WO2018117889A1

WO2018117889A1 - Prodcess of producing a plastic material, plastic material and use of the plastic material

Info

Publication number: WO2018117889A1
Application number: PCT/RS2017/000017
Authority: WO
Inventors: Miroslav Filep
Original assignee: Miroslav Filep
Priority date: 2016-12-23
Filing date: 2017-12-22
Publication date: 2018-06-28
Also published as: EP3559093A1; RS20161167A1; RS57664B1

Abstract

Product- A filled plastic profile generally is a term related to tectonics and recycling, is made out of recycled materials gained by special processes in specially adjusted machinery, consists of shell (extended, plastic hollow profile of various lenghts, sizes, shapes, and sections) and fillig (made out of concrete from recycled materials, whereas the concrete itself can be a product of its own considering it has excellent thermo-isolating properties, elasticity etc.) is also made by specific processes. Filled plastic profile has a wide range of usage as end products (fence pole, road sign pole, electric wiring pole, construction materials for prefabricated buildings, defensive nets in agriculture, as a segment in production of benches, shelves etc.) which need weather resistence, salt, corrosion, chemical resistences, which don't need any further maintance in terms of painting, protecting, and it's pleasent to look at and durable. Filled plastic profile can replace usual materials (wood, iron, concrete poles) and give better performances considering its firmness can be from extremely firm to extremely elastic (it depends on the method and technology used in the production, and the intended usage), and yet, easy to manipulate and furtherly amend.

Description

PRODCESS OF PRODUCING A PLASTIC MATERIAL, PLASTIC MATERIAL AND USE OF THE PLASTIC MATERIAL

TECHNICAL FIELD

In a broad sense, the product benefits construction and recycling industries, and in effect it refers to the phased processing of firstly, raw materials which through further processing compound into a single product- a filled plastic profile. The product- a filled plastic profile consists of 75-80% waste materials which were not recyclable using as yet known recyclatory technologies. Its exterior (external shell) is an oblong hollow plastic profile made of raw materials using special recyclatory processes, and its interior is a concrete-material filling made of raw materials using a special recyclatory process. These components are homogenized in a machine specifically customized for this purpose (fig.l;fig.2).

A filled plastic profile has a wide range of utilization. It can be used as:

- a final product (post, girder, beam, batten or crossbar of various intended usages, traffic sign pole, prefabricated buildings construction, hail-protection nets in agriculture, various stanchions in pomiculture, vineyards etc.), or as a semifinished product- a segment (replacing a wooden or an iron (steel) beam, crossbar, batten), as a part for manufacturing products of other industrial branches (exterior or interior furniture, garden furniture, park benches, storehouse shelves, segments of products which require weather resistance, moisture resistance, corrosion resistance, salts resistance, electricity resistance etc. but require no or very little maintenance and are resistant to chemical exposure, disinfectants, cleaning agents etc.) and represents filled profiles whose production has several stages and homogenizes different, and until now, incompatible materials in recyclatory processes, it can come in various shapes and sizes depending on intended usages, its cross-section can vary in size and it can be round, spherical, oval, semi-oval, rectangular, quadratic or any other shape whilst possessing exceptional features in comparison to known materials such as wood, concrete or iron (steel) used in production of posts or profiles, and still pleasant to the eye, solid, durable, easy to transport, easy to handle and very convenient for further processing.

Besides the filled plastic profile as the final product, the filling itself, as a component produced using special production process, which is used to fill the oblong hollow plastic profile (as a stage of filled plastic profiles production) represents a separate invention that has separate utility and intended usage. In other words, The filling of a filled plastic profile represents a product (concrete made of recycled materials) or a semiproduct (it can be industrially made only as a component) with intended use of producing new types of concrete which would, in broad sense, refer to construction industry.

TECHNICAL PROBLEM

Technical problems that could be solved with this inventions are:

- Working out a product-material with wide range of applicability (in construction industry, traffic industry, agriculture, wide range of applicability products etc.) that can be an adequate replacement for products traditionally made of materials such as wood, iron (steel) and concrete. A product that possesses superior features and higher performance than traditional materials, while not requiring any maintenance. - Making a product i.e. component/segment/repromaterial for various further processes and purposes, which is made mostly of waste materials, which are in abundance, but were unusable in recycling technologies. Which would result in recycling a large portion of communal waste materials into a new, useful, economical product.

- Making a product without the emission of harmful gases, without consumption of natural resources, all that while drastically reducing the amount of unusable, unrecyclable waste materials, using a 100% green and environment-friendly production technologies.

- Making a green, recycled product that can, in its entirety, be recycled again to make a new recyclatory materials for production of that same, recycled product once again.

BACKGROUND ART

Various fencing poles (garden fences, farms, highway fences etc.), just like most of the net-carrying posts, sign posts, power line and telephone line posts, prefabricated building constructions, anti hail net support pillars for vineyards, raspberry plantations, orchards; staircases, furniture parts, or complete furniture, especially garden furniture, benches, shelves etc. are traditionally made out of common materials including wood, iron (steel) profiles and concrete.

Even though wood is a solid material , it deteriorates due to weather conditions, insect infestation etc. Regardless of the regular and expensive maintenance (treating it against insects, protective and decorative lacquers and varnishes) its condition deteriorates inevitably.

The use of iron profiles is also widespread in manufacture of the aforementioned products. Iron profiles are also affectable from rust and deterioration, especially due to exposure to salts and weather conditions, and also require regular, expensive and often complicated maintenance.

Products that are made of concrete also deteriorate over the course of time due to exposure to salts and weather conditions. Besides that, those products are impractical for transportation, manipulation and further processing.

The author of the invention, aware of the flaws of aforementioned traditional materials, had decided to come up with a new product (by adjusting and modifying the existing machinery, tools, and by bringing innovations to a known technology) which will eliminate the aforementioned flaws of the traditional materials with its high performance features which enables much easier manipulation in terms of transport, installment and further processing (in case that the final product, or the material is a component in the manufacture of another new product), that is resistant to all weather conditions, exposure to salts and chemical agents, and still, not require any further investment in terms of various protective varnishes, painting while being pleasant to the eye, long lasting and solid.

DISCLOSURE OF INVENTION

The basis of the invention- a filled plastic profile, consists of production of the oblong hollow plastic profiles of various cross-sections and shapes that have rough inner surfaces, so that the homogenization would be more successful after the filling with the recycled materials concrete. In other words, the result is a more solid, more compact, inseparable compound product consisted of 70-80% waste materials. The oblong hollow plastic profiles are manufactured in a particular way, and consist several plastic materials (noncombinative in production processes until now) to gain a unique product with numerous positive features (firm, but not brittle, flexible and elastic, always returning to its normal form if bent). Hollow plastic profiles are afterwards filled with concrete made of recycled materials which is consisted of triturated scrap glass and triturated mixed plastic, i.e. finely triturated scrap plastic in a special homogenization process (cement and water are used as a binder later on). This method of production results in the creation of a new type of recycled concrete, which can be (according to its intended usage) extremely firm and solid, or more or less elastic, resistant to impacts, extreme pressures, with adjustable weight according to its intended usage, but always a lot lighter than the traditional concrete mixtures, depending on the amount of aforementioned two recyclatory components in the recipe. A filled plastic profile is a product that represents the compound of the aforementioned components which can effectively replace wooden, iron or concrete post, pillar, support beam etc. and have superior features and properties because its handled, manipulated and processed easier than the products made of traditional materials (it's easy to cut through, it's easily drilled, anchored or screwed, without disturbing its structure). It's convenient for transport, installment, it's attractive, solid, long lasting, and does not require constant regular maintenance, and it's resistant to weather conditions, chemical exposure, exposure to salts, insect infestation, and it's a nonconductor (does not conduct electricity). Besides all that, the production of the filled plastic profile is ecological, and can be re-recycled time and time again.

Besides the compound product- a filled plastic profile (which possesses the interior made of recycled concrete), the component (recycled homogenized glass and plastic) is an innovative component that can be used (as a product or a semiproduct) instead of the traditional concrete for: cementing pathways, as different types of concretes in construction industry, for making concrete elements, especially decorative concrete elements which need to have a lesser specific gravity of the concrete, places where the concrete needs to be more resistant to vibrations, places where concrete should have better insulating abilities in comparison to traditional concrete.

BEST MODE FOR CARRYING OUT OF THE INVENTION

Material-product, a filled plastic profile is a compound, unique product which consists of the oblong, hollow, plastic profile (as an external shell) of various cross-section sizes and shapes, filled with a new type of material (concrete made of recycled materials), which is produced in a series of special processes, using specially adjusted and modified tools and machinery, takes several stages, and, whose production materials consist of 70-80% recycled repromaterials.

To produce a filled plastic profile, the production of the oblong hollow plastic profile, first. This is preceded by the preparation of necessary, suitable repromaterials:

- A mixture of recycled plastic masses in exactly right proportions and amounts: PP;

PELLD; PEHD; PELD; PVC, is used to create the oblong, hollow plastic profile, using special technological method, using specially adjusted and modified machinery. The method used for the production of a filled plastic profile:

STAGE 1: the process of making repromaterials used to produce the oblong hollow plastic profile - Scrap PP (polypropylene 80-90R rigidity) is triturated to sizes up to 4mm in the granulation mill, then washed and dried (to remove all possible impurity), using a known method.

- Scrap PELLD (of low density polyethylene, 10-15R rigidity) is washed, dried, mixated in the machine gain mixate (half granulate) with granulation of up to 4mm, using a known method.

- Scrap PEHD (high density polyethylene, 35-40R rigidity) is washed, dried and milled (or mixated) to up to 4mm granulation, using a known method.

- Scrap PELD (low density polyethylene, 10-15R rigidity) is washed, dried and mixated to up to 4mm granulation, using a known method.

Scrap rigid PVD (polyvinyl chloride, 1 10- 120R rigidity) is washed, dried and triturated to up to 4mm granulation, using a known method.

- The separately gained materials are not yet ready for extrusion process

- In further processing, 60% (of the total final mass, expressed in kg) of the prepared PP which is, using the method of rotation and friction, heated up to the temperature of 55- 60°C is poured into the mixer with specially modified rotary mechanism (installed instead of pre-existing rotary blade) at the speed of 1400 rotations per minute (r/min). Upon reaching that temperature of the mixture, which is still rotating, PEHD 25% is added, and heated up to the temperature of 55-60°C. Upon reaching that temperature, 7.5% PELD mixate is added to the mixture and heated up to the temperature of 55-60°C, after which 7.5% PELLD is added to the mixture and heated up to the temperature of 60- 70°C. Upon reaching the desired temperature, the mixture is discharged from the specially adjusted and modified mixer. The plastic mass gained using this method is very well homogenized and ready for extrusion. It is essential that the process is done in this particular order considering all different melting points of the different types of plastic, and different points of changing the physical properties of these plastic masses, also different specific gravities i.e. different bulk densities. Using this method, these different types of plastic are perfectly homogenized by being melted using extrusion, and thus so, provide equable quality of the product. If the product- an oblong, hollow plastic profile should have a tree bark look (aesthetic, decorative, fig. 3), i.e. to have shallow furrows of various and random lengths and shapes on the exterior, 10-15% triturated hard PVC will be added to the mixture. If this is the case, the mixture will have that same amount (in percentages, expressed in kg) less PP (this, of course means that it's treated in the mixer alongside with the PP). Composite materials can also be added to the mixture in the aforementioned order (multilayered plastic foils consisting of 3-9 layers, that consist of more than 80% PELD or PEHD, which were not recyclable using known methods due to consisting of up to 20% materials such as PA, PET, PVC) instead of 10-15% PELD and PELLD, or instead of 10-15% PEHD.

The aforementioned materials \vere noncombinative using any known method of recycling technologies until now i.e. primarily due to different processing temperatures of the different plastic types, and different bulk densities, mixing these plastics could not provide a useful product or repromaterial.

- The plastic mass of mixate prepared this way is ready for extrusion, i.e. for the production process of the oblong hollow body, profile, considering that the mass should constantly be added into the extruding machine while the temperature of the mass remains at 35-40°C. In case there are composite materials in the mass, there is a possibility that it also contains trails of PA also, which is hydroscopic even on room temperature, and it can cause problems in further production process.

- Colouring pigments, UV stabilizations and incombustion (self-extinguish) additives can be added to the processed mass using a known technology.

STAGE 2: the oblong hollow plastic profile production process

The oblong hollow plastic profiles production process uses extrusion machinery that has specially adjusted and modified mechanism. Extrusion of the prepared mass is done on temperatures of 160-180°C at 26-32 r/min (rotation per minute) of the spiral extrusion mechanism,

Depending on the specially adjusted and modified tools, the shape of the oblong hollow plastic profile can (in cross-section) be rounded, semicircular, oval, rectangular, quadratic etc. (fig. 4;5;6;7) and comes in different sizes, wall thickness, inner and outer mensuration (measurement including wall thickness, or just the cross-section of the hollow part) depending on its intended use. The oblong hollow plastic profile production process can be done in two ways using known methods:

1. Mechanic pulling of the material out of the extrusion mechanism through vacuum mechanisms including a cooling bath

2. Mechanic pushing of the material through gear that have direct cooling systems (no vacuum included)

If the production process is done using these methods, the temperature of the water in the vacuum bath i.e. cooling mechanism must not exceed 20°C so the oblong hollow plastic profiles would come out of the production perfectly straight (unless requested otherwise).

The oblong hollow plastic profiles can come in various sizes (wall thickness, length, cross- section etc.) and in different cross-section shapes (rounded, oval, quadratic, rectangular, semicircular etc.) which depends on which specially modified and adjusted gear is installed in shape of the gear installed, it must be specially modified and adjusted so that the inner wall of the oblong hollow plastic profile would be slightly furrowed and rough (fig. 8) without having any effect to the outer wall structure which must look pleasing to the eye.

The oblong hollow plastic are ready for the next stage of the production of a filled plastic profile. It is recommended they are put away where they are not exposed to any possible negative influence. The oblong hollow plastic profiles produced using these methods, using this particular recipe posses features and characteristics: - Satisfactory firmness and solidness, without being brittle or fragile (as they would be if they were made of only PP, or hard PVC)

- They posses satisfactory toughness, elasticity and flexibility. That means they are resistant to any permanent bending (they can be bent, but they always return to the original, straight position), and also resistant to the force of impact.

STAGE 3: preparation of the repromaterials for production of recyclate concrete

To gain the final product- a filled plastic profile, the oblong hollow plastic profile needs to be filled. However, to get to the first stage of the filling process, repromaterial (the mixture) needs to be prepared which represents a whole new processing stage in recyclate concrete production.

The recyclate concrete (concrete made of recycled materials) consists of the following components:

- Triturated or mixated waste plastic (various types of unrecyclable plastic or unrecyclable using known methods)

- Triturated waste glass (reinforced glass, packaging glass [bottles etc.], car glass)

- Water

Cement (as a binding material) with plasticizer

- Some optional additives that would help accelerate homogenization, or to accelerate the homogenization in low temperature environment

- * Waste glass processing procedure as a component for recyclate concrete production

- The glass needs to be triturated in a specially adjusted and modified milling machinery without impurities (paper, small stones, sand, earth, mud) to a desired granulation of 1 - 4mm (to gain sharply edged glass granulate) and sort the glass granules according to their size after the granulation.

- Sharply edged glass granules are very important firstly for better homogenization with the plastic in the mixer, and secondly, for better composition into the furrows of the inner walls of the oblong hollow plastic profile during the vibrational filling process (the sharp edges of the glass fits the furrows of the inner walls of the oblong hollow plastic profile imitating hook binding).

- Glass granules should not be bigger than 4mm for the sake of better homogenization and compactness of the filling.

- * Waste plastic processing procedure as a component for recyclate concrete production

If the production process includes composite materials (multilayered plastic foils consisting of 3-9 layers, that consist of more than 80% PELD or PEHD, which were not recyclable using known methods due to consisting of up to 20% materials such as PA, PE, PET, PVC), the process starts at firstly triturating, then mixing in the mixing machinery at 2400 r/min (rotations per minute) using specially modified and adjusted rotary blades. When the mixed mass reaches the desired temperature and the point of changed physical properties (inside the mixing machinery), after the trituration, rotation, friction, and changes its state of aggregation (melts) to almost liquid state, (2-3%) cold

water is quickly added. Considering that mixed mass (plastic and glass) will be required in the next stage of processing, granulated glass (desired amounts in percentages, depending on the recipe) can be added into the mixer alongside the almost liquid plastic in rotation mixing with water. Practically, because of the hugely different melting points

- of the plastic and the glass, the liquid plastic mass will simply adhere to glass granules. After a sudden and fast cooling process, the plastic toughens, and the rotary blades cut it to small granules conjoined with glass.

This method can be used with all mixatable plastic masses (every type of low bulk density plastic that have low melting point, which are light, but at the same time dimensious, thin)

- When processing harder, heavier types of plastic, and plastics with higher melting points, it must be triturated to desired granulation first. Due to its higher bulk density it does not have to be homogenized with the triturated glass granules in the mixer (it is possible, but it is not economical). This plastic component category includes all scrap compound plastic types, for example, shellings of cable lines, and all other polymers and copolymers which are not economical for recycle using any known method of recycling. Even trails of impurities, like rubber, various metals, do not represent a problem in the process, even though they cannot be separated into basic components.

PHASE 4: Recyclate concrete production process

- To gain concrete made of recycled materials, it is necessary to mix the prepared components with cement, water, plasticizer in a concrete mixer or some other machine used for the same purpose.

The best quality of the concrete made of recycled materials (also the most compatible for further processing) is achieved if the glass and plastic mass is beforehand homogenized in the mixer (earlier described process), and if before the very mixing process this mass is heated to the temperatures of 30-35° in a specially adjusted and modified mixing machine. The mass of glass and triturated hard plastic needs to be heated also (if not homogenized before, this mixture needs to be heated to the temperature of 60-70°C. Upon reaching that particular temperature, 5% of PELLD is added to the mass and treated for 3-4 minutes so the homogenization is finished properly). It is recommended that the water is not too cold (20-25°C at least).

Example 1 : recyclate concrete recipe (extremely tough and solid, mildly elastic)

- Glass (triturated) 60%

- Plastic mixate 10%

- Water 9 %

Example 2: recyclate concrete recipe (extremely elastic, resistant to torsions )

- Cement —-20%

- Plasticizer 0.5-1%-

Glass (triturated) 10%

Plastic (triturated (low rigidity, soft)) 60%

- Water- 9%

Example 3: recyclate concrete recipe (Solid, tough, mildly elastic, extremely light weight)

- Cement -20%

- Plasticizer 0.5-1%

- Glass (triturated) 10%

- Compound plastic mix 60%

- Water- 8-9%

If the product needs to be extremely solid and tough, but have less elasticity, and more heavier, the mix will have more triturated glass, and less triturated plastic (the same percentage of triturated glass is increased, as the amount of triturated plastic is decreased).

If the product needs to be more elastic, percentage of the soft, low rigidity plastic will be increased.

If the product needs to be as light as possible, percentage of the plastic mixate will be increased.

The possibilities are infinite. It is essential that no matter the combinations, percentage of the cement must not be below 15%. If needed, additives for acceleration of homogenization, or additives for homogenization in low temperature environments can be added in the recyclate concrete mixture.

The mass is to be poured into the concrete mixer according to the recipe, and mixed until it becomes partially liquid (not totally liquid) homogenized mixture. After that, the recyclate concrete is ready for further processing i.e. filling of the oblong hollow plastic profiles, or serve its purpose as a separate product.

Concrete made of recycled materials (recyclate concrete) represents a product made through recycling of the materials, and it can replace traditional concrete types, especially where lighter types of concrete are required. It has better thermal isolatory properties, it's elastic, resistant to vibrations, it can have rough surfaces to prevent any slippage or sliding, or it can be extremely tough and solid. Recyclate concrete can withstand extreme torsion pressures, and return to its initial state.

Recyclate concrete can be 100% recycled, and has a wide range of applicability.

Recyclate concrete can be reinforced using known methods.

Also, the components for production of the recyclate concrete can be industrially produced, homogenized, packed and sold as a recyclatory component for the production of recyclate concrete (plastic homogenized with glass in premade ratios, depending on intended use), which would significally reduce the consumption of the natural resources and help save the environment.

PHASE 5: process of filling the oblong hollow plastic profile with recyclate concrete

For the process of filling the oblong hollow plastic profiles, a specially adjusted and modified vibrating machinery. In the process, the bottom end of the oblong hollow plastic profiles is sealed using a protective seal, and put straight vertically in the machine. The filling is administered from the top end of the oblong hollow plastic profile placed vertically in a specially adjusted and modified machine which constantly vibrates in all directions during the filling process so the concrete made of recycled materials fills the oblong hollow plastic profile equally and settle in propperly.

Material-product a filled plastic profile can be REINFORCED using known methods depending on the presupposed requirements and its intended use.

After the filling of the oblong hollow plastic profile of desired shape and size with concrete made of recycled materials is finished, the protective seal is placed on the top end also, and filled plastic profiles are put away in specially designed holders in horizontal position where the drying process begins.

After 4-6 hours, the protective seals are to come off to eliminate the closed container effect and accelerate the drying process. The drying process (concretion) lasts for 5-7 days in room temperature, though it can be accelerated by additional heating and ventilating.

Usually, after the drying process (either naturally or in accelerated method), a filled plastic profile is ready for use (with protective plastic or rubber seals placed once again on both ends). Ends of a filled plastic profile can have decorative details (fig. 9).

INDUSTRIAL APPLICATION OF THE INVENTION

A filled plastic profile can be produced in assembly line production, industrially, in accordance to the described process using specially adjusted and modified machines and tools, with justified economic efficiency considering its extremely wide range of applicability (mostly in construction industry as posts for all types of fencing, protective net girder, sign posts, prefabricated building construction, components for furniture construction etc.) and extremely wide range of cheap repromaterials, which contain 70-80% (waste) recycled materials (many of them) that were not recycled until now. It can efficiently replace traditionally used materials like wood, iron (steel) profiles and concrete profiles. That means that it is very significant in perservation of the natural resources and the environment. Aside from the product- a filled plastic profile, there is also a product- recyclate concrete which besides being the filling material of the aforementioned product, can represent a product which can be used and applied separately, mostly in construction industry, and also be effectively industrially produced in accordance with the described process and be extremely applicable in pathway construction, construction of concrete elements etc. especially in places where lighter types of concrete, concretes that have better thermo-isolatory properties, elastic concretes are required.

The production of this product, a filled plastic profile is 100% ecological (there is no emission of harmful gases, harmful vapours, combustion in the production processes), and after its use, it can be recycled in its entirety as a component for the same or a different product.

BRIEF DESCRIPTION OF DRAWINGS

1/5 Fig. l ;fig 2 represents a cross-section of the rounded filled plastic profiles.

2/5 Fig.3 represents a filled plastic profile with protective seal and conspicuous decorative detail- shallow texture.

3/5 Fig.4; fig.5;fig6;fig7 represents various shapes of the filled plastic profiles (in cross- section)- rounded, semicircular, quadratic, rectangular.

4/5 Fig.8 represents furrowed (rough) inner wall of the oblong hollow plastic profile and lasting homogenization with the concrete made out of recycled materials (recyclate concrete)

5/5 Fig. 9 represents a filled plastic profile with a decorative detail.

Claims

1. The process of production of plastic material out of recycled plastic characterized by adding 45% of PP into the mixer in full rotation at 1400 r/min and heated by rotation and friction to the temperature of 55-60°C, upon reaching that temperature adding 25% of PEHD to the mixer in full rotation and heating the mass by rotation and friction to the temperature of 55-60°C, then, upon reaching that temperature adding 7.5% of PELD to the mixer in full rotation and heating the mass to the temperature of 55-60°C, then, upon reaching that temperature, adding 7.5% of PELLD to the mixer in full rotation and heating the mass to the temperature of 60-70°C, after that, upon reaching that temperature, also adding 15% of PVC to the mixer in full rotation and heating the mass to the temperature of 60-70°C, after that, the mass is emitted from the mixer by which the homogenization has been finished, gaining plastic mixate- a material which is used to gain the final plastic material- product by using the method of extrusion.

2. Plastic material gained from recycled plastic which can be gained in accordance with the process described in claim 1 characterized by consisting of 45% PP, 25% PP, 7.5% HD, 7.5% PELD, 7.5% PELLD, 15% PVC.

3. The use of the plastic material in accordance with claim 1 characterized by gaining an oblong hollow plastic profile.

4. The use of plastic material in accordance with claim 1 characterized by gaining a filled plastic profile.

5. The use of filled plastic profile in accordance with claim 4 characterized by filling the oblong hollow plastic profile with concrete made of recycled materials, which consists of 20% triturated glass granulated to up to 4mm, 50% triturated plastic granulated to up to 4mm which are homogenized in a mixer on temperature of 60-70°C, gaining an aggregate that's mixed with 20% cement, 0.5-1% plasticizer and 9% water.