Reconstituted composite materials derived from waste made by solid state pulverization

Abstract

A method of making polymeric composite particles from polymeric scrap material, virgin polymeric material, or mixtures thereof and glass particles by subjecting a mixture of the polymeric particles and glass particles to a solid state shear pulverization and in-situ polymer compatibilization.

1 . (canceled) 
     
     
         2 . (canceled) 
     
     
         3 . Reconstituted composite particles produced by a method comprising the steps of:
 a) Comminuting a single bin recycling mixture composed of post-consumer polymeric material and glass scraps;   b) effecting a chemical change to said mixture by application of applying mechanical energy thereto through solid state shear pulverization in the presence of cooling to form reconstituted composite particles; and   c) discharging said reconstituted composite particles.   
     
     
         4 . The reconstituted composite particles of  claim 3  wherein the solid state shear pulverization is effected by a co-rotating screw pulverizer. 
     
     
         5 . The reconstituted composite particles of  claim 3 , wherein said single bin recycling mixture contains 1 to 40 wt. % of glass scraps. 
     
     
         6 . The reconstituted composite particles of  claim 3 , wherein said glass scraps are is pulverized to form glass particles which have less than 500 microns maximum dimension in said mixture. 
     
     
         7 . The reconstituted composite particles of  claim 3 , wherein said mechanical energy effects a chemical change that includes bond rupture. 
     
     
         8 . The reconstituted composite particles of  claim 3 , wherein said polymeric material is a quantity of polymeric chips, said chips having a size in the range of about 0.10 to 0.30 inches maximum width dimension and about 0.02 to 0.06 thickness dimension. 
     
     
         9 . The reconstituted composite particles of  claim 3 , wherein the polymeric material comprises two or more polymeric materials selected from the group consisting of HDPE, LDPE, LLDPE, PP, PS, PET, PVC, polycarbonate, acrylonitrile butadiene styrene, and polyphenylene oxide. 
     
     
         10 . The reconstituted composite particles of  claim 6 , wherein said glass scraps have a particle size of 0.5 to 150 microns in said mixture. 
     
     
         11 . The reconstituted composite particles of  claim 10 , wherein said polymeric material contains polymeric chains that include silyl or siloxane constituents. 
     
     
         12 . A powder of reconstituted composited particles produced by a method comprising the steps of:
 a) Comminuting a single bin recycling mixture composed of post-consumer polymeric material and glass scraps to form a composite mixture;   b) introducing said composite mixture into a pulverization device having an inlet for said composite mixture, means for pulverizing said composite mixture to effect chemical change by means of solid state shear pulverization in the presence of cooling during the pulverization, an outlet for said pulverized said powder of reconstituted composite particles, and means for cooling the temperature of said composite mixture between said inlet and outlet;   c) cooling said composite mixture to maintain said composite material mixture in a solid state without melting within the pulverization device;   d) pulverizing said solid state composite mixture within the pulverization device to chemically alter said composite mixture; and   e) discharging said resulting powder of reconstituted composite particles from said outlet.   
     
     
         13 . The powder of  claim 12 , wherein said means for pulverizing is the solid state shear pulverization that is effected by a co-rotating screw pulverizer. 
     
     
         14 . The powder of  claim 12 , wherein said composite material contains 1 to 40 wt. % of glass scraps. 
     
     
         15 . The powder of  claim 12 , wherein said glass scraps are pulverized to form particles which have less than 500 microns maximum dimension in said composite mixture. 
     
     
         16 . The powder of  claim 2   13 , wherein said solid state shear pulverization effects a chemical change that includes bond rupture. 
     
     
         17 . The powder of  claim 12 , wherein said polymeric material is a quantity of polymeric chips, said chips having a size in the range of about 0.10 to 0.30 inches maximum width dimension and about 0.02 to 0.06 thickness dimension. 
     
     
         18 . The powder of  claim 12 , wherein the polymeric material comprises two or more polymeric materials selected from the group consisting of HDPE, LDPE, LLDPE, PP, PS, PET, PVC, polycarbonate, acrylonitrile butadiene styrene, and polyphenylene oxide. 
     
     
         19 . The powder of  claim 15 , wherein glass particles have a particle size of 0.5 to 150 microns in said powder of reconstituted composite particles. 
     
     
         20 . The powder of  claim 19 , wherein said post-consumer polymeric material contains polymeric chains that include silyl or siloxane constituents.