10 hours.
In a second step, the dried biomass, a predetermined amount of at least one additive, and a predetermined amount of polyvinyl chloride (PVC) resin and IP-PVC resin are mixed at a predetermined speed for a time period in the range of 15 minutes to 60 minutes, followed by drying at a second predetermined temperature for a second predetermined time period to obtain a dried mixture.
In accordance with an embodiment of the present disclosure, the predetermined amount of the polyvinyl chloride (PVC) resin is in the range of 0 mass% to 50 mass%.
In accordance with an embodiment of the present disclosure, the predetermined amount of the internally plasticized polyvinyl chloride (IP- PVC) is in the range of 3 mass% to 60 mass%.
In accordance with an embodiment of the present disclosure, the predetermined amount of the additive is in the range of 10 mass% to 20 mass%.
In accordance with an embodiment of the present disclosure, the internally plasticized polyvinyl chloride comprises:
• diallyl phthalate in an amount in the range of 1 mass% to 35 mass% with respect to the total amount of the internally plasticized polyvinyl chloride; and
• polyvinyl chloride (PVC) in an amount in the range of 65 mass% to 99 mass% with respect to the total amount of the internally plasticized polyvinyl chloride.
In an exemplary embodiment, the internally plasticized polyvinyl chloride comprises:
• diallyl phthalate is in an amount of 33.3 mass% with respect to the total amount of the internally plasticized polyvinyl chloride; and
• polyvinyl chloride (PVC) is in an amount of 66.7 mass% with respect to the total amount of the internally plasticized polyvinyl chloride.
In accordance with an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a lubricating agent, a binder/an impact modifier, a thermal stabilizer, and an inorganic filler.
In accordance with an embodiment of the present disclosure, the binder/impact modifier is at least one selected from the group consisting of poly(butyl methacrylate-co-methyl methacrylate), polymethyl methacrylate-co-methacrylic acid, poly(methyl methacrylate-co-methyl methacrylate), acrylates copolymers, diene based copolymers, and chlorinated polyethylene (CPE). In an exemplary embodiment, the binder/impact modifier is poly(butyl methacrylate-co-methyl methacrylate).
In accordance with an embodiment of the present disclosure, an amount of the binder/impact modifier is in the range of 4 mass% to 8 mass%. In an exemplary embodiment, an amount of the binder/impact modifier is 6.5 mass%.
The binder/impact modifier helps to bind PVC to the biomass (sugarcane bagasse) and enhances the impact properties.
In accordance with an embodiment of the present disclosure, the thermal stabilizer is selected from the group consisting of methyl tin stabilizer and tribasic lead sulphate.
In accordance with an embodiment of the present disclosure, an amount of the thermal stabilizer is in the range of 0.5 mass% to 3 mass%. In an exemplary embodiment, an amount of the thermal stabilizer is 1.6 mass%.
In accordance with an embodiment of the present disclosure, the inorganic filler is selected from calcium carbonate, talc, titanium dioxide, and silicon dioxide. In an exemplary embodiment, the inorganic filler is calcium carbonate.
In accordance with an embodiment of the present disclosure, an amount of the inorganic filler is in the range of 3 mass% to 8 mass%. In an exemplary embodiment, an amount of the inorganic filler is 6.5 mass%.
In accordance with an embodiment of the present disclosure, the lubricating agent is at least one selected from the group consisting of fatty acid salt, fatty acid ester, paraffin wax, and polyethylene wax.
In accordance with an embodiment of the present disclosure, an amount of the lubricating agent is in the range of 0.1 mass% to 0.5 mass%. In an exemplary embodiment, an amount of the lubricating agent is 0.2 mass%.
In accordance with an embodiment of the present disclosure, the fatty acid salt is at least one selected from the group consisting of calcium stearate, tribasic lead stearate, dibasic lead stearate, glycerol mono stearate, and lead stearate. In an exemplary embodiment, the fatty acid salt is calcium stearate.
In accordance with an embodiment of the present disclosure, an amount of the fatty acid salt is in the range of 0.5 mass% to 0.9 mass%. In an exemplary embodiment, an amount of the fatty acid salt is 0.6 mass%.
In accordance with an embodiment of the present disclosure, the fatty acid ester is at least one selected from the group consisting of ester of C8/C18 fatty acid.
In accordance with an embodiment of the present disclosure, the C8/C18 fatty acid is selected from stearic acid and sebacic acid. In an exemplary embodiment, the C8/C18 fatty acid is stearic acid.
In accordance with an embodiment of the present disclosure, an amount of the fatty acid ester is in the range of 0.5 mass% to 0.9 mass%. In an exemplary embodiment, an amount of the fatty acid ester is 0.75 mass%.
In accordance with an embodiment of the present disclosure, the predetermined speed is in the range of 1000 rpm to 2000 rpm. In an exemplary embodiment, the predetermined speed is 1700 rpm.
In accordance with an embodiment of the present disclosure, the second predetermined temperature is in the range of 60 ºC to 120 ºC. In an exemplary embodiment, the second predetermined temperature is 100 ºC
In accordance with an embodiment of the present disclosure, the second predetermined time period is in the range of 1 hour to 3 hours. In an exemplary embodiment, the second predetermined time period is 2 hours.
In a third step, the dried mixture is melt mixed at a third predetermined temperature for a third predetermined time period followed by drying to obtain the composition.
In accordance with an embodiment of the present disclosure, the third predetermined temperature is in the range of 110 ºC to 140 ºC. In an exemplary embodiment, the third predetermined temperature is 100 ºC
In accordance with an embodiment of the present disclosure, the third predetermined time period is in the range of 1 hour to 3 hours. In an exemplary embodiment, the third predetermined time period is 3 hours.
In accordance with an embodiment of the present disclosure, a speed during the extrusion process is in the range of 20 rpm to 80 rpm. In an exemplary embodiment, a speed during the extrusion process is 30 rpm.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Example 1: Preparation of a composition for preparing wood-like material, in accordance with the present disclosure
32.3 mass% of sugarcane bagasse (SB) powder (biomass) with an average particle size of 81 microns was completely dried in a vacuum oven at 80? for 10 hrs to obtain a dried sugarcane bagasse (dried biomass). Then, dried sugarcane bagasse, 43.6 mass% of polyvinyl chloride resin (PVC), 4.8 mass% of internally plasticized polyvinyl chloride (IP-PVC) resin, 6.5 mass% of Poly(butyl methacrylate-co-methyl methacrylate (chemical binder or impact modifier which is thermoplastic base compound), 3.2 mass% of calcium stearate (inorganic filler) , 0.6 mass% of ester of stearic acid (fatty acid ester), 0.6 mass% of glycerol mono stearate (fatty acid salt), 0.2 mass% of polyethylene wax (lubricating agent), 6.5 mass% of calcium carbonate (inorganic filler) and 1.6 mass% of methyl tin stabilizer (thermal stabilizer) were mixed in high-speed mixture at 1700 rpm for 30 minutes followed by drying in oven at 100 °C for 60 minutes for complete drying, in case if moisture get absorbed by fillers to obtain a dried mixture. Further, the dried mixture was passed through a single screw extruder in melt mixing step at 30 rpm at a temperature in the range of 155 ºC to 190? to obtained the composition in the form of small granules. The so obtained granules were dried in oven again for 3 hrs at 100? to remove trapped moistures. The dried granules made in second step were used to make sheet using compression moulding technique at temperature 190?.
Example 2: Preparation of a composition for preparing wood-like material, in accordance with the present disclosure
The same experimental procedure was followed as mentioned in example 1 except 32.3 mass% of sugarcane bagasse (SB), 33.9 mass% of PVC and 14.5 mass% of IP-PVC were used.
Example 3: Preparation of a composition for preparing wood-like material, in accordance with the present disclosure
The same experimental procedure was followed as mentioned in example 1 except 32.3 mass% of sugarcane bagasse (SB), 24.2 mass% of PVC and 24.2 mass% of IP-PVC were used.
Example 4: Preparation of a composition for preparing wood-like material, in accordance with the present disclosure
The same experimental procedure was followed as mentioned in example 1 except 32.3 mass% of sugarcane bagasse (SB), 0 mass% of PVC and 48.5 mass% of IP-PVC were used.
Example 5: Preparation of a composition for preparing wood-like material (by using groundnut husk), in accordance with the present disclosure
The same experimental procedure was followed as mentioned in example 1 except groundnut husk (GH) (biomass) was used instead of sugarcane bagasse (SB). The PVC/IP-PVC/GH composition also showed similar properties as PVC/ IP-PVC/SB composition.
Comparative Example 1: Preparation of a composition for preparing wood-like material

The same experimental procedure was followed as mentioned in example 1 except 40 mass% of sugarcane bagasse (SB), 60 mass% of PVC and 0 mass% of IP-PVC were used.
Table -1: Processing conditions of PVC/SB composition using with and without IP-PVC and its mechanical properties of the composition
S No. Composition Example 1 Example 2 Example 3 Example 4 Comp. example 1
Extrusion process parameters
1 T1 155 °C 155 °C 155 °C 155 °C 155 °C
2 T2 175 °C 175 °C 175 °C 175 °C 175 °C
3 T3 185 °C 185 °C 185 °C 185 °C 185 °C
4 T4 190 °C 190 °C 190 °C 190 °C 190 °C
5 RPM 30 30 30 30 30
6 Torque 40 Nm 15.6 Nm 13 Nm 7 Nm 47 Nm
7 Pressure 57.7 bar 45 bar 35 bar 17.5 bar 101 to 104 bar
Mechanical properties
1 Tensile strength (MPa) 20 19 15 3.9 18
2 Elongation @ Break (%) 0.60 0.7 0.65 3.4 5.6
3 Impact strength (J/m) 22 23 18 35 23
4 Flexural Strength (MPa) 46 43 32 8 49
5 Hardness (D) 82 81 80 47 81

From Table 1, it is evident that the higher performance characteristics like tensile, flexural and impact strength and hardness properties of the composition obtained in examples 1-4 was obtained as compared to the composition obtained in the comparative example 1 (devoid of IP-PVC).
Table-2: ICP analysis of biomass fillers i.e. sugarcane bagasse and ground nut husk
Sample name mass %Al2O3 mass %CaO mass %Fe2O3 mass %K2O mass %SiO2 mass %MgO
Sugarcane bagasse (SB) 1.82 5.25 3.60 7.91 70.44 1.83
Ground nut husk (GH) 3.13 3.17 4.36 7.72 74.37 0.57

From Table 2, it is evident that the ICP analysis of sugarcane bagasse (SB) and ground nut husk (GH) shown higher concentration of silica which helps in higher performance characteristics of composition.
Figure 2 illustrates a particle size distribution for a) sugarcane bagasse; and b) ground nut husk, in accordance with an embodiment of the present disclosure.
From Figure 2, it is evident that the particle size distribution of the sugarcane bagasse and the ground nut husk has an average diameter of 81 µm.
Figure 3 illustrates scanning electron microscope (SEM) images of PVC/ sugarcane bagasse (SB) composition for a) 4.8 mass% of IP-PVC (used in example 1); b) 24.2 mass% of IP-PVC (used in example 3); and c) 48.5 mass% of IP-PVC (used in example 4).
From Figure 3, it is evident that variation in the amount of IP-PVC does not affect the morphology of the PVC/SB composition. Further, even when the composition of the present disclosure is devoid of PVC (example 4), the morphology of the composition is uniform.
Figure 4 illustrates images of demo products made from composition of the present disclosure.
PVC/IP-PVC/SB composition tested for screw nailing, drilling, and hand Shaw test. All test shown positive sign towards the PVC composition.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a composition for wood-like material that:
• has smooth surface quality;
• has relatively better performance characteristics; and
• has comparatively higher mechanical properties;
and
the process for preparing a composition for wood-like material that:
• is simple and economical; and
• is scalable.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising, will be understood to imply the inclusion of a stated element, integer or step,” or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A composition for preparing wood-like material comprising:
(a) polyvinyl chloride (PVC) resin in an amount in the range of 0 mass% to 50 mass% with respect to the total amount of said composition;
(b) internally plasticized polyvinyl chloride (IP- PVC) in an amount in the range of 3 mass% to 60 mass% with respect to the total amount of said composition;
(c) a biomass in an amount in the range of 25 mass% to 40 mass% with respect to the total amount of said composition; and
(d) an additive in an amount in the range of 10 mass% to 20 mass% with respect to the total amount of said composition.
2. The composition as claimed in claim 1, wherein said internally plasticized polyvinyl chloride comprises:
• diallyl phthalate in an amount in the range of 1 mass% to 35 mass% with respect to the total amount of said internally plasticized polyvinyl chloride; and
• polyvinyl chloride (PVC) in an amount in the range of 65 mass% to 99 mass% with respect to the total amount of said internally plasticized polyvinyl chloride.
3. The composition as claimed in claim 1, wherein said biomass is at least one selected from the group consisting of sugarcane bagasse, ground nut husk, rice husk, and bamboo fibers.
4. The composition as claimed in claim 1, wherein said biomass has a particle size in the range of 20 microns to 150 microns.
5. The composition as claimed in claim 1, wherein said additive is at least one selected from the group consisting of a lubricating agent, a binder/an impact modifier, a thermal stabilizer and an inorganic filler.
6. The composition as claimed in claim 5, wherein said lubricating agent is at least one selected from the group consisting of fatty acid salt, fatty acid ester, paraffin wax, and polyethylene wax.
7. The composition as claimed in claim 6, wherein said fatty acid salt is at least one selected from the group consisting of calcium stearate, tribasic lead stearate, dibasic lead stearate, glycerol mono stearate, and lead stearate; and said fatty acid ester is at least one selected from the group consisting of ester of C8/C18 fatty acid.
8. The composition as claimed in claim 6, wherein said C8/C18 fatty acid is selected from the group consisting of stearic acid and sebacic acid.
9. The composition as claimed in claim 5, wherein said binder/impact modifier is at least one selected from the group consisting of poly(butyl methacrylate-co-methyl methacrylate), polymethyl methacrylate-co-methacrylic acid, poly(methyl methacrylate-co-methyl methacrylate), acrylates copolymers, diene based copolymers, and chlorinated polyethylene (CPE).
10. The composition as claimed in claim 5, wherein said thermal stabilizer is selected from the group consisting of methyl tin stabilizer, and tribasic lead sulphate.
11. The composition as claimed in claim 5, wherein said inorganic filler is selected from calcium carbonate, talc, titanium dioxide, and silicon dioxide.
12. The composition as claimed in claim 1, is characterized by having:
• tensile strength in the range of 2 MPa to 30 MPa;
• elongation break in the range of 0.5% to 4%;
• izod impact in the range of 15 J/m to 45 J/m;
• flexural strength in the range of 5 MPa to 55 MPa; and
• hardness in the range of 45 D to 85 D.
13. A process for the preparation of a composition, said process comprising the following steps:
a) drying a biomass at a first predetermined temperature for a first predetermined time period to obtain a dried biomass;
b) mixing said dried biomass, a predetermined amount of at least one additive, and a predetermined amount of polyvinyl chloride (PVC) resin and IP-PVC resin at a predetermined speed for a time period in the range of 15 minutes to 60 minutes, followed by drying at a second predetermined temperature for a second predetermined time period to obtain a dried mixture; and
c) melt mixing said dried mixture at a third predetermined temperature for a third predetermined time period followed by drying to obtain said composition.
14. The process as claimed in claim 13, wherein said biomass is at least one selected from the group consisting of sugarcane bagasse, ground nut husk, rice husk, and bamboo fiber.
15. The process as claimed in claim 13, wherein said biomass has a particle size in the range of 20 microns to 150 microns.
16. The process as claimed in claim 13, wherein said first predetermined temperature is in the range of 50 ºC to 120 ? and said first predetermined time period is in the range of 5 hours to 10 hours.
17. The process as claimed in claim 13, wherein said additive is at least one selected from the group consisting of a lubricating agent, a binder/an impact modifier, a thermal stabilizer and an inorganic filler.
18. The process as claimed in claim 17, wherein said binder/impact modifier is at least one selected from the group consisting of poly(butyl methacrylate-co-methyl methacrylate), polymethyl methacrylate-co-methacrylic acid, poly(methyl methacrylate-co-methyl methacrylate), acrylates copolymers, diene based copolymers, and chlorinated polyethylene (CPE).
19. The process as claimed in claim 17, wherein said lubricating agent is at least one selected from the group consisting of fatty acid salt, fatty acid ester, paraffin wax, and polyethylene wax.
20. The process as claimed in claim 19, wherein said fatty acid salt is at least one selected from the group consisting of calcium stearate, tribasic lead stearate, dibasic lead stearate, glycerol mono stearate, and lead stearate; and said fatty acid ester is selected from the group consisting of esters of C8/C18 fatty acid.
21. The process as claimed in claim in claim 20, wherein said C8/C18 fatty acid is selected from the group consisting of stearic acid and sebacic acid.
22. The process as claimed in claim in claim 17, wherein said thermal stabilizer is selected from the group consisting of methyl tin stabilizer, and tribasic lead sulphate.
23. The process as claimed in claim in claim 17, wherein said inorganic filler is selected from calcium carbonate, talc, titanium dioxide, and silicon dioxide.
24. The process as claimed in claim 13, wherein said internally plasticized polyvinyl chloride comprises:
• diallyl phthalate in an amount in the range of 1 mass% to 35 mass% with respect to the total amount of said internally plasticized polyvinyl chloride; and
• polyvinyl chloride (PVC) in an amount in the range of 65 mass% to 99 mass% with respect to the total amount of said internally plasticized polyvinyl chloride.
25. The process as claimed in claim 13, wherein said predetermined speed is in the range of 1000 rpm to 2000 rpm; said second predetermined temperature is in the range of 60 ºC to 120 ºC; and said second predetermined time period is in the range of 30 minutes to 180 minutes.
26. The process as claimed in claim 13, wherein said third predetermined temperature is in the range of 110 ºC to 140 ºC; and said third predetermined time period is in the range of 1 hour to 3 hours.
27. The process as claimed in claim 13, wherein said predetermined amount of said polyvinyl chloride (PVC) resin is in the range of 0 mass% to 50 mass%.
28. The process as claimed in claim 13, wherein said predetermined amount of said internally plasticized polyvinyl chloride (IP- PVC) is in the range of 3 mass% to 60 mass%.
29. The process as claimed in claim 13, wherein an amount of said biomass is in the range of 25 mass% to 40 mass%.
30. The process as claimed in claim 13, wherein said predetermined amount of said additive is in the range of 10 mass% to 20 mass%.
31. The process as claimed in claim 13, wherein a speed during the extrusion process is in the range of 20 rpm to 80 rpm.
Dated this 17th day of December, 2022

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI