Method for producing a building material form a mixture of unscr

Details Method for producing a building material form a mixture of unscr Method for producing a building material form a mixture of unscr

1996-04-01

1997-10-14

Theisen, Mary Lynn

Plastic and nonmetallic article shaping or treating: processes

Forming articles by uniting randomly associated particles

Stratified or layered articles

264122, 264DIG69, B29C 3502, B29C 4302

Patent

active

056768958

DESCRIPTION:

BRIEF SUMMARY
The invention relates to a method for producing a building material from a mixture of unscreened thermoplastic waste and mineral, preferably mineral aggregate, in which method the crushed and/or screened mineral and plastic waste are washed, whereafter the mineral is heated to a predetermined temperature, and a given amount of plastic granules or plastic flakes made from the unscreened thermoplastic waste is mixed with the heated mineral, and the resulting mass is pressed into building elements.
In connection with this invention, unscreened thermoplastic waste means all types of plastics that melt when heated and solidify when cooled, can be remelted and thereby made usable. Thermoplastic waste is today recyclable if it is screened. However, this application presents a method in which unscreened thermoplastic waste can be used as secondary raw material. In connection with this invention, mineral aggregate means crushed aggregate or macadam made of natural stone, gravel, sand, or gypsum waste or other mineral or expanded clay as well as crushed brick or crushed concrete, which is municipal or industrial waste and which has been screened into given grain sizes.
A method of this kind is previously known for example in connection with producing road surfacing material, which is disclosed in the publications WO 90/00161 and FR 2 563 212, for example. In the known method, plastics are mixed with heated mineral aggregate, using predetermined additives and plasticizers, with the purpose of affecting the behaviour of the above mentioned mixture of plastics and mineral aggregate. The plastics are of predetermined grade and type, and thus this method does not utilize plastic waste.
The publication SE 450 572 also discloses a method for manufacturing a building material which consists of a mixture of mineral aggregate and cement and to which plastic granules have bean added without melting them. Slabs and pipes, for example, are made from this mixture by casting.
The publication DE 3 837 430 also discloses a method in which products are manufactured from a mixture of mineral aggregate and acrylic plastic by casting or injection.
The plastic raw materials used in the above mentioned and known production methods are unused or equivalent new materials, and they are primarily intended to increase the demand for plastics and to expand various uses of plastics.
In addition to the above, the publications NL 8 200 730 and JP 72 044 542 disclose a method in which waste or recycled plastic is utilized by mixing the same with hot mineral aggregate and thus forming a mass suitable for use as a building material.
One of the major problems with the present thermoplastic waste reclaimed for secondary use is that only certain types of thermoplastic waste are reclaimed. A secondary raw material made from specific clean thermoplastic waste also replaces new thermoplastic raw material to a high extent. Secondary use of thermoplastic waste is restricted by important factors such as whether the reclaimed thermoplastic waste contains only one type of thermoplastic, whether it consists of reclaimed thermoplastic of uniform good quality, and what kind of products can be manufactured therefrom. If the above questions concerning thermoplastics cannot be answered satisfactorily or if it is not known what kind of products can be manufactured from the reclaimed raw material, the reclaimed thermoplastic is plastic waste unsuitable for secondary use by the plastics industry, and as such it today ends up loading the capacity of dumps. There is no secondary use for unscreened thermoplastic waste, because the reclaimed raw material to be used contains such mutually incompatible types of plastics as cause problems in manufacturing processes in the plastics industry. Problems occurring in the manufacturing process include gassing and the relative effect of different types of plastics having different viscosities at the same temperature. One of the most difficult problems with the secondary use of unscreened, reclaimed thermoplastic waste is to combine t

REFERENCES:
patent: 5124125 (1992-06-01), Brent
patent: 5401452 (1995-03-01), Lubowitz
patent: 5439625 (1995-08-01), Schmidt
patent: 5500174 (1996-03-01), Scott
Derwent Abstract of NL-A-8200730.
Derwent Abstract of WO 93/14154.

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