Mixed polymeric structural material and method

Claim 2

A mixed polymeric composition comprising an intimate mixture of a comminuted filler and an adhesive polymer binder to form a continuous phase firmly bonding said filler particles together, the total polymer resin content comprising from 20% to 75% by weight of said composition, said filler comprising a comminuted fraction from a front-end solid waste system comprising glass, cellulose and its derivatives, inorganic oxides and mixed polymer resins, including a significant quantity of polyethylene and polymer incompatible with polyethylene, said polymer binder comprising a polyethylene-compatible polymer selected from the group consisting of polypropylene, polyethylene, ethylene-propylene rubber, styrene-butadiene rubber, natural rubber, polystyrene, coumarone-indene copolymers, poly(ethylene-vinyl acetate) copolymers, polyisobutylene, and mixtures thereof.

Claim 3

A composition as in claim 1 in which said binder comprises at least two resinous adhesive polymers compatible with each other.

Claim 4

A composition as in claim 1 in which said binder comprises 10 to 90% by weight of said composition.

Claim 5

A composition as in claim 1 in which said binder is selected from the group consisting of polyethylene, ethylene-propylene rubber, and mixtures thereof.

Claim 6

A composition as in claim 1 in which no single polymeric resin incompatible with polyethylene is present in the composition in sufficient quantities to form an interface with the binder of sufficient length to provide a significant weakened fault line.

Claim 7

A composition as in claim 5 in which no single resin incompatible with polyethylene is present in an amount greater than about 12%.

Claim 8

A composition as in claim 1 in which the glass portion of the filler comprises 1 to 80% of the polymer filler.

Claim 9

A composition as in claim 1 in which cellulose and its derivatives comprise from 1 to 80% by weight.

Claim 10

A composition as in claim 1 in which the majority of said filler is sized in gradations varying from 12 to 600 mesh size and is characterized by non-homogeneous mesh size and individual filler particles with irregular rough shapes.

Claim 11

In a process for forming a filled polymeric composition, the steps of a. comminuting municipal or industrial solid waste, b. classifying the comminuted solid waste into a light fraction and a heavy fraction, said former fraction comprises a majority of combustible organic materials including film plastics, cellulose and its derivatives, said heavy fraction comprising a majority of glass, inorganic oxides, mixed resins, and cellulose and its derivatives, steps (a) and (b) forming a portion of a front-end resource recovery process, c. intimately mixing a filler comprising a front-end fraction selected from the group consisting of said light and heavy comminuted garbage fractions in the unpyrolyzed, unincinerated state, said filler including a significant quantity of polyethylene and resin incompatible with polyethylene with sufficient flowable binder, said polymer binder comprising a polyethylene-compatible polymer selected from the group consisting of polypropylene, polyethylene, ethylene-propylene rubber, styrene-butadiene rubber, natural rubber, polystyrene, coumarone-indene copolymers, poly(ethylenevinyl acetate) copolymers, polyisobutylene, and mixtures thereof, to form a continuous phase capable of firmly bonding the filler, the total polymer content comprising from 20% to 75% by weight of said composition, d. forming the mixture of step (c) into a desired configuration while in a flowable state, and e. solidifying said binder to form a solid composition in which said binder is adhesively bonded to said filler particles.

Claim 12

In a process for forming a filled polymeric composition, the steps of a. comminuting municipal or industrial solid waste, b. classifying the comminuted solid waste into a light fraction and a heavy fraction, said former fraction comprises a majority of combustible organic materials including film plastics, cellulose and its derivatives, said heavy fraction comprising a majority of glass, inorganic oxides, mixed resins, and cellulose and its derivatives, steps (a) and (b) forming a portion of a front-end resource recovery process, c. intimately mixing a filler comprising a front-end fraction selected from the group consisting of said light and heavy comminuted garbage fractions in the unpyrolyzed, unincinerated state, said filler including a significant quantity of polyethylene and resin incompatible with polyethylene with sufficient flowable binder, said polymer binder comprising a polyethylene-compatible polymer selected from the group consisting of polypropylene, polyethylene, ethylene-propylene rubber, styrene-butadiene rubber, natural rubber, polystyrene, coumarone-indene copolymers, poly(ethylenevinyl acetate) copolymers, polyisobutylene, and mixtures thereof, to form a continuous phase capable of firmly bonding the filler, the total polymer content comprising from 20% to 75% by weight of said composition, d. forming the mixture of step (c) into a desired configuration while in a flowable state, and e. solidifying said binder to form a solid composition in which said binder is adhesively bonded to said filler particles.

Claim 13

A process as in claim 10 in which said front-end fraction comprises the light fraction.

Claim 14

A process as in claim 10 in which said front-end fraction comprises the heavy fraction.

Claim 15

A process as in claim 10 in which the heavy fraction comprises a majority of glass and inorganic oxides, and a minor portion of mixed resins.

Claim 16

A process as in claim 10 in which said binder comprises at least two resinous adhesive polymers compatible with each other.

Claim 17

A process as in claim 10 in which said binder comprises from 10 to 90% by weight of the composition.

Claim 18

A process as in claim 10 in which the binder is selected from the group consisting of polyethylene, ethylene propylene rubber, and mixtures thereof.

Claim 19

A process as in claim 10 in which the total quantity of no single polymer incompatible with polyethylene is present in sufficient quantities to form an interface with polyethylene of sufficient length to provide a significantly weakened fault line.

Claim 20

A process as in claim 10 in which the total quantity of polymer incompatible with polyethylene comprises no greater than 15% by weight of the composition.

Claim 21

A process as in claim 10 in which the binder is polyethylene.

Claim 22

A process as in claim 19 in which the binder comprises scrap or off-grade virgin polyethylene.