Description:

TECHNICAL FIELD
The present disclosure relates to field of manufacturing lightweight brick. Particularly, but not exclusively, the present disclosure is directed towards a method of manufacturing plastic embedded lightweight brick by using waste plastic material.
BACKGROUND
Plastic waste is a significant environmental problem with far-reaching impacts on ecosystems, human health, and the planet as a whole. Some of the key issues associated with plastic waste are environmental pollution, microplastics, toxic chemicals, harm to marine life, greenhouse gas emissions, limited biodegradability, resource depletion, waste management challenges, health concerns etc. Plastic waste, especially single-use plastics like bags, bottles, and packaging, often ends up in the environment, polluting ecosystems such as oceans, rivers, forests, and urban areas. Such pollution harms wildlife, marine life, and plants, leading to entanglement, ingestion, and habitat destruction. Plastic materials eventually break down into smaller fragments called microplastics, which are less than 5 millimeters in size. These microplastics are pervasive in the environment and have been found in soil, water, air, and even in the food we consume, raising concerns about their potential impact on human health.
Many plastics contain additives, such as plasticizers and flame retardants, that can leach into the environment and pose risks to both ecosystems and human health. Some of these chemicals have been linked to hormonal disruption, developmental issues, and other health problems. Marine animals often mistake plastic items for food, leading to ingestion and potentially fatal consequences. Plastic waste can also entangle marine life, causing injuries and restricting movement. Further, the production and disposal of plastics contribute to greenhouse gas emissions. The extraction of fossil fuels for plastic production and the incineration of plastic waste release carbon dioxide and other pollutants into the atmosphere, exacerbating climate change. Most conventional plastics are not biodegradable in a reasonable timeframe. They can persist in the environment for hundreds of years, taking up valuable space in landfills and natural habitats.
The production of plastics relies heavily on fossil fuels like oil and natural gas. This not only contributes to resource depletion but also links plastic production to the energy industry and its environmental impacts. Proper disposal and recycling of plastic waste can be challenging, particularly in regions with inadequate waste management infrastructure. As a result, plastic waste often ends up being burned or disposed of in unsustainable ways. The presence of plastics in the environment and their potential to release harmful chemicals raise concerns about human exposure to these substances and their long-term health effects.
Conventionally, a plurality of measures have been exploited to reduce the volume of waste plastic by means of Reduce Single-Use Plastics, reusing the plastic bags and containers, promote plastic-free initiatives, avoid microbeads etc. However, such conventional measures do not adequately reduce plastic waste. Therefore, there is a need for a process of manufacturing material by consuming waste plastic without hampering the environmental balance.
The present disclosure is directed to overcome one or more limitations stated above, and any other limitation associated with the prior arts.
SUMMARY
The present disclosure provides a method of manufacturing plastic embedded lightweight brick. The method comprises processing collected waste plastic to prepare powder form of plastic, mixing cement, fly ash, waste plastic powder, lime, gypsum, aluminium powder, and soluble oil as per mix design to prepare a slurry, and pouring the slurry into one or more molds and make the molds rest for setting. The method further includes demolding the mold cakes using demolding machine, preparing cake cubes of predefined size by cutting the mold cakes horizontal and vertical direction respectively; and curing the cake cubes to make the same ready for use.
The foregoing summary in 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.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The novel features and characteristic 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 flowchart showing a method of manufacturing plastic embedded lightweight brick, in accordance with an embodiment of the present disclosure; and
Figure 2 illustrates a flowchart showing steps of processing waste plastic, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
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.
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 alternative falling within the spirit and the scope of the disclosure.
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.
Embodiments of the present disclosure provide a method of manufacturing plastic embedded lightweight brick. The method comprises processing collected waste plastic to prepare powder form of plastic, mixing cement, fly ash, waste plastic powder, lime, gypsum, aluminium powder, and soluble oil as per mix design to prepare a slurry, and pouring the slurry into one or more molds and make the molds rest for setting. The method further includes demolding the mold cakes using demolding machine, preparing cake cubes of predefined size by cutting the mold cakes horizontal and vertical direction respectively; and curing the cake cubes to make the same ready for use. The processing of the collected waste plastic comprises the steps of making the waste plastic dust free by using an eco-dust remover; feeding the dust free plastic into an agglomerator to convert the plastic into lumps; and feeding the plastic lumps into a pulveriser to prepare plastic powder.
The following paragraphs describe the present disclosure with reference to Figures 1 and 2. In the figures, Figure 1 is an exemplary method of the present disclosure and illustrates various steps of the method (100) for manufacturing plastic embedded lightweight brick. The method (100) enables manufacturers to produce lightweight brick by using waste plastic upon having a environ friendly pre-processing of the waste plastic. The method (100) therefore provides technique to create building materials is an innovative approach that can help address both the environmental issues caused by plastic waste and the demand for sustainable construction materials. The method (100) therefore eliminates the problem of landfills and oceans by waste plastic, thereby reducing its negative impact on the environment. Further, using waste plastic reduces the need for traditional construction materials like wood, which can help preserve forests and natural resources, Therefore, the present invention saves cost, time, fuel, energy, environment and manual effort as compared to the traditional methods of producing building materials.
However, it is understood by a person skilled in the art that the size and configuration of the required set of machinery for accomplishing the method (100) may be variable in accordance with the requirement of the different types of installation environment. Any such variation/modification shall be construed to be within the scope of the present disclosure.
As illustrated in Figure 1, the method (100) comprises one or more blocks to be performed to manufacture plastic embedded lightweight brick. The order in which the method (100) is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Additionally, individual blocks may be deleted from the methods without departing from the spirit and scope of the subject matter described herein.
At block (102), collected waste plastic is processed to prepare powder form of plastic. Waste plastic refers to discarded or unwanted plastic materials that are no longer useful or needed. These plastic materials are typically disposed of or discarded because they have served their intended purpose, are damaged, or are no longer functional. Waste plastic is a significant environmental concern due to its persistence in the environment, potential to cause pollution, and negative impacts on ecosystems and human health. Waste plastic can come in various forms, including single-use plastics such as plastic bags, straws, disposable cutlery, and water bottles etc., packaging materials, containers, plastic film, discarded electronics and appliances etc.
The collected waste plastic is processed to prepared a powder form of the waste plastic. The processing of waste plastic is performed in a manner so as to avoid any kind of environmental impacts. Processing waste plastic involves various methods to transform discarded plastic materials into useful products or materials, thereby reducing their environmental impact and promoting recycling.
Therefore, the received galvalume dross is melted within the induction furnace. Further, the method of processing the waste plastic via steps as illustrated in Figure 2.
At block (122), the waste plastic are made dust free. In one embodiment, the waste plastic is made dust free by using an eco-dust remover. An "eco dust remover" typically refers to a device or product designed to remove dust and particulate matter from the air or surfaces in an environmentally friendly and sustainable manner. Dust removal is important for maintaining indoor air quality, reducing allergens, and creating a clean and healthy living or working environment. Some features and concepts that an eco-friendly dust remover might incorporate are High-Efficiency Particulate Air (HEPA) Filtration, low energy consumption, natural filtration materials, recyclable or biodegradable filters, solar-powered or renewable energy, reusable components, smart sensors and automation, non-toxic materials etc.
HEPA filters are designed to capture particles as small as 0.3 microns, including dust, pollen, pet dander, and even some bacteria. An eco-friendly dust remover could use HEPA filters to effectively remove airborne particles. The dust remover is configured to consume minimal energy, by potentially using energy-efficient motors and components to reduce its environmental impact. The use of natural filtration materials like activated charcoal, bamboo, or cotton fibers in eco dust remover, which can effectively capture and neutralize dust particles. The filters are created from recyclable or biodegradable materials, reducing the waste generated by the dust remover. The eco dust remover can be integrated with renewable energy sources like solar panels to power the dust remover, minimizing its reliance on traditional electricity sources. The dust remover is configured with components that can be easily cleaned and reused, reducing the need for frequent replacement and reducing waste.
At block (124), the dust free plastic is fed into an agglomerator to convert the plastic into lumps. An agglomerator is a machine used to convert plastic waste, including fine particles, into larger agglomerates or lumps. These agglomerates are easier to handle, transport, and process further into new plastic products In one embodiment, the dust-free plastic particles are fed into the agglomerator. The agglomerator consists of a rotating drum or chamber equipped with blades, knives, or other agitating mechanisms. Inside the agglomerator, the plastic particles are subjected to mechanical agitation and friction. The blades or agitators mix and tumble the particles, causing them to collide and adhere to each other. Some agglomerators also provide controlled heating to the plastic particles during the process. The combination of heat and compression helps soften the plastic and encourages particles to stick together, forming larger lumps or agglomerates. After the agglomeration process, the plastic agglomerates are cooled down to solidify. The machine's rotation is stopped, and the agglomerates are discharged from the agglomerator.
At block (126), the plastic lumps are fed into a pulveriser to prepare plastic powder. A pulverizer, also known as a grinder or mill, is a machine used to reduce large plastic lumps or particles into smaller particles or powders. Such process is particularly useful for converting plastic waste into a more manageable form that can be used as a raw material in various manufacturing processes. The plastic lumps are fed into the pulverizer's hopper or feeding mechanism. The pulverizer typically consists of a grinding chamber with rotating blades or hammers. Inside the grinding chamber, the plastic lumps are subjected to high-speed rotation of blades or hammers. The impact and friction between the plastic lumps and the grinding elements break down the lumps into smaller particles. Depending on the desired particle size, the pulverized plastic may go through a classification process to separate particles of the desired size from larger ones. Screens or sieves can be used to achieve the desired particle size distribution.
The process of pulverization generates heat. Some pulverizers have cooling mechanisms to prevent overheating of the plastic particles during the grinding process. The pulverized plastic particles, now in the form of plastic powder, are collected and discharged from the pulverizer. The plastic powder can vary in size and texture based on the specific equipment and processing parameters used.
The resulting plastic powder can be used as a raw material for various applications, such as extrusion, injection molding, 3D printing, or other manufacturing processes.
Upon processing the waste plastic into plastic powder, the plastic powder is further processed as illustrated in Figure 1.
At block (104), cement, fly ash, waste plastic powder, lime, gypsum, aluminium powder, and soluble oil are mixed as per mix design to prepare a slurry. In one embodiment, cement, fly ash, waste plastic powder, lime, gypsum, aluminium powder, and soluble oil are mixed as per mix design to prepare a slurry. A slurry is a mixture of a liquid and solid particles, often used in various industrial processes and applications. In the context of plastics and waste processing, slurry might refer to a mixture of water or another liquid along with cement, fly ash, waste plastic powder, lime, gypsum, aluminium powder, and soluble oil. In one embodiment, the ratio of mixing the required ingredients is cement in 14% of dry weight, fly ash in 70.82% of dry weight, waste plastic powder in 6% of dry weight, lime in 8% of dry weight, gypsum in 1% of dry weight, aluminium powder in 0.04% of dry weight, and soluble oil in 0.14% of dry weight. The cement used is Ordinary Portland Cement of grade 53, lime used is lime powder, and soluble oil is prepared by blending of chemicals. Fly Ash is a waste material of thermal power station. The type of plastics that are used is all kinds of waste plastic while most of them are polypropylene (PP), Low Density Polyethylene (LDPE), High Density Polyethylene (HDPE), and Multilayered plastic in powdered form. Some example of these kind of plastics are wrappers of chips, biscuits, polythene bags, plastic can, container, chair, table etc. Lime that is used, is basically quick lime powder which is obtained from burning of calcium carbonate limestone. Gypsum is used in POP (Plaster of Paris) form. Rock Gypsum is processed into powdered form. Aluminium powder is obtained from Bauxite ore. Further, soluble oil is prepared by blending of some imported chemicals. Soluble oil is used in liquid form which color is pale yellow.
In an example, for preparation of 1 cubic meter of mortar batching is as follows:
Cement – 100 kg (14% of dry weight)
Fly Ash – 500 kg (70.82% of dry weight)
Waste Plastic – 40 kg (6% of dry weight)
Lime – 55 kg (8% of dry weight)
Gypsum – 8kg (1% of dry weight)
Al powder – 320 gm (0.04%)
Sol oil – 1 litre (0.14%)
At block (106), the slurry is poured into one or more molds and make the molds rest for setting. In one embodiment, when poured into molds, the slurry fills the mold cavities, and after a curing or solidification process, it takes on the desired shape of the mold. Molds are chosen that have the desired shape and dimensions for the objects like brick. Molds can be made from materials like metal, plastic, silicone, or other suitable materials. Depending on the mold material and the slurry mixture, a mold release agent might be necessary to ensure that the cured object can be easily removed from the mold once solidified. The slurry mixture is carefully poured into the mold cavities. The slurry flows and fills the mold to take on the shape of the desired object. The molds are kept in rest for 4 – 5 hours to obtain final setting.
At block (108), the mold cakes are demolded using demolding machine. In one embodiment, a demolding machine, also known as a mold release machine or mold extraction machine, is a device designed to automate and facilitate the removal of finished products or components from molds. Such machine is commonly used in manufacturing processes where objects are created by pouring or molding materials into specific shapes. Demolding machines help improve efficiency, accuracy, and consistency in the production process by automating the demolding or extraction step. Demolding machines are designed to work with molds that have been prepared for easy extraction of the finished objects. This might involve using appropriate mold release agents or designing molds with specific features to aid in demolding. The demolding machine typically uses mechanical, hydraulic, pneumatic, or other mechanisms to grasp, lift, and extract the finished product from the mold cavity. Demolding machines are equipped with controls that allow operators to set parameters such as the amount of force applied during extraction, the speed of extraction, and other relevant factors. This ensures that the demolding process is consistent and doesn't damage the object or mold. To prevent damage to the mold or the extracted object, demolding machines often incorporate sensors or feedback mechanisms that detect resistance or obstacles during the extraction process. Such configuration helps avoid excessive force or misalignment.
At block (110), cake cubes of predefined size are prepared by cutting the mold cakes horizontal and vertical direction respectively. In one embodiment, upon demolding of cakes, each of the cake is pushed to a horizontal cutting machine where the whole cake is cut in horizontal direction by keeping a distance between two axes as per desired size. Further, upon cutting each of demolded cakes horizontally, each of the cake is pushed to a vertical cutting machine where the whole cake is cut in vertical direction by keeping a distance between two axes as per desired size.
At block (112), the cake cubes are cured to make the same ready for use. The process of curing lightweight bricks made from plastic waste involves the careful application of heat, pressure, and time to achieve proper bonding and solidification of the materials. Curing is a critical step in the production of bricks, as it determines the strength, durability, and overall quality of the final product. In one embodiment, the cake cubes of desired size are pushed into an autoclave machine for rapid curing, wherein steams are injected into each of the cake cubes in a closed and air tight chamber, the cake cubes are retained in steams for at least 9 hours at 210°C temperature, and subsequently steams are released through one or more valves.
In an experiment, the lightweight brick mad of waste plastic showed the following results:
Parameters Value
Compressive Strength 38-45 Kg/Cm2
Dry Density 700-800 Kg/m3
Water Absorption 6-7%
Fire Resistance 6 Hrs.
Thermal Conductivity .089 W/m-k
Drying Shrinkage .04%
Noise Reduction Coefficient 0.467

Advantages of the present disclosure:
The present disclosure provides a method (100) which can enable manufacturers to produce manufacturing plastic embedded lightweight brick. Such brick provide value to the market in terms of quality and advantages over the existing bricks. Since it is made out of waste plastic, the plastic helps in increasing the drying shrinkage of the brick which leads to the non-occurring of hairline cracks. Due to the use of waste plastic, the water absorption of the brick becomes less. This is one of the main factors for the brick to have less weathering effect. Also, the brick is made lightweight with the help of aluminum powder. Being lightweight, total dead load of the structure reduces upto 40% in comparison to the red clay bricks, hence the cost of the whole structure decreases. The brick has been developed in larger size. The larger size reduces the total no. of mortar joints in the walls which leads to the less consumption of cement and sand in the joints and hence cost of the cement reduces.
Further, the plastic embedded lightweight brick provides a major social value to the society and to the environment as it leads to plastic waste management. The main social aim of such brick is to reduce and recycle the waste plastic to some extent.
Again, this brick provides a different a way of using the waste plastic. Here the soft multi-layered plastic is being used which mainly are not in use in the market. The main part is that these waste plastics are used without burning it, so it does not emit any gases to the environment. Over all, by recycling that part of waste plastics which is not in any use, the bricks are trying to give a value to the society and environment. Also, in a recent LCA (Life Cycle Analysis) report, prepared by Monk Spaces, our brick is found to be CARBON NEGATIVE. In manufacturing of 1 Kg. of our product we consume 0.44 kg of Carbon di Oxide from environment. Therefore, there is a huge impact to the environment.
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.
Equivalents:
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.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations.
In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

, Claims:
We claim:
1. A method of manufacturing plastic embedded lightweight brick, the method comprising:
processing collected waste plastic to prepare powder form of plastic;
mixing cement, fly ash, waste plastic powder, lime, gypsum, aluminium powder, and soluble oil as per mix design to prepare a slurry;
pouring the slurry into one or more molds and make the molds rest for setting;
demolding the mold cakes using demolding machine;
preparing cake cubes of predefined size by cutting the mold cakes horizontal and vertical direction respectively; and
curing the cake cubes to make the same ready for use.
2. The method as claimed in claim 1, wherein the processing of the collected waste plastic comprises the steps of:
making the waste plastic dust free by using an eco-dust remover.
feeding the dust free plastic into an agglomerator to convert the plastic into lumps; and
feeding the plastic lumps into a pulveriser to prepare plastic powder.
3. The method as claimed in claim 1, wherein a ratio of mixing the required ingredients is cement in 14% of dry weight, fly ash in 70.82% of dry weight, waste plastic powder in 6% of dry weight, lime in 8% of dry weight, gypsum in 1% of dry weight, aluminium powder in 0.04% of dry weight, and soluble oil in 0.14% of dry weight.
4. The method as claimed in claim 1, wherein upon pouring the slurry into the one or more molds, the molds are kept in rest for 4 – 5 hours to obtain final setting.
5. The method as claimed in claim 1, wherein upon demolding of cakes, each of the cake is pushed to a horizontal cutting machine where the whole cake is cut in horizontal direction by keeping a distance between two axes as per desired size.
6. The method as claimed in claim 1, wherein upon cutting each of demolded cakes horizontally, each of the cake is pushed to a vertical cutting machine where the whole cake is cut in vertical direction by keeping a distance between two axes as per desired size.
7. The method as claimed in claim 1, wherein curing the cake cubes comprises the steps of:
pushing the cake cubes of desired size into an autoclave machine for rapid curing, wherein steams are injected into each of the cake cubes in a closed and air tight chamber, the cake cubes are retained in steams for at least 9 hours at 210°C temperature, and subsequently steams are released through one or more valves.
8. The method as claimed in claim 1, wherein the cement used is Ordinary Portland Cement of grade 53, lime used is lime powder, and soluble oil is prepared by blending of chemicals.