Systems and Methods for Fungible Densification of Recyclable Plastics

Abstract

The present invention relates to a system and method for densification of recyclable plastics. The densification apparatus may include one or more hoppers for receiving plastic materials (mixed or segregated by resin identification code). After the plastic is inserted into the hopper, a shredder grinds the plastic into plastic shreds which are suitably sized for subsequent melting and compression into an ingot. The system meters the quantity of shredded plastic within the hopper for a threshold level required to generate a fungible ingot. Once that level has been reached, a conveyer may transport a set volume or weight of the plastic shreds to a compression cylinder. In the compression cylinder the plastic shreds are heated, using a heating element, to above a minimum melting temperature. In some embodiments, the minimum melting temperature is a melting temperature above a lowest melting temperature of the mixed types of plastics. The melted plastic is then simultaneously compressed via a piston into a mold for the generation of the ingot/coin.

1 . A method for treatment of recyclable plastics comprising:
 densifying a plastic, wherein the densification of the plastic includes reducing the plastic into dimensionally smaller plastic fragments, and compacting the dimensionally smaller plastic fragments to reduce volume; and   fungitizing the densified plastic, wherein the fungitizing includes molding the plastic fragments into at least one standardized form corresponding to at least one known value.   
     
     
         2 . The method as recited in  claim 1 , wherein method is consumer oriented and further comprises:
 completing an electrical circuit through a lid to enable operation;   shielding the region where the plastic is reduced from access by a user;   dissipating heat in order to keep areas accessible by the user below a critical temperature; and   sequestering gasses produced during fungitizing of the plastic from the user.   
     
     
         3 . The method as recited in  claim 1 , wherein the densification of the plastic further includes providing several openings of varying shapes and sizes that instruct a user to insert a specific plastic into a specific opening so as to develop at least one stream of identifiable plastic. 
     
     
         4 . The method as recited in  claim 1 , wherein the molding further includes at least one of heating the plastic fragments to above a minimum melting temperature, and packing the plastic fragments into a standardized container. 
     
     
         5 . The method as recited in  claim 1 , wherein the densification of the plastic further includes separating, utilizing a vacuum, plastic bags from plastic bottles prior to reducing the plastic bottles into dimensionally smaller plastic fragments. 
     
     
         6 . The method as recited in  claim 1 , wherein the reducing the plastic into dimensionally smaller plastic fragments includes at least one of thermal reduction, mechanical reduction, optical reduction, chemical reduction, and exothermic chemical reaction. 
     
     
         7 . The method as recited in  claim 4 , wherein the plastic includes mixed types of plastics, and wherein the minimum melting temperature is a melting temperature above a lowest melting temperature of the mixed types of plastics. 
     
     
         8 . The method as recited in  claim 4 , wherein the minimum melting temperature is about 266 degrees Fahrenheit for High Density polyethylene, about 230 degrees Fahrenheit for Low Density polyethylene, about 500 degrees Fahrenheit for polyethylene terphthalate, about 320° degrees Fahrenheit for polypropylene, about 150 to 240 degrees Fahrenheit for polystyrene, about 167-194 degrees Fahrenheit for Polyvinyl Chloride, and about 270 to 450 degrees Fahrenheit for mixed plastics. 
     
     
         9 . The method as recited in  claim 1 , wherein the at least one standardized form is at least one ingot of particular weight, size, and marking 
     
     
         10 . The method as recited in  claim 1 , wherein the ingot is a coin, wherein the coin includes an embossed identification, wherein the coin is a particular shape to denote at least one of composition and value, and wherein the coin is inserted into a carrying magazine with several other coins. 
     
     
         11 . The method as recited in  claim 10 , wherein the coin includes at least one of a company trademark, logo, character design, an advertisement, a barcode identification, QR code, and data matrix. 
     
     
         12 . An apparatus for the treatment of recyclable plastics, the apparatus comprising:
 a densifyer configured to reduce the plastic into dimensionally smaller plastic fragments, and further configured to compact the dimensionally smaller plastic fragments to reduce volume; and   a fungitizer configured to fungitize the densified plastic by molding the plastic fragments into at least one standardized form corresponding to at least one known value.   
     
     
         13 . The apparatus as recited in  claim 12 , wherein the apparatus is consumer oriented and further comprises:
 an electrical circuit through a lid configured to enable operation of the fractionator when the lid is closed;   at least one barrier configured to shield the reducer from access by a user;   at least one of insulation and a fan configured to dissipate heat in order to keep the exterior of the apparatus below a critical temperature; and   a filtration system configured to sequester gasses produced during fungitizing of the plastic from the user.   
     
     
         14 . The apparatus as recited in  claim 12 , further comprising several openings of varying shapes and sizes that instruct a user to insert a specific plastic into a specific opening so as to develop at least one stream of identifiable plastic. 
     
     
         15 . The apparatus as recited in  claim 12 , wherein the molding further includes at least one of heating the plastic fragments to above a minimum melting temperature, and packing the plastic fragments into a standardized container. 
     
     
         16 . The apparatus as recited in  claim 12 , wherein the densifyer further includes a vacuum system configured to separate plastic bags from plastic bottles prior to reducing the plastic bottles into dimensionally smaller plastic fragments. 
     
     
         17 . The apparatus as recited in  claim 12 , wherein the fractionator includes at least one of a thermal reducer, mechanical reducer, optical reducer, chemical reducer, and exothermic chemical reaction based reducer. 
     
     
         18 . The apparatus as recited in  claim 15 , wherein the plastic includes mixed types of plastics, and wherein the minimum melting temperature is a melting temperature above a lowest melting temperature of the mixed types of plastics. 
     
     
         19 . The apparatus as recited in  claim 15 , wherein the minimum melting temperature is about 266 degrees Fahrenheit for High Density polyethylene, about 230 degrees Fahrenheit for Low Density polyethylene, about 500 degrees Fahrenheit for polyethylene terphthalate, about 320° degrees Fahrenheit for polypropylene, about 150 to 240 degrees Fahrenheit for polystyrene, about 167-194 degrees Fahrenheit for Polyvinyl Chloride, and about 270 to 450 degrees Fahrenheit for mixed plastics. 
     
     
         20 . The apparatus as recited in  claim 12 , wherein the at least one standardized form is at least one ingot of a particular weight, size and marking. 
     
     
         21 . The apparatus as recited in  claim 12 , wherein the ingot is a coin, wherein the coin includes an embossed identification, wherein the coin is a particular shape to denote at least one of composition and value, and wherein the coin is inserted into a carrying magazine with several other coins. 
     
     
         22 . The apparatus as recited in  claim 21 , wherein the coin includes at least one of a company trademark, logo, character design, an advertisement, a barcode identification, QR code, and data matrix. 
     
     
         23 . An apparatus for densification and fungitization of recyclable plastics to generate an ingot, the apparatus comprising:
 a reducer configured to fracture a plastic into plastic shreds;   a hopper configured to meter the plastic shreds for a threshold quantity;   a conveyer configured to transport the plastic shreds from the hopper once the threshold quantity is reached, to a compressor;   a heating element coupled to the compressor configured to heat the plastic shreds within the compressor to above a minimum melting temperature;   a piston configured to densify the heated plastic shreds; and   a mold configured to receive the densified heated plastic shreds and form them into a plastic ingot of at least one standardized size, shape and weight.   
     
     
         24 . A method for densification and fungitization of recyclable plastics to generate an ingot, the method comprising:
 reducing a plastic into plastic shreds;   metering the plastic shreds for a threshold quantity;   heating the plastic shreds within the compressor to above a minimum melting temperature of the plastic;   compacting the heated plastic shreds; and   forming the heated compacted plastic shreds into a plastic ingot of at least one standardized size, shape and weight.