U.S. patent application number 13/839018 was filed with the patent office on 2014-01-16 for thermoformed structural composites.
The applicant listed for this patent is James Chapman, David A. Hubbell, Ronald Matthew Sherga. Invention is credited to James Chapman, David A. Hubbell, Ronald Matthew Sherga.
Application Number | 20140018502 13/839018 |
Document ID | / |
Family ID | 49914521 |
Filed Date | 2014-01-16 |
United States Patent
Application |
20140018502 |
Kind Code |
A1 |
Sherga; Ronald Matthew ; et
al. |
January 16, 2014 |
Thermoformed Structural Composites
Abstract
The present invention is generally directed to methods and
systems for making thermoformed structural elements and composites,
including the use of composites, dissimilar or variable processing
materials. The present invention avoids the expense and the
technical issues of the present art on how difficult it is to
`clean` said `dirty` recycled materials so that they are acceptable
to the extrusion process and or the injection mold process. The end
products can have the same outward appearance as those products
made by the more demanding, more expensive extrusion process and or
injection process, but the present invention's end products can be
pre-engineered to have significantly, unexpectedly, improved
physical and chemical properties.
Inventors: |
Sherga; Ronald Matthew;
(Arlington, TX) ; Chapman; James; (Mantua, NJ)
; Hubbell; David A.; (Fort Walton Beach, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sherga; Ronald Matthew
Chapman; James
Hubbell; David A. |
Arlington
Mantua
Fort Walton Beach |
TX
NJ
FL |
US
US
US |
|
|
Family ID: |
49914521 |
Appl. No.: |
13/839018 |
Filed: |
March 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61698767 |
Sep 10, 2012 |
|
|
|
61671750 |
Jul 15, 2012 |
|
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Current U.S.
Class: |
525/184 ;
525/233 |
Current CPC
Class: |
C08L 55/02 20130101;
B29C 51/082 20130101; B29K 2105/26 20130101; Y02W 30/62 20150501;
B29K 2105/16 20130101; C08L 77/00 20130101; B29B 17/0042 20130101;
B29C 51/02 20130101; C08L 2207/20 20130101; C08L 2207/20 20130101;
C08L 101/00 20130101; C08L 55/02 20130101; C08L 2205/03 20130101;
B29C 51/002 20130101; C08L 25/06 20130101; C08L 67/03 20130101;
C08L 33/20 20130101; B29K 2101/12 20130101; C08L 101/00
20130101 |
Class at
Publication: |
525/184 ;
525/233 |
International
Class: |
C08L 33/20 20060101
C08L033/20 |
Claims
1. A thermoformed structural-composite construct comprising: a
first material having a first melting pointing, a first thermal
mass, a first thermal energy density, a first thermal-energy
gradient, and a first structural integrity, a second material
having a second melting pointing, a second thermal mass, a second
thermal energy density, a second thermal-energy gradient, and a
second structural integrity, said first and second materials are
compressed between a first matched die and a second matched die to
create heat and pressure by utilizing the differential between said
first and second melting points, thermal-mass,
thermal-energy-densities, thermal-energy gradients and structural
integrities in the individual near-melt-point range vis-a-vis
pressure-heat ratio for just said first material but does not
approach the melting point for the second material, and a third
composite material thermoformed from the merged compression of said
first material with said second material, said third composite
material thermo-formed without distinct shear planes.
2. The construct of claim 1, wherein said materials include one of
the following: phase-separated mixtures, immiscible blends,
Polyethylene Terephthalate (PET), or poly(vinyl alcohol) (PVA).
3. The construct of claim 1, wherein said materials include polymer
originating from waste streams of various origins, cellulose
acetate materials from cigarette filters, or packaging
fillings.
4. The construct of claim 1, wherein said materials include
co-mingled material
5. The construct of claim 1, wherein said materials include one of
the following: High-Density Polyethylene (HDPE), Vinyl/Polyvinyl
Chloride (PVC), Low-Density Polyethylene (LDPE), Polypropylene
(PP), Polystyrene (PS), Acrylonitrile butadiene styrene (ABS), High
impact polystyrene (HIPS), polylactide (PLA), Nylon, Polycarbonate
(PC), Acrylic, or Fiberglass.
6. The construct of claim 1, wherein said materials include one of
the following: thermoset epoxies, thermoset polyesters, thermoset
silicones, thermoset phenolics, vulcanized rubber,
polyoxybenzylmethylenglycolanhydride (bakelite), cross-linked
polyethylene (PEX), Polyurethane (PU), carbon fiber, flame
retardant plastics, fiber reinforced plastics.
7. The construct of claim 1, wherein said materials are one of the
following: glass filled plastics, cured silicone, mixed plastics,
metals, paper, or shape memory plastics (SMP).
8. The construct of claim 1, wherein said materials possess one or
more of the following: pigments, inks, adhesives, chlorine,
styrene, and Olefin.
9. The construct of claim 1, wherein said materials include
engineered grade plastics recovered from electronic waste,
electrical waste, and automotive waste.
10. The construct of claim 1, wherein said materials are one of the
following: recycled thermoplastics, thermoset plastics, and
non-plastic materials.
11. The construct of claim 1, wherein said materials directly
reduced from a grind-state to one or more of the following states:
film-state, sheet-state, plate-state, laminate film-state, laminate
sheet-state, laminate plate-state,
12. The construct of claim 1, wherein said materials are reinforced
via fibers, tensioned during the manufacture of said composite, or
tensioned during the manufacture of said composite.
13. A method of making a thermoformed structural-composite
construct comprising the steps of: providing a first material
having a first melting pointing, a first thermal mass, a first
thermal energy density, a first thermal-energy gradient, and a
first structural integrity, providing a second material having a
second melting pointing, a second thermal mass, a second thermal
energy density, a second thermal-energy gradient, and a second
structural integrity, combining under compressed pressure and heat
said first and second materials between a first matched die and a
second matched die, said combination uses the differential between
said first and second melting points, thermal-mass,
thermal-energy-densities, thermal-energy gradients and structural
integrities in the individual near-melt-point range vis-a-vis
pressure-heat ratio for said first material but does not approach
the melting point for the second material, producing a third
composite material thermoformed from merged compression of said
first material with said second material, said third composite
material thermoformed without distinct shear planes, configuring
the third composite material for a predetermined use.
14. The method of claim 13, wherein said materials include one of
the following: phase-separated mixtures, immiscible blends,
Polyethylene Terephthalate (PET), or poly(vinyl alcohol) (PVA).
15. The method of claim 13, wherein said materials include polymer
originating from waste streams of various origins, cellulose
acetate materials from cigarette filters, or packaging
fillings.
16. The method of claim 13, wherein said materials include
co-mingled material
17. The method of claim 13, wherein said materials include one of
the following: High-Density Polyethylene (HDPE), Vinyl/Polyvinyl
Chloride (PVC), Low-Density Polyethylene (LDPE), Polypropylene
(PP), Polystyrene (PS), Acrylonitrile butadiene styrene (ABS), High
impact polystyrene (HIPS), polylactide (PLA), Nylon, Polycarbonate
(PC), Acrylic, or Fiberglass.
18. The method of claim 13, wherein said materials include one of
the following: thermoset epoxies, thermoset polyesters, thermoset
silicones, thermoset phenolics, vulcanized rubber,
polyoxybenzylmethylenglycolanhydride (bakelite), cross-linked
polyethylene (PEX), Polyurethane (PU), carbon fiber, flame
retardant plastics, fiber reinforced plastics.
19. The method of claim 13, wherein said materials are one of the
following: glass filled plastics, cured silicone, mixed plastics,
metals, paper, or shape memory plastics (SMP).
20. The method of claim 13, wherein said materials possess one or
more of the following: pigments, inks, adhesives, chlorine,
styrene, and Olefin.
21. The method of claim 13, wherein said materials include
engineered grade plastics recovered from electronic waste,
electrical waste, and automotive waste.
22. The method of claim 13, wherein said materials are one of the
following: recycled thermoplastics, thermoset plastics, and
non-plastic materials.
23. The method of claim 13, wherein said materials directly reduced
from a grind-state to one or more of the following states:
film-state, sheet-state, plate-state, laminate film-state, laminate
sheet-state, laminate plate-state,
24. The method of claim 13, wherein said materials are reinforced
via fibers, tensioned during the manufacture of said composite, or
tensioned during the manufacture of said composite.
25. A thermoformed structural-composite construct made by a process
comprising the steps of: providing a first material having a first
melting pointing, a first thermal mass, a first thermal energy
density, a first thermal-energy gradient, and a first structural
integrity, providing a second material having a second melting
pointing, a second thermal mass, a second thermal energy density, a
second thermal-energy gradient, and a second structural integrity,
combining under compression between a first matched die and a
second matched die to create pressure and heat applied to said
first and second materials, said combination uses the differential
between said first and second melting points, thermal-mass,
thermal-energy-densities, thermal-energy gradients and structural
integrities in the individual near-melt-point range vis-a-vis
pressure-heat ratio for first said material but does not approach
the melting point for the second material; producing a third
composite material thermoformed from the merged compression of said
first material with said second material, said third composite
material thermoformed without distinct shear planes, and
configuring the third composite material for a predetermined
use.
26. The construct prepared according to claim 25 wherein said
materials include one of the following: phase-separated mixtures,
immiscible blends, Polyethylene Terephthalate (PET), or poly(vinyl
alcohol) (PVA).
27. The construct prepared according to claim 25 wherein said
materials include polymer originating from waste streams of various
origins, cellulose acetate materials from cigarette filters, or
packaging fillings.
28. The construct prepared according to claim 25 wherein said
materials include co-mingled material
29. The construct prepared according to claim 25 wherein said
materials include one of the following: High-Density Polyethylene
(HDPE), Vinyl/Polyvinyl Chloride (PVC), Low-Density Polyethylene
(LDPE), Polypropylene (PP), Polystyrene (PS), Acrylonitrile
butadiene styrene (ABS), High impact polystyrene (HIPS),
polylactide (PLA), Nylon, Polycarbonate (PC), Acrylic, or
Fiberglass.
30. The construct prepared according to claim 25 wherein said
materials include one of the following: thermoset epoxies,
thermoset polyesters, thermoset silicones, thermoset phenolics,
vulcanized rubber, polyoxybenzylmethylenglycolanhydride (bakelite),
cross-linked polyethylene (PEX), Polyurethane (PU), carbon fiber,
flame retardant plastics, fiber reinforced plastics.
31. The construct prepared according to claim 25 wherein said
materials are one of the following: glass filled plastics, cured
silicone, mixed plastics, metals, paper, or shape memory plastics
(SMP).
32. The construct prepared according to claim 25 wherein said
materials possess one or more of the following: pigments, inks,
adhesives, chlorine, styrene, and Olefin.
33. The construct prepared according to claim 25 wherein said
materials include engineered grade plastics recovered from
electronic waste, electrical waste, and automotive waste.
34. The construct prepared according to claim 25 wherein said
materials are one of the following: recycled thermoplastics,
thermoset plastics, and non-plastic materials.
35. The method of claim 25, wherein said materials directly reduced
from a grind-state to one or more of the following states:
film-state, sheet-state, plate-state, laminate film-state, laminate
sheet-state, laminate plate-state,
36. The construct prepared according to claim 25 wherein said
materials are reinforced via fibers, tensioned during the
manufacture of said composite, or tensioned during the manufacture
of said composite.
Description
RELATED U.S. APPLICATION DATA
[0001] These applications are related to Provisional Patent
Application Ser. No. 61/698,767 filed on Sep. 10, 2012 entitled
"Thermoformed Structural Composites," and Provisional Patent
Application Ser. No. 61/671,750 filed on Jul. 15, 2012 entitled
"Thermoformed Structural Composites" and priority is claimed to
these earlier filings under 35 U.S.C. .sctn.119(e). The Provisional
Patent Applications and all related filings are incorporated by
reference into this utility patent application.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention is generally directed to methods and
systems for making thermoformed structural elements and composites,
including the use of composites, dissimilar or variable processing
materials.
BACKGROUND OF THE INVENTION
[0003] There is a major unresolved challenge in recycling mixed
plastics and mixed plastics with non-plastic-contaminates. The
difficulty with this type of recycling process is that the
different plastics used in the recycling process are not compatible
with each other. There is an inherent inability of two or more
plastics to undergo mixing or blending, which means that some
plastics cannot be mixed together during the recycling process.
Also, different types of plastics are immiscible at the molecular
level, and there are significant differences in processing
requirements at the macroscopic level with respect to the different
plastic inputs.
[0004] Even a small amount of the wrong type of plastic can ruin an
entire container or bale of recycled material. Co-mingled material
is worth significantly less than sorted material. Mixed or
co-mingled plastics are frequently contaminated with such items as
metals, paper, pigments, inks, adhesives, carbon fiber, flame
retardants, fiber reinforced plastics, glass filled plastics, cured
silicon and rubber.
[0005] A primary reason for these differences is the different
melting points associated with different plastic resins, or the
inability of certain plastics to undergo a "re-melting" process.
Plastics involved in recycling activities can be considered in two
broad categories: thermoplastics and thermoset. Comparing these
types, in the present art, thermoplastics are much easier to adapt
to recycling.
[0006] Thermoplastic polymers can be heated and formed, then heated
and formed again and again. The shape of the polymer molecules are
generally linear or slightly branched. This means that the
molecules can flow under pressure when heated above their melting
point. Thermoset polymer plastics, on the other hand, undergo a
chemical change when they are heated, creating a three-dimensional
network. Thermosets cannot be re-melted or remolded and therefore
have been traditionally difficult to recycle. Typical types of
thermosetting plastics are Polyurethane (PU), epoxies, polyesters,
silicones and phenolics, with vulcanized rubber being an excellent
example of a thermosetting and also
polyoxybenzylmethylenglycolanhydride (bakelite).
[0007] Materials made from two polymers mixed together are called
blends. In general, polymers cannot be homogeneously mixed with one
another, and even attempting to mix most polymers will result in
phase-separated mixtures.
[0008] An example of phase-separated mixtures or immiscible blends
is polystyrene and polybutadiene, which are immiscible polymers.
When you mix polystyrene with a small amount of polybutadiene, the
two polymers will not blend together. Polystyrene is generally a
stiff, brittle, material that will break or shatter if bent.
Polybutadiene separates from the polystyrene into usually small,
isolated, sphere-shaped item, and the polybutadiene spheres in the
blend are elastic in nature and absorb energy under stress.
[0009] The polystyrene and polybutadiene immiscible blend bends and
does not break like polystyrene by itself. The immiscible blends of
polystyrene and polybutadiene are known as high-impact polystyrene,
or HIPS.
[0010] Another example of a immiscible blend is one made from
Polyethylene Terephthalate (PET) and poly(vinyl alcohol) (PVA) The
blend results in PET and PVA separating into individual sheetlike
layers. This blend is particularly useful in the making of plastic
bottles for carbonated liquids.
[0011] "Recycling and Recovery of Plastics," by loop Lemmens
recognizes a recent trend in the increased use of polymer mixtures,
blended polymers and novel plastic combinations. An example of
`novel` plastic is cross-linked polyethylene (PEX) Crosslinking
polyethylene changes the polymer from a thermoplastic to a
thermoelastic polymer. Once it is fully crosslinked, polyethylene
tends not to melt but merely to become more flexible at higher
temperatures.
[0012] Examples of problems in recycling plastics include cases
where a quantity of recycled PET is contaminated with a small
amount of PVC. The PVC will release hydrochloric-acid gas before
the process temperature to melt the PET is reached, and the
released gas will degrade the PET. In the reverse, where a small
amount of PET contaminates recycled PVC, the PET will remain in
solid form after the PVC reaches its melting point, which results
in crystalline PET inhabiting the post-melt-cooled PVC
structure.
[0013] A major problem in the recycling of PVC is its high chlorine
content of raw PVC, and the hazardous additives added to the
polymer to achieve the desired material quality. PVC requires
separation from other plastics and sorting before mechanical
recycling. PVC recycling is difficult because of high separation
and collection costs, loss of material quality after recycling, and
the low market price of recycled PVC compared to virgin PVC.
[0014] There are thousands of different varieties of plastic resins
or mixtures of resins, and most plastics have a code number or
classification. Plastics not identified by code numbers are
difficult to recycle. These items, such as computer keyboards, do
not fit into the numbering system that identifies plastics used in
consumer containers.
[0015] Bazant & Cedolin address concerns about the stability of
structural composites, such as the composites made from recycled
materials. Namely, Bazant & Cedolin state: "[t}hree-dimensional
instabilities are important for solids with a high degree of
incremental anisotropy, which can be either natural, as is the case
for many fiber composites and laminates, or stress-induced, as is
the case for highly damaged states of materials" and "[t]he typical
three-dimensional instabilities are the surface buckling and
internal buckling, as well as bulging and strata folding."
[0016] Bazant & Cedolin state that " . . . three dimensional
buckling modes described . . . no doubt play some role in the final
phase of compression failures. For example, Bazant (1967) showed
that a formula based on . . . thick-wall buckling . . . agrees with
his measurements of the effects of the radius-to-wall thickness
ratio on the compressive failure stress of fiber-glass laminate
tubes. On the other hand, other physical mechanisms, particularly
the propagation of fractures or damage bands, are no doubt more
important for the theory of compression failure. The reason is
two-fold: (1) The calculated critical states for the
three-dimensional instabilities require some of the tangential
moduli to be reduced to the same order of magnitude as some of the
applied stress components, which can occur only in the final stage
of the failure process; and (2) the body at this stage might no
longer be adequately treated as a homogeneous continuum."
[0017] Bazant & Cedolin address " . . . orthotropic composites
that have a very high stiffness in one direction and a small shear
stiffness may suffer three-dimensional instabilities such as
internal buckling or surface buckling. These instabilities, which
involve buckling of stiff fibers (glass, carbon, metal) restrained
by a relatively soft matrix (polymer), are analogous to the
buckling of perfect columns. When the fibers are initially curved,
one may expect behavior analogous to the buckling of imperfect
columns. In particular, the initial curvature of fibers causes
fiber buckling, which reduces the stiffness of the composite. It
also gives rise to transverse tensions, which may promote
delamination failure."
[0018] Urquhart & O'Rourke address three dimensional
instabilities as follows: "[w]henever a material is subjected to
compression in one direction, there will be an expansion in the
direction perpendicular to the compression axis. When this
expansion is resisted, lateral compressive stresses are developed,
which tend to neutralize the effect of the longitudinal compressive
stress, and thus increase resistance against failure. This is the
principle involved in the use of spiral or hooped reinforcement . .
. ".
[0019] Also, Urquhart & O'Rourke state that "[w]ithin the limit
of elasticity the hooped reinforcement is much less effective than
longitudinal reinforcement, Such reinforcement, however, raises the
ultimate strength of the column, because the hooping delays
ultimate failure . . . ", and the material" . . . continues to
compress and to expand laterally, thus increasing the tension in
the bands, while final failure occurs upon the excessive stretching
or breaking of the hooping." "As long as the bond between the . . .
" fiber and the polymer " . . . is effective, the two materials
will deform equally, and the intensities of the stresses will be
proportional to their moduli of elasticity."
[0020] A structural system's failure mode can be defined as the
characteristics bounded by that known as "catastrophic" or
"localized" within the said system, wherein the term "catastrophic"
indicates a system-wide structural failure involving progressive
individual and sub-systemic structural element(s) failures and the
term "localized" indicates a system or sub-system arrest of
structural failure and/or redistribution of the force(s) which
resulted in the initial failure-mode of the initial failed
structural element.
[0021] One of the unexpected results of full-scale testing of the
present invention's physical manifestations, is the damping effect
of the present invention to structural "shock", such as the
characteristic of nailing or directly impacting physical samples of
the present invention.
[0022] U.S. Pat. No. 6,497,956 (956) issued Dec. 24, 2002, to
Phillips et al., teaches that " . . . high density polyethylene
(HDPE) . . . " and " . . . plastic lumber made from HDPE, PVC, PP,
or virgin resins has been characterized as having insufficient
stiffness to allow its use in structural load-bearing
applications." "For example, it is noted that non-reinforced
plastic lumber products typically have a flexural modulus of only
one-tenth to one-fifth that of wood such as Douglas fir, . . . "
U.S. Pat. No. 5,212,223 discusses the inclusion of short glass
fibers within reprocessed polyolefin and further teaches doing so
to increase the stiffness of the non-reinforced plastic lumber by a
factor of 3:4. However, none of the prior art known to applicant is
capable of fabricating plastic lumber having the structural
stiffness and strength of products made according to the present
invention . . . "
[0023] U.S. Pat. App. No. 20070045886, filed Mar. 1, 2007, by
Johnson teaches that: " . . . composite lumber is currently used
for decking, railing systems and playground equipment. Sources
indicate that there currently exists a $300 million per year market
for composite lumber in the United States. It is estimated that 80%
of the current market uses a form of wood plastic composite (WPC).
It is estimated that the other 30% is solid plastic. A wood plastic
composite (WPC) refers to any composite that contains wood
particles mixed with a thermaloset or thermoplastic . . . . The
presence of wood fiber increases the internal strength and
mechanical properties of the composite as compared to, e.g., wood
flour." And, `[f]or example, the addition of wood fillers into
plastic generally improves stiffness, reduces the coefficient of
thermal expansion, reduces cost, helps to simulate the feel of real
wood, produces a rough texture improving skid resistance, and
allows WPC to be cut, shaped and fastened in a manner similar to
wood."
[0024] Also, "[t]he addition of wood particles to plastic also
results in some undesirable characteristics. For example, wood
particles may rot and are susceptible to fungal attack, wood
particles can absorb moisture, wood particles are on the surface of
a WPC member can be destroyed by freeze and thaw cycling, wood
particles are susceptible to absorbing environmental staining,
e.g., from tree leaves, wood particles can create pockets if
improperly distributed in a WPC material, which may result in a
failure risk that cannot be detected by visual inspection, and wood
particles create manufacturing difficulties in maintaining
consistent colors because of the variety of wood species color
absorption is not consistent. Plastics use UV stabilizers that fade
over time. As a result, the wood particles on the surface tend to
undergo environmental bleaching. Consequently, repairing a deck is
difficult due to color variation after 6 months to a year of sun
exposure."
[0025] "In a typical extrusion composite design, increased load
bearing capacity capability may be increased while minimizing
weight by incorporating internal support structures with internal
foam cores. Examples of such designs are taught in U.S. Pat. Nos.
4,795,666; 5,728,330; 5,972,475; 6,226,944; and 6,233,892."
[0026] "Increased load bearing capacity, stability and strength of
non-extruded composites has been accomplished by locating
geometrically shaped core material in between structural layers.
Examples of pre-formed geometrically shaped core materials include
hexagon sheet material and lightweight woods and foam. Problems
associated with typical preformed core materials include
difficulties associated with incorporating the materials into the
extrusion process due to the pre-formed shape of the
materials."
[0027] "Other efforts to increase strength with composite fiber
design have focused on fiber orientation in the composite to obtain
increased strength to flex ratios. In a typical extrusion composite
process, the fiber/fillers are randomly placed throughout the
resin/plastic. Therefore increasing strength by fiber orientation
is not applicable to an extrusion process."
[0028] "Foam core material has been used in composites for
composite material stiffening, e.g., in the marine industry, since
the late 1930's and 1940's and in the aerospace industry since the
incorporation of fiber reinforced plastics."
[0029] "Recently, structural foam for core materials has greatly
improved in strength and environmental stability. Structural core
material strengths can be significantly improved by adding fibers.
Polyurethane foams can be modified with chopped glass fibers to
increase flexible yield strength from 8,900 psi-62,700 psi."
[0030] "Prior art patents tend to describe foam core materials as
rigid or having a high-density. However structural mechanical
properties of the foam core tend not to be addressed. A common
method to obtain a change in load capacity is to change the density
of the material. For example, this can be done in a polyurethane in
which water is being used as a blowing agent. The density of a
polyurethane decreases with the increase in water
concentration."
[0031] "One problem that may occur when a core material and a
structural material are not compatible both chemically and
physically is delamination. Chemical and physical incompatibility
can result in composite structures that suffer structural failures
when the core material and the structural material separate from
one another."
[0032] "[C]oefficient of thermal expansion (CTE)" is discussed in
Johnson, as well as "[t]he conformable core material is injected
into and around internal structural support members of an extruded
member. Preferably, while the member is being extruded, the core
material is injected to replace air voids within the member. The
injection of conformable structural core material at the same time
and same rate as the structural member is being extruded produces
significant improvements by increasing load bearing capacity,
stability and overall strength and by improving economic
feasibility. For example, a rigid polyurethane foam is
approximately 10 times less expensive per volume than PVC.
Therefore, by replacing some interior volume of an extruded member
with foam, the PVC volume is reduced while maintaining the same
structural strength or greater. Therefore, the injection of a
conformable foam results in a significant cost savings. In some
applications, the injectable conformable structural core material
may be applied to an extruded member that has been previously
cured."
[0033] "One benefit of an injectable conformable structural core
material is that the core material is not limited by the structural
design of the composite member because the core material conforms
to the geometric shapes present in structure."
[0034] "Although a core material and a structural material may be
initially combined into a composite member without regard to the
CTE's of each, this does not guarantee structural integrity over
time. Therefore, the invention of the application involves
tailoring of the conformable structural core material by the
selection of optimal amounts of structural fillers to achieve a
desired CTE of the materials. The step of tailoring the structural
core material provides a solution for composite structural design
regardless of the composition of the materials."
[0035] "One aspect of the invention is directed towards the
mechanical interaction and the relationship between a selected
thermal plastic and a selected foam core material. Thermal plastics
have mechanical properties that are influenced by environmental
temperatures. For example, thermal plastics are stronger at colder
temperatures but are more brittle. Thermal plastics are weaker in
warmer weather, but are more flexible."
[0036] "Foam for an internal core material inside a thermal plastic
material may be tailored to overcome variations in structural
strengths of thermal plastics. For example, an ideal core material
is selected to possess thermal expansion properties that offset the
thermal sag characteristics of thermal plastic structural material
that the structural material experiences due to thermal heating in
the environment. The thermal expansion of the core and mechanical
stiffness of the composite may be tailored to achieve desired
strength and internal pressure, resulting in mechanical stiffening
of the composite."
[0037] "The interaction of thermal sag of the thermal plastic
material in relationship to the thermal expansion of the internal
core material may be considered to select an ideal foam for use
with a particular plastic. Ideally, the materials will function as
a true composite. Because of the enormous uses of this invention
associated with composite design and their applications with the
overwhelming selection of materials and their combinations, the
method described herein allows for optimal material pairings to be
determined. As internal cross members of a structural member and
the exterior structure undergo mechanical weakening as the
temperature increases, a selected internal core material having an
optimal thermal expansion with enhanced thermal mechanical
properties will improve the rigidity and the mechanical strength of
the combined composite in a manner similar to inflating an
automobile tire to increase mechanical rigidity of the rubber."
[0038] "A further advantage associated with the use of core
materials such as foams are thermal insulation properties of the
foam. A significant mechanical advantage is achieved by reducing
the heat transfer rate from the surface of a structural member to
an internal support structure of the composite, thereby thermally
shielding the internal support structure from heat fluctuations and
maintaining increased internal strengths of the cell structures in
the composite during elevated temperatures."
[0039] "CTE can be tailored in a composite matrix to improve
surface functionality between the structural material and the core,
thereby reducing the shear stresses that are created by thermal
cycling at the contact interface of the two materials. Polyurethane
foam densities are directly proportional to the blowing agent,
typically water. The less water, the tighter the cell structure,
which results in higher density foams."
[0040] "In a closed cell structure, controlling internal forces
caused by thermal cycling produced by the core material can be
accomplished by tailoring the CTE. The CTE of a core material may
be tailored by adjusting an amount of filler in the core material.
For example, fillers such as chop fibers and micro spheres will
have much lower CTE in the structural foam. The CTE of glass
spheres is approximately 100 times smaller than most resin
materials."
[0041] "Glass spheres or ceramic spheres have enormous compression
strength in comparison to the foam cells created by blowing agents.
Therefore, the addition of micro spheres will not only provide the
ability to tailor the CTE of the foam but it will replace low
compression strength cell structures with higher strength cell
structures."
[0042] "The incorporation of chop fibers adds dramatic cross
structural strength throughout the foam. Applicant's mechanical
model analysis clearly illustrates an increased strength of
materials resulting from the presence of core material regardless
of the mechanical structure. The analysis was directed to extruded
PVC. Some of the extruded PVC members were filled with chopped
fibers and some were not. The chopped fibers increased strength of
the structural member and decreased the CTE. The additives of
selected fillers to the foam core materials illustrate similar
characteristics. Selecting appropriate materials for a composite is
complicated because composites are not homogeneous materials.
However, composites are required to function as a homogeneous
structure without structural deviation. The models clearly show how
reinforcing fibers increases load bearing capabilities in the
composite materials."
[0043] "Manmade fibers and fillers can be used to improve
mechanical properties as well as to lower CTE's of a core material.
Ideally, filler materials should be environmentally stable and
malleable into desired geometric configurations so that they may be
incorporated into a structural design. Examples of fiber materials
include fiberglass, carbon and nylon. These fibers can be cut to a
specific length with a desired diameter that can be incorporated
into an injection molding process either from the plastics
manufacturer if the desired material is a foam plastic. If the
resin is a reactive material such as polyurethane foam, the fillers
and fibers can be combined either in the liquid stage prior to
mixing the reactive components or in the foam mixing chamber prior
to being extruded. The coefficient of thermal expansion is directly
related to the volume fillers to plastics ratio."
[0044] "Solid core materials can be made from high-density
polyurethane, polyureas and epoxy materials etc., having high
strength and fast cure times. These materials may be filled with
fillers or micro spheres to produce high strength injectable core
materials."
SUMMARY OF THE INVENTION
[0045] The present invention is generally directed to methods and
systems for making thermoformed structural elements and composites,
including the use of composites, dissimilar or variable processing
materials. A comparison of test data shows the present invention
possesses unexpected improved properties that the present art does
not have.
[0046] Materials used originate from polymer waste streams of
various origins, primarily engineer grade plastics recovered from
electronic-waste and industrial scrap such as from automotive
production. Materials also will include fibrous polymer waste
recovered from 100% post consumer sourcing or other waste streams
where standard methods of recovery have been to landfill, or waste
to energy. The innovative recovery and reuse of these waste streams
is a key component of our inventiveness and technology.
[0047] The present invention avoids the expense and the technical
issues of the present art on how difficult it is to `clean` said
`dirty` recycled materials so that they are acceptable to the
extrusion process and or the injection mold process.
[0048] The end products can have the same outward appearance as
those products made by the more demanding, more expensive extrusion
process and or injection process but the present invention's end
products can be pre-engineered to have significantly, unexpectedly,
improved physical and chemical properties.
[0049] An object of the present invention is a thermoformed
structural-composite construct utilizing the differential between
certain materials' melt-point(s), said different material(s)
thermal-mass, thermal-energy-densities, thermal-energy gradient(s)
and structural integrity/stability in said material(s) in the
individual near-melt-point range vis-a-vis pressure-heat ratio,
consisting primarily of recycled thermoplastics, thermoset
plastics, and non-plastic materials and directly reduced from
grind-states to a laminate film and or sheet and or plate-state
which is reinforced via fibers, having an average length greater
than the composite's thickness, which are tensioned during the
manufacture of said composite.
[0050] Another object of the present invention is the elimination
of costs and loss of time-value associated with separation of
waste-stream plastics into thermoplastics, thermosets, and
non-plastics and then the elimination and loss of time-value of
conversion of such materials into film and or sheet and or plate
before such materials enter a thermoforming process.
[0051] An object, in reference with the previous paragraphs, of the
present invention is to eliminate the direct labor costs associated
with `grinding` plastic material, to such a condition, in
preparation to pelletizing said plastic material, so as to feed
said pelletized plastic material before extruding plastic material
into sheet, thereby readying said plastic sheet material for
shearing and or cutting such, before placement of cut plastic sheet
material in a thermoform.
[0052] Another object, in reference with the previous paragraphs,
of the present invention is to eliminate the direct labor costs
associated with pelletizing said plastic material, so as to feed
said pelletized plastic material before extruding plastic material
into sheet, thereby readying said plastic sheet material for
shearing and or cutting such, before placement of cut plastic sheet
material in a thermoform.
[0053] Yet another object, in reference with the previous
paragraphs, of the present invention is to eliminate the direct
labor costs associated with extruding plastic material into sheet,
thereby readying said plastic sheet material for shearing and or
cutting such, before placement of cut plastic sheet material in a
thermoform.
[0054] Still another object, in reference with the previous
paragraphs, is the elimination of the capital equipment referenced
above as the present art preparation for and conduction of
thermoforming. Some examples are the manufacturing equipment
directly involved in pelletizing equipment and or the extruding
plastic material into sheet equipment. Also eliminated are
handling, storage and indirect equipment, building(s) associated
with such and the indirect labor costs directly related with
maintenance of said same.
[0055] A further object of the present invention is to ease and
encourage the use of post-consumer plastics in thermoform
operations. By eliminating the need to pelletize and or
sheet-extrude plastic material(s) before thermoforming, the
significant costs, involved in `separation` and or `cleaning`
post-consumer plastic material, are eliminated.
[0056] A still further object of the present invention is to
utilize waste-stream plastics which the present art has
difficulties in economically separating for recycling and using in
finished products. An example is waste-stream plastics which are a
mix of ABS plastic and PVC. ABS and PVC have very similar
specific-gravities and melt-points. While the two have the
aforementioned commonalities in the present art examples,
difficulties arise when such mixes are extruded or injection
molded. The present invention allows the use of such plastic mixes
in the manufacture of finished products.
[0057] Yet another object of the present invention utilizes the
formation, via the thermoforming operation of structurally bridging
internal structural differences. In addition to the above, the
present invention provides the use of `foaming` material(s),
included with the above referenced thermoform-able plastic
material(s), which when said `foaming` materials is/are triggered,
provides heat, or additional heat, and provides pressure or
additional pressure to the thermoform process.
[0058] A further aspect of the present invention is providing a
well distributed non-thermoform-able material(s) throughout a
thermoformed item. Yet another aspect of the present invention is
providing well distributed thermoform-able materials, of different
melt-points, throughout a thermoformed item.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] FIG. 1 illustrates the process of forming an embodiment of a
thermoformed composite.
[0060] FIG. 2 illustrates the process of forming an embodiment of a
thermoformed composite.
[0061] FIG. 3 illustrates the process of forming an embodiment of a
thermoformed composite.
[0062] FIG. 4 illustrates the process of forming an embodiment of a
thermoformed composite.
[0063] FIG. 5 illustrates the process of forming an embodiment of a
thermoformed composite.
[0064] FIG. 6 illustrates the process of forming an embodiment of a
thermoformed composite.
[0065] FIG. 7 illustrates the process of forming an embodiment of a
thermoformed composite.
[0066] FIG. 8 is a flowchart illustrating the production
process.
[0067] FIG. 9 illustrates an embodiment of various materials
combined prior to production.
[0068] FIG. 10 illustrates an embodiment of various materials
combined prior to production.
[0069] FIG. 11 illustrates an embodiment of various materials
combined prior to production.
[0070] FIG. 12 illustrates an embodiment of various materials
combined prior to production.
[0071] FIG. 13 illustrates an embodiment of various materials
combined prior to production.
[0072] FIG. 14 illustrates a press used to create a sheet of
thermoformed composite.
[0073] FIG. 15 illustrates a thermoformed composite after
production.
[0074] FIG. 16 illustrates a thermoformed composite after
production.
[0075] FIG. 17 illustrates a thermoformed composite after
production shaped into a square.
[0076] FIG. 18 illustrates a perspective view of a thermoformed
composite after production shaped into a square.
[0077] FIG. 19 illustrates a thermoformed composite after
production shaped into an octagon.
[0078] FIG. 20 illustrates a thermoformed composite after
production shaped into a square sign.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0079] The invention utilizes the manufacturing process known as
`thermoforming`. The thermoform process combines thermally charging
a material, usually a material such as plastic sheet, to a pliable
or plastic-state, and pressing, frequently via a vacuum, into a
desired shape. The thermoformed item is usually then allowed to
cool resulting in a hardening of the thermoformed material.
Thermoforming is frequently the lowest-cost-manufacturing process,
over other processes, due in part to usually lower tooling costs
and greater factory flexibility.
[0080] Thermoform methods and systems are usually subdivided,
denoted, as "thin-gauge" and "thick-gauge". By industry standard,
thin-gauge methods and systems usually mean a finished product that
is 1.5 mm (0.059 in.) or less in thickness. Thick-gauge methods and
systems usually mean a finished product which is 3 mm (0.12 in.) or
greater in thickness.
[0081] The present invention is applicable regardless of the final
thermoformed product's thickness. For clarity, the following will
address the typically encountered `thick-gauge` methods and
systems, it being understood that the invention is not limited by
the thickness of the end product.
[0082] The present invention utilizes the difference in melt
temperatures of materials commonly encountered in thermoform
operations. For example, the melt point for nylon, depending on
specific configuration, is above 420 degrees F., while amorphous
ABS has an effective melt point above 220 degrees F. Such
differentials in melt point vis-a-vis the thermoform process allows
for a blending of two or more materials which once through a
thermoform can result in specific structural-composites.
[0083] The present invention utilizes the differences in energy per
unit mass (specific energy or thermal-energy-density) of the
materials during the construction of the present invention's
structural-composites physical manifestations. For example,
physically mixing two materials with different
thermal-energy-densities results in an entity in which heat
transfer occurs between the two materials when thermal energy is
externally applied to said mixture.
[0084] The present invention utilizes the differences in the
thermal-energy gradient (rate of temperature change with distance)
of the materials during the construction of the present invention's
structural-composites physical manifestations. For example,
physically mixing two materials with different thermal-energy
gradients results in an entity in which the heat transfer rate
occurs between the two materials when thermal energy is externally
applied to said mixture.
[0085] An example of a commercial application of two materials,
with different melt points, which may be configured into a
structural-composite is where nylon fiber and a plate of ABS
plastic is thermoformed at a temperature above the melt point of
the ABS plastic but below the melt point of the nylon. The standard
thermoform combination of heat and pressure will cause the ABS
plastic to flow into and surround the nylon-fiber(s).
[0086] The character of the physical interface between the nylon
weave and the ABS plastic is deterministic via the character of the
nylon-fiber and geometry before, during and after the thermoform
process. The structural aspects of the referred to above nylon/ABS
structural-composite is deterministic based on the significantly
different mechanical properties of the chosen nylon-type,
size-length-diameter of individual nylon fiber(s), fiber
configuration(s) and chosen ABS plastic-type.
[0087] Substitution of the referred above ABS plastic `plate` with
ABS plastic pre-extrusion `grind` and reconfiguration of the above
referred flexible nylon-fiber(s) explicitly describes one of the
intents of the present invention.
[0088] Use of a material, in a configuration, such as, but not
limited to, ABS plastic pre-extrusion `grind`, allows the inclusion
of, and mix with, the `grind` material(s) which may or may not be
normally thermoform-able. Examples of material(s) which might be
`included` and or `mixed`, before thermoforming, with a
thermoform-able `grind`, are ceramic(s), metal(s), organic(s) and
the like.
[0089] Use of a `foaming` material `mixed` with the above referred
thermoform-able `grind` allows the deterministic nature of a
`foaming` material to provide and or enhance the `pressure` aspect
of commonly encountered thermoform operations. Examples of, but not
limited to, `foaming` materials are polystyrene and or
polyurethane. Such `foaming` material(s) may be `triggered` to
`foam` before, during, or after the thermoforming of the desired
structural-composite. In the use of foaming materials, such as
foaming polyurethane and polystyrene, the activation of the foaming
action can be designed to occur before, during, and or after
thermoforming the intended structural composite. Activation of the
foaming action after the construction of the structural composite
allows intended results such as internal pressurizing of said
structural composite.
[0090] As a general statement, a thermoform-able `grind` has a
lower density than said `grind` material post-thermoform. That is,
the heat/pressure of the thermoform operation densifies the
`grind`. The process of `squeezing` or distorting via the
thermoform operation, results in an increase in the
surface-area-to-volume (S/V) ratio.
[0091] Thermoform-able materials may be categorized as `virgin`
(meaning materials which do not have a history) `post-industrial`
(meaning materials which were involved in a manufacturing process
but were not consumed) and `post-consumer` (meaning materials which
were completely used in the manufacture of an item which was sold
or consumed by another entity).
[0092] A specific to the present invention is the recycling of
post-consumer items consisting of relatively high percentages of
thermoform-able materials. Post-consumer recycle of solid waste has
been costly in execution. Recycling post-consumer plastic solid
waste has been particularly difficult to achieve. There are a
number of reasons for this inability in the present art, it lacks
economic methods to physically separate plastics of similar
specific-gravities but with different physical and or chemical
properties. Another reason is that post-consumer plastic solid
waste is frequently embedded with non-plastic materials which are
frequently uneconomic to be detectable.
[0093] The present invention relates to predetermined dimensional
structural composites and similar load carrying structural
elements. Such load carrying structural element design, advancing
the present art, address the following engineering characteristics:
(a) components that do not rust, corrode, or decompose when exposed
to fresh water and/or sea water and/or sewage and/or water-borne
creatures, plants, insects or other such, (b) components that do
not require special handling equipment on the installation
job-site, or factory floor, (c) Components that are easy to
transport to installation job-site, or factory floor, (d)
Components that allow for ease of handling and rigging, in
installation and or assembly applications, with other structural
element sections, (e) Components that do not require new expensive
installation equipment, (f) Components that allow for quick field
jointing or assembly with other structural element sections, (g)
Structural element sections which are certified and in use by state
agencies and approved for use by Federal and State Agencies, (h)
Components that allow the use of existing engineering design codes,
addresses pertinent engineering design consensus standards and
specifications, and (i) Composites' elements that are geometrically
similar in cross-section to that which they are intended to be
structural substitutes.
[0094] The present invention's economic vitality centers on three
aspects. First, full-scale testing of examples of the present
invention's physical expressions show that said examples provide
factors-of-magnitudes higher unit strengths than common grades of
un-reinforced recycled plastic with similar stiffness or load to
deflection ratios. As such, modest engineering design efforts will
result in significant reductions in the present invention's
materials-costs while providing the customer with equivalent
product utility,
[0095] Second, the present invention's physical manifestations, if
engineered to common un-reinforced recycled plastic engineering
characteristics, is of significantly lower mass (or weight)
resulting in lower transportation costs. And, third, the present
invention's significantly lower mass (or weight) results in easier
assembly or installation labor costs either in a factory
environment and or construction site.
[0096] Similar structural aspects are in play involving hardware
fastener applications such as screws, bolts and nails except that
shear is usually an initial structural failure mechanism, where
said failure is in the recycled plastic and not the fastener,
followed immediately with bending moment carried by the recycled
plastic element located between the point of initial shear failure,
usually located at or near the shank of the fastener some distance
from the surface of the recycled plastic element. Such structural
failure mode behavior provides some mitigation from catastrophic
structural failure when a given fastener/lumber-element connection
is loaded beyond its capacity.
[0097] The present invention's preferred embodiment is a
thermoformed structural-composite construct utilizing the
differential between certain materials' melt-point(s), said
different material(s) thermal-mass, thermal-energy-densities,
thermal-energy gradient(s) and structural integrity/stability in
said material(s) in the individual near-melt-point range vis-a-vis
pressure-heat ratio, consisting primarily of recycled
thermoplastics, thermoset plastics, and non-plastic materials.
[0098] The present invention's physical manifestations may be
addressed as thermoformed structural-composites constructed
utilizing the differential between certain materials'
melt-point(s), said different material(s) thermal-mass,
thermal-energy-densities, thermal-energy gradient(s) and structural
integrity/stability in said material(s) in the individual
near-melt-point range vis-a-vis pressure-heat ratio, consisting
primarily of recycled thermoplastics, thermoset plastics, and
non-plastic materials and directly reduced from grind-states to a
laminate film and or sheet and or plate-state.
[0099] An alternative preferred embodiment is as described above
with said thermoformed structural-composites constructed utilizing
the differential between certain materials' melt-point(s), said
different material(s) thermal-mass, thermal-energy-densities,
thermal-energy gradient(s) and structural integrity/stability in
said material(s) in the individual near-melt-point range vis-a-vis
pressure-heat ratio, consisting primarily of recycled
thermoplastics, thermoset plastics, and non-plastic materials and
directly reduced from grind-states to a laminate film and or sheet
and or plate-state which is reinforced via fibers, having an
average length greater than the composite's thickness, which are
tensioned before or during the manufacture of said composite.
[0100] An alternative preferred embodiment utilizes the
differential between certain materials' melt-point(s), said
different material(s) thermal-mass, thermal-energy-density,
thermal-energy gradient(s) and structural integrity/stability in
said material(s) in the individual near-melt-point range vis-a-vis
pressure-heat ratio. That is, if a first material A has a
melt-point of X, and if a second material B has a melt-point of
X+1, and a third material has a melt-point of X+2, for a given
`pressure`, then, by thermal-energy-management alone, the resultant
thermoformed product is deterministic.
[0101] If said materials A's, B's & C's thermal-gradient's
nature are known, for a given `pressure`, then by
thermal-energy-management alone, the length of time required to
thermoform the resultant product is deterministic. Design of such a
deterministic product may begin with material C placed in the
thermoform press, followed by material B placed on top of material
A, followed in turn with the placement of material A on top of
material B. For a given `pressure`, with the addition of
thermal-energy, A will reach its melt-point before B & C. If
not constrained, material A will `flow` past material B and
co-mingle with material C. The addition of more thermal-energy will
then cause material B to reach its melt-point and, if not
constrained, will co-mingle with the mixture of A & C.
[0102] Specific to this alternative preferred embodiment and
demonstrated viable by one of the present invention's co-inventors,
if material C is recycled nylon-fiber thread, and material B is
recycled post-consumer electronic-waste Acrylonitrile butadiene
styrene (ABS) plastic and material A is white (translucent) High
Impact Polystyrene (HIPS) then the resultant product is as
referenced above. That is, a structural composite consisting of
unmelted nylon-fiber thread encased in ABS plastic which in turn is
encased in white (translucent) HIPS.
[0103] A further refinement specific to this alternative preferred
embodiment, utilizes pre-heating the nylon-fiber providing a
thermal-mass lower than the nylon-fiber's melt-point but higher
than the ABS melt-point. This configuration allows the on-set of
ABS melt while the ABS insulates the HIPS material. Addition of
thermal-energy and pressure causes the ABS to flow and encase the
nylon before the HIPS melt-point is reached.
[0104] Specific to that configuration referenced above, the
resultant product has nylon-fiber density concentrated on the
structural-composite element's side opposite to the element's
concentration of HIPS on the other side. As such in an application
wherein the structural-composite element is subject to a
bending-moment, such as but not limited to, shelving, with the HIPS
surface up and the nylon-fiber concentrated surface down, the
tensile strength of the nylon-fiber will allow for a thinner panel
than otherwise.
[0105] Further, it has been observed that due to the migration of
the plastic flowing into and throughout the nylon-fiber, due in
part to the pressure aspects of the thermoforming process, said
nylon-fiber(s) are straightened and stretched out. Said tensioning
of said nylon-fiber(s) becomes `locked` if the plastic is allowed
to fully solidify before said pressure is released. The said
pretension-ing of the nylon-fiber and the resultant pre-compressing
of the plastic allows for higher than otherwise tensile loads on
the plastic items of the present invention's
structural-composite.
[0106] Specific to that configuration referenced above in this
alternative preferred embodiment, utilizing the process of
pre-heating the nylon-fiber providing a thermal-mass lower than the
nylon-fiber's melt-point but higher than the ABS melt-point, in
conjunction with or alternatively as a separate function, the HIPS
material may be pre-chilled so as to delay the on-set of the HIPS
thermal-gain and it reaching its melt-point.
[0107] It being noted that other materials and other materials'
geometry apply to the above. For example, the referenced
nylon-fiber may be substituted with fiberglass and or carbon-fiber
and or like materials. Such substitutions, in addition to the
originally mentioned nylon, may be used in different geometrical
configurations, such as but not limited to screens, grating, or
other micro-structural shapes.
[0108] Yet another alternative preferred embodiment utilizes the
differential between certain materials' melt-point(s) and the
requirement of well designed structural-composites for shear
transfer between opposing extreme fibers such that, if tensile-tear
is optimal, shear strength, for a given composite is greater than
compressive strength which in turn is greater than the composite's
tensile strength. It being a given that most recycled plastic
composites structurally fail catastrophically in compression and
most strata or laminates catastrophically fail in either
compression or shear or both.
[0109] This alternative preferred embodiment utilizes melt-point
differentials. Specific examples for the referenced embodiment may
include polyethylene terephthalate (PET), Nylon-fiber &
acrylonitrile butadiene styrene (ABS). Under atmospheric pressure,
PET melts at +/-480 degrees F., while Nylon-fiber melts at +/-500
degrees F. and ABS melts at +/-220 degrees F. It should be kept in
mind that thermoforming pressures, usually, significantly, reduce
melt-points and the use of recycled materials usually have some
`contaminates` which will move individual melt-points.
[0110] To achieve the desired structural-composite characteristics
of a failure-mode based on tensile-tear, rather than catastrophic
compressive or shear failure, a determination is made to the
quantity of nylon-fiber at the extreme-fiber and the distance to
the neutral axis, in the case of bending moment. The distance from
the extreme-fiber to the neutral axis determines the thickness of
the composite's core material which in this example consists of the
high melt-point recycled PET. To provide the significant shear
transfer, between extreme-fibers, required the referenced PET
material is presented to the thermoforming process with passages
which will allow migration, during the thermoforming process, of
the nylon-fibers which will sandwich the PET materials. Said
migration of the nylon-fibers will be encouraged by the melt of ABS
material which will sandwich the nylon-fibers and the PET core
materials.
[0111] Ingress of the nylon-fibers, through the referenced PET
material core's passages, put said migrated nylon-fibers in shear
with the application of a bending-moment on this embodiment of the
present invention. It can be seen that to achieve this embodiment
the operating temperature and pressure of the thermoform process
need only be such as to melt and cause flow of the lower melt-point
ABS material.
[0112] There are seven different identified types of plastic
usually involved in recycling activities plus a number of other
types of plastics and materials frequently encountered in
co-mingled waste-streams. Some of these, but not limited to,
materials addressed in the present invention are: (1) Polyethylene
Terephthalate (PET)--typical melt-point range +/-490 F to 510 F
(255 C to 265 C) PET density is greater than water. Recycled PET is
frequently used in such items such as textiles, carpets, fiber
fillings for apparel, audio cassettes, soft drink bottles, water
bottles, plastic jars, and some plastic wrappings, (2) High-Density
Polyethylene (HDPE)--typical melt-point range +/-250 F to 275 F
(120 C to 137 C). HDPE is frequently used in plastic milk cartons,
juice and liquid detergent containers. Recycled HDPE is used in
such items as plastic pipes, agricultural and plant containers,
trash cans and buckets, (3) Vinyl/Polyvinyl Chloride (PVC)--typical
melt-point range +/-212 F to 500 F (100 C to 260 C). PVC is
frequently used in piping, liquid detergent containers, food
wrappings and blister packaging. (4) Low-Density Polyethylene
(LDPE)--typical melt-point range +/-257 F to 278 F (125 C to 137
C). LDPE is frequently used in plastic bags and garment bags.
Recycled LDPE is frequently used in plastic trash bags, plastic
tubing and plastic lumber. (5) Polypropylene (PP)--typical
melt-point range +/-320 F to 330 F (160 C to 165 C). PP is
frequently used in the automotive industry, also for bottle tops,
battery casings and carpets. (6) Polystyrene (PS)--typical
melt-point range +/-365 F to 500 F (180 C to 260 C). PS is
frequently used in meat packing, protective packing and packing
foam. (7) OTHER: Usually layered or mixed plastic. Common examples
are headlight lenses and safety glasses; No recycling
potential--must be landfilled. (8) polyvinyl alcohol (PVA)--typical
melt-point range +/-356 F to 374 F (180 C to 190 C). (9)
Acrylonitrile butadiene styrene (ABS)--typical melt-point range
+/-218 F to 260 F (103 C to 128 C). (10) High impact polystyrene
(HIPS)--typical melt-point range +/-392 F to 500 F (200 C to 260
C). (11) polylactide (PLA)--typical melt-point range +/-302 F to
320 F (150 C to 160 C). (12) Nylon--typical melt-point range +/-428
F to 510 F (220 C to 265 C). (13) Polycarbonate (PC)--typical
melt-point range +/-510 F (+/-265 C). (14) Acrylic--typical
melt-point range +/-572 F to 600 F (+/-300 to 315 C). (15)
Fiberglass--typical melt-point range +/-2075 F (+/-1121 C).
[0113] Another, special case, is shape memory plastics (SMP). SMPs
are plastics which if deformed using heat and external force, and
then are allowed to cool-harden, when they are heated again they
return to their original shape. This is a typical characteristic in
plastics having a cross-linked structure. SMPs do not usually melt
so recycling them is difficult.
[0114] Those knowledgeable in the present art of recycling plastics
with or without `contaminates` will understand that equipment,
facilities and operations usually required to complete the
recycling process includes many and varied configurations. To name
but a few: air classifiers, mechanical classifiers, sink-float
tanks, hydrocyclones, froth flotation, dissolution, hydrolisys,
pyrolysis, laser spectral analysis, and electrostatic
separation.
[0115] The present invention avoids most of the expenses associated
with the above referenced. What is required is a typically
encountered operation known as mechanical grinding. Recycled
plastics are fed into mechanical grinders where they're ground into
flakes. Most post-consumer plastics, in addition to being of as
referenced above, a mixed plastic nature, collected for recycling
have traditionally nonrecyclable materials attached such as paper,
metal parts or glass. The product of such an operation is known in
the industry as "dirty" regrind. Traditionally, this material would
have to be "cleaned" in order to be recycled.
[0116] The above referenced `cleaning` operation usually first uses
air to remove materials lighter than plastic, such as paper labels.
The grit is then passed through scrubbers to materials such as
oils, glue residues and inorganic dust. The plastic grit is then
run through a "float/sink" tank(s) where heavier plastics heavier
than water sink and lighter plastics float.
[0117] The recovered plastic is usually re-melted and converted
into pellet form before being used in traditional
injection-molding, blow-molding or extrusion-molding.
[0118] FIG. 1 illustrates the process of forming an embodiment of a
thermoformed composite. Upper plate 1 and lower plate 2 hold a
matched die set having a male segment 3 and a female segment 4.
Addressing FIG. 1, from left to right, the left-most plates 1 and 2
hold the matched die set 3 and 4. A thermoform-able material 5,
which in the present art is frequently pre-heated, is placed
between die set 3 and 4. Through heat and pressure, thermoform-able
material 5 is converted into the desired end-shape.
[0119] The desired shape may be flat, V-shaped, rounded, or any
other bent or molded shape. Different die sets are used to achieve
the different desired shapes. The thermoform-able material 5 is
removed from the die set once it has completely cooled. It should
be noted that the term "thermoform-able" is used here as reference
to specific material(s) melt-point for a given thermal-mass plus
pressure.
[0120] FIG. 2 illustrates the process of forming an embodiment of a
thermoformed composite. The process of FIG. 2 is similar to the
process of FIG. 1. Plates 1 and 2 hold the matched die set 3 and 4.
Unlike FIG. 1, that demonstrates a single they material 5, FIG. 2
shows three distinct materials 5, 6 and 7. Through the
thermoforming process of heat and pressure, materials 5, 6 and 7
are structurally laminated into a finished desired product.
[0121] This thermoforming process is sometimes known as the
`strata-process`. As the term `strata-process` implies the
`laminated` together materials retain their individual structural
integrities. That is, for example as shown in FIG. 2, the
thermoforming process of materials 5, 6 and 7 provides the intended
results of two distinct shear-planes. Said two distinct
shear-planes being that structural interface between materials 5
and 6 and materials 6 and 7.
[0122] FIG. 3 illustrates the process of forming an embodiment of a
thermoformed composite. The process of FIG. 3 is similar to the
process of FIG. 1. Addressing FIG. 3, from left to right, the
left-most plates 1 and 2 hold the matched die set 3 and 4. Similar
to FIG. 2, FIG. 3 shows three distinct materials 5, 6, and 7 which
through the thermoforming process of heat and pressure are
structurally melded into a single finished desired structural
composite 8. Composite 8 is a product without defined distinct
shear-planes.
[0123] An example of this process is the pre-thermoforming
sandwiching of a fiber material such as nylon fiber and or
fiberglass strand and or carbon-fiber material 6 having a
melt-point higher than the material(s) 5 and 7. The invention's
thermoforming operation elevates the thermal-mass of material(s) 5
and 7 to or above the melt-point of material(s) 5 and 7 but does
not approach the melt-point of the fiber material 6. Through the
invention's thermoforming process, materials 5, 6 and 7 merge
together to form a single structural entity 8 without distinct
shear-planes.
[0124] FIG. 4 illustrates the process of forming an embodiment of a
thermoformed composite. The process of FIG. 4 is similar to the
process of FIG. 1. FIG. 4 is similar to FIG. 3 but with the
addition of material 9. Plates 1 and 2 hold the matched die set 3
and 4. As in FIG. 3, FIG. 4 shows three distinct materials 5, 6 and
7 which through the thermoforming process of heat and pressure are
structurally melded into a single finished desired structural
composite 8. Composite 8 is a product without defined distinct
shear-planes.
[0125] FIG. 4 also shows referenced material 9. The present
invention allows the use of material which has not been pre-formed
into sheets and or plates. The present invention allows the
formation of a combination of a single structural composite 8 with
a strata material 9 having a distinct shear-plane.
[0126] FIG. 5 illustrates the process of forming an embodiment of a
thermoformed composite. The process of FIG. 5 is similar to the
process of FIG. 1. FIG. 5 is similar to FIG. 4 except that material
9 is of a different nature. Materials 5, 6, and 7 and material 9
are thermoformed such that the present invention's thermoforming
operations melds with materials 5 6 and 7 and material 9 to form a
single structural entity 10 without distinct shear-planes.
[0127] FIG. 6 illustrates the process of forming an embodiment of a
thermoformed composite. The process of FIG. 6 is similar to the
process of FIG. 1. FIG. 6 is similar to FIG. 5 but without any
pre-formed sheet materials 5, 6 and 7 as depicted in other previous
FIGURES. Material 9 is thermoform-able material(s) or
thermoform-able materials(s) and non-thermoform-able material(s)
mixture. The present invention's direct reduction of material 9 to
a single structural entity without distinct shear-planes, reduces
direct materials costs.
[0128] Examples include thermoform-able recycled post-consumer
electronic-waste ABS plastic grind and or recycled nylon fiber,
recycled polypropene and/or the like. Mixtures of thermoform-able
and non-thermoform-able grind may include non-thermoform-able
materials such as titanium dioxide, ceramic dust, metal filings,
marble dust, shale flake and/or the like. It should be noted that
the terms "thermoform-able" and "non-thermoform-able" are used here
as reference to a specific material's melt-point for a given
thermal-mass plus pressure. As such, for example, a mixture of ABS
grind with nylon fibers and a thermoform operating effective
temperature higher than the melt-point for a chosen ABS but lower
than the melt-point for a chosen nylon would by definition have the
nylon to be considered "non-thermoform-able" material(s) for the
example's mixture.
[0129] FIG. 7 illustrates the process of forming an embodiment of a
thermoformed composite. The process of FIG. 7 is similar to the
process of FIG. 1. FIG. 7 is similar to FIG. 6 but with
structural/micro-structural elements 11 included with the
afore-referenced recycled grind material(s) 9. Said structural
elements 11 may include recycled fiberglass air filter structures,
recycled spent industrial filter structures, recycled plastic
extrusion, metallic and metallic/plastic screens, and or scraps of
such and similar screening and such for the purpose of forming a
single structural entity without distinct shear-planes.
[0130] Now referring to FIG. 8, a flowchart illustrates the
production process. Various sources are gathered into a
pre-processing facility 811 or a warehouse or sorting facility 812.
Pre-processing facility 811 may be used for size reduction or
cleaning if needed. Some of the various material sources may be:
(801) EScrap or Auto scrap recycler Polymer related and or textile;
(802) Textile recycler that includes PET, Nylons from carpet,
clothing or seating; (803) C&D or Glass Recycler-fiber,
granules or matting; (804) Waste firms, recyclers and WTE plants,
any source of waste, packaging, materials handling, or industrial
by-products.
[0131] The material is retrieved from the pre-processing facility
811 or warehouse facility 812 and brought to a production facility
820. The production facility 820 uses presses to create sheets or
blanks. Further processing such as thermoforming, cutting,
painting, silk screening or laser etching may also be
performed.
[0132] After production, the new sheets or blanks are sent out of
the production facility 820 to be used for various products. Some
of these products consist: (830) Sign market or Wayfinders, which
includes ADA compliant signage, Thermoformer, or other value add
processors; (831) barrier applications such as paneling or sea
wall/casement; (832) highway signage and other outdoor vehicle and
pedestrian signage (e.g. stop signs, parking signs, etc.).
[0133] Many sources may be used for the material. Primary sourcing
are certified EScrap recovery facilities such as MBA Polymers,
GEEP, MEXTEK, CEAR, SIMS and others. By sourcing polymers generated
from these EScrap recovery locations, a new end usage is being
created for this problematic scrap. In addition, other non polymer
material, especially glass from CRT monitors, are hoped to be
included as part of the composite recipe, once deemed safe. If
safety cannot be assured, the other glass sourcing mentioned, will
suffice.
[0134] These recovery processes are mandated and policy driven
under producer responsibility policies or as part of landfill
diversion requirements around the world. The shortage of many
materials in the EScrap stream drive the overall recovery efforts.
In so doing, the larger volume materials are ignored. This is
comparable to the illegal poaching of rare species such as Rhinos
in order to get the horn, but leave the carcass of the rest of the
animal to waste. We help provide and support the legitimate
recovery of materials domestically and around the globe.
[0135] Similar materials are also able to be recovered from auto
scrap, packaging and consumer goods. Other material sourcing as
part of the composite recipe include glass fibers recovered from
building insulation or made from recovered glass from packaging,
old insulation, CRT glass, or other post consumer glass fiber
sourcing.
[0136] Such programs are often part of a closed loop process by the
OEM'S of the glass products or from waste firms as part of their
waste contracts. Examples would be Owens Corning, Waste Management,
Johns Manville, and CertainTeed who need recovery of these
materials to meet internal corporate pledges (CSR) or as part of a
requirement in order to sell new materials. The composite disclosed
herein is a value added alternative to landfill and improper
disposal.
[0137] The other component materials are recovered from post
consumer textile waste; specifically flooring waste and or carpet.
The key materials recovered from this sourcing channel are nylon
(polyamide) waste, PP (polypropylene) waste or PET waste. The
fibrous components of these materials lend themselves to helping
create a matrix type structure during the melting and forming of
the composites.
[0138] In addition, these materials can also be pre melted to form
a base material or pelletlflake/chip, that can be used in the
composite structure as well. Other flooring components such as PVC
will play a role in composites where the end market will allow PVC
content or prefers it. PVC has an inherently flame retardant
quality that lends itself to certain applications other materials
do not provide. Since, it is also available as a post consumer
material in large supply, we see it as an interchangeable option as
needed.
[0139] In referring to the EScrap supply earlier, we also have
incorporated PVC wire strippings from EScrap recovery facilities or
auto scrap/metal scrap plants. This is another highly problematic
scrap where our composite helps to provide an effective alternative
solution to landfill, burning or illegal disposal.
[0140] These post consumer waste materials are all then shipped to
a central location in various forms: bales of fiber, chips or
pellets primarily. They can also be entire parts that we can
process ourselves if need be. After these materials arrive at the
centralized location, various blending methods. This can range from
hand blending in a bucket to large batch blending in industrial
blending equipment to meet volume needs.
[0141] The blending of these large distinctive and problematic
waste streams have not been done before and offer a unique set of
properties and performance that add value and offer a value added
non landfill or non incineration option heretofore not previously
performed. Further refining and blending is accomplished at the
hydraulic press or mechanical press. It is at that point, that
layering of the materials and or the dispersion of materials in a
mold of various shapes can be performed. These layers allow for the
melt differentials or similarities to complement each other in a
unique and performance enhancing fashion.
[0142] A similar example might be the way concrete is laid down
using rebar and or fiber additives. Certain systems for charting
carbon fiber composites use a sheet process built layer upon layer
under heat. The composite disclosed herein uses unique combinations
of waste materials that each contribute to adding strength, flame
retardancy, impact or temperature tolerance improvement and
improved weather-ability in order to create a finished sheet
products to be used in various end applications as is, or to be
submitted for further processing such as thermoforming, cutting,
painting, silk screening or laser etching.
[0143] FIG. 9 illustrates various materials combined prior to
production. Layered above a material sheet 900, are a fiberglass
layer 901 and foam or wood layer 902. Other materials may also be
used in place of the layers. Sheets of different materials may also
be used as long as they provide a solid outer layer that helps the
layered materials retain a sturdy shape while pressed during
production.
[0144] FIG. 10 illustrates various materials combined prior to
production. Layered above a material sheet 1000, are a fiberglass
layer 1001 and foam or wood layer 1002. The layered materials 1001
and 1002 may be arranged in a pre-determined shape. The shape
depicted in FIG. 10 is an octagon shape (e.g. stop sign). Other
materials may also be used in place of the layers. Sheets of
different materials may also be used as long as they provide a
solid outer layer that helps the layered materials retain a sturdy
shape while pressed during production.
[0145] FIG. 11 illustrates various materials combined prior to
production. Layered above a material sheet 1100, are various forms
of string, yarn and thread 1101. Other materials may also be used
in place of the layers. Sheets of different materials may also be
used as long as they provide a solid outer layer that helps the
layered materials retain a sturdy shape while pressed during
production.
[0146] FIG. 12 illustrates various materials combined prior to
production. Layered above a material sheet 1200, are various forms
of string, yarn and thread 1201. Other materials may also be used
in place of the layers. Sheets of different materials may also be
used as long as they provide a solid outer layer that helps the
layered materials retain a sturdy shape while pressed during
production.
[0147] FIG. 13 illustrates various materials combined prior to
production. Layered above a material, sheet 1300, are various forms
of string, yarn and thread 1301. Another material sheet 1305 is
placed on top the string/yarn/thread layer 1301. Material sheets
1300 and 1305 cooperate to sandwich the string/yarn/thread layer
1301. Other materials may also be used in place of the layers.
Sheets of different materials may also be used as long as they
provide a solid outer layer that helps the layered materials retain
a sturdy shape while pressed during production.
[0148] FIG. 14 illustrates an exemplary press used to produce the
finished composite sheet. The press is known in the art and
provides equally dispersed pressure along the top and bottom of the
sheet. This equally dispersed pressure ensures the sheet has equal
thickness throughout its planar axis. Preferably, the press uses a
hydraulic pressure to compress the layers. If thermoforming, an
intense heat is also used to thermally "melt" the layers together
and create a single bonded layer
[0149] FIG. 15 illustrates a thermoformed composite after
production. The composite comprises material sheet layers and a
string/yarn/thread layer. The layers have been compressed together
and heated to create a single composite sheet. The new composite
sheet comprises the strengths of the individual layers from the
pre-production. The new composite sheet may be further shaped and
formed into a pre-determined shape to be used for signage,
paneling, etc. The new composite sheet is designed to be lighter,
stronger, and more eco-friendly than the conventional signage
material. The inherent, yet unique qualities, such as impact
properties, flame retardancy, rigidity, cold crack resistance and
melt variances each contribute to end properties that allow for
uses that are not achievable if each material were to be used on
its own.
[0150] FIG. 16 illustrates a thermoformed composite after
production. The composite comprises material sheet layers and a
string/yarn/thread layer. The layers have been compressed together
and heated to create a single composite sheet. The new composite
sheet comprises the strengths of the individual layers from the
pre-production. The new composite sheet may be further shaped and
formed into a pre-determined shape to be used for signage,
paneling, etc. The new composite sheet is designed to be lighter,
stronger, and more eco-friendly than the conventional signage
material. The inherent, yet unique qualities, such as impact
properties, flame retardancy, rigidity, cold crack resistance and
melt variances each contribute to end properties that allow for
uses that are not achievable if each material were to be used on
its own.
[0151] FIG. 17 illustrates a thermoformed composite after
production. The composite comprises material sheet layers and
another material layer. The layers have been compressed together
and heated to create a single composite sheet. The new composite
sheet comprises the strengths of the individual layers from the
pre-production. The new composite sheet may be further shaped and
formed into a pre-determined shape to be used for signage,
paneling, etc.
[0152] In FIG. 17, the composite sheet has been cut and shaped into
a square. Other shapes are also allowable. The new composite sheet
is designed to be lighter, stronger, and more eco-friendly than the
conventional signage material. The inherent, yet unique qualities,
such as impact properties, flame retardancy, rigidity, cold crack
resistance and melt variances each contribute to end properties
that allow for uses that are not achievable if each material were
to be used on its own.
[0153] FIG. 18 illustrates a perspective view of a thermoformed
composite after production. The composite comprises material sheet
layers and another material layer. The layers have been compressed
together and heated to create a single composite sheet. The new
composite sheet comprises the strengths of the individual layers
from the pre-production. The new composite sheet may be further
shaped and formed into a pre-determined shape to be used for
signage, paneling, etc.
[0154] In FIG. 18, the composite sheet has been cut and shaped into
a square. Other shapes are also allowable. The new composite sheet
is designed to be lighter, stronger, and more eco-friendly than the
conventional signage material. The inherent, yet unique qualities,
such as impact properties, flame retardancy, rigidity, cold crack
resistance and melt variances each contribute to end properties
that allow for uses that are not achievable if each material were
to be used on its own.
[0155] FIG. 19 illustrates a thermoformed composite after
production. The composite sheet has been shaped into an octagon
form. The new composite sheet is designed to be lighter, stronger,
and more eco-friendly than the conventional signage material. The
inherent, yet unique qualities, such as impact properties, flame
retardancy, rigidity, cold crack resistance and melt variances each
contribute to end properties that allow for uses that are not
achievable if each material were to be used on its own.
[0156] FIG. 20 illustrates a thermoformed composite after
production. The composite sheet has been shaped into a square sign.
The sign includes graphics and lettering that is formed during the
thermoforming process. This is done by having the graphic and/or
lettering as part of a negative imprint of the press dies. This
allows the layered materials to not be fully compressed in the
negative imprint areas while completely compressed in the
non-negative imprint areas.
[0157] Negative imprints in the dies are common to the art of
molding and casting. The new composite sheet is designed to be
lighter, stronger, and more eco-friendly than the conventional
signage material. The inherent, yet unique qualities, such as
impact properties, flame retardancy, rigidity, cold crack
resistance and melt variances each contribute to end properties
that allow for uses that are not achievable if each material were
to be used on its own.
[0158] The invention uses a unique combination of materials
recovered from various waste streams or recycling processes to
create various recipes and formulas to serve a variety of end
markets. The combinations from these unrelated sources and material
types are combined and formed, using thermoforming and hydraulic
pressure to create composites not currently available. They also
divert materials from landfills or illegal disposal in to a value
added series of products such as signage, sheet and board type
products for the disability community, military or government
sector and transportation markets.
[0159] The inherent, yet unique qualities, such as impact
properties, flame retardancy, rigidity, cold crack resistance and
melt variances each contribute to end properties that allow for
uses that are not achievable if each material were to be used on
its own. Energy, emissions and water savings from the use of such
materials have also been documented in various life cycle studies
by the EPA and NGO's. Thereby making these materials and/or end
products suitable for numerous environmental credits; LEED, Carbon
offsets and diversionary credits.
[0160] As in the claims above to include the use of a `foaming`
material `mixed` with the above referred thermoform-able `grind`
allows the deterministic nature of a `foaming` material to provide
and or enhance the `pressure` aspect of commonly encountered
thermoform operations. Such `foaming` material(s) may be
`triggered` to `foam` before, during, or after the thermoforming of
the desired structural-composite. In the use of foaming materials,
the activation of the foaming action can be designed to occur
before, during, and or after thermoforming the intended structural
composite. Activation of the foaming action after the construction
of the structural composite allows intended results such as
internal pressurizing of said structural composite.
[0161] It will be apparent to those skilled in the art, that is, to
those who have knowledge or experience in this area of technology
that many uses and design variations are possible for the invention
disclosed herein. The above detailed discussion of various
alternative and preferred features and embodiments will illustrate
the general principles of the invention. Other embodiments suitable
for other applications will be apparent to those skilled in the art
given the benefit of this disclosure. The particular combination of
parts described and illustrated herein is intended to represent
only certain embodiments of the present invention.
* * * * *