Method of making composite tiles containing waste plastic

Details Method of making composite tiles containing waste plastic Method of making composite tiles containing waste plastic

1994-08-12

1998-04-21

Ahmad, Nasser

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

Composite article making

264 457, 264112, 264122, 264250, 264310, 2642711, 2642791, 26437816, 26437817, 428 99, 4289044, B29C 4513

Patent

active

057414548

DESCRIPTION:

BRIEF SUMMARY
BACKGROUND OF THE INVENTION

This present invention concerns a manufacturing process and a composite tile of plastic material obtained by said process.
The plastic materials composed of the waste of some industrial processes (for example in the shoe-making sector), and/or coming from plastic objects of current use being put out of use, are frequently crushed to be used again in subsequent transformations.
The latter recovery operation, however, is not always cost-effective and possible as the crushed material in some cases assumes such poor properties that it is not possible to use it again not even in the manufacture of low quality products.
As a consequence of this it is known that much plastic waste is accumulated in landfills, causing considerable storage problems as it cannot be burned due to the environmental pollution that would ensue from its combustion process.
The purpose of this present invention, as characterised by its claims, is therefore to eliminate the above mentioned drawbacks.


BRIEF DESCRIPTION OF THE INVENTION

The invention solves the problem of making, by means of a suitable manufacturing process, a composite tile in which plastic material of a suitable quality for the environment in which the tile will be used is injected into a mould so as to form an outer shell of the tile, inside which, at a later stage, waste plastic material is injected with the function of filling the tile.
The fundamental advantage obtained by this present invention lies in the fact that waste plastic materials, not directly reusable, are cost-effectively re-used with a considerable reduction in the problems of environmental hazards caused by their accumulation in landfills.
Moreover the amount of plastic material of greater value, forming the outer layer of the tile, can be reduced to a minimum thereby contributing to reduce the ever growing demand for plastic materials of the first transformation with the benefit of containing energy consumption and primary resources that are normally used for the manufacture of plastic materials.
Additional advantages and characteristcs of the process and of the product in accordance with the invention will be highlighted in the following detailed description and with the aid of drawings given purely by way of example and not as a limit, in which:


BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 illustrate two operative stages of the manufacturing process for said tiles;
FIG. 3 illustrates one form of making the tiles according to the invention;
FIG. 3A shows a detail af a variant made on the tile of FIG. 3;
FIG. 4 illustrates a cross-section, made along the section line IV--IV, of the tile of FIG. 3;
FIG. 5 shows a detail of a possible variant made on the tile of FIG. 3.


DETAILED DESCRIPTION OF THE INVENTION

With reference to the figures notice that the invention essentially consists of a manufacturing process of a composite tile (5) (FIGS. 3,4) made of plastic material provided with one outer layer (4) made of quality first transformation plastic material, i.e., virgin material, with suitable properties for its use, arranged so as to surround a second layer (7) of plastic material, preferably waste plastic, formed on the inside. The side (8) and on the outer edges (9) hide the second layer (7), inside the body of the tile (5).
The process comprised the following operative stages: a primary punch (1A) and a matrix (2) associated to enable the formation of the first layer (4) of the tile (5) between them; matrix (2) and of the primary punch (1A); in its association with the matrix (2), between the first layer (4), supported by the matrix (2) and the secondary punch (1B), a cavity (6) to contain the waste thermoplastic material; formation of a second layer (7) of plastic material arranged inside the tile (5).
The plastic material forming the first layer (4), formed on the outside, of the tile (5) is made so as to have features suited to the environment where the tile (5) has to be used.
For this purpose, for instance, it may be made of non-toxic and washable material

REFERENCES:
patent: 3328499 (1967-06-01), Barnette
patent: 3457133 (1969-07-01), Barnette
patent: 3519525 (1970-07-01), Jackstadt
patent: 3800016 (1974-03-01), Roberts
patent: 4401050 (1983-08-01), Britt et al.
patent: 4795603 (1989-01-01), Nagayasu
patent: 4942072 (1990-07-01), Chung
patent: 5075057 (1991-12-01), Hoedl
patent: 5514310 (1996-05-01), Sander

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