Use of recycled packaging in polymer composite products

Abstract

A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.

What is claimed is: 
     
         1 . A polymer composite comprising:
 recycled multilayer material in an amount of 20-60% by weight; and   organic filler in an amount of 40-60% by weight.   
     
     
         2 . The polymer composite of  claim 1  wherein said recycled multilayer material comprises an olefin, a polyester, and a metal. 
     
     
         3 . The polymer composite of  claim 2  wherein said recycled multilayer material comprises polyethylene, polyethylene terephthalate, and aluminum. 
     
     
         4 . The polymer composite of  claim 1  wherein said recycled multilayer material is comprised of recycled aluminized packaging. 
     
     
         5 . The polymer composite of  claim 1  wherein said recycled multilayer material is comprised of at least one recycle stream such that said recycled multilayer material is comprised of polyethylene in an amount of about 70-92% by weight, polyethylene terephthalate in an amount of about 1-20% by weight, and aluminum in an amount of about 1-20% by weight. 
     
     
         6 . The polymer composite of  claim 1  wherein said recycled multilayer material is in an amount of about 20-35% by weight. 
     
     
         7 . A polymer composite comprising:
 polyethylene in an amount of 10-30% by weight;   recycled multilayer material in an amount of 10-30% by weight; and   organic filler in an amount of 40-60% by weight.   
     
     
         8 . The polymer composite of  claim 7  wherein said recycled multilayer material comprises an olefin, a polyester, and a metal. 
     
     
         9 . The polymer composite of  claim 8  wherein said recycled multilayer material comprises polyethylene, polyethylene terephthalate, and aluminum. 
     
     
         10 . The polymer composite of  claim 7  wherein said recycled multilayer material is comprised of recycled aluminized packaging. 
     
     
         11 . The polymer composite of  claim 7  wherein said recycled multilayer material is comprised of at least one recycle stream such that said recycled multilayer material is comprised of polyethylene in an amount of about 70-92% by weight, polyethylene terephthalate in an amount of about 1-20% by weight, and aluminum in an amount of about 1-20% by weight. 
     
     
         12 . The polymer composite of  claim 1  wherein said polymer composite is a component selected from the group consisting of deck boards, railings, and sheet products. 
     
     
         13 . A method for manufacturing a polymer composite, said method comprising:
 providing a recycled multilayer material;   providing an organic filler; and   mixing said recycled multilayer material with said organic filler to form a polymer composite comprised of said recycled multilayer material and said organic filler.   
     
     
         14 . The method of  claim 13  wherein said recycled multilayer material is comprised of pelletized aluminized packaging. 
     
     
         15 . The method of  claim 13  wherein said recycled multilayer material comprises an olefin, a polyester, and a metal. 
     
     
         16 . The method of  claim 15  wherein said recycled multilayer material comprises polyethylene, polyethylene terephthalate, and aluminum. 
     
     
         17 . The method of  claim 13  wherein said recycled multilayer material is comprised of at least one recycle stream such that said recycled multilayer material is comprised of polyethylene in an amount of about 70-92% by weight, polyethylene terephthalate in an amount of about 1-20% by weight, and aluminum in an amount of about 1-20% by weight. 
     
     
         18 . The method of  claim 13  wherein:
 said recycled multilayer material is in an amount of 20-60% by weight of said polymer composite; and 
 said organic filler is in an amount of 40-60% by weight of said polymer composite. 
 
     
     
         19 . The method of  claim 13  further comprising the step of:
 providing polyethylene; 
 wherein said polyethylene is mixed with said recycled multilayer material and said organic filler to form said polymer composite comprised of said recycled multilayer material, said organic filler, and said polyethylene. 
 
     
     
         20 . The method of  claim 19  wherein:
 said polyethylene is in an amount of 10-30% by weight of said polymer composite; 
 said recycled multilayer material is in an amount of 10-30% by weight of said polymer composite; and 
 said organic filler is in an amount of 40-60% by weight of said polymer composite. 
 
     
     
         21 . The method of  claim 20  wherein said recycled multilayer material is comprised of an olefin, a polyester, and a metal. 
     
     
         22 . The method of  claim 13  wherein said mixing step includes extruding said recycled multilayer material with said organic filler. 
     
     
         23 . The method of  claim 22  further comprising the step of co-extruding a cap layer on said polymer composite.