Use of recycled packaging in polymer composite products

Abstract

A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.

Description

[0001]This application claims the benefit of U.S. Provisional Application No. 61 / 696,476, filed Sep. 4, 2012, which is hereby incorporated by reference in its entirety.BACKGROUND AND SUMMARY OF THE INVENTION[0002]Exemplary embodiments of the present invention relate generally to composite products and related methods for manufacturing such products. Composite materials can offer many benefits as compared to natural materials such as wood. However, despite many years of development, there is still a need to improve the formulation, manufacturing, and resulting characteristics of composite materials.[0003]Many composite products are made from virgin materials. However, virgin materials may be in limited supply and / or costly. Thus, there is a need to use at least a portion of recycled material in the formulation of a composite. There is also a need to use at least a portion of recycled material for sustainability reasons and also to potentially earn LEED points.[0004]There is also a ne...

AI Technical Summary

Benefits of technology

[0006]Additionally, there is a need to improve the manufacturability of composite materials to obtain desirable products. For instance, the use of recycled materials may impact the extrudability of the composite material. It may also limit the adhesion of a cap layer to a substrate.

[0007]Furthermore, when exposed to the sun, composite materials can become hot to the touch, especially relative to natural wood. As such, there is a need to transfer heat away from a surface of a composite product and/or minimize the static charge of a composite material. In particular, there is a need to transfer heat away from or otherwise cool the surface of composite decking and railing components.

[0008]Present exemplary embodiments may satisfy some or all of the aforementioned needs. An exemplary embodiment may use recycled packaging (e.g., juice pouches or other types of aluminized packaging) or other types of multilayer materials (e.g., films) in the production of a polyethylene, polypropylene, other olefin, or ionomer composite to obtain one or more of the aforementioned advantages.

Problems solved by technology

However, virgin materials may be in limited supply and/or costly.

A drawback of typical composites using recycled materials is that the physical characteristics of the composites may lack in comparison to the same composites made with virgin materials.

For example, characteristics such as coefficient of thermal expansion, modulus of rupture, modulus of elasticity, moisture sensitivity, peak load, and other mechanical characteristics may be adversely impacted by the use of recycled materials in many common composites.

With respect to decking products such as deck planks and rails, the reduction of such characteristics may lead to increased sagging or other types of deterioration.

For instance, the use of recycled materials may impact the extrudability of the composite material.

It may also limit the adhesion of a cap layer to a substrate

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