Abstract: Disclosed herein is a method for recycling synthetic turf that includes agglomerating a plurality of synthetic turf fragments and extruding the agglomerated material. The method produces a recycled material suitable for use as infill in a synthetic turf. Accordingly, an infill for synthetic turf and a synthetic turf including that infill are also disclosed herein.

Abstract: This invention is to an improved method for cleaning contaminated polymer when that polymer is to be blended with clean material. The method involves combining the contaminated material and the clean material in a compartmentalized pellet wherein the contaminated material is placed in the outermost compartment, the clean material is placed in an inner compartment and then subjecting the pellet to an extraction process.

Abstract: Methods using solid-state shear pulverization and melt mixing and related polymer-carbon nanotube composites, as can be used to affect various mechanical and/or physical material properties.

Abstract: Methods using solid-state shear pulverization and melt mixing and related polymer-carbon nanotube composites, as can be used to affect various mechanical and/or physical material properties.

Abstract: A molded article such as a floor tile is made from recycled carpet waste which includes a polyvinyl chloride component in the backing material and fiber component having a melting point above the melting point of polyvinyl chloride. A mixture of the recycled carpet material is shredded and additional polyvinyl chloride is fed to an extruder where the polyvinyl chloride is melted without melting the carpet fibers. The resulting mixture is discharged and molded, such as by injection molding, to form a molded product. The molded product includes a continuous matrix of polyvinyl chloride having recycled carpet fibers uniformly dispersed therein. The molded article contains about 45% to about 85% of polyvinyl chloride, about 5% to about 20% of recycled carpet fibers, up to about 5% of a plasticizer and up to about 5% of an ethylene copolymer by weight based on the total weight of the product.

Abstract: This invention is to an improved method for cleaning contaminated polymer when that polymer is to be blended with clean material. The method involves combining the contaminated material and the clean material in a compartmentalized pellet wherein the contaminated material is placed in the outermost compartment, the clean material is placed in an inner compartment and then subjecting the pellet to an extraction process.

Abstract: A method of forming a reinforced building product from garbage, comprising the steps of sorting garbage, shredding plastics within the garbage, shredding fibers within the garbage, heating the shredded plastics, forming a slurry from the plastics and fibers, disposing the slurry within an extrusion cavity, extruding the fluid through a venturi, and allowing the extruded materials to cool. Garbage is separated into plastics, fibers, and other materials. Plastics are shredded to facilitate melting. Fibers are shredded to macroscopic lengths no greater than a maximum internal diameter of a venturi. The plastics are melted. The melted plastics are mixed with fibers and other material to form a slurry that is extruded from a cavity through a venturi, thereby causing significant alignment of the shredded fibers within the slurry in an outer region of the extruded slurry. Cooled, there is reinforced building material.

Abstract: A process is described for production of a biaxially oriented film which comprises at one crystallizable thermoplastic as main constituent and comprises at least 500 ppm, based on the weight of thermoplastic, of a pigment. The production process uses at least 20% by weight, based on the weight of the film, of recycled material of the same type whose molecular weight has been increased by condensation processes.

Abstract: A method for producing a composite product including a substrate material and a binder, wherein either the binder includes a plastics material in an emulsion form, or a plastics material is added to an emulsion including the substrate material. The invention is also directed to composite products including a particulate substrate and particles of a plastics material therein.

Abstract: There is provided a treatment method of efficiently separating an additive component from a resin component for the purpose of treating and recycling a thermoplastic resin composition containing an additive. The treatment method includes heating and agitating the thermoplastic resin composition containing the additive together with a solvent for dissolving at least part of the additive at a temperature ranging from the glass transition temperature of the thermoplastic resin to the boiling point of the solvent inclusive, and separating and recovering the solvent in a liquid state in which at least part of the additive is dissolved, so that at least part of the additive is separated and removed from the thermoplastic resin composition.

Abstract: Invention relates to a process for producing a single-layer or multilayer film by extrusion or coextrusion, biaxial orientation, and heat setting based on crystallizable thermoplastics whose principal constituent is a crystallizable thermoplastic having a standard viscosity SV (DCA) of from 600 to 1000. The thermoplastic is mixed prior to extrusion or coextrusion with 50% by weight (based on the total weight of all thermoplastics) of a secondary thermoplastic having a standard viscosity SV (DCA) of more than 900 to 1500, the standard viscosity SV (DCA) of the two thermoplastics differing by at least 100 units. The secondary thermoplastic is a byproduct or waste product from the production of PET plastic bottles or originates from recycled PET bottles.

Abstract: A method of making plastic materials, such as plastic lumber, wherein recyclable plastics are sorted into at least two categories and the recyclable plastics in each category are then shredded and chipped, extruded, and mixed with selected colour concentrates to produce the plastic materials of a selected colour. This invention allows for the control of the selected colour to enable replication of such colour of the plastic materials, regardless of any variation in colour of the recycled plastics in each category.

Abstract: A granular material for use as a filter in the purification of sewage. The granular material is comprised of pre-sorted and cleaned plastic material wastes. A process for producing the same is provided.

Abstract: A durable erosion control blanket featuring a novel synthetic fiber filler is disclosed. The erosion control blanket of the present invention addresses the need for a particularly resilient erosion control blanket through the use of a post-consumer, crimped, polyester fiber filler material. In one embodiment, the post-consumer fiber material is of polyethylene terephthalate (PET) readily available in post-consumer form from the recycling of soda bottles. In short, a preferred filler material for the blanket of the present invention would utilize recycled soda bottle material which has been converted into a crimped, highly-resilient fibrous filler. It is, thus, possible to achieve the desired physical and mechanical properties in the erosion control blanket of the present invention while conserving natural resources to some extent by using a readily available post-consumer polymer material.

Abstract: The present invention relates to a molded article laminated with fabric wherein a thermoplastic resin (A) has a fabric, made up of fibers of a highly heat resisting thermoplastic resin (B), adhered to the surface thereof, wherein the thermoplastic resin (A) of the molding contains the highly heat resisting thermoplastic resin (B) constituting the fibers and wherein the highly heat resisting thermoplastic resin (B) is present as a microdispersion of melt-blended minute particles in the thermoplastic resin (A), and a method not only for reprocessing the mold flashes at the time of the preparation of molded articles laminated with fabric but also for reprocessing the defective molded articles laminated with fabric which come from the production line and are destined to be discarded.

Abstract: Coated moldings coated, on surfaces of moldings, with paint constituted of a thermoplastic resin having affinity for a thermoplastic resin used as a main constituent of the moldings. Method and apparatus for recycling the coated moldings are also described in which the coated moldings are crushed by means of a crusher and the crushed moldings are molded in a mold to provide fresh moldings, followed by coating, by means of a coating device, the fresh moldings on surfaces thereof with a paint constituted of a thermoplastic resin having affinity for the thermoplastic resin for the moldings.

Abstract: The invention relates to a recycled ABS resin. The recycled ABS resin is obtained by recycling an ABS resin formed into parts by injection molding of a virgin material thereof and used mainly in electric and electronic equipments.

Abstract: The invention provides, as a method for producing a multi-layer foamed sheet whose scale-like appearance has been improved by means of a multi-layer circular die coextrusion method, a method for producing a multi-layer foamed sheet having foam layers and non-foam layers by a multi-layer circular die coextrusion method which is a method for producing a multi-layer foamed sheet wherein the shear stress at the interface of each layer is 5000 Pa or higher and not higher than 50000 Pa, a method for producing a multi-layer foamed sheet wherein the resin of said non-foam layer is a linear propylenic resin having a melt flow rate of 5 to 30 g/10 minutes, and a method for producing a multi-layer foamed sheet wherein the resin of said foam layer is a propylenic resin whose melt tension (MT) at 190° C. and melt flow rate (MFR) at 230° C. satisfy the following equation A: MT?7.52×MFR (?0.

Abstract: A durable erosion control blanket featuring a novel synthetic fiber filler is disclosed. The erosion control blanket of the present invention addresses the need for a particularly resilient erosion control blanket through the use of a post-consumer, crimped, polyester fiber filler material. In one embodiment, the post-consumer fiber material is of polyethyleneterephthalate (PET) readily available in post-consumer form from the recycling of soda bottles. In short, a preferred filler material for the blanket of the present invention would utilize recycled soda bottle material which has been converted into a crimped, highly-resilient fibrous filler. It is, thus, possible to achieve the desired physical and mechanical properties in the erosion control blanket of the present invention while conserving natural resources to some extent by using a readily available post-consumer polymer material.

Abstract: In a process for upgrading cleaned used plastic material to be reclaimed, all steps are performed in a continuous way so as to extrude continuously the plastic material to provide elongated strands thereof, cutting the strands continuously as they are supplied by extrusion to convert them into pellets. Then, the pellets are fed without any intermediate storage to a continuous crystallizer in a stream of hot gas to heat the pellets to crystallizing temperature.

Abstract: A method of making polymeric particulates wherein polymeric scrap material, virgin polymeric material and mixtures thereof are supplied to intermeshing extruder screws which are rotated to transport the polymeric material along their length and subject the polymeric material to solid state shear pulverization and in-situ polymer compatibilization, if two or more incompatible polymers are present. Uniform pulverized particulates are produced without addition of a compatibilizing agent. The pulverized particulates are directly melt processable (as powder feedstock) and surprisingly yield a substantially homogeneous light color product. The pulverized particulates also can be more intimately mixed than mixtures which are provided by only melt mixing, and can be melt processed without a significant delay in achieving phase inversion. The pulverized particulates also provide a stable microstructure.

Abstract: A front cover, a rear cover and a base portion are crushed into a crushed material, and further pelletized into a recycled plastic pellet. The recycled plastic pellet is used as a part of a molding material to produce mold plastic parts for a photosensitive material. When the molding material is melt in heat, a thermoplastic resin is deteriorated by heat or modified. Therefore, properties and qualities of recycled plastic mold parts are less than those of new ones. Further, when the thermoplastic resin is deteriorated by heat, the photosensitive material reacts with the thermoplastic resin to decomposed products having an bad influence on photographic characteristics. In order to prevent the deterioration by heat, oxidation inhibiting materials are added, and in order to absorb the decomposed products, carbon blacks are added.

Abstract: Preferred embodiments of the present invention comprise a method of manufacture utilizing significant amounts of R-PET and the preform and/or beverage bottle produced thereby. The method preferably comprises washing colored beverage bottles and substantially clear beverage bottles to remove any surface filth, forming colored R-PET flakes from the washed colored beverage bottles, and forming substantially clear R-PET flakes from the washed substantially clear beverage bottles. The colored R-PET flakes are preferably blended with the substantially clear R-PET flakes to form blended flakes having substantially homogenous color. The blended flakes are color corrected if so desired, and the blended flakes are then pelletized. The pelletized flakes are preferably combined with V-PET to form a preform which is then preferably shaped into a beverage bottle.

Abstract: Synthetic roofing products such as simulated slate and clay tile shingles, and other products, such as flower pots, floor coverings, plastic pallets and the like are compression molded from a mixture of ultra low density polyethylene binder and a filler which may comprise recycled rubber products such as E.D.P.M (ethylene propylene diene monomer) and S.B.R. (styrene butadiene rubber). Colorants may be added to the mixture prior to final molding. Many of the products, especially synthetic shingles, are less expensive, easier to handle, and more durable than the slate or clay tile shingle product simulated.

Abstract: A process for manufacturing an article (10) by forming different portions of the article from different materials including using filler materials that are incorporated into a molten resin prior to forming the article. The selection of the resin and the filler materials impart differing properties to the article in the location where the materials were directed. The filler materials may include ceramic powders, clays, polymeric resins selected for their material properties, recycled materials, whisker materials and the like. The article may be subjected to an adhesion fluid, such as a gas or liquid, after formation in order to adhere all filler particles to the surrounding resin. If the adhesion treatment is acidic in nature, an optional step of neutralizing the article with hydroxides, carbonates or the like may be useful.

Abstract: A process for manufacturing an article using a predetermined amount of crumb rubber comprising the steps of selecting an article to be manufactured, determining a maximum amount of recycled rubber which can be used in manufacturing the article selected. A particle size for recycled rubber to be used is determined and a binder for binding the recycled rubber is selected. The amount of binder required to be added is determined. Curing agents to be used in the process are selected and their weight determined. The components are mixed in a mixer and heated to a predetermined temperature. The mixture is removed and a mold is filled with the mixture. The mixture is then molded at a predetermined temperature and a predetermined pressure being at least sufficient to cure the mixture so as to form the article previously selected and then the molded product is removed from the mold.

Abstract: A resilient article and method of manufacturing the same using recycled materials are described. Predetermined amounts of thermoset material and thermoplastic binder are mixed and extruded into a die, from which the mixture emerges in the form of a sheet having the approximate thickness of the finished article. The mixture then enters a calibrator, which more precisely shapes the sheet to the desired thickness. The sheet is then cooled and cut to the desired dimensions to provide the finished article. The thermoset material used in the mixture is preferably ground vehicle tire rubber with the fabric and metal removed and the thermoplastic binder is preferably waste polyethylene. The apparatus and method according to the present invention is particularly well suited for manufacturing resilient articles for use as expansion joint material.

Abstract: A running length of fastener product is formed of longitudinally pre-oriented synthetic resin. The product is characterized by a base web and an array of discrete fastener elements protruding from at least one side of the web, the web being in a laterally stretched molecular oriented condition. After forming a preform having discrete fastener elements integral with a base web in a stretchable state, the preform is stretched in a manner that substantially increases the fastener element spacing and reduces the thickness of the base web. A machine is shown that is capable of lengthwise orienting before forming and widthwise stretching after forming, which employs controlled heating to render the product widthwise stretchable while preserving or achieving a desired shape of the fastener elements.

Abstract: A woody formed article, characterized as being produced by admixing a woody material W and, as a binding agent, a fibrous and/or ribbon shaped thermoplastic resin R which is easy to be intertwined with the woody material W, and molding the resultant mixture. The thermoplastic resin R is preferably admixed in a state of being heated and melted. A method for producing a woody formed material, characterized in that it comprises providing a mat M of a raw material mixture Mx of a woody material W and a fibrous and/or ribbon-shaped thermoplastic resin R and subjecting the mat M to heat pressing, or comprises, in admixing the woody material W with the above fibrous thermoplastic resin R, stretching and thinning the resin R by means of a hot wind and/or a cold wind pressure, and admixing homogeneously it with the woody material W by utilizing a negative pressure zone due to the hot wind and/or the cold wind, to prepare a mat M of a raw material mixture Mx, and then subjecting the mat M to pressing.

Abstract: A granular material for use as a filter in the purification of sewage. The granular material is comprised of pre-sorted and cleaned plastic material wastes. A process for producing the same is provided.

Abstract: A product obtained from the use of sweeping materials, more particularly by means of recycling domiciliary sweepings. The product obtained by the present invention may be: posts, tables, rods, braces, moldings, cords, roadside ditches, boards or plates (like agglomerated wood) for the manufacture of all type of mouldable products such as, rods, sewers, posts, and any other product that can be made from a mouldable plastic-based material. It comprises of: a first component containing plastic polyethylene and polypropylene materials in a proportion that ranges between 25% and 30% of the final weight of the product; a second component of plastic PET type materials ranges between 30% and 40% of the total weight of the product; and a third component selected from: PVC, styrene, polyamides, polycarbonates, polystyrene, ABS, aluminum and cardboard.

Abstract: A process for manufacturing a plastic pipe from recycled crushed PET starting material includes kneading the starting material under the influence of heat while removing moisture therefrom so as to prevent hydrolysis of the PET material and thereafter feeding the mixture to an extruder and passing the extruded mixture to a corrugator while cooling at a temperature gradient of between −10° C./min and −50°/min so as to form a crystalline plastic pipe.

Abstract: Waste plastics including solid plastics, thin plastics, and foamy plastics are fed into a ring die of an extrusion molding machine. The waste plastics are either semi-melted or melted, and are then extruded onto an outer circumferential surface the ring die through die cavities. Thus, granular plastic moldings are extruded onto the outer circumferential surface of the ring die through the die cavities, and are then cut or scraped from the outer circumferential surface of the ring die. The pellets have a melt-solidified surface, and have a strength sufficient to reach a predetermine zone in a raceway of a furnace and a grain diameter sufficient to be fed at a velocity higher than a limiting velocity thereof during injection to the furnace.

Abstract: Fibers obtained by opening waste plastics of different kinds and fibers obtained by opening wastepaper are mutually woven, and molded under heat and pressure. As a result, different kinds of waste plastics can be recycled without requiring separation or classification.

Abstract: Plastic lumber having sufficient stiffness and strength to allow its use in structural and load-bearing applications. The plastic lumber is composed of a thermoplastic polymer, a thermosetting polymer cured with reinforcing fibers and, preferably, a coupling agent and foaming or blowing agent. As a preferred embodiment, the thermosetting polymer and reinforcing fibers are sourced from recycled materials, specifically, sheet molding compounds and bulk molding compounds.

Abstract: A process and the product produced by the process in which recycled asphalt shingles are reduced into granules which are then heated to a temperature above 212° F. in order to evaporate any water contained in the material. Once substantially all the water has been evaporated, the heated granules are then placed in a suitable mold and compressed under high pressure to form a block of the desired size and shape after which the blocks are removed from the mold and used on low-traffic volume areas such as patios, sidewalks, driveways, etc.

Abstract: The present invention provides a plastic recycling system, including a first granulator for reducing plastic waste to a first particle size. The system also includes a second granulator for reducing plastic waste to a second particle size. A frictional melting structure is provided which melts the first particles and the second particles via use of a rotating plate.

Abstract: The invention relates to a method for recycling polyethylene terephtalate (PET) flakes, characterized in that the flakes are extruded and granulated under vacuum, after which the granulate is aftercondensed in a solid phase under vacuum. Extrusion is preferably carried out in differentiated vent zones and aftercondensation of the solid phase is dependent on temperature, vacuum and time spent in a tumble dryer. Said dryer ensures the even and careful mixing and constant viscosity of the PET product. Said method is used in particular for making PET beverage bottles.

Abstract: The invention provides new methods for recycling thermoset materials such as natural rubbers, synthetic rubbers, silicone rubbers, and other elastomers and cross-linked polymers (e.g., isoprene rubbers; butyl rubbers; ethylene-propylene-diene rubbers, “EPDM”; nitrile, or acrylonitrile butadiene rubbers, “NBR”; styrene-butadiene rubbers, “SBR”; hard rubbers such as EBONITE®; mixtures of vulcanized rubbers from discarded tires). The invention is based on the discovery that by combining powdered or particulate thermoset materials with lubricants such as aromatic or paraffinic rubber processing oils or volatile solvents, the thermoset materials can be recycled under moderate temperature and pressure conditions to rapidly produce materials having physical properties comparable to those of virgin thermoset materials. The resulting materials can, for example, be extruded or compaction molded into new shapes such as panels.

Abstract: There is disclosed a method for manufacturing products through the use of waste materials of various kind, such as heterogeneous plastic materials, wood, minerals, etc., derived from recycling processes, differentiated waste collection systems, solid urban wastes, industrial processing scraps or by-products, and the like, such products being adapted to be used in a wide range of most varied applications, particularly though not exclusively for manufacturing structural parts and decorative finishes for office furniture as well as furniture for cinematoghraph theatres, communities, concert halls and the like.

Abstract: A process for producing a polyester composition, comprising polyester and a metal salt of an aliphatic carboxylic acid, whereby a metal salt and polyester are fed together into a vented extruder as a raw material. The raw material has a specific resistance of not less than 1×107 &OHgr;·cm upon melting and a metal atom concentration of 0.5 to 1,000 ppm based on the polyester composition. This process is industrially useful for producing a polyester composition which can be used to form sheets using an electrostatic pining method.

Abstract: A molded article such as a floor tile is made from recycled carpet waste which includes a polyvinyl chloride component in the backing material and fiber component having a melting point above the melting point of polyvinyl chloride. A mixture of the recycled carpet material is shredded and additional polyvinyl chloride is fed to an extruder where the polyvinyl chloride is melted without melting the carpet fibers. The resulting mixture is discharged and molded, such as by injection molding, to form a molded product. The molded product includes a continuous matrix of polyvinyl chloride having recycled carpet fibers uniformly dispersed therein. The molded article contains about 45% to about 85% of polyvinyl chloride, about 5% to about 20% of recycled carpet fibers, up to about 5% of a plasticizer and up to about 5% of an ethylene copolymer by weight based on the total weight of the product.

Abstract: A resilient article and method of manufacturing the same using recycled materials are described. Predetermined amounts of thermoset material and thermoplastic binder are mixed and extruded into a die, from which the mixture emerges in the form of a sheet having the approximate thickness of the finished article. The mixture then enters a calibrator, which more precisely shapes the sheet to the desired thickness. The sheet is then cooled and cut to the desired dimensions to provide the finished article. The thermoset material used in the mixture is preferably ground vehicle tire rubber with the fabric and metal removed and the thermoplastic binder is preferably waste polyethylene. The apparatus and method according to the present invention is particularly well suited for manufacturing resilient articles for use as expansion joint material.

Abstract: A molded article such as a floor tile is made from recycled carpet waste which includes a polyvinyl chloride component in the backing material and fiber component having a melting point above the melting point of polyvinyl chloride. A mixture of the recycled carpet material is shredded and additional polyvinyl chloride is fed to an extruder where the polyvinyl chloride is melted without melting the carpet fibers. The resulting mixture is discharged and molded, such as by injection molding, to form a molded product. The molded product includes a continuous matrix of polyvinyl chloride having recycled carpet fibers uniformly dispersed therein. The molded article contains about 45% to about 85% of polyvinyl chloride, about 5% to about 20% of recycled carpet fibers, up to about 5% of a plasticizer and up to about 5% of an ethylene copolymer by weight based on the total weight of the product.

Abstract: A manufacturing method for providing a cement bonded wood chip product, a resin bonded wood chip product and a simulated wood product, in which recycled wooden members and recycled resinous members are pulverized after having been mixed. Accordingly, a mixing process and a pulverizing process can be integrated into one single line, reducing the space as well as laborious work and efficient operation in a plant.

Abstract: A composite article including a hollow form filled with a mixture of thermoplastic, a thermoset including ground whole tire waste and a processing aid. Also disclosed is a process for extruding a mixture of thermoplastic, thermoset including ground whole tire waste and a processing aid, in which the mixture is extruded through a die into a hollow form to form a filled article.

Abstract: A method for producing a compound from a plastics material with fixed fiber inlay uses a heated screw-type extruder (1) in which filaments (2) are drawn by means of automatic drawing-in, are cut up and mixed there and are subsequently removed as a finished fiber compound. To achieve a high content of long fibers in the finished fiber compound, before entering the extruder (1) the filaments (2) are impregnated with the plastics material in an impregnation tool (3).

Abstract: A method of producing a composite stratiform material uses at least one extruder having a pair of co-rotating screws to co-extrude at least three layers, each layer having polypropylene and at least one filler. In a carrier layer the filler is particulate organic filler, and in first and second outer layers the filler is an inorganic filler. The co-extrusion provides for interfusion of the carrier layer with the outer layers at mutually opposite layer interfaces. The particulate organic filler of the carrier layer is either vegetabilic or wood which is extruded by a co-rotational extruder. The inorganic filler is introduced into at least one second extruder for extruding at least one of the outer layers.

Abstract: In a recycling process, granulated plastic material coated with a paint film is melted in an extruder. During extrusion, the paint film is volatilized and removed by vacuum from the melted granulate stream. Additives are admixed with the particulates and any remaining paint film in an extruder. Water is introduced into the melted plastic stream in the extruder to neutralize toxic material levels discharged from the extruder and from the extruded plastic material.

Abstract: An extruded composite structural artificial lumber product is manufactured from wood fiber and polyethylene, including recycled polyethylene, by reducing the wood fiber and polyethylene each to a finely divided particles, mechanically mixing the wood fiber and polyethylene particles together with a measured amount of a powdered endothermic foaming agent, mechanically mixing the mixture, without pre-pelletization, in a twin-screw extruder where it is compressed and heated until it becomes plastic and homogenous, and then extruding the plastic mixture, using vacuum to remove vaporized moisture and other excess volatiles, through a molding die which forms structural profile of the desired product.