Recycled composite materials and related methods

Abstract

Methods of producing particles of fiber and resin from fiber-resin composite materials are disclosed. The particles may be combined with a resin system and optionally combined with fillers, binders or reinforcements to produce new cured solid composite products.

What is claimed is: 
     
         1 . A method of producing particles from recycled composite materials comprising
 (a) shredding composite materials to form small pieces of shredded composite materials; and   (b) grinding said small pieces of shredded composite materials to form smaller particles of composite materials.   
     
     
         2 . The method of  claim 1  wherein said composite materials are cured or uncured fiberglass or glass fiber-reinforced plastic. 
     
     
         3 . The method of  claim 1  wherein said composite materials are composite windmill turbine blades. 
     
     
         4 . The method of  claim 1  further comprising using the particles to form a solid composite product. 
     
     
         5 . A method of forming the solid composite product according to  claim 4  comprising
 (a) producing particles according to the method of  claim 1 ; and 
 (b) combining said particles with resin to form a mixture; 
 (c) disposing of the mixture in a form or mold; and 
 (d) curing the mixture to form a solid composite product. 
 
     
     
         6 . The method of  claim 5  wherein said mixture further comprises binders, fillers, resins, catalysts, strengthening agents or combinations thereof before curing. 
     
     
         7 . The method of  claim 6  wherein said wherein said mixture comprises aggregate of solid particulates. 
     
     
         8 . The method of  claim 7  wherein said wherein said mixture comprises aggregate of solid particulates and silica. 
     
     
         9 . The method of  claim 5  wherein said product emits no volatile organic compounds or hazardous air pollutants. 
     
     
         10 . A cured composite product comprising
 (a) particles of composite materials according to the method of  claim 1 ;   (b) aggregate; and   (c) resin;   wherein said composite product is cured.   
     
     
         11 . The composite product of  claim 10 , wherein the resin in the cured composite product comprises less than about 30% by weight of the cured product. 
     
     
         12 . The composite product of  claim 10 , wherein said particles of composite materials comprises about 15% by weight of the cured product. 
     
     
         13 . The composite product of  claim 10 , wherein said product further comprises silica of about 30% by weight of the cured product. 
     
     
         14 . The composite product of  claim 10 , wherein said aggregate comprises about 50% by weight of the cured product. 
     
     
         15 . The composite product of  claim 10 , wherein said particles of composite material has an average fiber length of less than about one-half inch in diameter. 
     
     
         16 . The composite product of  claim 10 , wherein said particles of composite material has an average fiber length of about one-quarter inch in diameter. 
     
     
         17 . The composite product of  claim 10 , wherein said particles of composite material has an average fiber length of from about one-eighth inch to about one-half inch in diameter. 
     
     
         18 . The composite product of  claim 10 , wherein said composite product withstands compressive stress of at least about 10,000 psi with a compressive strain of less than about 7%. 
     
     
         19 . The composite product of  claim 10 , wherein the weight of said composite product increases less than about 1% after immersion in water for 24 hours. 
     
     
         20 . The composite product of  claim 10 , wherein said product emits no volatile organic compounds or hazardous air pollutants.