US 12,227,458 B2
High performance glossy finish green hybrid composites with variable density and an improved process for making thereof
Pappu Asokan, Habibganj Naka Bhopal (IN); Manoj Kumar Gupta, Habibganj Naka Bhopal (IN); Alka Mishra, Habibganj Naka Bhopal (IN); Edward Peters, Habibganj Naka Bhopal (IN); Ajay Kulshreshth, Habibganj Naka Bhopal (IN); Sanjai Kumar Singh Rathore, Habibganj Naka Bhopal (IN); and Avanish Kumar Srivastava, Habibganj Naka Bhopal (IN)
Assigned to COUNCIL OF SCIENTIFIC & INDUSTRIAL RESEARCH, New Delhi (IN)
Appl. No. 17/052,193
Filed by COUNCIL OF SCIENTIFIC AND INDUSTRIAL RESEARCH, New Delhi (IN)
PCT Filed Feb. 9, 2019, PCT No. PCT/IN2019/050107
§ 371(c)(1), (2) Date Nov. 1, 2020,
PCT Pub. No. WO2019/211862, PCT Pub. Date Nov. 7, 2019.
Claims priority of application No. 201811016873 (IN), filed on May 4, 2018.
Prior Publication US 2021/0053875 A1, Feb. 25, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. C04B 26/18 (2006.01); C04B 18/04 (2006.01); C04B 18/08 (2006.01); C04B 18/12 (2006.01); C04B 18/14 (2006.01); C04B 18/16 (2023.01); C04B 18/20 (2006.01); C04B 18/24 (2006.01); C04B 26/16 (2006.01); C04B 111/00 (2006.01)
CPC C04B 26/18 (2013.01) [C04B 18/0481 (2013.01); C04B 18/08 (2013.01); C04B 18/12 (2013.01); C04B 18/14 (2013.01); C04B 18/16 (2013.01); C04B 18/20 (2013.01); C04B 18/248 (2013.01); C04B 26/16 (2013.01); C04B 2111/00767 (2013.01); C04B 2201/20 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A process for making a glossy finish reinforced polymer composite sheet, the process comprising:
a. dry and wet processing waste particulates using water having a temperature of about 60° C. to produce processed waste particulates, the processed waste particulates consisting of a combination of non-functionalized industrial waste particulates and non-functionalized natural fibers;
b. homogeneously mixing the processed waste particulates of step a) with a polymeric binder system and a catalyst, at a temperature ranging from 60 to 80° C. for a time period ranging from 12 to 24 hours, to obtain a particulate reinforced polymer composite having 50 to 80% by volume of the processed industrial waste particulates and 5 to 35% by volume of the processed natural fibers, wherein the polymeric binder system is made of one or more of an epoxy resin, a polyester resin or a polyurethane resin;
c. using compression molding, casting and fabricating a glossy finish composite sheet from the reinforced polymer composite of step b) at varying temperature ranging from 16±2° C. to 75±2° C. and at varying casting pressure ranging from 2 to 95 kg/cm2 in a single operation mode; and
d. natural and/or hot air oven curing the fabricated glossy finish composite sheet of step c), at a temperature ranging from 60 to 120° C. for a time period ranging from 12 to 24 hours, to obtain a glossy finish reinforced polymer composite sheet, wherein the hot air oven curing is performed by mechanical ejecting or automatic ejecting, wherein
the produced glossy finish reinforced polymer composite sheet exhibits a tensile strength in the range of 22-105 MPa and a tensile modulus in range of 2450-8400 MPa.