Recycled material pellets

Abstract

This specification describes recycled material pellets comprising shredded glass fiber waste containing glass fibers and a thermoplastic binder, wherein the thermoplastic binder constitutes at least about 2% by weight of the recycled material pellets.

Description

Technical Field

[0001] The present invention relates to recycled material pellets containing shredded glass fiber waste materials, particularly recycled material pellets containing shredded glass fiber waste materials derived from recycled composite materials, wherein the shredded glass fiber waste materials contain glass fibers and a thermoplastic binder. The present invention also relates to a method for manufacturing such recycled material pellets.

Background Art

[0002] Composite materials containing glass fibers are used in various components and products. In particular, glass fibers reinforce structural components such as automotive parts or related components. Composite materials containing glass fibers are also used for ceiling panels, floor panels, and wall panels.

[0003] Glass fiber waste is generally ultimately landfilled due to the difficulty of handling caused by its low density and high dust content. There is a need for new solutions that can recover and reuse glass fiber waste.

[0004] It is desirable to provide an improved and efficient method for recycling glass fiber-containing composite materials. It may also be desirable to provide a method for recycling glass fiber-containing composite materials that retains a relatively long fiber length to enable reuse in structural components.

Summary of the Invention

[0005] Most generally, the present invention provides recycled material pellets containing shredded glass fiber waste materials, wherein the shredded glass fiber waste materials contain glass fibers and a thermoplastic binder.

[0006] In one aspect, the present invention is a recycled material pellet containing shredded glass fiber waste materials containing glass fibers and a thermoplastic binder, <![CDATA[ ]]>The present invention provides recycled material pellets in which a thermoplastic binder constitutes at least about 2% by weight of the recycled material pellets.

[0007] The inventors have found that the present invention provides recycled material pellets that facilitate the handling of shredded glass fiber waste. The inventors have found that the present invention provides improved recycling efficiency for glass fiber waste containing glass fibers and thermoplastic binders. Glass fiber waste may originate from recycled glass fiber-containing composite materials. Surprisingly, the inventors have found that the glass fibers and thermoplastic binders in glass fiber waste can be incorporated into recycled material pellets without the addition of other materials and can be reused in other structural components and products. Composite materials containing glass fibers and thermoplastic binders are generally shredded to enable the recycling and reuse of the material. However, this process has drawbacks, resulting in the generation of "fine particles" and dust, thereby limiting the handling, input, and application of shredded glass fiber waste. Surprisingly, the provision of recycled material pellets as described herein has been found to enable improved ease of handling of shredded glass fiber waste through the reduction of dust and "fine particles." The recycled material pellets provided are also easier to process than conventional shredded fiberglass waste.

[0008] In one embodiment, shredded fiberglass waste constitutes at least 90% by weight of the recycled material pellets, for example, at least about 95% by weight or at least about 98% by weight in the case of recycled material pellets. In the embodiment, the pellets consist of or are essentially made of shredded fiberglass waste. This may be advantageous in increasing the recycling efficiency of shredded fiberglass waste. Furthermore, this may result in ease of processing and manufacturing.

[0009] In another embodiment, the thermoplastic binder constitutes up to approximately 30% by weight of the recycled material pellets. In one embodiment, the thermoplastic binder constitutes approximately 2% to approximately 25% by weight of the recycled material pellets. The inventors have found that pelletization is improved with increasing amounts of thermoplastic binder. Different amounts of thermoplastic binder may be preferred for different shredded glass fiber waste materials.

[0010] In one embodiment, the thermoplastic binder constitutes up to approximately 30% by weight of the recycled material pellets, and the glass fibers constitute at least 25% by weight of the recycled material pellets.

[0011] Different ratios of thermoplastic binder to glass fiber will produce different pellets. The amounts of thermoplastic binder and glass fiber allow for process adjustments to suit the end use of the recycled material pellets, thereby enabling the use of different shredded glass fiber waste materials.

[0012] In some embodiments, the recycled material pellets are approximately 150 kg / m³ 3 ~About 1000kg / m 3 It has a density within the range of, for example, recycled material pellets have a density of approximately 300 kg / m³. 3 ~about 800kg / m 3 It may have a density within the range.

[0013] Densities within the above range may be beneficial because the inventors have found that, compared to shredded glass fiber waste, the ease of handling of recycled material pellets is improved and the dust content can be reduced.

[0014] In one embodiment, the glass fibers have an aspect ratio of at least 5:1. Maintaining a glass fiber aspect ratio of at least 5:1 may be advantageous in order to enable the recycled material pellets to be used for reinforcing applications such as the manufacture of structural components.

[0015] In one embodiment, the glass fibers have a fiber length of at least about 0.5 mm. By providing such recycled material pellets containing glass fibers having a relatively long fiber length, for example, at least about 0.5 mm, it becomes possible to use the pellets for reinforcement applications due to the associated advantageous mechanical properties.

[0016] In one embodiment, the recycled material pellets have a diameter in the range of about 2 to about 10 mm. In one embodiment, the recycled material pellets have a length in the range of about 1 to about 50 mm.

[0017] In another aspect, the present invention provides a method for producing recycled material pellets, the method being: To provide shredded glass fiber waste containing glass fibers and a thermoplastic binder, wherein the thermoplastic binder constitutes at least about 2% by weight of the shredded glass fiber waste, This includes compressing shredded glass fiber waste to form recycled material pellets.

[0018] In one embodiment, shredded glass fiber waste is compressed to approximately 150 kg / m³. 3 ~About 1000kg / m 3 This forms recycled material pellets having a density within a specified range. This may be beneficial for the handling, storage, and / or application of shredded fiberglass waste.

[0019] In one embodiment, compression of shredded glass fiber waste is achieved at a temperature of at least 40°C, for example, at least 60°C. The inventors have found that using heat to form pellets can be beneficial. By applying heat, higher quality pelletization may be achieved by, for example, forming pellets containing glass fibers with improved lengths, such as glass fibers having a length of at least about 0.5 mm which are useful in reinforcing applications (for example, by reducing the amount of compression required to form the pellets).

[0020] In another aspect, the present invention provides recycled material pellet products manufactured according to the method described herein.

[0021] Overall, the inventors have found that the present invention yields shredded glass fiber waste that can be recycled and reused. The recycled material pellets exhibit improved fluidity and handling. The inventors have also found that the usefulness of shredded glass fiber waste is increased because the mechanical properties can be preserved by retaining the length of the glass fibers. The higher bulk density of recycled material pellets compared to shredded glass fiber waste also allows the same mass of glass fibers to occupy a smaller volume, which is also advantageous for transport and storage. The method of producing recycled material pellets, thereby recycling glass fibers and thermoplastic binders, enables relatively simple processing of waste glass fiber-containing composite materials. This method also facilitates the processing of glass fiber-containing pellets through input and mechanical or pneumatic transport. The pellets described herein can also be used to produce recycled glass, for example, by burning the pellets to remove the binder material and melting the glass fibers. The inventors have found that the pellets described herein, in particular when the pellets contain glass fibers having a fiber length of at least about 0.5 mm, can be used for reinforcing applications, such as in the manufacture of automotive parts.

[0022] In another embodiment, the present invention is Recycled material pellets containing shredded glass fiber waste, which includes glass fibers and a thermoplastic binder, The present invention provides recycled material pellets in which a thermoplastic binder constitutes at least about 2% by weight of the recycled material pellets, and shredded glass fiber waste constitutes at least 90% of the recycled material pellets.

[0023] In another embodiment, the present invention is Recycled material pellets containing shredded glass fiber waste, which includes glass fibers and a thermoplastic binder, Thermoplastic binders constitute up to approximately 15% by weight of the recycled material pellets, and glass fibers constitute at least 80% by weight of the recycled material pellets. Recycled material pellets: approximately 150 kg / m³ 3 ~About 1000kg / m 3 We provide recycled material pellets having a density within a specified range.

[0024] In a further embodiment, the present invention A recycled material pellet made from compressed and shredded glass fiber waste consisting of glass fibers and a thermoplastic binder, The present invention provides recycled material pellets in which a thermoplastic binder constitutes at least about 2% by weight of the recycled material pellets.

[0025] The present invention includes combinations of embodiments, aspects, and preferred features described herein, unless such combinations are clearly unacceptable or explicitly avoided. [Brief explanation of the drawing]

[0026] Embodiments and experiments illustrating the principle of the present invention will be discussed with reference to the attached drawings. [Figure 1] This is a photograph of the glass fiber waste material used by the method of Example 9 described herein. [Figure 2]These are photographs of multiple recycled material pellets formed by the method of Example 9 described herein. [Modes for carrying out the invention]

[0027] Next, aspects and embodiments of the present invention will be described with reference to the attached drawings. Further aspects and embodiments will be obvious to those skilled in the art.

[0028] Recycled material pellets This specification describes recycled material pellets comprising shredded glass fiber waste, wherein the shredded glass fiber waste comprises glass fibers and a thermoplastic binder, the thermoplastic binder constituting at least about 2% by weight of the recycled material pellets.

[0029] In this specification, the term “glass fiber” is used to refer to a series of continuous glass filaments (the term “continuous” as used herein is used to refer to fibers / filaments whose length is many times longer than their diameter, for example, at least about 5000 times longer than their diameter, for example, at least about 10000 times longer than their diameter). Glass fibers used in composite materials constituting structural components such as automotive parts may be supplied as glass fiber strands (or tows). The glass fibers described herein may have sizing agents on their surfaces, for example, sizing agents applied to the glass fibers during their formation. The sizing agents may include components such as film-forming agents, lubricants, and coupling agents that facilitate the formation and / or use of the glass fibers in the matrix resin. In some embodiments, the glass fibers include polyester-compatible sizing agents or epoxy-compatible sizing agents.

[0030] Any suitable glass reinforcing fiber, such as E glass, E-CR glass (e.g., Advantex™ glass fiber available from Owens Corning), C glass, H glass, S glass, and glass fibers made from AR glass types, can be used in the composite material.

[0031] The pellets described herein are formed from shredded glass fiber waste materials, and the term "shredded glass fiber waste materials" is used herein to refer to waste materials containing glass fibers and a thermoplastic binder, and the waste materials are shredded while removing the glass fiber waste materials from their original positions or shredded / cut / ruptured prior to compression as described herein (e.g., shredded / cut / ruptured for placement in a compression device). Examples of glass fiber waste materials include ceiling panels, gypsum boards, floor boards, and wall boards containing glass fiber non-woven veils. Other examples of glass fiber waste materials include chopped strand mat (CSM), such as non-woven fabric materials such as CSM having a thermoplastic binder, and optionally, the areal weight of the CSM ranges from about 150 to about 900 g / m 2 of. However, any waste material containing glass fibers and a thermoplastic binder may be used. The waste material may also include fillers, such as mineral fillers.

[0032] The glass fibers of the shredded glass fiber waste materials before being formed into pellets generally have a fiber length within the range of about 0.1 to about 200 mm, a filament diameter of at least about 5 μm, and an aspect ratio of at least 5:1. <000,0197> The glass fibers of the pellets described herein may have a fiber length of up to about 50 mm, for example, up to about 40 mm, up to about 30 mm, up to about 20 mm, or up to about 10 mm (i.e., the length of the glass fibers of the shredded waste material after compression). In a preferred embodiment, the glass fibers of the pellets described herein have a fiber length of at least about 0.5 mm (i.e., the length of the glass fibers of the shredded waste material after compression). The fiber length of the glass fibers can be measured using microscopic analysis, for example, microscopic analysis of the glass fibers after the pellets have been burned to remove the binder.

[0034] In the embodiment, the glass fibers in the shredded glass fiber waste before and after compression have a filament diameter in the range of about 5 μm to about 25 μm, for example, the glass fibers have a filament diameter in the range of about 10 μm to about 20 μm, or about 15 μm to about 20 μm.

[0035] Glass fibers may constitute at least about 10% by weight of the recycled material pellets, for example, at least about 15% by weight, at least about 20% by weight, at least about 25% by weight, at least about 30% by weight, at least about 35% by weight, at least about 40% by weight, at least about 45% by weight, at least about 50% by weight, at least about 55% by weight, at least about 60% by weight, at least about 65% by weight, at least about 70% by weight, at least about 75% by weight, at least about 80% by weight, at least about 82.5% by weight, at least about 85% by weight, at least about 87.5% by weight, at least about 90% by weight, at least about 92.5% by weight, at least about 95% by weight, at least about 97% by weight, or at least about 98% by weight.

[0036] In this embodiment, glass fibers may constitute about 10% to about 98% by weight of recycled material pellets, for example, about 15% to about 98% by weight of recycled material pellets, about 20% to about 98% by weight of recycled material pellets, about 25% to about 98% by weight of recycled material pellets, about 30% to about 98% by weight of recycled material pellets, about 40% to about 98% by weight of recycled material pellets, about 50% to about 98% by weight of recycled material pellets, about 60% to about 98% by weight of recycled material pellets, about 65% to about 98% by weight of recycled material pellets, about 70% to about 98% by weight of recycled material pellets, about 75% to about 98% by weight of recycled material pellets, about 80% to about 98% by weight of recycled material pellets, or about 90% to about 98% by weight of recycled material pellets.

[0037] In one embodiment, at least 60% by weight of the glass fibers in the shredded glass fiber waste before compression have a fiber length of at least about 0.5 mm, for example, at least about 1 mm, at least about 2.5 mm, at least about 5 mm, at least about 7.5 mm, or at least about 10 mm. In another embodiment, at least 70% by weight of the glass fibers in the shredded glass fiber waste before compression have a fiber length of at least about 0.5 mm, for example, at least 70% by weight of the glass fibers in the shredded glass fiber waste before compression have a fiber length of at least about 1 mm, at least about 2.5 mm, at least about 5 mm, at least about 7.5 mm, or at least about 10 mm. In the embodiment, at least 80% by weight of the glass fibers in the shredded glass fiber waste before compression have a fiber length of at least about 0.5 mm, for example, at least 80% by weight of the glass fibers in the shredded glass fiber waste before compression have a fiber length of at least about 1 mm, at least about 2.5 mm, at least about 5 mm, at least about 7.5 mm, or at least about 10 mm. The fiber length of the glass fibers can be measured using microscopic analysis.

[0038] In the embodiment, the glass fibers in the shredded glass fiber waste (i.e., the glass fibers of the shredded glass fiber waste before compression / pelletization) have a fiber length in the range of about 0.5 mm to about 50 mm, for example, the glass fibers in the shredded glass fiber waste have a fiber length in the range of about 0.5 mm to about 40 mm. In the embodiment, the glass fibers have fiber lengths in the range of approximately 0.5 mm to approximately 50 mm before compression. For example, the glass fibers are in the range of approximately 0.5 mm to approximately 50 mm, approximately 0.5 mm to approximately 25 mm, approximately 0.5 mm to approximately 12.5 mm, approximately 0.5 mm to approximately 10 mm, approximately 0.5 mm to approximately 7.5 mm, approximately 0.5 mm to approximately 5 mm, approximately 0.5 mm to approximately 2.5 mm, approximately 0.5 mm to approximately 1 mm, approximately 1 mm to approximately 50 mm, approximately 1 mm to approximately 25 mm, approximately 1 mm to approximately 12.5 mm, approximately 1 mm to approximately 10 mm, approximately 1 mm to approximately 7.5 mm, and approximately 1 mm to The fiber lengths are in the following ranges: approximately 5 mm, approximately 1 mm to approximately 2.5 mm, approximately 2.5 mm to approximately 50 mm, approximately 2.5 mm to approximately 25 mm, approximately 2.5 mm to approximately 10 mm, approximately 2.5 mm to approximately 7.5 mm, approximately 2.5 mm to approximately 5 mm, approximately 5 mm to approximately 50 mm, approximately 5 mm to approximately 25 mm, approximately 5 mm to approximately 10 mm, approximately 5 mm to approximately 7.5 mm, approximately 7.5 mm to approximately 50 mm, approximately 7.5 mm to approximately 25 mm, approximately 7.5 mm to approximately 10 mm, approximately 10 mm to approximately 50 mm, approximately 10 mm to approximately 25 mm, and approximately 25 mm to approximately 50 mm. The fiber length of glass fibers can be measured using microscopic analysis.

[0039] In the embodiment, 40% to 99% by weight of the glass fibers in the shredded glass fiber waste (i.e., the glass fibers of the shredded glass fiber waste before compression / pelletization) have a fiber length in the range of about 0.2 mm to about 10 mm. For example, at least about 45% by weight of the glass fibers may have a fiber length in the range of about 0.5 mm to about 7 mm, at least about 65% by weight of the glass fibers may have a fiber length in the range of about 0.5 mm to about 7 mm, or at least about 85% by weight of the glass fibers may have a fiber length in the range of about 0.5 mm to about 7 mm.

[0040] In one embodiment, at least 60% by weight of the glass fibers in the shredded glass fiber waste (i.e., the glass fibers in the shredded glass fiber waste before compression / pelletization) have an aspect ratio of at least about 5:1, for example, at least 60% by weight of the glass fibers have an aspect ratio of at least about 10:1, at least about 50:1, at least about 100:1, at least about 250:1, at least about 500:1, or at least about 1000:1. In another embodiment, at least 70% by weight of the glass fibers have an aspect ratio of at least about 5:1, for example, at least 70% by weight of the glass fibers have an aspect ratio of at least about 10:1, at least about 50:1, at least about 100:1, at least about 250:1, at least about 500:1, or at least about 1000:1. In one embodiment, at least 80% by weight of the glass fibers have an aspect ratio of at least about 5:1, for example, at least 80% by weight of the glass fibers have an aspect ratio of at least about 10:1, at least about 50:1, at least about 100:1, at least about 250:1, at least about 500:1, or at least about 1000:1. In another embodiment, at least 90% by weight of the glass fibers have an aspect ratio of at least about 5:1, for example, at least 90% by weight of the glass fibers have an aspect ratio of at least about 10:1, at least about 50:1, at least about 100:1, at least about 250:1, at least about 500:1, or at least about 1000:11. In the embodiment, at least 95% by weight of the glass fibers have an aspect ratio of at least about 5:1, for example, at least 95% by weight of the glass fibers have an aspect ratio of at least about 10:1, at least about 50:1, at least about 100:1, at least about 250:1, at least about 500:1, or at least about 1000:1. The aspect ratio of the glass fibers in the shredded glass fiber waste can be determined by microscopic analysis.

[0041] Recycled material pellets contain a thermoplastic binder.

[0042] The thermoplastic binder constitutes up to approximately 30% by weight of the recycled material pellets. In the embodiment, the thermoplastic binder constitutes up to approximately 30% by weight of the recycled material pellets, for example, up to approximately 25% by weight, up to approximately 20% by weight, up to approximately 15% by weight, up to approximately 10% by weight, up to approximately 7.5% by weight, up to approximately 5% by weight, up to approximately 2.5% by weight, up to approximately 2% by weight, or up to approximately 1% by weight of the recycled material pellets.

[0043] The thermoplastic binder constitutes at least about 2% by weight of the recycled material pellets. In embodiments, the thermoplastic binder constitutes, for example, at least about 5% by weight, at least about 10% by weight, at least about 15% by weight, at least about 20% by weight, at least about 25% by weight, or at least about 30% by weight of the recycled material pellets. In embodiments, the thermoplastic binder constitutes approximately 2% to approximately 30% by weight of the recycled material pellets, for example, approximately 2% to approximately 30% by weight, or approximately 5% to approximately 30% by weight, or approximately 10% to approximately 30% by weight, or approximately 30% to approximately 25% by weight, or approximately 20% to approximately 30% by weight, or approximately 25% to approximately 30% by weight, or for example, approximately 2% to approximately 25% by weight, or approximately 5% to approximately 25% by weight, or approximately 10% to approximately 25% by weight, or approximately 15% to approximately 25% by weight, or approximately 20% to approximately 25% by weight, or It constitutes, for example, a range of approximately 2% to 20% by weight of recycled material pellets, or approximately 5% to 20% by weight, or approximately 10% to 20% by weight, or 15% to 20% by weight, or for example, a range of approximately 2% to 15% by weight of recycled material pellets, or approximately 5% to 15% by weight, or approximately 10% to 15% by weight, or for example, a range of approximately 2% to 10% by weight of recycled material pellets, or approximately 5% to 10% by weight, or for example, a range of approximately 2% to 5% by weight of recycled material pellets.

[0044] In the embodiment, the thermoplastic binder has a glass transition temperature of up to about 90°C, for example, up to about 85°C, up to about 80°C, up to about 75°C, up to about 70°C, up to about 65°C, up to about 60°C, or up to about 55°C. In the embodiment, the thermoplastic binder has a glass transition temperature of at least about 30°C, for example, at least about 40°C, or at least about 50°C. In the embodiment, the thermoplastic binder has a glass transition temperature in the range of about 30°C to about 90°C, for example, in the range of about 55°C to about 70°C, or in the range of about 60°C to 90°C.

[0045] The glass transition temperature of a thermoplastic binder can be determined using differential scanning calorimetry (DSC) according to EN ISO 1153357-2 (Determination of Glass Transition Temperature). The glass transition temperature of a thermoplastic binder can be determined using differential scanning calorimetry (DSC) according to EN ISO 1153357-2 (Determination of Glass Transition Temperature), and the glass transition temperature is determined as the value provided in the second heating cycle. The glass transition temperature of a thermoplastic binder can be determined by heating the thermoplastic binder from -60°C to 120°C under an airflow of 80 mL / min at a heating rate of 10 K / min, according to the EN ISO 1153357-2 test method. In this embodiment, the glass transition temperature of the thermoplastic binder may be determined by heating the thermoplastic binder at a heating rate of 10 K / min under an airflow of 80 mL / min, heating from -60°C to 120°C, then holding at 120°C for 5 minutes, then cooling from 120°C to -60°C at a cooling rate of 10 K / min, then holding at -60°C for 5 minutes, and then heating again from -60°C to 120°C at a heating rate of 10 K / min, and the glass transition temperature is determined as the value provided in the second heating cycle.

[0046] In the embodiment, the thermoplastic binder comprises or is composed of a thermoplastic resin selected from epoxy resin, polyester resin, or polyvinyl alcohol resin.

[0047] In this embodiment, the recycled material pellets are approximately 150 kg / m³ 3 ~About 1000kg / m 3 It has a density within the range of [this range]. In some embodiments, the recycled material pellets have a maximum density of approximately 900 kg / m³. 3 For example, a maximum of approximately 800 kg / m 3 , maximum about 700kg / m 3 , maximum about 600kg / m 3 , or up to approximately 500 kg / m 3 It has a density of at least about 200 kg / m³. In some embodiments, the recycled material pellets have a density of at least about 200 kg / m³. 3 For example, at least about 250 kg / m 3 , at least about 300 kg / m 3 , at least about 350 kg / m 3 , at least about 400 kg / m 3 , at least about 450 kg / m 3 , or at least about 500 kg / m 3 It has a density of approximately 150 kg / m³. In some embodiments, the recycled material pellets have a density of approximately 150 kg / m³. 3 ~about 800kg / m 3 For example, approximately 200 kg / m 3 ~Approx. 750kg / m 3 , about 200kg / m 3 ~about 700kg / m 3 , about 200kg / m 3 ~about 650kg / m 3 , about 200kg / m 3 ~about 600kg / m 3 , about 200kg / m 3 ~about 550kg / m 3 , about 200kg / m 3 ~about 500kg / m 3 , about 250kg / m 3 ~about 800kg / m 3 , about 250kg / m 3 ~about 700kg / m 3 , about 250kg / m 3 ~about 600kg / m 3 , about 250kg / m 3 ~about 500kg / m 3 , about 300kg / m 3~about 800kg / m 3 , about 300kg / m 3 ~about 700kg / m 3 , about 300kg / m 3 ~about 600kg / m 3 , about 300kg / m 3 ~about 700kg / m 3 , about 300kg / m 3 ~about 600kg / m 3 , about 400kg / m 3 ~about 800kg / m 3 , about 400kg / m 3 ~about 700kg / m 3 , or approximately 400 kg / m 3 ~about 600kg / m 3 It has a density within the specified range. The density of recycled material pellets can be measured using a standard density substitution method.

[0048] In the embodiment, the recycled material pellets have a diameter of less than about 60 mm, less than about 50 mm, less than about 40 mm, less than about 30 mm, less than about 20 mm, less than about 10 mm, less than about 8 mm, or less than about 6 mm, or less than about 4 mm. For example, the diameter of the recycled material pellets may be at least about 2 mm, or at least about 3 mm, and for example, the diameter of the recycled material pellets may be in the range of 2 to 10 mm. For example, the diameter of the recycled material pellets may be at least about 5 mm, or at least 10 mm, or at least about 20 mm, and for example, the diameter of the recycled material pellets may be in the range of 5 to 30 mm.

[0049] In embodiments, recycled material pellets may have a maximum length of about 100 mm, for example, a maximum length of about 50 mm. In embodiments, the length of recycled material pellets may range from about 1 to about 50 mm, for example, from about 5 mm to about 50 mm, or from about 10 mm to about 40 mm, or from about 15 to 20 mm. In embodiments, the length of recycled material pellets may be at least about 1 mm.

[0050] In the embodiment, the recycled material pellets include glass fibers and a thermoplastic binder. In the embodiment, the recycled material pellets include additional fibers in addition to the glass fibers and thermoplastic binder. Examples of other fibers that may be included include polymer fibers such as PET, or carbon fibers. In the embodiment, the additional fibers may constitute up to about 10% by weight of the recycled material pellets, for example, up to about 5% by weight, up to about 3% by weight, up to about 2% by weight, up to about 1% by weight, up to about 0.5% by weight, or up to about 0.1% by weight of the recycled material pellets.

[0051] In embodiments, the recycled material pellets include glass fibers and a thermoplastic binder. In embodiments, the recycled material pellets may include fillers in addition to glass fibers and a thermoplastic binder. Examples of fillers that may be present in shredded glass waste include mineral fillers such as calcium carbonate, titanium dioxide, and / or aluminum trihydrate. In embodiments, the pellets may contain up to about 70% by weight of filler, 65% by weight of filler, or 60% by weight of filler, for example, up to about 55% by weight, up to about 50% by weight, up to about 45% by weight, up to about 40% by weight, up to about 35% by weight, up to about 30% by weight, up to about 25% by weight, or up to about 20% by weight of filler. In embodiments, the pellets may contain about 0 to about 60% by weight of filler, for example, 0 to about 40% by weight, 0 to about 30% by weight, or 0 to about 20% by weight of filler, based on the total weight of the pellets. In the embodiment, the pellets contain substantially no filler (for example, less than about 5% by weight of filler, less than about 3% by weight of filler, less than about 2% by weight of filler, less than about 1% by weight of filler, or less than about 0.5% by weight of filler, relative to the total weight of the pellets).

[0052] In the embodiment, the recycled material pellets consist of shredded glass fiber waste, which comprises glass fibers and a thermoplastic binder. In other words, in the embodiment, the recycled material pellets contain only glass fiber waste, which consists of glass fibers and a thermoplastic binder, and there are no additional materials such as fillers in the recycled material pellets.

[0053] In some embodiments, the recycled material pellets consist of compressed glass fiber waste, which consists of glass fibers and a thermoplastic binder, with glass fibers accounting for about 65% to about 98% by weight of the glass fiber waste, and the thermoplastic binder accounting for 2 to 35% by weight of the glass fiber waste. In some embodiments, the recycled material pellets consist of compressed glass fiber waste, which consists of glass fibers and a thermoplastic binder, with glass fibers accounting for about 70% to about 98% by weight of the glass fiber waste, and the thermoplastic binder accounting for 2 to 30% by weight of the glass fiber waste. In some embodiments, the recycled material pellets consist of compressed glass fiber waste, which consists of glass fibers and a thermoplastic binder, with glass fibers accounting for about 80% to about 98% by weight of the glass fiber waste, and the thermoplastic binder accounting for 2 to 20% by weight of the glass fiber waste. In some embodiments, the recycled material pellets consist of compressed glass fiber waste, which consists of glass fibers and a thermoplastic binder, with the glass fibers making up about 90% to 98% by weight of the glass fiber waste, and the thermoplastic binder making up 2% to 10% by weight of the glass fiber waste.

[0054] A suitable thermoplastic binder is polyvinyl alcohol.

[0055] Method for producing recycled material pellets This specification provides shredded glass fiber waste containing glass fibers and a thermoplastic binder, wherein the thermoplastic binder constitutes at least about 2% by weight of the shredded glass fiber waste, and describes a method for compressing the shredded glass fiber waste to form recycled material pellets.

[0056] In the embodiment, the thermoplastic binder has a dynamic viscosity η in the range of about 1 to about 400 Pa.s at 130°C, for example, in the range of about 10 to about 400 Pa.s. The dynamic viscosity η of the thermoplastic binder at 130°C can be determined by employing a heating-cooling-heating cycle using a binder sample having a thickness of 400 μm and a diameter of 25 mm, with a 0.1% deformation in planar geometry and a frequency of 1 Hz, where the sample is heated from 30°C to 130°C at a rate of 3°C / min, cooled from 130°C to 30°C, and heated from 30°C to 130°C at a rate of 3°C / min.

[0057] In the embodiment, recycled material pellets are manufactured in a range of approximately 5 MPa to approximately 300 MPa, for example, approximately 10 MPa to approximately 300 MPa, approximately 50 MPa to approximately 300 MPa, approximately 100 MPa to approximately 300 MPa, approximately 150 MPa to approximately 300 MPa, approximately 200 MPa to approximately 300 MPa, approximately 250 MPa to approximately 300 MPa, approximately 5 MPa to approximately 250 MPa, for example, approximately 10 MPa to approximately 250 MPa, approximately 50 MPa to approximately 250 MPa, approximately 100 MPa to approximately 250 MPa, approximately 150 MPa to approximately 250 MPa, approximately 200 MPa to approximately 250 MPa, approximately 5 MPa to approximately 200 MPa, for example This may include compressing shredded glass fiber waste at pressures in the range of approximately 10 MPa to approximately 200 MPa, approximately 50 MPa to approximately 200 MPa, approximately 100 MPa to approximately 200 MPa, approximately 150 MPa to approximately 200 MPa, approximately 5 MPa to approximately 150 MPa, for example, approximately 10 MPa to approximately 150 MPa, approximately 50 MPa to approximately 150 MPa, approximately 100 MPa to approximately 150 MPa, approximately 5 MPa to approximately 100 MPa, for example, approximately 10 MPa to approximately 100 MPa, approximately 50 MPa to approximately 100 MPa, approximately 5 MPa to approximately 50 MPa, for example, approximately 10 MPa to approximately 50 MPa, or approximately 5 MPa to approximately 10 MPa.

[0058] In some embodiments, producing recycled material pellets may involve compressing shredded glass fiber waste at a pressure exceeding at least about 50 MPa and up to about 400 MPa, for example, at at least about 75 MPa, at least about 125 MPa, or at least about 175 MPa.

[0059] In the embodiment, at least 60% by weight of the glass fibers in the recycled material pellets have fiber lengths in the range of about 0.5 mm to about 20 mm, for example, at least 60% by weight of the glass fibers have fiber lengths in the range of about 0.5 mm to about 15 mm, about 0.5 mm to about 12.5 mm, about 0.5 mm to about 10 mm, about 0.5 mm to about 7.5 mm, about 0.5 mm to about 5 mm, about 0.5 mm to about 2.5 mm, about 1 to 20 mm, about 1 mm to about 15 mm, about 1 mm to about 12.5 mm, about 1 mm to about 10 mm, about 1 mm to about 7.5 mm, about 1 mm to about 5 mm, about 1 mm to about 2.5 mm, about 2.5 mm to about 20 mm, about 2.5 mm The fibers have lengths in the following ranges: approximately 15mm, approximately 2.5mm to approximately 12.5mm, approximately 2.5mm to approximately 10mm, approximately 2.5mm to approximately 7.5mm, approximately 2.5mm to approximately 5mm, approximately 5mm to approximately 20mm, approximately 5mm to approximately 15mm, approximately 5mm to approximately 10mm, approximately 5mm to approximately 7.5mm, approximately 7.5mm to approximately 20mm, approximately 7.5mm to approximately 15mm, approximately 7.5mm to approximately 12.5mm, approximately 7.5mm to approximately 10mm, approximately 10mm to approximately 20mm, approximately 10mm to approximately 15mm, approximately 10mm to approximately 12.5mm, approximately 12.5mm to approximately 20mm, approximately 12.5mm to approximately 15mm, or approximately 15mm to approximately 20mm. The fiber length of glass fibers can be measured using microscopic analysis, for example, by microscopic analysis of glass fibers after the binder has been removed by burning the pellets.

[0060] In the embodiment, the glass fibers and thermoplastic binder are shredded before compression. For example, the glass fibers and thermoplastic binder can be shredded by any shredding technique known in the art.

[0061] In one embodiment, compressing the composition to form recycled material pellets includes heating the composition to a temperature of at least about 30°C, for example, at least about 40°C, at least about 50°C, at least about 60°C, at least about 70°C, at least about 80°C, at least about 90°C, or at least about 100°C. In another embodiment, compressing the composition to form recycled material pellets further includes heating the composition to a temperature of at least about 30°C, for example, at least about 40°C, at least about 50°C, or at least about 60°C. In yet another embodiment, compressing the composition to form recycled material pellets further includes heating the composition to a temperature of up to about 100°C, for example, up to about 80°C, up to about 70°C, or up to about 60°C. In yet another embodiment, compressing the composition to form recycled material pellets further includes heating the composition to a temperature in the range of about 40°C to about 70°C, for example, in the range of about 50°C to about 70°C, or at least about 100°C. In the embodiment, compressing the composition to form recycled material pellets includes heating the composition at a temperature of about 60°C. In the embodiment, compressing the composition to form recycled material pellets includes heating the composition at a temperature in the range of about 30°C to about 100°C, for example, in the range of about 40°C to about 80°C, or at least about 50°C to about 70°C. In the embodiment, the glass fibers and thermoplastic binder are supplied from a nonwoven bale or from a composite material containing a nonwoven bale.

[0062] The term "nonwoven veil" refers to a lightweight fiberglass material (approximately 10-200 g / m²) composed of randomly oriented fiberglass, a binder, and optionally a filler. 2 For example, approximately 20 to 150 g / m 2 , or approximately 20 to 100 g / m 2 It is commonly used to describe the area weight (of a range). Bales can be formed by a wet process. Nonwoven bales can be recycled nonwoven bales, for example, supplied from ceiling boards, floor boards, or wall boards.

[0063] In the embodiments, compression is achieved using any one of the following: a pellet mill, a mechanical screw press, a piston press, a roller press, a tablet molding machine, a rolling granulator, a mixer granulator, biomass compression, densification under vacuum, or a combination thereof. [Examples]

[0064] Examples of recycled material pellets and related embodiments described herein are provided below. These examples should not be considered limiting to the disclosure, but merely to teach how to carry out the methods of the disclosure and obtain products.

[0065] Examples 1-9 The inventors conducted research to establish the importance of including a thermoplastic binder in shredded glass fiber waste.

[0066] The inventors used eight different glass fiber waste materials. Two of the glass fiber waste materials contained glass fibers and a thermoplastic binder. Six of the glass fiber waste materials contained glass fibers and a thermosetting binder. One of these glass fiber waste materials also contained thermoplastic stitching yarn, and the total amount of thermoplastic material in the glass fiber waste material was less than 2% by weight (approximately 1% by weight).

[0067] All of the glass fiber waste was shredded and prepared. Each shredded composition was compressed under the same conditions using a Mandoka Pellet Mill.

[0068] Shredded glass fiber waste used in Examples 1-8 Example 1: WUCS (Wet Use Chopped Strand) contains glass fiber, water, and a thermosetting binder. The material used contains 92.7% by weight of glass fiber, 0.3% by weight of thermosetting binder, and 7% by weight of water.

[0069] Example 2: Dry WUCS (Dry Wet Use Chopped Stand) contains glass fiber and a thermosetting binder. The material used contains 99.7% by weight of glass fiber and 0.3% by weight of thermosetting binder.

[0070] Example 3: The shredded UD woven fabric (unidirectional) contains glass fibers, a thermosetting binder, and thermoplastic stitching yarn. The material used contains 98.5% by weight of glass fibers, 0.5% by weight of a thermosetting binder, and about 1% by weight of thermoplastic polyester stitching yarn.

[0071] Example 4: The shredded cake crust contains glass fibers and a thermosetting binder. The materials used contain 98% by weight of glass fibers and 2% by weight of a thermosetting binder.

[0072] Example 5: The shredded CFM (Continuous Filament Mat) contains glass fibers and a thermosetting binder. The material used contains 96% by weight of glass fibers and 4% by weight of thermosetting binder.

[0073] Example 6: The shredded CSM (Chopped Strand Mat) contains glass fibers and a thermoplastic binder. The material used contains 96% by weight of glass fibers and 4% by weight of thermoplastic binder.

[0074] Example 7: Dry-use chopped strands containing glass fibers and a thermosetting binder. The material used contained 99% by weight of glass fibers and 1% by weight of a thermosetting binder.

[0075] Example 8: The shredded NW fabric (nonwoven fabric) contains glass fibers and a thermoplastic binder. The material used contains 80% by weight of glass fibers and 20% by weight of thermoplastic binder.

[0076] As shown in Table 1 below, shredded glass fiber waste containing a thermoplastic binder exhibited good processability and formed pellets. Shredded glass fiber waste without a thermoplastic binder did not form pellets. In some cases, powder was formed, but pellets were not. The inventors found that a thermoplastic binder is necessary to significantly improve pelletization. These results indicate that a thermoplastic binder is important in glass fiber waste, but a thermoplastic binder can be added to glass fiber waste that does not contain an inherent thermoplastic binder.

[0077] The pellets defined in the table below are at least approximately 150 kg / m³. 3 It has a density and a diameter of at least 2 mm.

[0078] [Table 1]

[0079] Example 9 Recycled material pellets were manufactured by supplying glass fiber waste. The glass fiber waste was in the form of nonwoven bales. The nonwoven bales contained glass fibers and a thermoplastic binder. The nonwoven bales were shredded. The shredded nonwoven bales had a yield of 100 kg / m². 3 It had a density of . The shredded nonwoven flooring bale of glass fibers and thermoplastic binder was compressed in a Mandoka Pellet Mill to form pellets. The resulting recycled material pellets had a diameter of 6 mm and a density of 800 kg / m³. 3 That was the case.

[0080] Figure 1 shows the 100 kg / m³ used in Example 9. 3 This shows a photograph of a shredded nonwoven veil with a density of [density].

[0081] Figure 2 shows the 800 kg / m³ formed in Example 9. 3The image shows a photograph of the resulting recycled material pellets having a density of [density].

[0082] The inventors have found that by providing such recycled material pellets, the fluidity of shredded glass fiber waste containing glass fibers and a thermoplastic binder is improved. The recycled material pellets have increased density compared to shredded nonwoven flooring bales. Along with the increased density, the inventors have found that the amount of dust is reduced compared to shredded nonwoven flooring bales. The overall ease of handling of these materials is improved.

[0083] Therefore, the inventors have discovered that the handling and input of glass fiber composite materials can be improved by compressing shredded glass fiber waste containing glass fibers and a thermoplastic binder. The inventors have also found that high-value materials can be reused from glass fiber composite materials by providing recycled material pellets. This may be particularly advantageous when used on a large scale.

[0084] Apparatus used in the examples Mandoka Pellet Mill - The composition is introduced inside the die within the pellet mill. A spreader is present within the pellet mill to ensure uniform distribution of the composition. As the die rotates, rollers compress the composition through the die's holes. A cutter, coplanar with the outside of the die, separates the exposed recycled material pellets from the die.

[0085] Measurement method used in the example Pellet integrity To measure the integrity of the pellets, they are circulated in a circular metal passage by compressed air.

[0086] This test simulates the effects on pellets as they are transported pneumatically along the extrusion line between the storage area and the extruder.

[0087] The steps for integrity testing are as follows: 1) Weigh the sample. 2) Place the sample in a circular metal container. 3) Introduce compressed air into the container. 4) After the set time, stop the compressed air. 5) Remove the sample from the container and sift it through a sieve. 6) Collect the portion of the sample that passes through the sieve. These portions will form a mat. 7) Determine the loss rate by comparing the weight of the mat to the original weight of the sample.

[0088] The diameter of the sieve mesh is 4 mm.

[0089] The integrity of the pellets prepared according to Example 9 was measured using the method described above.

[0090] The first test conducted used compressed air at a pressure of 0.25 MPa, a test time of 1 minute, and 50 g of pellets. The loss rate was found to be 4.6 g / kg.

[0091] The second test conducted used compressed air at a pressure of 0.4 MPa, a test time of 2 minutes, and 150 g of pellets. The loss rate was found to be 7.3 g / kg.

[0092] The measured loss rate indicates that the pellets produced in Example 9 have good handling properties.

[0093] density The apparent bulk density of shredded fiberglass waste was determined using a standard apparent bulk density method. The mass of one liter of shredded fiberglass waste was measured and used to determine the density of the shredded fiberglass waste.

[0094] The apparent bulk density of the recycled material pellets was determined using a standard apparent bulk density method. The mass of one liter of recycled material pellets was measured and used to determine the pellet density.

[0095] All density measurements were performed at standard room temperature.

[0096] The inventors anticipate that shredded glass fiber waste containing other amounts of glass fibers and a thermoplastic binder, for example, a composition containing glass fibers and a thermoplastic binder, wherein the thermoplastic binder is in the range of 2% to 30% by weight, will provide recycled material pellets having similar advantages to the compositions used in the above examples.

[0097] The inventors of this invention have found that approximately 250 kg / m³ 3 We anticipate that lower densities, such as those mentioned above, may improve the retention of glass fiber length and therefore improve the mechanical properties of the glass fibers. The inventors anticipate that a density of approximately 700 kg / m³ may be possible. 3 We anticipate that higher densities, such as those mentioned above, can improve the handling ease of the shredded glass fiber waste composition and potentially reduce the loss rate.

[0098] Further research by the inventors has led to the development of higher densities, for example, 0.70 g / m³. 3 Compared to 0.97g / m 3 Recycled material pellets possessing the above characteristics were found to exhibit higher structural integrity and greater resistance to pneumatic transport, as there was no loss during testing using the above method. Such recycled material pellets can be produced using the pellet mill method described above.

[0099] The inventors conducted further research to investigate the effect of temperature on the integrity of recycled material pellets. They produced two sets of pellets using the same compressed and shredded fiberglass waste. One set of pellets was produced at 40°C using an 18mm die. The other set of pellets was produced at 60°C using an 18mm die. The inventors found that the pellets formed at 60°C exhibited higher structural integrity when tested using the method described above, indicating greater resistance to pneumatic transport. The pellets can be produced using the pellet mill method described above.

[0100] The inventors believe that further advantages in terms of the structural integrity of the manufactured pellets can be provided by using glass fiber waste consisting of a thermoplastic binder and glass fibers as described herein. Studies conducted by the inventors suggest that using glass fiber waste consisting of a thermoplastic binder and glass fibers as described herein provides pellets with improved structural integrity with respect to a given amount of thermoplastic binder compared to pellets formed from glass fiber waste containing glass fibers, a thermoplastic binder, and a filler.

[0101] The features disclosed in the preceding description, the following claims, or the accompanying drawings may be expressed as appropriate in their specific forms, or in terms of means for carrying out the disclosed functions, or methods or processes for obtaining the disclosed results, and may be used individually or in any combination of such features to realize the present invention in a variety of forms.

[0102] While the present invention has been described in relation to the exemplary embodiments described above, many equivalent modifications and variations will become apparent to those skilled in the art when given this disclosure. Therefore, the exemplary embodiments of the present invention described above are illustrative and not limiting. Various modifications to the embodiments described can be made without departing from the spirit and scope of the invention.

[0103] To avoid any doubt, any theoretical explanations provided herein are provided for the purpose of improving the reader's understanding. The inventors do not wish to be bound by any of these theoretical explanations.

[0104] Any section headings used herein are for structural purposes only and should not be construed as limiting the subject matter described herein.

[0105] Throughout this specification, including in the following claims, unless otherwise specified in the context, the terms “comprise” and “include,” as well as variations such as “comprises,” “comprising,” and “including,” will be understood to mean the inclusion of the integer or step or group of integers or steps stated, but not the exclusion of any other integer or step or group of integers or steps.

[0106] Where used herein and in the appended claims, the singular forms “a,” “an,” and “the” refer to multiple subjects unless the context clearly indicates otherwise. Ranges may be expressed herein as “about” one particular value to and / or “about” another particular value. Where such ranges are expressed, another embodiment includes one particular value to and / or another particular value. Similarly, where values ​​are expressed as approximations by the use of the antecedent “about,” it will be understood that a particular value forms another embodiment. The term “about” with respect to numbers is optional and means, for example, + / - 10%.

Claims

1. Recycled material pellets containing compressed and shredded glass fiber waste, which includes glass fibers and a thermoplastic binder, Recycled material pellets wherein the thermoplastic binder constitutes at least about 2% by weight of the recycled material pellets.

2. The recycled material pellet according to claim 1, wherein the shredded glass fiber waste constitutes at least 90% by weight of the recycled material pellet.

3. The recycled material pellet according to claim 1 or 2, wherein the thermoplastic binder constitutes up to about 30% by weight of the recycled material pellet, and the glass fibers constitute at least 25% by weight of the recycled material pellet.

4. The recycled material pellet according to any one of claims 1 to 3, wherein the thermoplastic binder constitutes an amount of about 2% to about 25% by weight of the recycled material pellet.

5. Approximately 150kg / m ３ ~Approx. 1000kg / m ３ A recycled material pellet according to any one of claims 1 to 4, having a density within the range.

6. Approximately 300kg / m ３ ~Approx. 800kg / m ３ Recycled material pellets according to claim 5, having a density within the range.

7. The recycled material pellet according to any one of claims 1 to 6, wherein the glass fibers have an aspect ratio of at least 5:

1.

8. The recycled material pellet according to any one of claims 1 to 7, wherein the thermoplastic binder has a glass transition temperature in the range of about 30°C to about 80°C.

9. A recycled material pellet according to any one of claims 1 to 8, having a diameter in the range of approximately 2 to approximately 10 mm.

10. A recycled material pellet according to any one of claims 1 to 9, having a length in the range of approximately 1 to approximately 50 mm.

11. The recycled material pellet according to any one of claims 1 to 10, wherein the glass fibers have a fiber length of at least about 0.5 mm.

12. The aforementioned recycled material pellets A recycled material pellet according to any one of claims 1 to 11, comprising compressed and shredded glass fiber waste consisting of glass fibers and a thermoplastic binder, wherein the thermoplastic binder constitutes at least about 2% by weight of the recycled material pellet.

13. A method for producing recycled material pellets, To provide shredded glass fiber waste containing glass fibers and a thermoplastic binder, wherein the thermoplastic binder constitutes at least about 2% by weight of the shredded glass fiber waste, A method comprising compressing the aforementioned shredded glass fiber waste to form recycled material pellets.

14. By compressing the aforementioned shredded glass fiber waste, approximately 150 kg / m³ is obtained. ３ ~Approx. 1000kg / m ３ A method for producing recycled material pellets according to claim 13, wherein recycled material pellets having a density within a range are formed.

15. A method for producing recycled material pellets according to claim 13 or 14, wherein the compression of the shredded glass fiber waste is carried out at a temperature in the range of about 50°C to about 70°C.

16. A recycled material pellet product manufactured according to the method described in claims 13 to 15.

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