CA2232555C - An improved process of recycling waste polymeric material and an article utilizing the same - Google Patents

An improved process of recycling waste polymeric material and an article utilizing the same Download PDF

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Publication number
CA2232555C
CA2232555C CA 2232555 CA2232555A CA2232555C CA 2232555 C CA2232555 C CA 2232555C CA 2232555 CA2232555 CA 2232555 CA 2232555 A CA2232555 A CA 2232555A CA 2232555 C CA2232555 C CA 2232555C
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CA
Canada
Prior art keywords
polymeric material
waste polymeric
mixture
granulated
recycling waste
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA 2232555
Other languages
French (fr)
Other versions
CA2232555A1 (en
Inventor
Mark L. Grizzle
Lynn E. Preston
Stephen A. Zegler
Paul L. Weinle
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tarkett USA Inc
Original Assignee
Collins and Aikman Floor Coverings Corp
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Filing date
Publication date
Application filed by Collins and Aikman Floor Coverings Corp filed Critical Collins and Aikman Floor Coverings Corp
Publication of CA2232555A1 publication Critical patent/CA2232555A1/en
Application granted granted Critical
Publication of CA2232555C publication Critical patent/CA2232555C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/04—Particle-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/13—Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0072—Roughness, e.g. anti-slip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/732—Floor coverings
    • B29L2031/7322—Carpets
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Abstract

The present invention provides for an improved process for recycling waste polymeric material comprising a mixture of waste polymeric material wherein the waste polymeric material includes from about 0 to 40 percent aliphatic polyamidematerial; granulating and densifying the chopped mixture into fragments at leastabout 100 times smaller than the size of the waste polymeric material; and extruding the ground mixture at a temperature that does not exceed the temperature at which the largest portion of polymer based material decomposes.

Claims (34)

1. A process for recycling waste polymeric material, said process comprising:
a. coarsely chopping a mixture of waste polymeric material wherein the waste polymeric material includes from about 0 to 40 percent aliphatic polyamide material;
b. granulating the chopped mixture into fragments at least an order of magnitude smaller than the original size of the waste polymeric material;
c. densifying the granulated mixture into a pelletized material;
d. extruding the pelletized material at a temperature that does not exceed the temperature at which the major portion of the polymer waste material decomposes; and e. positioning the extruded granulated material to overlie and adhere to a backcoating of the carpet.
2. The process to Claim 1, wherein the temperature of extrusion is less than about 400°F.
3. The process of Claim 1, wherein an oleophobic adhesive layer is positioned to overlie and adhere to the secondary backing layer, and a releasable cover is removably attached to the oleophobic adhesive layer.
4. The process of Claim 1, wherein the densifying of the granulated materials increases the extruding of the pelletized material over non-densified granulated materials by approximately 400 percent.
5. The process of Claim 1, wherein the process includes the step of forming a carpet tile.
6. The process of Claim 1, wherein the extruded granulated material is flexible and easy to handle.
7. A process for recycling waste polymeric material, the process comprising the steps of:
a. chopping a mixture of waste polymeric material wherein the waste polymeric material has about 0 to 40 percent aliphatic polyamide material;
b. granulating the chopped mixture into fragments that are smaller than the original size of the waste polymeric material;
c. densifying the granulated mixture into pelletized material;
d. extruding the pelletized material at a temperature at less than 400°F;
e. calendering the extruded granulated material to provide for a secondary backing layer for a carpet; and f. positioning the secondary backing layer to overlie and adhere to a backcoating of a carpet.
8. The process of Claim 7, wherein an oleophobic adhesive layer is positioned to overlie and adhere to the backing layer, and a releasable cover is removably attached to the oleophobic adhesive layer.
9. The process of Claim 7, wherein the process includes the step of forming a carpet tile.
10. The process of Claim 7, wherein the secondary backing layer is flexible, can be rolled and is easy to handle
11. A process for recycling waste polymeric material, the process comprising the steps of:
a. chopping a mixture of waste polymeric material wherein the waste polymeric material has about 0 to 40 percent aliphatic polyamide material;
b. granulating the chopped mixture into fragments that are smaller than the original size of the waste polymeric material;
c. densifying the granulated mixture into pelletized material;
d. extruding the pelletized material at a temperature at less than 400°F; and e. forming and molding the extruding material to provide an article of manufacture.
12. A process for recycling waste polymeric material and for forming an article utilizing the resulting recycled material, the process comprising the steps of:
a. chopping a mixture of waste polymeric material wherein the waste polymeric material has about 0 to 40 percent aliphatic polyamide material;
b. granulating the chopped mixture into fragments that are smaller than the original size of the waste polymeric material;
c. densifying the granulated mixture into a pelletized material;
d. extruding the pelletized material at a temperature at less than 400°F;
e. calendering the extruded granulated material to provide a secondary backing layer for a carpet;
f. adhering the secondary backing to a carpet;
g. adhering an oleophobic adhesive layer with a releasable cover to the secondary backing layer; and h. forming a carpet tile.
13. A process for recycling waste polymeric material, said process comprising: granulating a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material; densifying the granulated mixture of waste polymeric material; and extruding the granulated mixture at a temperature less than about 400 °F to form an extrudate of the waste polymeric material.
14. A process for recycling waste polymeric material according to claim 1 further comprising calendering the extrudate to form a sheet of recycled material.
15. A process for recycling waste polymeric material according to claim 1 further comprising: forming the extrudate into a backing layer for a floor covering; and adhering the backing layer to a back surface of the floor covering.
16. A process for recycling waste polymeric material according to claim 1 further comprising cryongenically grinding the granulated mixture of waste polymeric material.
17. A process for recycling waste polymeric material, said process comprising: granulating a mixture of waste polymeric material wherein the waste polymeric material includes from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material; densifying the granulated mixture of waste polymeric material; and forming the granulated mixture of waste polymeric material into a sheet.
18. A process for recycling waste polymeric material according to claim 5 wherein the step of forming the granulated mixture includes extruding the granulated mixture at a temperature less than about 400 °F.
19. A process for recycling waste polymeric material according to claim 5 wherein the step of forming the granulated mixture includes calendering the waste polymeric material to form the sheet.
20. A process for recycling waste polymeric material according to claim 5 further comprising adhering the sheet to a floor covering to form a backing layer thereof.
21. A process for recycling waste polymeric material according to claim 5 further comprising cryongenically grinding the granulated mixture of waste polymeric material.
22. A process for recycling waste polymeric material, said process comprising: cryongenically grinding a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material; and extruding the granulated mixture at a temperature less than about 400 °F to form an extruded article.
23. A process for recycling waste polymeric material according to claim 10 further comprising the step of granulating the mixture of waste polymeric material into fragments at least an order of magnitude smaller than the original size of the waste polymeric material.
24. A process for recycling waste polymeric material according to claim 10 further comprising calendering the extruded article to form a sheet of recycled material.
25. A process for recycling waste polymeric material according to claim 10 further comprising: forming the extruded article into a backing layer for a floor covering; and adhering the backing layer to a back surface of the floor covering.
26. A process for recycling waste polymeric material according to claim 10 further comprising: forcing the extruded article through a die, thereby imparting a predetermined cross-sectional shape to the extruded article; and passing the extruded article through a cooling section to cool the extruded article so that the cross-sectional shape imparted by the die is maintained.
27. A process for recycling waste polymeric material according to claim 14 further comprising cutting the extruded article to form an article of manufacture.
28. A process for recycling waste polymeric material, said process comprising: granulating a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material; densifying the granulated mixture of waste polymeric material; extruding the granulated mixture at a temperature less than about 400 °F to form an extrudate of the waste polymeric material; and calendering the extrudate to form a sheet of recycled material.
29. A process for recycling waste polymeric material according to claim 16 further comprising adhering the calendered extrudate to a floor covering to from a backing layer thereof.
30. A process for recycling waste polymeric material according to claim 16 further comprising cryongenically grinding the granulated mixture of waste polymeric material.
31. A process for recycling waste polymeric material, said process comprising: cryongenically grinding a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material; densifying the granulated mixture of waste polymeric material; and forming the granulated mixture of waste polymeric material into a sheet.
32. A process for recycling waste polymeric material according to claim 19 wherein the step of forming the granulated mixture includes extruding the granulated mixture at a temperature less than about 400 °F.
33. A process for recycling waste polymeric material according to claim 19 wherein the step of forming the granulated mixture includes calendering the waste polymeric material.
34. A process for recycling waste polymeric material according to claim 19 further comprising adhering the sheet to a floor covering to form a backing layer thereof.
CA 2232555 1997-07-18 1998-03-17 An improved process of recycling waste polymeric material and an article utilizing the same Expired - Lifetime CA2232555C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/897,264 1997-07-18
US08/897,264 US5914353A (en) 1995-08-21 1997-07-18 Process of recycling waste polymeric material and an article utilizing the same

Publications (2)

Publication Number Publication Date
CA2232555A1 CA2232555A1 (en) 1999-01-18
CA2232555C true CA2232555C (en) 2002-05-28

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CA 2232555 Expired - Lifetime CA2232555C (en) 1997-07-18 1998-03-17 An improved process of recycling waste polymeric material and an article utilizing the same

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US (1) US5914353A (en)
EP (1) EP0891848A3 (en)
CA (1) CA2232555C (en)

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CA2232555A1 (en) 1999-01-18
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EP0891848A2 (en) 1999-01-20

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