Composite products and manufacturing method

Abstract

A composite product and a method of manufacturing the composite product are disclosed. The composite product includes (a) a polymeric material binder and a metal-bearing material or (b) the polymeric material binder and a carbon-bearing material. The 5 method includes heating and mixing the components of the composite product and thereafter forming the heated mixture into a final product shape, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product.

1 . A method of manufacturing a composite product in the form of (a) a polymeric material binder and a metal-bearing material or (b) the polymeric material binder and a carbon-bearing material that comprises heating and mixing the components of the composite product and thereafter forming the heated mixture into a final product shape, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product. 
     
     
         2 . The method of manufacturing the composite product that comprises the polymeric material binder and the metal-containing material defined in  claim 1  includes mixing sources of carbon other than the polymeric material binder, with the metal-bearing material and the polymeric material. 
     
     
         3 - 5 . (canceled) 
     
     
         6 . The method defined in  claim 1  comprises mixing the metal-bearing material and the polymeric material binder so that there is a uniform dispersion of the metal-bearing material through the product. 
     
     
         7 . The method defined in  claim 1  comprises mixing the carbon-bearing material and the polymeric material binder so that there is a uniform dispersion of the carbon-bearing material through the product. 
     
     
         8 . The method defined in  claim 1  comprises heating the mixture of the components of the product at a temperature that is sufficiently high to completely melt the polymeric material binder. 
     
     
         9 - 12 . (canceled) 
     
     
         13 . The method defined in  claim 1  includes forming the heated mixture into the composite product by extruding the heated mixture. 
     
     
         14 . A composite product comprises a metal-bearing material and a polymeric material that acts as a binder for the metal-bearing material. 
     
     
         15 . The product defined in  claim 14  comprises other materials, such as materials that are sources of carbon other than the polymeric material binder. 
     
     
         16 . A composite product comprises a carbon-bearing material and a polymeric material that acts as a binder for the carbon-bearing material. 
     
     
         17 . The product defined in  claim 16  comprises a metal-bearing material. 
     
     
         18 . The product defined in  claim 14  comprises a continuous network of the polymeric material and a uniform dispersion of the metal-bearing material. 
     
     
         19 . (canceled) 
     
     
         20 . The product defined in  claim 14  comprises an outer covering of the polymeric material 
     
     
         21 - 22 . (canceled) 
     
     
         23 . The product defined in  claim 14  wherein the polymeric material is a recycled polyethylene such as a low density polyethylene or a high density polyethylene or a recycled polypropylene. 
     
     
         24 - 25 . (canceled) 
     
     
         26 . The product defined in  claim 14  being made completely from recycled materials, with each of the polymeric binder material and the metal-bearing material being recycled materials. 
     
     
         27 - 29 . (canceled) 
     
     
         30 . A method for producing a molten metal that comprises supplying the composite product defined in  claim 14  as a feed material for the method, with the composite product being formed by the method defined in  claim 1  with sufficient strength and toughness to be able to be handled within a high temperature processing plant for carrying out the method of producing the molten metal and to be charged into a high temperature furnace in the plant without significant breakdown of the product into smaller sized products, with generation of fines outside and/or inside the furnace. 
     
     
         31 . A method for producing a molten metal that comprises supplying the composite product defined in  claim 14  as a feed material for the method, with the composite product being formed by the method defined in  claim 1  to be sufficiently large and have required mechanical properties such as strength to withstand high temperature and reactive conditions in a high temperature furnace in a high temperature processing plant for carrying out the method to facilitate controlled dissolution of the product in the furnace over a required time period. 
     
     
         32 . The product defined in  claim 16  comprises a continuous network of the polymeric material and a uniform dispersion of the carbon-bearing material. 
     
     
         33 . The product defined in  claim 16  comprises an outer covering of the polymeric material. 
     
     
         34 . The product defined in  claim 16  wherein the polymeric material is a recycled polyethylene such as a low density polyethylene or a high density polyethylene or a recycled polypropylene. 
     
     
         35 . The product defined in  claim 16  being made completely from recycled materials, with each of the polymeric binder material and the carbon-bearing material being recycled materials. 
     
     
         36 . A method for producing a molten metal that comprises supplying the composite product defined in  claim 16  as a feed material for the method, with the composite product being formed by the method defined in  claim 1  with sufficient strength and toughness to be able to be handled within a high temperature processing plant for carrying out the method of producing the molten metal and to be charged into a high temperature furnace in the plant without significant breakdown of the product into smaller sized products, with generation of fines outside and/or inside the furnace. 
     
     
         37 . A method for producing a molten metal that comprises supplying the composite product defined in  claim 16  as a feed material for the method, with the composite product being formed by the method defined in  claim 1  to be sufficiently large and have required mechanical properties such as strength to withstand high temperature and reactive conditions in a high temperature furnace in a high temperature processing plant for carrying out the method to facilitate controlled dissolution of the product in the furnace over a required time period.