Multifunctional hybrid particle fiber board from agro-residues and process for preparation thereof
The present invention relates to a multifunctional hybrid particle board and a process for manufacturing hybrid unlaminated and laminated green composite particle boards/fibre board and panels with variable density, mechanical strength, thermal conductivity and water absorption with epoxy and polyester resin system under compression moulding machine. Preparation process describe a process to effectively utilise agro-residues/particulates/fibres to avoid its burning and resultant air and environmental pollution. The applications of the fabricated unlaminated and laminated hybrid particle board for use in architectural cladding panels, partition panels, wall panels.
1 . A multifunctional hybrid particle fiber board from agro-residues comprising paddy straw, wheat straw, and stubble particulates, and from jute fabric with a density in a range of 1.7-2.4 g/cc, wherein the multifunctional hybrid particle fiber board comprises processed fibers with a density in a range of 0.65-1.40 g/cc, a tensile strength in a range of 20-38 MPa, a tensile modulus in range of 0.5-4.55 GPa, a flexural strength 30 to 48 MPa, impact strength in a range of 1220-2650 J/m 2 , a water absorption capacity in a range of 2-62.34%, a thickness swelling in a range of 3.94-22.13%, and a thermal conductivity in a range of 0.1247 W/mK to 0.4695 W/mK, and wherein said multifunctional hybrid particle fiber board has no emission of volatile organic compounds (VOC) or formaldehyde.
2 . A process of production of the multifunctional hybrid particle fiber board from agro-residues as claimed in claim 1 , wherein the process comprises the steps of:
a. dry and wet processing of an agrowaste to obtain fibres of a uniform length and removing moisture from agrowaste particulates and fibers;
b. homogeneous dry mixing of the agrowaste obtained in step (a) wherein (5-80%) of agrowaste particulates are mixed with a mineral waste (80%), a resin (8-10%) and a catalyst (0.5-5%) along with a pigment resin (0.2 to 0.5%) using a mechanical stirrer at 50-4000 rpm followed by compression moulding using a compression moulding machine to prepare a glossy finish hybrid particle fiber board;
c. casting the glossy finish hybrid particle fiber board at a temperature in a range of 25-75° C. at a pressure in a range of 2-95 kg/cm 2 followed by curing at 50-120° C. for a duration in a range of 2-24 hrs; and
d. up scaling the glossy finish hybrid particle fiber board to dimensions of approximately 220 cm×120 cm with a varying thickness in a range of 6 mm to 50 mm to obtain the multifunctional hybrid particle fiber board.
3 . The process as claimed in claim 2 , wherein the agrowaste is selected from a group consisting of paddy straw, wheat straw, sisal fibre, jute fibre, banana fibre, flax, cotton, and hemp fibre, and processed fibres of the agrowaste have a size in a range of 5 μm-5 mm, a density in a range of 0.15-0.35 g/cc, a porosity of 55-85%; and the jute fabric has an elongation in a range of 2-15%, a tensile strength in a range of 250-800 MPa and a Young's modulus in a range of 5-10 GPa.
4 . The process as claimed in claim 2 , wherein the mineral waste is selected from the group consisting of marble waste, granite waste, stones waste, fly ash, red mud, lime sludge, gypsum rich waste, metallurgical waste, mining waste, chemical waste, fertiliser waste, glass fibre reinforced plastic waste, and silica fume, and wherein the mineral waste has a particle size below 200 μm, a density below 2.5 g/cc, a porosity in a range of 30-68% and a water holding capacity in a range of 2 to 110%.
5 . The process as claimed in claim 2 , wherein the resin is selected from the group consisting of epoxy resin and polyester, and polyurethane in a volume ratio ranging from 5-35%.
6 . The process as claimed in claim 2 , wherein the catalyst is selected from methyl ethyl ketone peroxide (MEKP), and aliphatic polyamine (Lapox K-6).
7 . The process as claimed in claim 2 , wherein the processed agrowaste particulates are mixed alone homogeneously with epoxy resin or a polyester at a volume ratio ranging from 5-70%, and reinforced to prepare unlaminated hybrid particle fiber board which is calendared with 5-15% of the jute fabric to prepare laminated hybrid particle fiber board.