RECONSTITUTED WOOD COMPOSITION COMPRISING POLYETHYLENE AND WOOD FLOUR AND PRODUCTION METHOD THEREOF

COMPOSITION DE BOIS ARTIFICIELLE A BASE DE POLYETHYLENE ET DE POUDRE DE BOIS, ET PROCEDE DE PRODUCTION ASSOCIE

English Abstract

The invention relates to a reconstituted wood composition comprising a mixture
of low-density polyethylene and waste wood flour which are recovered and
recycled from different industries and directly from open dumps. The inventive
composition is subjected to a process and consequently acquires
characteristics which transform same into an alternative construction material
for dwellings, door frames, window frames and accessories, such as trims, for
different types of buildings. The invention provides the appearance and
workability of wood at a low cost and even surpasses the natural resource by
offering the following advantages, namely: non combustibility, insulation,
thermal insulation, impermeability, malleability and rapid installation. In
addition, the composition is highly resistant to common climatic conditions
when used in any building.

French Abstract

L'invention concerne une composition de bois artificielle comprenant un mélange de polyéthylène basse densité et de poudre de bois résiduelle, ces composants étant récupérés et recyclés à partir de différentes industries et en provenance directe de décharges publiques. Cette composition est traitée afin de présenter des caractéristiques faisant d'elle un matériau de construction alternatif pour des habitations, des encadrements de portes, des fenêtres et des accessoires ainsi que pour des moulures à utiliser pour diverses constructions. La composition de l'invention permet non seulement d'obtenir l'aspect et la maniabilité du bois à faible coût, mais présente également des avantages qui vont au-delà des propriétés naturelles du bois, à savoir que ladite composition est : non combustible, isolante, thermique, imperméable, malléable et installée rapidement. La composition de l'invention présente en outre une grande résistance aux effets climatiques communs pour une utilisation dans tout type de construction.

Claims

CLAIMS
1.- A method to fabricate a composition of
artificial wood, featured because it consists of the
following steps:
a) - heat polyethylene waste in a percentage of 50% to
90%, preferably 75% at a temperature of 60°C to 100°C,
preferably 85°C; b) mix the polyethylene waste with
sawdust powder in a percentage of 10% to 50%, preferably
25%; c) cool the mixture as far as a temperature of 50°C
to 25°C, preferably 35°C; d) place the homogeneous
mixture in molds.
2.- The method according to claim 1, featured
because polyethylene waste is of low-density and is
selected from all kind of waste bottles.
3.- A composition of artificial wood, featured
because it contains 50% to 90%, preferably 7%% of low-
density polyethylene, 10% to 50% sawdust, preferably
25%, the low-density polyethylene is selected from
different kinds of bottles made from recycled plastic.
4.- The composition of artificial wood of claim 3
obtained based on either one of claims 1 and 2 above,
used in frames of doors, decorating material of any
infrastructure.
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Description

CA 02578764 2007-03-01
RECONSTITUTED WOOD COMPOSITION COMPRISING POLYETHYLENE
AND WOOD FLOUR AND PRODUCTION METHOD THEREOF
Field of the Invention
This invention refers to artificial wood, more
particularly, a composition of artificial wood that as
raw material contains sawdust powder and polyethylene,
as well as its manufacture and use.
The composition of artificial wood is a mixture of
low-density polyethylene and waste sawdust powder,
recovered and recycled from different industries and
directly from open-air trash dumps; when submitted to a
process, it acquires the features that transform it into
an alternative construction material for housing, door
frames, windows and accessories, as well as moldings for
various edifications, substituting wood in appearance
and manageability at a lost cost, surpassing the natural
resource with the advantage of being non-flammable, an
insulating, thermal, waterproof material, that is soft
and quickly installed; in addition to having strong
resistance to common climatic effects when used in any
building.
Background of the Invention
The constant reforestation of natural resources in
our country has lead scientists throughout the world to
search for alternative materials that reduce immoderate

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cutting of trees. This material recovers solid waste
such as sawdust powder and polyethylene, that
constitutes one of the major contaminants because of its
large quantity and difficult optimization and recycling,
because once placed in open-air trash dumps it becomes a
threat against health because of the toxic gas it
releases when entering combustion through the action of
heat and the enormous amount of parasites and bacteria
generated.
This material substitutes conventional wood as a
basic material in construction of housing, frames of
doors and windows, and accessories, as well as moldings
for various edifications, helping to preserve the
ecological balance by creating an alternative material
that reduces the consumption of wood as a natural
resources, and cuts down costs.
The raw materials that serve as the basis of this
material are sawdust powder and low-density polyethylene
found in solid waste in trash dumps in the form of
plastic straws, cups, bottles, containers, bags, etc.,
being able to mix them, a substance that is easily
moldable with which various forms may be built that in
functions and appearance substitute conventional wood.
U.S. Patent 2,700,796 presents a method of
obtaining artificial wooden products where waste from
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different types of wood are used, forming a
heterogeneous mass mixed with urea, dimethylurea and
water; obtaining a mass from which various products are
produced.
Patent GB598553 describes improvements in the
production of artificial wood by mixing synthetic resins
with sawdust; however, it does not describe the use of
polyethylene to obtain an artificial wood as proposed in
this invention.
Patent JP2000084909 describes the method for the
manufacture of artificial wood based on waste paper
material, additionally using an organic solvent based on
methyl chloride; however, it does not use sawdust in
such method.
Patent KR9701521 describes a method for the
manufacture of an artificial wood based on waste plastic
and fiber; however, it does not describe the use of low-
density polyethylene combined with sawdust in order to
obtain the product, which are used in this invention.
The composition of this invention is different to
the one of the above-mentioned documents, because
surprisingly, its percentages give it a compression
effect and a durability that have not been known
previously.
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DETAILED DESCRIPTION OF THE INVENTION
The invention refers to the method of producing
artificial wood that consists in placing an amount of
50% to 90%, preferably 75% of low-density polyethylene
in a container where it will be heated at a temperature
of 60 C to 100 C, preferably 85 C, once the polyethylene
takes a liquid form, it is placed in a mixer where 10%
to 50%, preferably 25% of sawdust is added, that is, for
every % part of polyethylene used, 1/ part of sawdust
powder is mixed. Once integrated in the sawdust mixture
and a homogeneous mixture has been obtained, the mixture
is let to cool until it reaches a temperature of 50 C up
to 25 C, preferably 35 C, once 80% of the total amount of
the substance has obtained a dark syrup moldable
condition, the mixture is poured into the molds
according to the desired final configuration, which
shall be submitted to a pressure ranging from 10 to 20
tons, preferably 15 tons.
The wood composition contains 50% to 90%,
preferably 7% of low-density polyethylene, 10% to 50%
sawdust, preferably 25%, the polyethylene is selected
from different kinds of recycled plastic bottles.
The main characteristic of this product is that for
every 20 kilograms of low-density polyethylene and three
kilograms of sawdust powder, a mixture of nine kilograms
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is obtained, with which proportionally three linear
meters of moldings or frames are made, with a weight of
three kilograms per linear meter.
Once the materials are placed together in the
composition of the wood mixture, the toxic elements that
are evaporated are eliminated, and no longer contaminate
the ground as much (by of optimization of recycling),
such as the environment, and there remains an inert
matter that once it is cold and compressed, would
neutralize the contaminating elements.
Characteristics of the composition of artificial
wood to be named Maderacel.
- Easily transported
- Quickly placed and applied
- Easy to handle
- Waterproof because of its origin
- Does not swell with dampness in comparison to
ordinary wood
- Avoids the formation of fungus and mold
- Is not affected by plagues such as moth and
termites
- Does not burn because of its high compacting
tonnage
- No specialized material is required to produce it
- Equals wood in its appearance and functions
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- The finish is apparent and may be varnished as
ordinary wood
- Does not require skilled hand labor in order to be
applied
- There is no limit to an architectural project as it
may be used in various applications and forms.
EXAMPLES
EXAMPLE 1
In a container, 75 kilograms of waste from bottles
of different kinds of plastic were heated at 95 C, mixing
the mixture with 25 kilograms of sawdust, it was later
cooled to a temperature of 40 C, obtaining a moldable
substance, that was placed in molds, which where
submitted to a pressure of 15 tons, with the final
result consisting in a product with characteristics that
permit it to be used as conventional wood.
EXAMPLE 2
In a container, 37.5 kilograms of waste bottles of
different kinds of plastics were heated at a temperature
of 85 C, and mixed with 12.5 kilograms of sawdust, it was
later cooled to a temperature of 35 C, obtaining a
moldable substance that was placed in molds, which were
submitted to a pressure of 15.5 tons, with the final
result consisting in a product with characteristics that
permit it to be used as conventional wood.
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Although this invention has been described here
referring to its particular modalities, various changes
and substitutions are proposed in the above description,
and one may appreciate than in certain cases some
characteristics of the invention will be used without a
use that corresponds to other characteristics, without
moving away from the scope of the invention as
established in the following claims.
I put on record that to this date, the best
method known by the applicant in order to put into
practice the above-mentioned invention is the one that
results clear from this description of the invention.
Having described the above invention, the content
of the following claims are clamed as property:
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