Board derived from recycled waste material comprising polyvinylchloride
A board for use in a construction related application, the board including: a) a core layer having first and second major surfaces and b) a first facing layer directly adjacent to the first major surface of the core layer, wherein the core layer includes recycled polyvinylchloride membrane waste material.
1 . A method for producing a board that is suitable for use in a construction related application and includes (i) a core layer having first and second major surfaces, and (ii) a first facing layer directly adjacent to the first major surface of the core layer, wherein the core layer includes recycled polyvinylchloride membrane waste material and comprises a thermoplastic bonding material including polyvinylchloride resin, the method comprising steps of:
I) providing a waste material feedstock including a first waste material fraction comprising polyvinylchloride membrane waste;
II) providing a second waste material fraction comprising residual fluff, which is a by-product that is separated from polyvinylchloride membrane waste when the membrane waste is processed to decrease the particle size of the membrane waste;
III) combining the first waste material fraction and the second waste material fraction to provide a waste material feedstock having 15-85 wt. % of the first waste material fraction and 15-85 wt. % of the second waste material fraction,
IV) heating and compressing the waste material feedstock obtained from step III) within a fixture to form the core layer of the board.
2 . The method according to claim 1 , wherein step III) further comprises:
mixing the first waste material fraction and the second waste material fraction with each other to obtain the waste material feedstock.
3 . The method according to claim 1 , wherein the first and/or second waste fraction is/are obtained from mechanical recycling of pre-consumer and/or post-consumer polyvinylchloride membrane waste.
4 . The method according to claim 3 , wherein the post-consumer polyvinylchloride membrane waste has been derived from mechanically fastened and/or ballasted and/or adhered roof systems.
5 . The method according to claim 1 , wherein first waste material fraction comprises a polyvinylchloride resin rich fraction obtained as a main product from mechanical recycling of polyvinylchloride membrane waste.
6 . The method according to claim 1 , wherein the second waste material fraction comprises fragments of synthetic and/or inorganic fibers.
7 . The method according to claim 1 , wherein the waste material feedstock further includes a third waste material fraction comprising shredded scrap paper and/or packaging waste and/or a fourth waste material fraction comprising recycled polyethylene-based post-industrial or post-consumer plastic waste.
8 . The method according to claim 7 , wherein the third waste material fraction comprises fragments of cellulose containing material and polyethylene.
9 . The method according to claim 1 , further comprising producing the residual fluff by separating it from the polyvinyl chloride membrane waste when the membrane waste is subjected to grinding, shredding, or chopping to reduce the particle size of the membrane waste, and then collecting the residual fluff.
10 . The method according to claim 1 , further comprising, after step III), positioning the first facing layer and a second facing layer on opposing heated surfaces of a hot-pressing machine, and then, in step IV) heating and compressing the waste material feedstock with the hot-pressing machine.