Moldable polymeric materials containing recycled automotive shredder residue (ASR) and methods of manufacture

Abstract

A moldable material containing at least 5% by weight of polymeric regrind material recovered from automobile shredder residue (ASR) and a method for producing the same are provided, including the steps of providing a polymeric material fractionated from ASR, grinding the polymeric material fractionated from ASR to form a regrind material, subjecting the regrind material to a liquid solution having a specific gravity and performing a liquid density separation, withdrawing from the surface of the liquid a plurality of fractions of the regrind material having a specific gravity less than the specific gravity of the liquid solution, conditioning the withdrawn fractions of the regrind material, blending each fraction of the regrind material with a first polymer to produce a polymer blend, compounding the polymer blend through the addition of at least one additive to produce a plastic compound, and feeding the resulting plastic compound into an extruder to produce the moldable material.

Description

[Technical Field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 404,356, filed September 7, 2022, entitled "MOLDABLE POLYMER MATERIAL CONTAINING RECYCLED AUTOMOTIVE SHREDDER RESIDUE (ASR) AND METHOD OF MANUFACTURE," which is incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE This disclosure relates generally to moldable polymeric materials comprising recycled ASR (automotive shredder residue) and methods for making the same. [Background technology]

[0003] All kinds of materials are used in the manufacture of consumer goods, such as home appliances and automobiles. These materials include ferrous metals, such as steel; non-ferrous metals, such as stainless steel, aluminum, and copper; and other non-metallic materials, such as plastics, rubber, insulation, and fabrics. This material assemblage presents an interesting challenge in the recycling process: namely, the challenge of separating the constituent materials as completely as possible for subsequent resale or downstream use in further manufacturing. Improved material separation results in more useful scrap, and therefore higher value. Therefore, there is a constant desire to improve material separation of post-consumer materials after shredding.

[0004] In the recycling process for automobiles and appliances, for example, the waste is typically transported to a junkyard where recyclable parts, hazardous liquids such as fuel and oil, and tires are collected. Engines and transmissions made from metallic materials are typically disassembled for recycling. The remains may be transported to a shredding facility for processes such as crushing, grinding, magnetic separation, vortex separation, and screen separation.

[0005] During the above shredding and sorting procedures, valuable metals such as ferrous and non-ferrous metals are recovered and separated. Other residues such as plastics, rubber, glass, and fibers generated during the above processes may also be recovered. The entire recovered residue is referred to as Automotive Shredder Residue (ASR). Techniques for separating and separating these basic ferrous, non-ferrous, and non-metallic materials are well known. [Prior art documents] [Non-patent literature]

[0006] [Non-Patent Document 1] ASTM D1238 Summary of the Invention [Problem to be solved by the invention]

[0007] However, after separation of ferrous and non-ferrous metals, the remaining non-metallic automotive shredder residue (ASR) still contains usable non-metallic materials. For example, approximately 20% of such non-metallic ASR contains usable non-metallic materials that can be recycled or reused in the further production of sustainable materials. Currently, such non-metallic automotive shredder residue (ASR) materials are largely disposed of in landfills. Therefore, a solution is needed to improve the recycling process of waste polymeric materials from post-consumer sources so that this additional non-metallic automotive shredder residue (ASR) can be reclaimed for use and incorporation into the further production of sustainable products. [Means for solving the problem]

[0008] A moldable material and method for producing the same are provided, comprising at least 5% by weight of polymeric regrind material recovered from automotive shredder residue (ASR). The moldable material includes a first polymer, which is a virgin thermoplastic material, and a second polymer, which is a recycled or reclaimed thermoplastic material. The first polymer and the second polymer together form a polymeric material blend. The first polymer comprises up to 95% by weight of the polymeric material blend. The second polymer comprises at least 5% by weight of the polymeric material blend. In one example, the second polymer is a regrind polymeric material recovered from waste plastic material from post-consumer sources, i.e., non-metallic automotive shredder residue (ASR). The moldable material is about 7% to about 20% filled with at least one additive and has a mass flow index (MFI) of about 5 to about 30 g / 10 min.

[0009] Moldable materials can be formed or otherwise produced via the method of the present invention. The method begins after processing, e.g., shredding, grinding, magnetic separation, vortex separation, and screen separation, of raw materials, such as residual automobile bodies, appliances, etc. During such shredding and sorting processes, valuable metals, such as ferrous and non-ferrous metals, are recovered. The remaining residue, such as plastics, rubber, glass, and fibers, generated during the aforementioned processes is defined herein as non-metallic automotive shredder residue (ASR).

[0010] Once non-metallic automotive shredder residue (ASR) is obtained or recovered and the polymeric material therefrom is selected and separated, the method of manufacture includes the steps of: providing the selected and separated polymeric material from the automotive shredder residue (ASR); pulverizing the selected and separated polymeric material from the automotive shredder residue (ASR) via a grinding process to form a polymeric regrind material; subjecting the polymeric regrind material to a liquid solution having a liquid solution specific gravity to perform a liquid density separation; removing from the surface of the liquid solution a plurality of pieces of polymeric regrind material having a specific gravity less than the liquid solution specific gravity; and removing the polymeric regrind material removed from the surface of the liquid solution. The method includes preparing a plurality of pieces of grind material; blending the polymer regrind material with a primary polymer to form a polymer blend; compounding the polymer blend through the addition of at least one additive to produce a plastic compound; feeding the plastic compound into an extruder to produce a moldable material comprising automotive shredder residue (ASR); cooling the extruded moldable material; pelletizing the extruded moldable material into a plurality of polymer pellets having a predetermined pellet shape; drying the plurality of polymer pellets; and deodorizing the plurality of polymer pellets.

[0011] The above and other features and advantages of the present teachings will be readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the present teachings, as defined in the appended claims, when considered in conjunction with the accompanying drawings.

[0012] The operation of the present invention can be better understood by reference to the detailed description taken in conjunction with the following figures. [Brief explanation of the drawings]

[0013] [Figure 1A] FIG. 1 is a schematic plan view of an exemplary shredder system. [Figure 1B] 1 is a schematic elevation view of an exemplary shredder system. [Figure 1C]FIG. 2 is a schematic enlarged view of an in-feed conveyor. [Figure 1D] FIG. 1 is a schematic enlarged view of post-consumer product exiting the in-feed conveyor and entering the hammer mill. [Figure 1E] FIG. 1 is an enlarged schematic cross-sectional view of a hammer mill with multiple feed rolls and an internal rotor. [Figure 1F] 1 is a schematic enlarged elevation view of an exemplary magnetic separator having at least one drum magnet. FIG. [Figure 1G] FIG. 1 is a schematic diagram of an exemplary exit conveyor for ferrous and non-ferrous materials after processing of shredded material in a magnetic separator. [Figure 2A] FIG. 1 is a schematic plan view of an exemplary separation system for separating non-ferrous metals and non-metallic automotive shredder residue (ASR). [Figure 2B] 1 is a schematic elevation view of an exemplary separation system for separating non-ferrous metals and non-metallic automotive shredder residue (ASR). FIG. [Figure 2C] FIG. 2 is a schematic enlarged view of a trommel screen. [Figure 2D] FIG. 2 is a schematic enlarged view of an eddy current separator. [Figure 2E] 1 is a schematic enlarged elevation view of a portion of an exemplary induction sorter with at least one finger in a first position. [Figure 2F] 1 is a schematic enlarged elevation view of a portion of an exemplary induction sorter with at least one finger in a second position. [Figure 3A] FIG. 1 is a schematic elevation view of an exemplary granulator or polymer grinder. [Figure 3B] 1 is a schematic elevation view of an exemplary flotation tank and conditioning apparatus for washing, rinsing, and drying multiple pieces of polymer regrind material. [Figure 3C] FIG. 1 is a schematic plan view of an exemplary flotation vessel and conditioning apparatus for washing, rinsing, and drying multiple pieces of polymer regrind material. [Figure 3D] 1 is a schematic elevation view of an exemplary plastics processing machine for extrusion and pelletization of moldable material; FIG. [Figure 3E]1 is a schematic perspective view of an exemplary drying and deodorizing apparatus for drying and deodorizing a plurality of pellets of moldable material. [Figure 4A] FIG. 1 is a flow diagram detailing the steps of the present method for producing a moldable polymeric material containing recycled non-metallic automotive shredder residue (ASR). [Figure 4B] 1 is a flow diagram illustrating in further detail step 101 of the method, i.e., providing selected and separated polymeric material from automotive shredder residue (ASR). DETAILED DESCRIPTION OF THE INVENTION

[0014] While the present disclosure may be described with respect to a particular application or industry, those skilled in the art will recognize the broader applicability of the present disclosure. The terms "a," "an," "the," "at least one," and "one or more" are used interchangeably to indicate the presence of at least one of an item. Such items may be present in plural unless the context clearly dictates otherwise. All numerical values ​​of parameters (e.g., amounts or conditions) herein, including the appended claims, should be understood to be modified in all instances by the term "about," regardless of whether "about" actually appears before the numerical value, unless expressly or clearly indicated otherwise from the context. "About" indicates that the stated numerical value allows for some imprecision (somewhat close to the exactness of the numerical value; approximately or reasonably close; approximately). Where the imprecision provided by "about" is not nevertheless understood in the art with this ordinary meaning, "about," as used herein, at least accounts for the variation that may result from ordinary methods of measuring and using such parameters. Moreover, disclosure of a range should be understood to specifically disclose every value within the range and sub-ranges as well.

[0015] The terms "comprising," "including," and "having" are inclusive and thus specify the presence of stated features, steps, operations, elements, or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be varied to the extent possible, and additional or alternative steps may be employed. As used herein, the term "or" includes any one and all combinations of the associated listed items. The term "any of" is understood to include any possible combination of the referenced items, including "any one of" the referenced items. The term "any of" is understood to include any possible combination of the referenced claims of the appended claims, including "any one of" the referenced claims.

[0016] Features shown in a figure may be combined with, substituted for, or modified by features shown in any of the figures. Unless otherwise specified, no feature, element, or limitation is mutually exclusive of any other feature, element, or limitation. Moreover, no feature, element, or limitation is absolutely necessary for operation. Any specific configurations shown in the figures are illustrative only, and the specific configurations shown do not limit the scope of the claims or the description.

[0017] For consistency and convenience, directional adjectives are employed throughout this detailed description that correspond to the illustrated embodiments. Those skilled in the art will recognize that terms such as "above," "below," "upward," "downward," "top," and "bottom" may be used descriptively with respect to the figures without representing a limitation on the scope of the invention as defined by the claims. Additionally, any numerical designations such as "first" or "second" are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way.

[0018] The term "longitudinal" as used throughout this detailed description and in the claims refers to a direction extending the length of a component. In some cases, a component may be identified with a longitudinal axis and a front and rear longitudinal direction along that axis. The longitudinal direction or longitudinal axis may also be referred to as the anterior-posterior direction or anterior-posterior axis.

[0019] The term "lateral" as used throughout this detailed description and in the claims refers to a direction extending across the width of a component. A lateral direction or axis may also be referred to as a transverse or horizontal axis or a lateral direction or axis.

[0020] The term "vertical" as used throughout this detailed description and in the claims refers to a direction generally perpendicular to both the horizontal and vertical directions.

[0021] Additionally, the term "proximal" refers to a direction closer to the center of a component. Similarly, the term "distal" refers to a relative location further away from the center of a component. Thus, the terms proximal and distal can be understood to provide generally opposing terms for describing relative spatial location.

[0022] Referring to the drawings, in which like reference numerals refer to like components throughout the several views, there is provided a moldable material containing recycled ASR (automotive shredder residue) and a method for making the same 100. In a general sense, there is provided a moldable material and a method for making the same that includes at least 5% by weight of polymer regrind material recovered from waste plastic material from post-consumer sources, i.e., post-consumer material recovered from automotive shredder residue (ASR).

[0023] More specifically, the moldable material can be produced in multiple grades, for example, a first grade plastic formulation suitable for use in making automotive structural parts such as scooters, dashboards, interior cover panels, and A-pillars, and a second grade plastic formulation suitable for use in making containers such as household items.

[0024] Moldable materials can be formed or otherwise produced via the present method 100, which begins after processing of raw materials, such as residual automobile bodies, appliances, etc. During such processing, valuable metals, such as ferrous and non-ferrous metals, are recovered, and the remaining residue, such as plastics, rubber, glass, and fibers, generated during such processing is defined herein as non-metallic automotive shredder residue (ASR). After recovery of the non-metallic automotive shredder residue (ASR) and fractionation of polymeric materials therefrom, selected and fractionated polymeric materials are provided from the non-metallic automotive shredder residue (ASR) and undergo a grinding process, liquid density separation, blending process, compounding process, extrusion process, and pelletization.

[0025] 1A-1E, a sample shredder and sorting system 10 is detailed. The sample shredder and sorting system 10 is utilized to complete method step 101, i.e., preparing selected and sorted recycled polymeric material from a source of automotive shredder residue (ASR). Method step 101 is further defined in FIG. 4B via substeps 201-206.

[0026] That is, in sub-step 201, raw shredded material 12, such as, but not limited to, automobiles, trucks, buses, appliances such as washers, dryers, refrigerators, and sheet metal, scrap, and waste metal, may be fed to shredder and sorting system 10 via infeed conveyor 14. Infeed conveyor 14 delivers raw shredded material 12 to a system of feed rolls 16 and a hammer mill 18 having at least one rotor 17 capable of breaking down shredded material 12 into discrete pieces of shredded material 20.

[0027] In substep 202, the raw shredded material 12 is shredded in a hammer mill 18 to produce a plurality of individual pieces of shredded material 20. Such shredded material 20 may be extracted from the hammer mill 18 and transported via an additional conveyor system to a plurality of sorting devices 22, 24, 26, 28, 30 configured to separate and sort the shredded material 20 into ferrous metals, non-ferrous metals, and non-metallic automotive shredder residue (ASR), as well as other residue groups such as plastics, rubber, glass, and fibers generated during the shredding process, as illustrated in Figures 1F-2F and method substeps 203-205.

[0028] To begin the sorting process, in substep 203, a group of ferrous metal shredded material 19 can be separated from non-ferrous shredded material 21, 23 using a magnetic separator 22 (FIG. 1F). The magnetic separator 22 can be a strong magnet, multiple magnets, a large magnetic roller, or the like. In one example, the magnetic separator 22 may comprise one or more drum magnets 27. The magnetic separator 22 can respond to the shredded material 20 and separate the shredded material 20 into a collection of ferrous metal 19 and a collection of non-ferrous material (non-ferrous metal 21 and non-metallic shredded material 23). Such ferrous metal 19 can be stored in a separate location, such as via a radial stacker, and recycled and reused in subsequent applications, such as being provided to a downstream foundry for use in further manufacturing.

[0029] 2A-2B, the remaining shredded material 20 is a separate collection of non-ferrous materials: non-ferrous metals 21 and non-metallic shredded material 23. Non-ferrous metals 21, such as stainless steel, copper, brass, zinc, aluminum, and lead, along with non-metallic shredded material 23, such as plastic, rubber, wood, glass, rock, soil, paper, film, textiles, and other metals, may be subjected to further sorting and separation.

[0030] As illustrated in step 204, the non-ferrous materials 21, 23 may be further subjected to size separation via at least one screen 24 or similar separation device (FIG. 2C). In one example, the screen 24 may be a flat mesh surface where items larger than the screen grid are maintained on and above the screen and items smaller than the screen grid can pass through. In another example, the screen 24 may be a trommel or rotary screen 24, whereby physical size separation of the non-ferrous materials 21, 23 is achieved as the materials spiral down a rotating drum, where undersized materials smaller than the screen openings pass through the screen while oversized materials exit at the opposite end of the drum. In some examples, the non-ferrous materials 21, 23 may be subjected to separation via multiple screens. For example, the non-ferrous materials 21, 23 may be passed through a first screen followed by a second screen to further separate the non-ferrous materials by size. The second screen or subsequent screens in the separation process may comprise a fine screen 26, etc.

[0031] 2A-2F and substep 205 of FIG. 4B, the variously sized collections of non-ferrous materials 21, 23 may then be subjected to further sorting and separation to separate the non-ferrous metals 21 from the non-metallic automotive shredder residue (ASR) material 23. In one example, as detailed in substep 401, the non-ferrous metals 21 may be separated from the non-metallic automotive shredder residue (ASR) material 23 via transfer of the materials 21, 23 to an eddy current separator 28 (FIG. 2D). The materials may be fed to the eddy current separator 28 via a vibratory feeder 29 or another suitable transfer device. The eddy current separator 28 further includes a rotor 27 disposed at the end of the belt 25. The outside of the rotor 27 may be lined with magnets of alternating polarity, or the rotor may be an electromagnet. In this manner, the non-ferrous metal materials 21 are caught in eddy currents generated by the rotating magnets. In other words, the non-ferrous metals 21 are thrown or repelled by the magnets and deposited onto a first product bin or receiving belt. The non-metallic automotive shredder residue (ASR) material 23 is unable to interact with the magnets and simply falls by gravity off the belt 25 onto a second product bin or another receiving belt.

[0032] As detailed in substep 402, in addition to the eddy current separator 28, an induction sorter 30 may act on the non-ferrous materials 21, 23 after the eddy current separator 28 to capture any remaining non-ferrous metals 21 that may remain unseparated or separated from the non-metallic automotive shredder residue (ASR) material 23. As shown in FIGS. 2E and 2F , the induction sorter 30 may include a conveyor 34 having an exit end 36, a plurality of sensors 38 disposed transversely to the conveyor 34, and an induction assembly 32 disposed at the exit end 36 of the conveyor 34. The induction assembly 32 may include a plurality of fingers 40 actuable between a first position 45 and a second position 47, each corresponding to one of the plurality of sensors 38.

[0033] In this manner, the non-ferrous metal materials 21, 23 disposed on the conveyor 34 follow a predetermined trajectory as they exit the exit end 36 of the conveyor 34, the predetermined trajectory being dependent at least on the speed of the conveyor 34. As each piece of non-ferrous metal material is detected on the conveyor 34 as it passes a respective sensor 38, the respective sensor 38 generates a detection signal and transmits the detection signal to the control unit 44.

[0034] The control unit 44 may include non-transitory computer-readable media. The term non-transitory computer-readable media includes any medium that participates in providing data (e.g., instructions) that can be read by a computer. Such media can take many forms, including, but not limited to, non-volatile media, volatile media, etc. Non-volatile media include, for example, optical or magnetic disks and other persistent memory. Volatile media include dynamic random access memory (DRAM), which typically constitutes main memory. Common forms of computer-readable media include, for example, floppy disks, flexible disks, hard disks, magnetic tape, any other magnetic media, CD-ROMs, DVDs, any other optical media, punch cards, paper tape, any other physical media with a pattern of holes, RAM, PROM, EPROM, FLASH-EEPROM, any other memory chip or cartridge, or any other computer-readable medium, and networked versions thereof. The non-transitory computer-readable medium stores or has written thereon or embodied thereon a set of computer-executable instructions for controlling the actuation of the plurality of fingers 40 between the first position 45 and the second position 47 based on detection signals received from the plurality of sensors 38.

[0035] Upon receiving a detection signal from one of the plurality of sensors 38, the control unit 44 is configured to actuate each finger 40 corresponding to each sensor 38 from a first position 45 (outside the predetermined trajectory) to a second position 47 (inside the predetermined trajectory) to contact each detected piece of non-ferrous metal material 21 and change its trajectory, thereby directing the contacted piece of metal material 21 to another metal material container or conveyor 55 different from the material container or conveyor 53 that receives the non-metallic material 23 following the unchanged predetermined trajectory (Figures 2E and 2F).

[0036] After most of the metals have been recovered from shredder material 20, the remaining mixture of materials is defined herein as non-metallic automotive shredder residue (ASR) 23. Non-metallic automotive shredder residue (ASR) material 23 may contain plastics, rubber, wood, glass, rock, soil, paper, film, textiles, etc., although plastics are often the predominant single material therein and may comprise from about 15% to about 90% of the non-metallic automotive shredder residue (ASR) 23. Such percentages may vary depending on the type of consumed material and the steps taken in the metal separation process.

[0037] This remaining non-metallic automotive shredder residue (ASR) material 23 contains usable non-metallic materials. For example, approximately 20% of such non-metallic automotive shredder residue (ASR) 23 contains usable non-metallic materials that can be recycled or reused in the further production of sustainable materials. Currently, such non-metallic materials are largely disposed of in landfills. Thus, a solution is needed to improve the post-consumer waste recycling process so that this additional non-metallic automotive shredder residue (ASR) 23 material can be reclaimed for use as a reclaimed moldable polymer material for incorporation into the further production of sustainable products.

[0038] 3A-3E, once most of the metals have been removed from shredded material 20 via upstream systems and processes 22, 24, 26, 28, and 30 in method substeps 201-205, the remaining non-metallic automotive shredder residue (ASR) material 23 can be further separated in substep 206 so that polymer or plastic materials are separated from other non-metallic materials, such as aggregates, textiles, paper, etc. In one example, this initial separation can be accomplished via several processes, including, but not limited to, sending the non-metallic automotive shredder residue (ASR) 23 to an air sorting system that can separate materials by size, weight, and / or density by directing targeted bursts of high-velocity air at each piece of material. The non-metallic automotive shredder residue (ASR) material 23 can be further selected and separated by mechanical sorting means, electronic sorting means, or manual picking by line workers. The selection and separation of polymeric material from the non-metallic automotive shredder residue (ASR) material 23 completes a substep of method step 101, i.e., providing selected and separated recycled polymeric material from a source of automotive shredder residue (ASR).

[0039] Returning to FIG. 4A, after selection and separation of the non-metallic automotive shredder residue (ASR) material 23, the selected polymeric material can undergo a grinding process in step 102 via a grinder or granulator 60 (FIG. 3A) to form a polymeric regrind material having a predetermined maximum size. The source plastic or polymer, optionally cut or ground to form smaller particles for processing, is generally known as regrind. The polymeric regrind material obtained from the automotive shredder residue (ASR) can be utilized for a variety of applications, including, but not limited to, chemical recycling. Chemical recycling processes, such as pyrolysis and depolymerization, can break down the plastic components of the automotive shredder residue (ASR) into their original monomers or other valuable chemical compounds for use in the production of new plastics. Thus, the predetermined maximum size of the regrind can be conveniently selected to achieve appropriate melting characteristics or reaction parameters when the regrind is processed. Such regrind products can be salable recycled materials themselves, valuable to downstream consumers and material processors.

[0040] 3B-3C, after the grinding process, in step 103, the polymer regrind material that is not itself sold as a recyclable material can be placed in a liquid solution for liquid density separation. The liquid solution can be contained in a flotation tank 52 or the like. The liquid solution can have a specific gravity of about 0.90 to about 1.30.

[0041] The source of polymer regrind material is a combination of multiple polymers (and potentially elastomers) with various material densities and specific gravities. In many cases, materials with higher specific gravities (denser than water or other aqueous solutions), such as elastomers, rubbers, and thermoset materials, will sink to the bottom of the flotation tank 52, while materials with lower specific gravities (less dense than water or other aqueous solutions), such as thermoplastics, polyphenylene ether (PPE), polypropylene (PP), and thermoplastic polyolefin (TPO), will float.

[0042] The liquid density separation process may further include, in step 104 (FIG. 4A), removing and recovering the polymer regrind material fractions that float in the respective liquid solutions, i.e., polymer regrind particles having a specific gravity less than the liquid solution specific gravity, and separating the polymer regrind material fractions that sink in the respective liquid solutions, i.e., polymer regrind particles having a specific gravity greater than the liquid solution specific gravity. Furthermore, the polymer regrind material fractions that sink in the respective liquid solutions may be recovered and subsequently processed for use in various industrial and consumer applications. For example, the sinking polymer material fractions may be subjected to an impurity removal process and / or pelletized into a plurality of pellets having a predetermined pellet shape. The pellets may serve as a sustainable source of raw material for injection molding, extrusion, and other manufacturing methods.

[0043] Removal of the polymer regrind material floating in each liquid solution, i.e., polymer regrind particles having a specific gravity less than the liquid solution specific gravity, can be completed via a skimming-style process that collects floating regrind pieces from the surface of the liquid solution. Such an exemplary skimming process may utilize a drum skimmer 54 (FIG. 3B) or another suitable skimming device for removing regrind from the surface of the liquid solution. Removal of the polymer regrind material sinking in each liquid solution, i.e., polymer regrind material particles having a specific gravity greater than the liquid solution specific gravity, can be completed by draining the floatation tank 52 of each liquid solution and recovering the polymer material that sinks to the bottom.

[0044] In some instances, the removed polymer regrind material suspended in each liquid solution, i.e., polymer regrind material particles having a specific gravity less than the liquid solution specific gravity, may be useful for producing multiple grades of blended polymer material. In one example, for a first grade material intended for further manufacturing, such as for producing automobile cover panels, kick scooters, dashboards, and A-pillars, the polymer regrind material may be introduced into a floatation vessel 52 containing a liquid solution having a first solution specific gravity (step 103). The first solution specific gravity may be from about 0.90 to about 1.0. In this manner, each regrind particle of the polymer regrind material having a specific gravity less than the first solution specific gravity floats to the top of the floatation vessel and remains suspended on the surface of the liquid solution. These first-grade regrind granules can then be removed from the surface of the liquid solution via skimmer 54 (step 104) and transported or conveyed to a designated area or device for conditioning (step 105), i.e., washing, drying, and rinsing the removed first-grade regrind granules.

[0045] After the first-grade regrind granules are removed from the surface of the liquid solution, the solution can be altered by adding water to increase the solution gravity from the first solution gravity to a second solution gravity. The second solution gravity can be from about 1.0 to about 1.30. As the solution gravity increases to the second solution gravity, additional polymer regrind granules having a specific gravity greater than the first solution gravity but less than the second solution gravity begin to float to the surface of the liquid solution. These second-grade regrind granules are suitable for use, for example, in further manufacturing of polymeric household containers, and can then be removed from the surface of the liquid solution via a skimming-style process to collect the floating regrind pieces from the surface of the liquid solution (step 104). Such an exemplary skimming process may utilize a drum skimmer 54 (FIG. 3B) or another suitable skimming device for removing the regrind from the surface of the liquid solution, and conveying or transporting the removed second-grade regrind granules to another designated area or device for conditioning (step 105), i.e., washing, drying, and rinsing. After the second-grade regrind granules are removed from the surface of the liquid solution, the solution may be drained from the floatation tank 52, and the remaining settled regrind granules having a specific gravity greater than 1.30 may be collected from the bottom of the floatation tank 52. Once recovered, such settled regrind granules having a specific gravity greater than 1.30 may then be processed for use in various industrial and consumer applications, including as a sustainable raw material source without further manufacturing processes.

[0046] As shown in FIG. 3D, the prepared primary regrind granules can then be blended (at step 106) with a primary polymer, such as virgin polypropylene (PP) polymer in granule or resin form. Such blending can be accomplished by adding the primary regrind granules and virgin polypropylene to a mixer in the desired proportions for the desired blend. In this manner, the primary polymer blend is a blend of virgin and recycled materials. Such an example can include at least 5% by weight recycled material (non-metallic automotive shredder residue (ASR) 23), with the remaining polymer (up to 95% by weight) being virgin material, such as polypropylene. In one particular exemplary embodiment, the primary polymer blend can include at least 25% by weight recycled material (non-metallic automotive shredder residue (ASR) 23), with the remaining polymer (up to 75% by weight) being virgin material (e.g., polypropylene).

[0047] The primary polymer blend can then be compounded in step 107 through the addition of one or more additives. In one example, the primary polymer blend may be compounded so that the resulting plastic compound is about 20% talc-filled. Talc-filled polypropylene exhibits improved stiffness, hardness, and heat resistance compared to the base resin. In another example, the primary polymer blend may be compounded so that the resulting plastic compound is about 20% glass-filled. Glass-filled polypropylene exhibits improved tensile strength compared to the base resin. Such primary plastic compounds (ASR, virgin polypropylene, and filler) exhibit a melt flow index (MFI) of about 10 to about 25 g / 10 min. In one preferred embodiment, the primary plastic compound exhibits an MFI of 20. An exemplary method for measuring melt index is described in ASTM D1238, which is incorporated by reference in its entirety.

[0048] The conditioned (washed, dried, and rinsed) secondary regrind granules can then be blended with a primary polymer, e.g., virgin polypropylene (PP) polymer resin (step 106). Such blending can be accomplished by adding the secondary regrind granules and virgin polypropylene to a mixer in the desired proportions for the desired blend. In this manner, the secondary polymer blend is a blend of virgin and recycled materials. Such an example may include at least 5% by weight recycled material (non-metallic automotive shredder residue (ASR) 23), with the remainder of the blend (up to 95% by weight) being virgin material, e.g., polypropylene. In one particular exemplary embodiment, the primary polymer blend may include at least 25% by weight recycled material (non-metallic automotive shredder residue (ASR) 23), with the remainder of the polymer (up to 75% by weight) being virgin material, e.g., polypropylene.

[0049] The secondary polymer blend can then be compounded in step 107 through the addition of one or more additives. In one example, the secondary polymer blend may be compounded so that the resulting plastic compound is approximately 7% talc-filled. Talc-filled polypropylene exhibits improved stiffness, hardness, and heat resistance compared to the base resin. In another example, the secondary polymer blend may be compounded so that the resulting plastic compound is approximately 7% glass-filled. Glass-filled polypropylene exhibits improved tensile strength compared to the base resin. Such secondary plastic compounds (non-metallic ASR23, virgin polypropylene, and filler) exhibit a melt flow index (MFI) of about 5 to about 30 g / 10 min. In one preferred embodiment, the secondary plastic compound exhibits an MFI of 10 g / 10 min. An exemplary method for measuring melt index is described in ASTM D1238, which is incorporated by reference in its entirety.

[0050] Other additives, including but not limited to pigments, various stabilizers, flame retardants, waxes, antioxidants, etc., can be utilized in each plastic formulation. For example, the addition of various plasticizers will not only improve the flexibility and durability of the final product, but also facilitate the processing of the material from resin form into a film or sheet. As known in the art, further additives and processing aids, such as mold release agents and lubricants, may also be included. It is understood that these additional non-filler additives do not significantly alter the desired melt flow index (MFI). It is understood that the combination of additives can customize the color and texture of the resulting moldable polymeric material.

[0051] After compounding the blend polymer material and filler (step 107), each plastic compound is fed into an extruder in step 108. Once in the extruder, each plastic compound is then heated and mechanically mixed within the extruder until the compound becomes a viscous fluid, after which it is extruded through a die via an extrusion screw. During extrusion, the mechanical process of forcing the polymer material through the die provides additional benefits, such as removing impurities from the material. Additionally, the die determines the cross-sectional shape of the resulting moldable polymer material, which contains at least 5% by weight of automotive shredder residue (ASR).

[0052] Exemplary plastic processing machines 67 with mixing, blending, compounding, and extrusion capabilities, such as those shown by way of example in FIG. 3D, are commercially available from manufacturers such as EREMA Plastics Recycling Systems and Starlinger Company.

[0053] The resulting moldable polymeric material containing at least 5% by weight of automotive shredder residue (ASR) exits the extruder through the die and is cooled. Once cooled, the resulting moldable polymeric material is pelletized into a plurality of pellets having a predetermined pellet shape in step 109. The predetermined pellet shape can maintain the same cross-sectional shape as the die. In this manner, the predetermined pellet shape can be customized for purposes of branding, source identification, and verification of the resulting moldable polymeric material containing at least 5% by weight of automotive shredder residue.

[0054] Once pelletized, the plurality of polymer pellets may be dried in step 110. Once dried, the plurality of polymer pellets may be deodorized (step 111) via drying and deodorizing system 70, as shown by way of example in Figure 3E, prior to shipment to a material consumer.

[0055] With respect to processes, systems, methods, etc. described herein, the steps of such processes, etc. have been described as occurring according to a certain order, but it should be understood that such processes may be performed in an order other than the order in which the described steps are described herein. Furthermore, it should be understood that it is possible to perform certain steps simultaneously, add other steps, or omit certain steps described herein. In other words, the process descriptions herein are provided for the purpose of illustrating particular embodiments and should not be construed as limiting the claimed invention.

[0056] The detailed description and drawings or figures support and explain the present teachings, the scope of which is defined only by the claims. Although some of the best modes and other embodiments for carrying out the present teachings have been described in detail, there are various alternative designs and embodiments for carrying out the present teachings as defined in the appended claims.

Claims

1. 1. A method for producing a moldable polymeric material comprising automotive shredder residue (ASR), comprising: Providing selected and separated recycled polymeric material from a source of automotive shredder residue (ASR); and grinding the selected and separated recycled polymeric material from the automotive shredder residue (ASR) through a grinding process to form a polymeric regrind material having a predetermined maximum size.

1. A method for producing a moldable polymeric material, comprising:

2. conducting a liquid density separation by introducing said polymer regrind material into a liquid solution having a liquid solution specific gravity of about 0.90 to 1.30; removing from the surface of the liquid solution a plurality of pieces of polymer regrind material having a specific gravity less than that of the liquid solution; and conditioning the plurality of pieces of polymer regrind material removed from the surface of the liquid solution, wherein conditioning the plurality of pieces of polymer regrind material is defined as at least one of washing, rinsing, and drying the plurality of pieces of polymer regrind material.

10. The method of making the moldable polymeric material of claim 1, further comprising:

3. blending the polymer regrind material with a primary polymer resin to form a polymer blend, the polymer regrind material comprising at least 5 wt.% of the polymer blend; compounding the polymer blend with at least one additive to produce a plastic compound; and feeding said plastic compound into an extruder to produce said moldable polymeric material containing automotive shredder residue (ASR); 3. The method of making the moldable polymeric material of claim 2, further comprising:

4. 4. The method of producing a moldable polymer material according to claim 3, further comprising pelletizing the extruded moldable polymer material comprising automotive shredder residue (ASR) into a plurality of polymer pellets having a predetermined pellet shape.

5. drying the plurality of polymer pellets; and deodorizing the plurality of polymer pellets.

5. A method for making the moldable polymeric material of claim 4, further comprising:

6. 3. The method of claim 2, wherein the liquid solution has a first solution specific gravity of about 0.90 to about 1.0 such that each piece of polymer regrind material having a specific gravity less than the first solution specific gravity floats on the surface of the liquid solution.

7. The plastic compound is a primary plastic compound, wherein: the polymer blend is about 20% loaded such that the at least one additive comprises up to about 20% by weight of the polymer blend; the first plastic compound has a melt flow index (MFI) of about 10 to about 25 g / 10 min; A method for producing the moldable polymeric material of claim 6.

8. performing liquid density separation, modifying the liquid solution with water such that the liquid solution has a second solution specific gravity of about 1.0 to about 1.30, and each piece of the polymer regrind material having a specific gravity greater than the specific gravity of the first liquid solution and less than the specific gravity of the second liquid solution floats on the surface of the liquid solution; and removing from the surface of the converted liquid solution each piece of the polymer regrind material having a specific gravity greater than the specific gravity of the first liquid solution and less than the specific gravity of the second liquid solution.

10. The method of making the moldable polymeric material of claim 6, further comprising:

9. the plastic compound is a secondary plastic compound; the polymer blend is about 7% loaded such that the at least one additive comprises about 7% by weight of the polymer blend; the secondary plastic compound has a melt flow index (MFI) of about 5 to about 30 g / 10 min; A method for producing the moldable polymeric material of claim 8.

10. 10. The method of producing a moldable polymeric material of claim 9, further comprising the step of removing a plurality of pieces of polymeric regrind material from the bottom of the flotation vessel, the pieces having a greater specific gravity than the liquid solution.

11. providing selected and fractionated polymeric materials from automotive shredder residue (ASR), feeding the raw material onto an infeed conveyor; producing shredded material by shredding the feedstock through a hammer mill; separating the shredded material into ferrous and non-ferrous materials via a plurality of magnets; separating the non-ferrous materials by density; separating the non-ferrous materials into non-ferrous metals and non-metallic automotive shredder residue (ASR); and Separating and selecting a group of polymeric materials from said non-metallic automotive shredder residue (ASR).

10. The method of making the moldable polymeric material of claim 1, further comprising:

12. separating the non-ferrous materials by density, feeding the non-ferrous materials through an air separation system to separate the non-ferrous metals from non-metallic automotive shredder residue (ASR); 12. A method of making the moldable polymeric material of claim 11, further comprising:

13. separating the non-ferrous materials into non-ferrous metals and non-metallic automotive shredder residue (ASR), feeding the non-ferrous materials to an eddy current separator so that the non-ferrous metals are separated from the non-metallic automotive shredder residue (ASR); 13. The method of making the moldable polymeric material of claim 12, further comprising:

14. 14. The method of producing a moldable polymeric material of claim 13, wherein the step of separating the non-ferrous materials into non-ferrous metals and non-metallic automotive shredder residue (ASR) further comprises the step of sending the non-metallic automotive shredder residue (ASR) to an induction separator, wherein the induction separator removes remaining non-ferrous metals from the non-metallic automotive shredder residue.

15. a first polymer that is a thermoplastic resin material and comprises less than about 95% by weight of said polymeric material blend; a second polymer that is a thermoplastic material and comprises at least 5% by weight of said polymeric material blend; A moldable material comprising: The moldable material, wherein the secondary polymer is a regrind polymer material recovered from waste polymer material recovered from automotive shredder residue (ASR).

16. the primary polymer comprises about 70% to about 75% by weight of the polymeric material blend; the secondary polymer comprises at least 25% by weight of the polymeric material blend; 16. The moldable material of claim 15.

17. 17. The moldable material of claim 16, wherein the moldable material is about 7% to about 20% filled, and the at least one additive comprises about 7% to about 20% by weight of the resulting plastic formulation.

18. 18. The moldable material of claim 17, wherein the resulting plastic compound is a grade 1 plastic compound having a melt flow index (MFI) of about 10 to about 25 g / 10 min.

19. 20. The moldable material of claim 18, wherein the at least one additive comprises about 20% by weight of the primary plastic compound, the primary plastic compound having a melt flow index (MFI) of about 20 g / 10 min.

20. 18. The moldable material of claim 17, wherein the resulting plastic compound is a second order plastic compound and has a melt flow index (MFI) of about 5 to about 30 g / 10 min.

21. 21. The moldable material of claim 20, wherein the at least one additive comprises about 7% by weight of the secondary plastic compound, the secondary plastic compound having a melt flow index (MFI) of about 10 g / 10 min.

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