Title: Recyclable composite materials articles of manufacture and structures and method of using composite materials
Abstract: Composite mixture materials made of recycled plastic, glass and rubber, and optionally, sand, gravel, coal combustion by-product and metal, and containing no petroleum distillates (unless a fire retardant or recycled asphalt pavement is used) are disclosed. Methods of using the composite mixture materials include making expansion joints in pavement, filling manhole cover recesses, filling potholes in pavement, making new pavements, and making panels, walls, blocks, impact protection walls, and other such structures. Methods of making the composite mixture materials include heating the components of the material in an inert gas environmentally friendly manner. Compressive pressure is applied to composite mixture materials used in making expansion joints, manhole cover recess fillers, and in filling potholes to build in an elastic strain to overcome both a composite material shrinkage on cooling solidification of the material and the thermal contraction of pavements, and in making the composite material for any other of the uses disclosed.
Patent Number: 6,984,670 Issued on 01/10/2006 to Meyers, III, et al.
| Inventors:
|
Meyers, III; John J. (Penfield, NY);
Swartz; John H. (Coraopolis, PA);
Kurczewski; Nathaniel G. (Moon Township, PA);
Kurczewski; Matthew J. (Moon Township, PA)
|
| Assignee:
|
Ace Tire & Parts, Inc. (Coraopolis, PA)
|
| Appl. No.:
|
470750 |
| Filed:
|
August 12, 2003 |
| PCT Filed:
|
August 12, 2003
|
| PCT NO:
|
PCT/US03/23259
|
| 371 Date:
|
August 12, 2003
|
| 102(e) Date:
|
August 12, 2003
|
| PCT PUB.NO.:
|
WO2005/019332 |
| PCT PUB. Date:
|
March 3, 2005 |
| Current U.S. Class: |
521/40; 521/40.5; 521/41; 521/45.5 |
| Current Intern'l Class: |
C08J 11/04 (20060101) |
| Field of Search: |
521/40,405,41,455
|
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Other References
WWW.babcocklumber.com/xpotent.html (May 2002).
|
Primary Examiner: Cain; Edward J.
Attorney, Agent or Firm: Webster; Robert J., Birch, Stewart, Kolasch & Birch, LLP
Claims
What is claimed is:
1. A cured compressed composite mixture material product having a built in elastic
strain that provides one or more enhanced composite material physical properties,
comprising the following recycled materials:
from about 40% to 60% by volume of polymers; from about 25% to 50% by volume
of rubber;
from about 10% to 20% by volume of glass; from about 5% to 15% by volume of sand and/or
recycled shingles; and
from about 10% to 15% by volume of small gravel and/or coal combustion by-product,
the total volume percentage of all components in the mixture being 100%; and
said product has a structure which retains a built-in elastic strain that exhibits
one or more enhanced physical properties.
2. The composite mixture material product of claim 1, wherein the material portions comprise:
about 45% by volume of polymers;
about 25% by volume of rubber;
about 15% by volume of glass;
about 5% by volume of sand and/or recycled shingles; and
about 10% by volume of small gravel and/or coal combustion by-product.
3. A cured compressed composite mixture material product having a built-in elastic
strain that provides one or more enhanced composite material physical properties,
comprising the following recycled materials:
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand;
from about 5% to 15% by volume of small stones and/or gravel and/or coal combustion by-product;
from about 2 to 5% by volume of metal of at least one type; and
from about 5% to 10% by volume fiberglass or asphalt shingles;
the total volume percentage of all components being 100%; and
said product has a structure which retains a built-in elastic strain that exhibits
one or more enhanced physical properties.
4. The composite material product of claim 3, wherein the metal is in the form
of small particles of recycled or virgin metal.
5. The composite material product of claim 3, wherein the volume percentage of
the metal is up to 5%.
6. The composite material product of claim 3, wherein the metal(s) is/are in
the form of particles dispersed throughout the composite material.
7. A combination of the composite material product of claim 3 and one or more
shaped metal rods or plates or meshes for structural reinforcement purposes.
8. A method of improving the mechanical binding of pre-made composite mix elements
in forming a composite material comprising the following recycled materials:
from about 40% to 60% by volume of polymers; from about 25% to 50% volume of rubber;
from about 10% to 20% by volume of glass; from about 5% to 15% by volume of sand
and/or recycled shingles; and
from about 10% to 15% by volume of small gravel and/or coal combustion by-product
the total volume percentage of all components in the mixture being 100%; and
having a built in elastic strain that provides one or more enhanced composite
material physical properties, comprising:
mixing the pre-made composite mix elements;
sand-blasting the elements with an abrasive material during mixing to roughen
the component surfaces and improve mechanical binding; and
retaining sand blast abrasive material in the mixture to form part of the composite
mixture material.
9. A method of forming a composite mixture material, comprising:
comminuting recycled materials including rubber, roof/siding shingles, glass,
coal combustion by-product, and polymeric material;
adding particulate material including sand, gravel, small stones, and metals
to the comminuted materials;
mixing the comminuted materials and particulate material;
heating the mixed materials to a temperature to melt the polymeric material to
form a fused together composite material;
applying a compressive stress load to the composite mixture prior to and during
its solidification builds into the mixture an elastic strain which provides the
solidified composite mixture a property to compensate against material shrinkage; and
forming a solid, densified composite mixture having a memory effect.
10. The method of claim 9, wherein forming the solid mixture comprises cooling
the heated mixture naturally and/or artificially.
11. The method of claim 9, wherein the particulate material is from the group
consisting essentially of sand, gravel, stones, metals, coal combustion by-product,
and ground up concrete and asphalt.
12. The method of claim 9 wherein heating uses hydrogen gas as a combustion fuel.
13. The method of claim 12, wherein substantially only water vapor is formed
as a product of combustion of the hydrogen fuel, thereby reducing atmospheric pollution.
14. The method of claim 9 further comprising heating the mixed materials in an
inert gas atmosphere to reduce atmospheric pollution and increase the strength
of the composite by avoiding oxidation of mixture polymer, plastic and rubber constituents.
15. The method of claim 9 further comprising using a hydrogen fuel cell generator
to heat the mixed material.
16. The method of claim 9 further comprising cooling the composite material to
form a solid.
17. The method of claim 9 further comprising applying a compressive force to
the material while forming the material.
18. The method of claim 9, wherein the polymer material is selected from the
group of all recycled polymers.
19. The composite material product of any of 3, wherein the composite mixture
material is about 50% lighter than concrete and has a tensile modulus and tensile
strength greater than concrete.
20. A structural member comprising a wall or panel made of the cured composite
mixture material product of claim 1.
21. A pipe or conduit made up of the cured composite mixture material product
of claim 1.
22. The method of claim 9, wherein the particulate material is from the group
consisting essentially of sand, gravel, roof/siding shingles and coal combustion by-product.
23. The method of claim 11, wherein the concrete and asphalt are recycled materials.
24. The method of claim 9, wherein the recycled materials include least one pre-made
solid piece of composite material together with a quantity of loose and heated
fill composite material surrounding the at least one solid piece, and
further comprising using the heated loose fill to melt a thin surface layer on
the at least one pre-made solid pieces such that when the combination is compressed
and cooled to a solidification temperature, a solid substantially homogeneous mass
is obtained.
25. The method of claim 9, wherein the heating step includes sanitizing the material.
26. A method of improving the strength of the composite mix of claim 8, comprising:
fine-grinding the glass, gravel and coal-combustion by-product constituents to
increase their bonding surface area and to reduce the tendency of the constituents
to bridge together to form voids in the composite mix material.
27. The product of any of 3, excluding binders and chemical adhesives.
28. The product of any of 3, wherein the constituents comprise recycled composite mix.
29. The product of any of 3, excluding any virgin petroleum distillates and/or
other non-recycled chemical additives.
30. The cured compressed composite mixture material product of claim 1, consisting
essentially of the following recycled materials:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand and/or recycled shingles; and
from about 10% to 15% by volume of small gravel and/or coal combustion by-product,
the total volume percentage of all components in the mixture being 100%.
31. The composite mixture material product of claim 1, wherein the material portions
consist essentially of:
about 45% by volume of polymers;
about 25% by volume of rubber;
about 15% by volume of glass;
about 5% by volume of sand and/or recycled shingles; and
about 10% by volume of small gravel and/or coal combustion by-product.
32. The cured compressed composite mixture material product of claim 3, consisting
essentially of the following recycled materials:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand and/or recycled shingles;
from about 5% to 15% by volume of small stones and/or gravel and/or coal combustion by-product;
from about 2 to 5% by volume of metal(s); and
from about 5% to 10% by volume fiberglass or asphalt shingles;
the total volume percentage of all components being 100%.
33. A structural member comprising the material recited in claim 1.
34. The method of claim 9, wherein the mixture material has no newly added chemicals
or petroleum distillates.
35. The cured compressed composite material product of 3, wherein the enhanced
physical properties of the cured compressed composite material comprise increased
composite material shrinkage compensation.
36. The cured compressed composite material product of 3, wherein the enhanced
physical properties of the cured compressed composite material product comprise
composite material expansion enhancement.
37. The cured compressed composite material product of 3, wherein the enhanced
physical properties of the cured compressed composite material product comprise
increased composite material compressive strength.
38. The cured compressed composite material product of 3, wherein the enhanced
physical properties of the cured compressed composite material comprise a memory
effect mechanism to heal indentation damage to the material.
39. A composite mixture material consisting essentially of the following recycled materials:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand and recycled shingles; and
from about 10% to 15% by volume of small gravel and coal combustion by-product,
the total volume percentage of all components in the mixture being 100%.
40. A composite mixture material consisting essentially of the following recycled materials:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand;
from about 5% to 15% by volume of small stones and/or gravel and/or coal combustion by-product;
from about 2 to 5% by volume of metal of at least one type; and
from about 5% to 10% by volume fiberglass or asphalt shingles;
the total volume percentage of all components being 100%.
41. A composite mixture material consisting essentially of the following recycled materials:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand and/or recycled shingles; and
from about 10% to 15% by volume of small gravel and/or coal combustion by-product,
the total volume percentage of all components in the mixture being 100%.
42. A composite mixture material, wherein the material portions consist essentially of:
about 45% by volume of polymers;
about 25% by volume of rubber;
about 15% by volume of glass;
about 5% by volume of sand and/or recycled shingles; and
about 10% by volume of small gravel and/or coal combustion by-product.
43. A composite mixture material, consisting essentially of the following recycled materials:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand and/or recycled shingles;
from about 5% to 15% by volume of small stones and/or gravel and/or coal combustion by-product;
from about 2 to 5% by volume of metal(s); and
from about 5% to 10% by volume fiberglass or asphalt shingles;
the total volume percentage of all components being 100%.
44. A composite mixture material, consisting essentially of the following recycled materials:
about 50% polymers by volume;
about 40% rubber by volume; and
about 10% glass.
45. A cured composite mixture material product having a built in elastic strain
that provides one or more enhanced composite material structural and energy absorbing
properties missing from the composite material without the built-in elastic strain,
comprising the following recycled materials:
from about 40% to 60% by volume of polymers; from about 25% to 50% by volume
of rubber;
from about 10% to 20% by volume of glass; from about 5% to 15% by volume of sand
and/or recycled shingles; and
from about 10% to 15% by volume of small gravel and/or coal combustion by-product,
the total volume percentage of all components in the mixture being 100%; and
said product has a structure which retains a built-in elastic strain that exhibits
one or more enhanced physical properties.
46. A compressed composite mixture material, consisting of the following recycled materials:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand and recycled shingles; and
from about 10% to 15% by volume of small gravel and coal combustion by-product,
the total volume percentage of all components in the mixture being 100%.
47. A composite mixture material consisting of:
about 45% by volume of polymers;
about 25% by volume of rubber;
about 15% by volume of glass;
about 5% by volume of sand and recycled shingles; and
about 10% by volume of small gravel and coal combustion by-product.
48. A compressed composite mixture material comprising:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand and/or recycled shingles;
from about 5% to 15% by volume of small stones and/or gravel and/or coal combustion by-product;
from about 2 to 5% by volume of metal(s);
from about 5% to 10% by volume fiberglass or asphalt shingles; and
containing no petroleum or petroleum by-products other than trace amounts thereof;
and wherein
the total volume percentage of all components is 100%.
49. A composite material consisting of:
about 45% by volume of polymers;
about 25% by volume of rubber;
about 15% by volume of glass;
about 5% by volume of sand and/or recycled shingles; and
about 10% by volume of small gravel and/or coal combustion by-product.
50. A compressed composite mixture material consisting of:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20 % by volume of glass;
from about 2% to 5% by volume of metal(s);
from about 5% to 10% by volume of fiberglass or asphalt shingles; and
wherein the total volume percentage of all components is 100%.
51. A composite mixture material consisting of:
about 45% by volume of polymers;
about 25% by volume of rubber;
about 15% by volume of glass;
about 5% by volume of sand and/or recycled shingles; and
about 10% by volume of small gravel and/or coal combustion by-product.
52. A compressed composite mixture material consisting of:
from about 40% to 60% by volume of polymers;
from about 25% to 50% by volume of rubber;
from about 10% to 20% by volume of glass;
from about 5% to 15% by volume of sand and/or recycled shingles;
from about 5% to 15% by volume of small stones and/or gravel and/or coal combustion by-product;
from about 2 to 5% by volume of metal(s);
from about 5% to 10% by volume fiberglass or asphalt shingles; and
wherein the total volume percentage of all components is 100%.
53. The compressed composite mixture material having a built in elastic strain
that provides one or more enhanced composite material physical properties of claim
1, wherein the enhanced physical properties comprise at least one of (1) polymer
shrinkage compensation; (2) thermal contraction compensation, (3) memory and self-healing
characteristics, and (4) enhanced impact strength tolerance.
54. The method of claim 9, further comprising:
re-heating the mixed materials to a temperature to melt the polymeric material
to form a fused together composite material;
re-applying a compressive stress load to the composite mixture prior to and during
its solidification builds into the mixture an elastic strain which provides the
solidified composite mixture a property to compensate against material shrinkage; and
re-forming a solid, densified composite mixture having a memory effect.
55. A composite mixture material made by the process of claim 8.
56. A composite mixture material made by the process of claim 9.
57. The compressed composite mixture material of claim 56, wherein the compressive
stress load to the composite mixture prior to and during its solidification to
build into the mixture an elastic strain (S) is applied according to the following equation:
S=ER[α
CLΔT+αMWΔT+FSW]M1/WFRμ
R where;
E
R is the modulus of elasticity of a specific component of the composite
mixture material;
α
C LΔT is the thermal contraction of the pavement;
α
M WΔT is the thermal contraction of the composite mix,
F
S W is the shrinkage of the composite material fill in the expansion joint;
M
1 is a Safety Factor Multiplier;
F
R is the fraction of said specific component of the composite material
fill in the expansion joint;
W is the width of the pavement expansion joint filled by composite material; and
μλ
R is the poison ratio of said specific component of
the composite material fill in the expansion joint.
Description
This Application is a continuation-in-part of PCT/US02/ 15160, filed on Jun.
14, 2002, with respect to which the United States is a designated state, benefit
of which is claimed under 35 USC §120.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to a composite material comprising recyclable rubber,
glass and polymeric materials and optimally containing some coal combustion by-product,
both fiberglass and asphalt roof/siding shingles, recyclable metals, virgin sand,
small stones, gravel and the like. The invention also relates to the manufacturing
process of the material, articles of manufacture using the composite material,
and other methods of using composite materials. The listed composite constituents
are employed in various compositions and with somewhat varied processed parameters,
depending upon the intended application/use; thus, it is to be recognized the composite
material will encompass an assortment of composite materials as disclosed in this document.
2. Description of Related Art
Composite materials used for building products and for pavement, including
pavement repair and expansion joints for pavements, typically include petroleum
products, including asphalt and recycled tires. The methods of manufacturing and
using petroleum products are not in general environmentally friendly.
The new composite material contains no petroleum products or chemical additives
such as, for example, asphalt, such as are used in asphalt pavements, and serves
to reduce growing rubbish and trash disposal problems caused by disposal items
such as, for example, coal-combustion by-product, automobile tires, glass, plastic
and/or glass containers, including bottles, etc. The manufacturing process that
produces the composite material involves some heating done within an inert gas
atmosphere to reduce environmental air pollution and prevent weakening the constituent
polymers by oxidation, thereby weakening the composite mixture material. Further,
the heating process requires raising the temperature of all the composite materials
to about 500° F. which sanitizes the recycled materials against bacteria.
Similar composite materials are also known. One example of such similar composite
materials is shown in U.S. Pat. No. 6,224,809 being used for automotive bumpers.
This material is disclosed as an elastomer together with a plastic alloy blend
and of elastomer and preferably, crumb rubber, held together by a matrix of a thermoplastic
polyethylene. Accordingly it, and other similar patents, use new, non-recycled
chemical compounds and materials derived from petroleum.
SUMMARY OF THE INVENTION
One aspect of the methods and materials according to this invention include a
new composite material using recyclables (glass, polymers, plastics, rubber, both
fiberglass and asphalt roof/siding shingles, coal combustion by-products, metals)
and that does not contain, newly added, petroleum products or new, non-recycled
chemicals. The roof/siding shingles add a source of small stone grit and further
add some recycled source of asphalt not necessary for this invention, but is acceptable
since it has been recycled. Some prior used materials, for example, certain sand
and gravel can be added to impart certain situation specific characteristics and
properties such as, for example, surface texture, surface friction, material density
(which do not significantly affect the resilience to breakage of the composite
mix material). Occasionally, if desired, or absolutely needed, chemicals such as,
for example a fire retardant chemical to further reduce the susceptibility of the
material to burn, or colorant(s),for example to affect the appearance of the composite
mix material can be added. The material according to this invention is normally
made entirely from recyclable materials, and may be used for methods of making
repairs in pavements, including concrete and asphalt pavements. The composite material
of this invention may be used to fill potholes in asphalt and concrete pavement,
fill manhole cover recesses, to make expansion joints in roadways, and in building
materials, such as, for example, building blocks, structural panels and other structural
elements including pipes and fixtures. The structural and energy absorbing properties
of the material, including damping out shock waves caused by impacts of an object
onto a structure made with the composite material and flexibility of the composite
material, make it suitable as a protective barrier to prevent serious physical
damage to structures, including buildings, water dams, nuclear facilities, defense
structures, bridge support structures, piers, factories, defense structures, airplane
cargo bays, any critical infrastructure, and the like. The materials of this invention
may be used in any of the aforementioned structures in above and/or below water locations.
In its most general terms, the material of the present invention can be used
as
a repair or filler material. In these uses, the material is filled into a recess
such as a crack, crevice, pothole, indentation, excavation, joint, cavity or the
like to a suitable level, and is allowed to cool under sufficient compressive force.
The compressive force is preferably sufficient to build in a significant elastic
strain, i.e., an elastic strain which significantly reduces and/or avoids polymer
shrinkage and material contraction during cooling and to thus prevent crack formation
around the periphery of the material. The rate of cooling is variable and can be
relatively rapid or relatively slow. These same principles can be applied when
using the material as a bulk paving product or when using the material to form
other structural materials. That is, the material is applied in a melted state,
and a compressive force is applied to the material as the material cools, prior
to and during its solidification. The significant elastic strain that is built
into the composite material (1) overcomes and/or compensates for polymer shrinkage
in a molding process application of the composite material; (2) maintains tight
contact of the composite material with pavement, or other materials and/or material
surfaces when used as an expansion joint material if the other surfaces shift apart
and/or thermally change dimension due to, for example, temperature changes; (3)
promotes self healing of the composite material after the material is physically
penetrated, such as, for example, scored, scratched, or gouged; and (4) increases
impact strength tolerance of the composite material. Values of such elastic strains
fall within the range of the applied manufacturing compressive stress.
Another aspect of the materials and systems and methods that involves a heating
step in manufacture, according to the invention is that the composite materials
of the invention may be heated in an inert atmosphere to reduce the possibility
of any chemical reactions to thereby reduce environmental air contamination, as
well as to reduce degradation of recycled component rubber and plastic material
constituents of the composite material. The heating also sanitizes the composite
mixture material against bacteria.
Another feature and advantage of the invention is that the composite material
is not limited to using a particular polymer or specific types of polymers, but
can use any number of assorted recycled polymers, and does not need to use filament
binders or adhesives or other specific binders. The composite materials according
to the invention use assorted recycled multi-polymer composition content to hold
together the composite material. Moreover, the percentage of the ingredients can
be tailored to a particular use.
These and other features and advantages of the invention are described in,
or are apparent from, the following detailed description of various exemplary embodiments
of the systems and methods according to this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Various exemplary embodiments of this invention will be described in detail,
with reference to the following figures, wherein:
FIG. 1 is a flow chart of exemplary embodiments of methods of making the composite
materials of this invention.
FIGS. 2A and 2B are cross-sectional views of a vertical plane through a pothole
to be filled according to the methods and with the materials of this invention;
FIG. 3A is a side elevational view of an expansion joint with an exemplary embodiment
of a reinforcing member according to this invention;
FIG. 3B is a top view of an expansion joint with an exemplary embodiment of
a reinforcing member according to this invention;
FIG. 4A is a diagrammatic side elevational view of an expansion joint showing
parameters involved in an engineering analysis of systems and methods of filling
an expansion joint according to this invention;
FIGS. 4B-4K are diagrammatic side elevational views of exemplary embodiments
of methods and a system for forming an expansion joint according to the invention;
FIGS. 5A-5G are views of various exemplary embodiments of a structural reinforcement
for use in potholes as shown in FIG. 5A according to this invention;
FIGS. 6A-6F are various views of structural panels made according to the systems
and methods and materials of this invention.
FIG. 7A is a top view of a first exemplary embodiment of a manhole cover extension
using the composite materials of this invention;
FIG. 7B is a side view of a first exemplary embodiment of a manhole cover extension
using the composite materials of this invention;
FIG. 7C is a top view of a second exemplary embodiment of a manhole cover extension
using the composite materials of this invention;
FIG. 7D is a side view of the second exemplary embodiment of a manhole cover
extension using the composite materials of this invention;
FIGS. 8A-8M are views of various protective wall embodiments using multiple
thin wall panels according to the systems, methods, and materials of this invention; and
FIGS. 8N-8O are views various exemplary embodiments of pivots supports for
various protective wall embodiments according to this invention.
The present invention is directed in particular to a composite material that
is suitable for a wide range of uses, including pavement repair, full pavement
area application, asphalt and concrete repair, joint expansion filler, building
material uses, wall and panel uses, fixture materials, piping materials, other
building materials, and the like. The material provides significant environmental
benefits, in terms of its composition of using all recycled materials and its manufacture
within an inert atmosphere, and it also provides waste disposal savings and cost
and time savings in its various uses and applications.
According to the present invention, the material is made substantially
entirely of recycled materials. Such recycled materials can be either post-consumer
use materials or can be materials from industrial sources. In the post-consumer
use context, the constituent materials can include, for example, but are not limited
to: polymer/plastics materials, such as from bottles, jars, containers, wrappings,
household items, children's toys, and the like; glass materials, such as from bottles,
jars, window panes, and the like; and rubber materials, such as from tires, mats,
and the like. Similar materials from industrial sources can likewise be used. These
materials preferably form a bulk of the material of the present invention. Thus,
for example, these materials may be provided in an amount of about 50% by volume
of the polymer/plastic material, about 35 percent of the rubber material and about
15% of glass material. Other containment amounts may be used for special applications.
When the plastics, glass and rubber materials are used, it is preferred that
the materials be recycled materials. Such use provides one of the benefits of the
present invention of increasing recycling of consumer and industrial materials.
Such recycled materials can be collected and processed post-consumer materials,
such as are commonly collected and processed from household and office recycling
programs. Alternatively, or in addition, the recycled materials can be collected
and processed from industrial uses, such as scrap, leftover, and the like materials.
In addition, the material of the present invention can include a desirable amount
of other recycled or non-recycled environmentally friendly material. For example,
the material can include an amount of one or more materials selected from sand,
stone, gravel, and the like. Such materials can be included, for example, to provide
texture, appearance and/or other properties such as additional compressive strength
and surface friction and color to the final product, and the like. In embodiments,
these materials can also be recycled materials. For example, the sand, grit, stone
or gravel can be obtained by crumbling used concrete, e.g., road slab concrete
or by using road stone, or other materials. However, as desired, these materials
can also be "virgin" or non-recycled materials. Furthermore recycled roof/siding
asphalt and fiberglass shingles, coal combustion by-products, including, for example,
coal ash, have proven to be useful additives to the composite material. If desired,
coal combustion by-product can be used in all of the composite mix applications
set forth in this disclosure. While coal combustion by-product is weaker in strength
than stone and gravel, its strength is comparative with sand and it is cost competitive
with sand, and aids in overall binding and filling in voids.
An aspect of the present invention, in certain exemplary embodiments, is that
the material is completely free of adding any new petroleum products. Thus, for
example, the composite material of the present invention is completely free of
such materials as asphalt or tar, and new petroleum-containing or petroleum based
products are not added during the compounding and/or manufacturing processes.
In another aspect of the present invention, in certain exemplary embodiments
thereof,
the material is essentially free of, i.e., contains at most trace or minor amounts
of, any such petroleum-based or petroleum containing products. In these embodiments,
the composite material of the present invention can include minor amounts of such
petroleum products. For example, trace or minor amounts of petroleum products can
be included, typically as being already part of one or more of the constituent
recycled materials. For example, the composite material of the present invention
can be formed using recycled materials such as, old tires, roof/siding shingles,
asphalt, including crumbled asphalt, and the like, which recycled materials may,
and often do, include petroleum products. It is preferred that additional separate
petroleum-based or petroleum-containing products are not added except as discussed
below, in paragraph [0017]. When such petroleum-containing recycled products are
used, such petroleum-based or petroleum-containing products are not considered
to be newly added to the composite material, and do not contribute to the characteristics
of the composite materials.
However, in other embodiments of the present invention, it may be desirable
to add small amounts of non-recycled material including petroleum-based or petroleum-containing
material, such as, for example, sand, gravel, metal or a conventional fire retardant
in order to provide desirable properties to improve characteristics of the composite
mix and to increase the environmentally friendly aspects of the invention. For
example, a conventional flame retardant added to the composite material which provides
safety characteristics and reduction of air pollution would be considered to be
within the scope of the invention of composite mixtures which consists essentially
of recycled materials.
FIG. 1 shows a diagram of exemplary facilities, equipment and processes which
can be used to manufacture the composite material of this invention. To begin with,
in step S
100, the rubber, glass, polymer material and/or any other materials
are delivered to storage. In step S
200, these materials are conveyed to
a comminution device to be ground and/or crushed to reduce them to small particles.
Next, in step S
300, the recyclable materials such as the rubber, roof/siding
shingles, any crushed coal combustion by-product, glass and polymer material are
comminuted to an appropriate size. Then, in step S
400, all of these ground
and crushed materials as well as the sand and the gravel are conveyed to storage.
Thereafter, in step S
500, the stored materials are conveyed by a metered
feeder to a mixer to mix all of the aforementioned materials, that is, the recycled
materials and any virgin materials. In step S
600, the materials are mixed
to form a relatively dry mix. Then a decision is made in step S
700 to convey
the materials directly to the site before heating and further mixing the mix components,
or not. If so, the materials are conveyed in step S
1000 to a utilization
site where the materials are further mixed and heated in step S
1100 on site
to form the composite mixture. If not, one proceeds to step S
800 to load
the mixed constituent materials into a mixer and heater vehicle and, in step S
900,
to heat and mix the materials in the vehicle enroute to a utilization site. Steps
S
1000 and S
1100 may employ a mixer that may be a portable, non-heated
mixer as one sees in normal concrete mixing delivery trucks that would deliver
this product to another heated mixer which is set up on a particular site so that
the polymer may be further mixed and heated at the site. Steps S
800 and
S
900 may employ a special mixer and heating truck unit for delivery to the
site. Then, in step S
1200, the composite mix is used to, for example, make
structures or structural elements, and/or repair potholes, make full pavements,
and/or form expansion joints. The forming may involve a compression step, as disclosed, infra.
Of course, as will be readily apparent to one skilled in the art, the processes
of the present invention are not limited to that shown in FIG. 1, and the process
steps shown therein are exemplary only. Thus, for example, it will be apparent
that the storage, conveying, and comminuting steps S
100-S
500 are
optional. For example, if the recycled and/or virgin raw materials are obtained
in an already comminuted state, ground or otherwise provided at the desired particle
size, then the comminuting steps will be unnecessary.
Likewise, it will be apparent that the storage and conveying steps may
be unnecessary, particularly in large volume applications where the recycled and/or
virgin raw materials are obtained directly from one or more suitable sources and
are processed immediately within any intervening storage steps. Under appropriate
circumstances, the recycled and/or virgin raw materials may be processed directly
from their source into the stated mixing operation without the need to store or
transport them.
Still further, it will be apparent that the mixed material need not be conveyed
or shipped to the site of actual use, such as by a non-heated or heated mixing
vehicle. Rather, in embodiments, it will be apparent that any of the described
process steps, including one or more of the storage, conveying, comminuting, and/or
mixing operations can be conducted at the actual site of use of the resultant composite
material. In these embodiments, one or more of the process steps can be conducted,
and the material exiting from the mixer can be directly applied to its desired use.
Still other modification of the describes processes will be apparent to one
skilled in the art based on the present disclosure. Such modified processes are
also within the scope of the present invention.
The composite mixture is solidified by cooling, which may be forced cooling and/or
natural cooling in a relatively cool ambient atmosphere.
Moreover, a single formulation temperature and application method can be
used for both summer and winter conditions, but the temperature of the mixed components
can be slightly varied in weather conditions such as occur in winter and summer.
Also, additional materials may be added to the mix such as recyclable metal
filings or ground up metals such as, for example, from tire steel reinforcement
belts. Many other of metals may be used in the composite mixture, including, for
example, iron, steel, stainless steel, copper, brass, aluminum, etc. When added
to the mix formulation, metals will increase the thermal conductivity of the mix
and thereby shorten the cooling time. Also, when using metals in a composite mix
material for use in piping, for example, a metal detector may be used to trace
hidden pipes such as underground piping.
Another aspect of the materials and systems and methods according to the
invention is a further reduction of environmental/air contamination by using hydrogen
as the fuel source for heating the composite material constituents, to release
only water vapor into the environment. If desired. the water vapor can be condensed
into liquid water to furnish an additional source of heat, i.e., the heat of condensation
o
