IMPROVED METHOD FOR THE MANUFACTURE OF A COMPOSITION FOR PRODUCING PARTITIONS BASED ON DIFFERENT MATERIALS, COMPOSITION AND PARTITION THUS OBTAINED

PROCEDE AMELIORE DE FABRICATION D'UNE COMPOSITION PERMETTANT DE FABRIQUER UNE CLOISON A BASE DE DIVERS MATERIAUX, LADITE COMPOSITION ET LA CLOISON AINSI OBTENUE

English Abstract

The invention relates to a composition which is used to produce partitions,
blocks, panels, etc. of any type and size, based on different materials such
as, for example, recycled paper and card. The invention also relates to the
partition produced and to the method used to produce the composition.
According to the invention, the partition obtained comprises an alternative
low-cost construction material having the following characteristics, namely:
non combustibility, thermal and acoustic insulation, easy workability and
rapid installation. In addition, the composition is highly resistant to
compression stresses and can be used for walls and slabs in the construction
of low-cost dwellings. The invention further relates to the method of
manufacturing said composition and to the partition thus produced.

French Abstract

L'invention concerne une composition permettant de fabriquer une cloison, un bloc, des panneaux, etc. de n'importe quels type et dimension à base de divers matériaux comme, par exemple, le papier et le carton recyclés. L'invention concerne également ladite cloison et le procédé permettant de fabriquer la composition. La cloison ainsi obtenue est un matériau de construction de rechange, à faible coût, incombustible, thermiquement et acoustiquement isolante, d'un maniement aisé et d'une installation rapide, qui offre une résistance élevée aux efforts de compression et qui peut être utilisée pour des murs et des faïences dans la construction de logements à coût réduit. L'invention concerne également le procédé permettant de fabriquer la composition et ladite cloison.

Claims

CLAIMS
1. A procedure to prepare a composition based
on recycled paper and cardboard used to fabricate
bricks, features for comprising the following steps:
A) collect the raw material consisting of all kind
of paper found in trash dumps, selected from carbon
paper, newspaper, cardboard, bristol board and all kind
of bond paper in a 10% to 9% percentage, preferably 93%;
B) once the raw material has been collected, it is cut
up in a same size, varying from 0.5 to 3 inches (1.27 cm
to 7.62 cm), preferably 1 inch (2.54 cm), so that it may
be easily handled; C) the raw material cut up is placed
in a container with water and left for about 2 to 3
hours in order that the raw material release the
cellulose until it forms a thick viscous consistency; D)
pass the thick and viscous raw material through some
rollers to withdraw the maximum amount of water and
dampness; E) place the raw material in a mixer rotating
slowly for about 7 to 15 minutes, the mixing process
must continue until a damp sandy consistency is
obtained; F) then clay is added in a proportion of 0.1%
to 4%, preferably 1.4%, and cement in a percentage of 2%
to 10%, preferably 5.6%, according to the resistance
requirements of the brick and how it will be used, these
components must be mixed slowly to avoid that clots form
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because of disintegration of the raw material; G) once
everything has been mixed, the material obtained is
transported on a band to a bin from which it is poured
into the molds to form the brick; H) on every brick
mold apply a compacting pressure of approximately 15 to
40 tons, preferably 15 to 20 tons for about 20 minutes
to one hour 30 minutes, according to the kind of brick
required, light or heavy, during this pressing process
empty spaces will be eliminated that may contain air; in
addition, this elimination of air enables the brick to
be more resistant to fire; I) dry and cure the brick
with air or steam.
2. The method according to claim 1, featured
because the clement is selected from among those
available in the market, preferably gray cement.
3. The method according to claim 1, featured
because the clay is selected from that available in the
market, preferably white clay or any kind of activated
carbon.
4. The method according to claim 1, because the
brick may be light or heavy measuring 7×-1-×-28
centimeters, compacted at pressure of 35 tons.
5. A composition based on recycled paper and
cardboard in order to fabricate bricks, featured because
it includes all kind of recycled paper and cardboard in
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a percentage of 10% to 95%, preferably 93%, clay in a
0.1% to 4% proportion, preferably 1.4%, cement in a
percentage of 2% to 10%, preferably 5.6%, all of this
must be adjusted up to 100%.
6. A composition based on paper and cardboard
according to claim 5, featured because the cement is
selected from those available in the market, preferably
gray cement.
7. A composition based on paper and cardboard
according to claim 5, featured because the paper is
selected from all kind of paper from trash dumps, as for
example, carbon paper, newspaper, cardboard, bristol
wood, and all kind of bond paper.
8. The use of a composition based on recycled paper
and cardboard of claim 5 in order to fabricate light and
heavy bricks for building walls.
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Description

CA 02578768 2007-03-01
IMPROVED METHOD FOR THE MANUFACTURE OF A COMPOSITION FOR
PRODUCING PARTITIONS BASED ON DIFFERENT MATERIALS,
COMPOSITION AND PARTITION THUS OBTAINED
BACKGROUND OF THE INVENTION
This invention refers to a composition used to
fabricate bricks from several materials, such as
recycled paper and cardboard, bricks and the procedure
to manufacture the compositions, the brick obtained is
an alternative construction material of low cost, non-
flammable, thermal insulator and acoustic, easy to
handle and quickly installed, in addition to high
resistance to compression stress and that may be used in
walls and slabs in building low-cost housing and the
procedure to manufacture this composition; to date the
procedures followed to manufacture compositions to
fabricate bricks or blocks use a basic material and have
included the use of diverse inorganic matters such as
sand, clay, pea gravel, fine gravel, cement, that
through several compression processes, high temperatures
or vibrations, are poured into various molds to obtain
the desired form; currently, there is no known
composition and a procedure to manufacture or fabricate
compositions based on recycled paper and cardboard to
fabricate light and heavy bricks for the construction of
walls in building low-cost housing and the procedure to

CA 02578768 2007-03-01
manufacture this composition that exclusively consists
of a synergist combination of organic material based on
recycled paper and cardboard, such as carbon paper,
newspaper, cardboard, bristol board and all kind of bond
paper.
DESCRIPTION OF THE INVENTION
This invention refers to a composition used to
fabricate bricks based on recycled paper and cardboard,
bricks and the procedure followed to produce the
composition, bricks used in building walls and
construction of low-cost housing, the composition of
this invention exclusively consists of all kind of paper
found in trash dumps as waste, as for example, carbon
paper, newspaper, cardboard, bristol board and all kind
of bond paper, combined with clay and cements this
combination surprisingly provides a cohesive effect with
improved resistance and a low cost, the paper and
cardboard used are one of the existing contaminants,
because once placed in open-air trash dumps, to date
there has been no manner of adequately recycling them,
the composition of this invention is formed by all kind
of paper and cardboard in a percentage of 10% to 95%,
preferably 93%, clay in a proportion of 0.1% to 4%
preferably 1.4%, cement in a percentage of 2% to 10%,
preferably 5.6%, all of which must be adjusted up to
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100%, the cement is selected among those available in
the market, preferably gray cement; additionally, the
clay used is clay available in the market, preferably
white clay or any kind of activated carbon and a
procedure for the manufacture or fabrication of
compositions based on recycled paper and cardboard, that
consists of the following steps: A) collect the raw
material which consists of all kind of paper found in
trash dumps, selected from carbon paper, newspaper,
cardboard, bristol board and all kind of bond paper in a
percentage of 10% to 95%, preferably 93%; B) once the
raw material has been collected, it is cut up in a same
size, varying from 0.5 to 3 inches (1.27 cm to 7.62 cm),
preferably 1 inch (2.54 cm), in such manner that it can
be easily handled; C) the raw material cut up is placed
in a container with water and left for about 2 to 3
hours in order that the raw material release the
cellulose until it forms a thick viscous consistency; D)
pass the thick and viscous raw material through some
rollers to withdraw the maximum amount of water and
dampness; E) place the raw material in a mixer rotating
slowly for about 7 to 15 minutes, the mixing process
must continue until a damp sandy consistency is
obtained; F) then clay is added in a proportion of 0.1%
to 4%, preferably 1.4%, and cement in a percentage of 2%
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CA 02578768 2007-03-01
to 10%, preferably 5.6%, according to resistance
requirements of the brick and how it will be used, these
components must be mixed slowly to avoid that clots form
because of disintegration of the raw material; G) once
everything has been mixed, the material obtained is
transported on a band to a bin from which it is poured
into the molds to form the brick; H) on every brick
mold apply compacting pressure of approximately 15 to 40
tons, preferably 15 to 20 tons for about 20 minutes to
one hour 30 minutes, according to the kind of brick
required, light or heavy, during this pressing process
empty spaces will be eliminated that may contain air; in
addition, this elimination of air enables the brick to
be more resistant to fire; I) dry and cure the brick
with air or steam.
In the composition, the clay works as a purifier
and retardant for a good mix of all the components, the
mixing process of all the components must be low to
avoid that clots and bubbles form caused by
disintegration of the raw material.
Once the bricks have been compacted, the product
obtained is placed on a wood platform to be transported
to a drying area, which is a roofed space to avoid
direct rays of the sun, helping the brick mixture to
cure and set, avoiding rapid loss of dampness, which
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CA 02578768 2007-03-01
deteriorates the resistance properties of the brick, the
drying process may also be carried out by directly
applying steam to the brick, which causes it to cure or
set faster.
Each brick obtained through this composition and
procedure has the following characteristics:
- Easy transportation
- Is quickly placed
- Resistant to concentrated sulfuric acid
- Resistance to the impact of a 45 caliber bullet
- Does not require skilled hand labor
- Reduces the cost of the structure, foundations,
walls and slabs up to 50%
- Increases productivity of hand labor
- Does not require false work
- Low weight per brick (1.0 Kg per piece)
- Specific 951 to 960 Kg/m (3) weight
- 30% waterproof
- Non-combustible type (B), when exposed to direct
fire, does not burn easily, it carbonizes without
letting off flames and avoids that fire be
transmitted to the next rooms of the construction
because of its compression (15 to 40 tons,
preferably 15 to 20 tons)
- High acoustic insulation (15% decibels)
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- High thermal insulation (11.7 Kcal/Hr/degrees C
- In outside walls it supports support winds of up
to 400 Km/hr
- Waterproof (50 - 60%)
- Is lighter in inside walls (up to 1:200 Kgs)
- Good resistance to flexion (3.32 Kg/cm (2)
- There is no limitation to the architectural
project, as even a saw may be used to cut the
walls.
- The bricks may be assembled because of their
structure.
EXAMPLES.
Example 1
The following composition is prepared following the
procedure described above, the composition includes 300
grams of cement, 5 kilograms of raw material consisting
of all kind of paper found in trash dumps, such as
carbon paper, newspaper, cardboard, bristol board and
all kind of bond paper, 75 grams of clay, a light brick
is formed measuring 7x-14x28 centimeters, with a weight
of 1.2 Kg, the preferably ratio for a light brick is
1:1:1.
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Example 2
The same procedure as in the previous example, but
using a composition that includes 600 300 grams of
cement, 5 kilograms of raw material consisting of all
kind of paper available in trash dumps, as for example,
carbon paper, newspaper, cardboard, bristol board and
all kind of bond paper, 75 grams of clay, a heavy brick
is formed measuring 7x14x28 centimeters with a weight of
1.2 to 3 Kg., the preferable ratio of the components for
weight is 1:2:3, once the mixing process has been
completed, the composition is deposited in the mold with
the desired form and is compacted at a 35 ton pressure;
additionally, once outside the molds, the fresh brick
will pass on to the drying process, either outside or by
steam.
Table 1 below shows several materials based on
which the brick can be manufactured. Some of these
materials correspond to patent applications that are
being filed simultaneously to this one.
Table 1
Sample Materials Used to Produce the Bricks.
1 Wood shavings, granulated styrene, clay, sand
and type 1 cement.
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2 Plastic, granulated styrene, clay, sand and
type 1 cement.
3 Plastic sand, granulated styrene, wood shavings
and type 1 cement.
4 Silica, granulated styrene and sawdust.
5 Newspaper, cardboard, clay, sand, wood shavings
and type 1 cement.
6 Styrene, gasoline, clay and sand.
7 Granulated styrene, clay, wood shavings, type 1
cement.
8 Newspaper.
9 Lampblack, clay, sand, plastic sand, type 1
cement.
10 Sugarcane molasses, plastic sand, clay, sand
and type 1 cement.
11 Sawdust, small white seashells and white
cement.
Table 2 below shows the results obtained from tests
applied to various bricks fabricated with materials
from table 1 above.
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Table 2
Sampl Width Thickne Length Area Weigh Load Stres Weigh
e cro s s Cm cm2 t Kg s t
No cm Kg Kg/cm Gr/cm
2 3
1 14.0 7.3 30.2 422. 2.491 5200 12.3 1.45
8
2 13.5 6.7 28.8 388. 2.685 6650 17.1 1.29
8
3 13.7 5.3 28.0 383. 2.077 1430 37.3 0.96
6 0
4 10.4 6.4 20.6 214. 1.537 8050 37.6 1.21
2
10.4 6.2 20.8 216. 1.960 2572 118.9 1.46
3 5
6 10.3 3.9 20.4 210. 1.119 1480 70.4 1.41
1 0
7 10.4 5.1 20.5 213. 1.209 1172 55.0 1.16
2 5
8 8.2 11.9 18.8 154. 0.414 2700 17.5 0.63
2
9 10.4 6.0 20.5 213. 1.426 1067 50.1 1.13
2 5
10.4 6.2 20.5 213. 1.905 6650 31.2 1-45
2
11 Irregul Irregul Irregul 477. 6.583 2680 56.1 2.17
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ar ar ar 5 0
Note: Stress obtained through compression tests.
This invention must not be considered limited
to the particular examples described above, but must be
understood to cover all aspects of the invention,
clearly as observed in the attached claims. Several
modifications, equivalent processes, as also, numerous
compositions and procedures to which this invention may
be applicable and shall be easy and clear for experts in
the art toward which this invention is focused, when
revising the specification.
I record evidence that to date, the best method
which the applicant knows 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 claimed as property: