Pellet formulation

Abstract

This invention generally relates to the formulation of thermoplastic pellets from a combination of raw sludge material from a paper mill with thermoplastic material from post industrial or consumer sources. Initially, waste raw sludge material is transported via a conveyor to a dryer for removal of excess water. The waste thermoplastic material is preferably shredded into a desired size and transported to a densifier. The dried sludge is added to the densifier where the shredded thermoplastic material and dried sludge is suitably mixed with additive agents. The mixed sludge and shredded thermoplastic material is then transported to a grinder for grinding. The ground material is then transported to a hopper for introduction into an extruder. The ground combined material is then subjected to an extrusion process for the formulation of thermoplastic pellets having supplemental fibers to enhance the properties for use as starting material in an injection molding process.

1 . A method of formulating thermoplastic pellets for use in an injection molding process comprising the following steps: 
 (a) obtaining a predetermined amount of a raw sludge material, the predetermined amount of raw sludge material including a predetermined percentage of water;    (b) removing at least a portion of the predetermined percentage of water by exposing the predetermined amount of raw sludge material to a dryer, thereby resulting in a predetermined amount of dried sludge material;    (c) obtaining a predetermined amount of plastic material;    (d) obtaining a predetermined amount of saw dust;    (e) a shredding step, the shredding step comprising shredding the predetermined amount of dried sludge material and the plastic material;    (f) a blending step, the blending step blending the predetermined amount of dried sludge material and the plastic material together with the predetermined quantity of saw dust to form a predetermined quantity of composite material;    (g) placing the predetermined quantity of composite material into a grinder to form a ground composite material;    (h) placing a predetermined quantity of the ground composite material into an extruder, thereby forming a strand; and    (i) feeding the strand into a peletizer to form pellets.    
     
     
         2 . The method of  claim 1  wherein steps (e) through (i) are sequential.  
     
     
         3 . The method of  claim 1  wherein the shredding step and the blending step take place in a densifier.  
     
     
         4 . The method of  claim 1  further comprising the step of placing the pellets into a container.  
     
     
         5 . The method of  claim 1 , the blending step further comprising: 
 adding a predetermined quantity of masking chemical.    
     
     
         6 . The method of  claim 5  wherein the masking chemical is BRAND ODOR COUNTERVAILANT 312E Formula.  
     
     
         7 . The method of  claim 1 , the blending step further comprising: 
 adding a predetermined quantity of lubricant.    
     
     
         8 . The method of  claim 7  wherein the lubricant is linseed oil.  
     
     
         9 . The method of  claim 1 , the blending step further comprising: 
 adding a predetermined quantity of biological inhibitor.    
     
     
         10 . The method of  claim 9  wherein the biological inhibitor is diodemthyl-p-tolylsulfone.  
     
     
         11 . The method of  claim 1 , the waste plastic material comprising polystyrene foam and polypropylene.  
     
     
         12 . The method of  claim 1  wherein extruder includes a hopper, step (h) further comprising placing a predetermined quantity of the ground composite material into the hopper, the predetermined quantity of the ground composite material flowing from the hopper into the extruder at a predetermined rate.  
     
     
         13 . A method of formulating thermoplastic pellets for use in injection molding processes comprising: 
 (a) obtaining raw sludge material;    (b) drying the raw sludge material, thereby obtaining dried sludge material;    (c) obtaining plastic material;    (d) obtaining saw dust;    (e) placing the plastic material, saw dust and dried sludge material into a densifier, the densifier forming a composite material of shredded plastic material, saw dust and dried sludge material;    (f) grinding the composite material into a ground composite material;    (g) feeding a predetermined quantity of composite material into an extruder;    (h) extruding the predetermined quantity of composite material, thereby forming at least one composite strand; and    (i) placing the at least one composite strand into a peletizer to form thermoplastic pellets.    
     
     
         14 . The method of  claim 13  wherein step (e) further comprises: 
 adding a predetermined quantity of masking chemical.  
 
     
     
         15 . The method of  claim 14  wherein the masking chemical is BRAND ODOR COUNTERVAILANT 312E Formula.  
     
     
         16 . The method of  claim 14  wherein step (e) further comprises: 
 adding a predetermined quantity of lubricant.  
 
     
     
         17 . The method of  claim 16  wherein the lubricant is linseed oil.  
     
     
         18 . The method of  claim 16  wherein step (e) further comprises: 
 adding a predetermined quantity of biological inhibitor.  
 
     
     
         19 . The method of  claim 18  wherein the biological inhibitor is diodemthyl-p-tolylsulfone.  
     
     
         20 . The method of  claim 18 , the plastic material comprising polystyrene foam and polypropylene.  
     
     
         21 . The thermoplastic pellets formed by the method according to  claim 20 , the thermoplastic pellets having a total weight wherein 35 to 45 percent by weight of the total weight of the thermoplastic pellets is formed of the polystyrene foam.  
     
     
         22 . The thermoplastic pellets of  claim 21  wherein 40 percent by weight of the total weight of the thermoplastic pellets is formed of the polystyrene foam.  
     
     
         23 . The thermoplastic pellets formed by the method according to  claim 20 , the thermoplastic pellets having a total weight wherein 21 to 31 percent by weight of the total weight of the thermoplastic pellets is formed of the polypropylene.  
     
     
         24 . The thermoplastic pellets of  claim 23  wherein 26 percent by weight of the total weight of the thermoplastic pellets is the polypropylene.  
     
     
         25 . The thermoplastic pellets formed by the method according to  claim 20 , the thermoplastic pellets having a total weight wherein 15 to 25 percent by weight of the total weight of the thermoplastic pellets is formed of the dried sludge material.  
     
     
         26 . The thermoplastic pellets of  claim 26  wherein 25 percent by weight of the total weight of the thermoplastic pellets is formed of the dried sludge material.  
     
     
         27 . The thermoplastic pellets formed by the method according to  claim 20 , the thermoplastic pellets having a total weight wherein 5 to 15 percent by weight of the total weight of the thermoplastic pellets is formed of the saw dust.  
     
     
         28 . The thermoplastic pellets of  claim 27  wherein 10 percent by weight of the total weight of the thermoplastic pellets is formed of the saw dust.  
     
     
         29 . The thermoplastic pellets formed by the method according to  claim 20 , the thermoplastic pellets having a total weight wherein 0 to 3 percent by weight of the total weight of the thermoplastic pellets is formed of the lubricant.  
     
     
         30 . The thermoplastic pellets of  claim 29  wherein 2 percent by weight of the total weight of the thermoplastic pellets is formed of the lubricant.  
     
     
         31 . The thermoplastic pellets of  claim 30 , the lubricant further comprising linseed oil.  
     
     
         32 . The thermoplastic pellets formed by the method according to  claim 20 , the thermoplastic pellets having a total weight wherein 0 to 1 percent by weight of the total weight of the thermoplastic pellets is formed of the masking chemical.  
     
     
         33 . The thermoplastic pellets of  claim 32  wherein 0.5 percent by weight of the total weight of the thermoplastic pellets is formed of the masking chemical.  
     
     
         34 . The thermoplastic pellets of  claim 33 , the masking chemical further comprising BRAND ODOR COUNTERVAILANT 312E Formula.  
     
     
         35 . The thermoplastic pellets formed by the method according to  claim 20 , the thermoplastic pellets having a total weight wherein 0 to 1 percent by weight of the total weight of the thermoplastic pellets is formed of the biological inhibitor.  
     
     
         36 . The thermoplastic pellets of  claim 35  wherein 0.5 percent by weight of the total weight of the thermoplastic pellets is formed of the biological inhibitor.  
     
     
         37 . The thermoplastic pellets of  claim 36 , the biological inhibitor further comprising diodemthyl-p-tolylsulfone.  
     
     
         38 . Thermoplastic pellets suitable for use in an injection molding process, the thermoplastic pellets comprising a combination of materials, the materials comprising polystyrene foam, polypropylene, dried sludge material and saw dust.  
     
     
         39 . The thermoplastic pellets of  claim 38  further comprising a lubricant.  
     
     
         40 . The thermoplastic pellets of  claim 39 , the lubricant further comprising linseed oil.  
     
     
         41 . The thermoplastic pellets of  claim 38  further comprising a masking chemical.  
     
     
         42 . The thermoplastic pellets of  claim 41 , the masking chemical further comprising BRAND ODOR COUNTERVAILANT 312E Formula.  
     
     
         43 . The thermoplastic pellets of  claim 42  further comprising a biological inhibitor.  
     
     
         44 . Thermoplastic pellets suitable for use in an injection molding process comprised of predetermined percentages by weight of the following materials: polystyrene foam, polypropylene, dried sludge material, saw dust, lubricant, masking chemical, and biological inhibitor.