Description:FIELD OF INVENTION

The invention relates to development of paver blocks from discarded plastic bags, discarded Fly ash, and discarded glassware in combination and avoid using water, sand, etc which are precious natural resources.

BACKGROUND OF THIS INVENTION

In impoverished Asian and African countries, where rubbish collection services are either ineffective or nonexistent, plastic pollution is most noticeable. However, the industrialized world also has issues with adequately collecting used plastics, particularly in nations with poor recycling rates. Particularly in India, the most populous areas, such as metropolises, are severely impacted by plastic pollution. Therefore, now is the ideal time to take action against plastic pollution by turning this waste into wealth and bringing it into the circular economy.

PRIOR ART

Materials Engineer Nzambi Matee, age 29, uses paver bricks. Matte is the creator of the Nairobi-based company Gjenge Makers, which pioneered a revolutionary technique for turning plastic trash into environmentally friendly products. She has developed inexpensive, lightweight bricks that are stronger than concrete and are constructed from recycled plastic and sand. This paver block was made by Marie using HDPE, sand, and glass bottles. They melt throughout the process and are then crushed using a hydraulic pressure mold to achieve the desired shape.

 
OBJECT OF THE INVENTION

The goal of this invention is to reduce the problem of recycling and offer a tool for solving issues so that there is no more plastic pollution in the environment.

The invention deals with a new method to make durable fly ash blocks using just waste plastic and waste glass alongwith waste fly ash, which combination is not known in prior art. This process of selection of ingredients and the process of preparing the block, both are significantly different from known prior art. The foregoing discussions show the originality, uniqueness and non-obvious nature of the current invention.

It is to be noted that ‘no water’ is used in this process as per invention.

It is to be noted that ‘no cement’ is used in this process as per invention.

It is to be noted that ‘no sand’ is used in this process as per invention.

DESCRIPTION OF INVENTION

The invention relates to paver blocks comprising the following components by weight percentage (select use)

a. Fly ash
b. Glass waste
c. Single use plastic

The components are mixed evenly according to the matching proportion and then are shaped by a mold. The invention does not adopt or utilise ‘time’ as an agent so as to avoid heat usage. The manufacturing process is simple and manufacturing cost is low.

The invention is disclosed in relation to fig. 1.

The invention required a few steps to be followed for preparing the block. The steps are detailed below :

Step 1: Sanitize by Isopropyl alcohol (IPA) carry bags that have been gathered from various sites by washing and drying them. The materials are only waste non-recyclable (single use) LDPE as a raw material.

Step 2: A small furnace was constructed to melt plastic waste by ignited externally because of the low molecular weight it can easily catch fire and start to melt & transfrom the solid to a liquid state (polymer to monomer) then liquified plastic was collected in the bottom of furnace which was kept at a temperature between 350 deg Celsius to 400 deg Celsius.

Step 3: Calculate the appropriate amounts of fly ash and waste glass powder based on the weight of the paver blocks and bricks. The percentage of fly ash, waste glass added is thus varied as per need. The waste glass and fly ash which may be fine as well as coarse is used to form the aggregate, which is cheap and easily available. The incorporation of waste glass powder as aggregate is advantageously used as “pozzolanic material”, as waste glass is siliceous material which in itself possesses very little cementitious value but will in finely divided form (powder) and in the presence of moisture chemically reacts to form compounds having cementitious properties. The other ingredients ‘fly ash’ which when released into atmosphere causes air pollution, has also been advantageously used as pozzolan to produce cementious compound in this invention. Hence use of the wasted fly ash is put to use and protecting the perilously unbalanced environment. The ‘fly ash’ allows a preparation of pozzolana block mix. Further the use of ‘fly ash’ ensures a good “compressive strength” of the prepared blocks. Due to this high strength the breakages/wastages doing transport and handling is minimized. The fly ash block is highly durable and less permeable also. These are also less porous, and highly resistant to water. Finally they are eco-friendly.

Step 4: Thoroughly combine the ingredients with the melted plastics and add pigments stir the content for a minute to make homogeneous content let it be a minute to give a time to react.

Step 5: Transfer the contents into the molds and let them set for 5 to 6 hours after three minutes of manual stirring in normal ambient condition.

These blocks are easy workability and usage of these blocks in construction technique is same as clay block construction and does not demand/require any extra training or knowledge for the reasons. These blocks are light weight.

Through extensive and repetitive tests, it was found that by using an appropriate fly ash to glass waste to plastic waste ratio, appropriate temperature, appropriate curing time, high grade fly ash blocks can be made. The invention can not only be used only for making paver blocks, but making bricks and other construction materials too.

This process uses “manual stirring” to vibrate the mixture in the mold prior to compaction. This reduces the density variation in the brick/block, resulting in more uniform strength and less damage.

As per invention, the fly ash mixture is adequately mixed and the mixture is placed into the mold to produce the block. It can be done manually by hand-feeding the mixed material into the mold or may be automated by method of pouring by gravity, feeding through known conveyer system etc. Then the mold can be vibrated or the content can be stirred. This is essential, as ‘clumps’ may be formed in the mixture, which means mixture fed into molds may have non-uniform voids between the clumps and the surface of the mixture is not levelled. Mold vibration and/or stirring causes mixture to settle in the mold producing a more uniform and denser mixture with a more levelled surface. This improves the quality of the brick/block.

Since ‘no water’ is used, the present invention does not suffer ‘curing’ step. Because fly ash reacts with water slower than cement, curing time of fly ash cement block needs longer curing time as is known in prior art. In this invention, water usage is wholly avoided. In this invention, curing is simple and demands a very short period.

Hence the 5-step method has been discussed in detail and full disclosure is made for good understanding of the invention. The prepared blocks will be ready for storage and transportation to the market place for use.

The present invention differs from the current procedure in the ways listed below :-

1. Only home and industrial trash are the main components of our raw resources. For instance, glass powder from both industrial and domestic zone trash, fly ash from the thermal power plant, and plastic from home garbage

2. This method as per invention melted the plastic in the right amounts, added fly ash and glass powder, and stirred the cast into the mold.

3. As per this invention, one can attain dimensions in accordance with the strength and codal requirements.

4. A condensate unit is recommended to prevent pollution during the preparation because this product can have the potential to generate harmful gases.

5. These blocks are made of molds and hence have uniform shape.

6. Uniform color and hence desirable appearance.

7. Light weight.

8. Good vibration absorption capacity.

9. Good compressive strength.

10. Plastering is not required due to smooth finish.

11. Less porous.

12. Less breakage.

13. Less wastage.

14. Environmental friendly as these are made of waste materials.

15. Ready to use with no need to soak in water before use.

16. Denser than normal red block.

17. Cost is lower.

18. There is essential avoiding use of ‘cement’ in preparing the blocks.

The foregoing disclosures have been provided with specific steps and selections for the purpose of explanation and should not be constrained as limiting the present invention and present invention extends to all functionality, equivalent structural and methods such as are within the scope of the appended claims.

As per invention in one aspect it is for a process of preparing paver blocks from waste plastic, fly ash and waste glassware comprising of collecting non-recyclable single use waste plastic, sanitizing the collected waste plastic and melting the waste plastic for conversion from polymer to monomer. Then adding a selected amount of siliceous fly ash and waste glass powder to the melted plastic based on the desired weight of the paver block. The ingredients are then mixed. The mixture is then transferred into molds. Manual stirring of contents of the molds is done for around 3 minutes. Then the contents of the molds is allowed to set for 5-6 hours thereby to cure and gain strength. Finally disloading the block from mold and transporting the block to storage.

The said method as disclosed is unique in using the combination of non-recyclable single use waste plastic, waste glass powder and waste fly ash to prepare the paver blocks which was and is not known in prior art.

The examples and embodiments are provided only for the purpose of understanding and none of them shall limit the scope of the invention. All variants and modifications as will be envisaged by skilled person are within the spirit and scope of the invention.
, Claims:WE CLAIM :

1. A process of preparing paver blocks from waste plastic, fly ash and waste glassware comprising of :
a. collecting non-recyclable single use waste plastic,
b. sanitizing the collected waste plastic,
c. melting the waste plastic for conversion from polymer to monomer,
d. determining and adding a selected amount of siliceous fly ash and waste glass powder to the melted plastic based on the desired weight of the paver block,
e. mixing the ingredients of step (d),
f. transferring the mixture into plurality of molds,
g. manual stirring of contents of the molds for around 3 minutes,
h. allowing the contents of the molds to set for 5-6 hours thereby to cure and gain strength,
i. disloading the block from mold and transporting the block to storage, and
the said method characterized in using the combination of non-recyclable single use waste plastic, waste glass powder and waste fly ash to prepare the paver blocks.