Granted Patent B2

US 9,290,645 · App. 14/002,629 · Granted Mar 22, 2016

Abstract

Claims (32)

1. A method of using, a masterbatch comprising the steps of:

(a) melt-mixing a masterbatch and a first thermoplastic resin to form a compound; and

(b) extrusion, molding, or calendering the compound to form a plastic article,

wherein the masterbatch has a weight percent in the plastic article ranging from about 1 to about 65 weight percent, and wherein the fly ash and/or cinders has a weight percent in the plastic article ranging from about 1 to about 58 weight percent;

wherein the master latch comprises

(i) fly ash and/or cinders comprising from about 72 to about 0.90 percent by weight of the masterbatch; and

(ii) a second thermoplastic resin, compatible with or the same as the first thermoplastic resin, to serve as a carrier for the fly ash and/or cinders.

2. The method of claim 1 , wherein the first thermoplastic resin and the second thermoplastic resin are selected from the group consisting of polyolefins, polyamides, polyesters, poly(meth)acrylates, polycarbonates, poly(vinyl halides), polyvinyl alcohols, polynitriles, polyacetals, polyimides, polyarylketones, polyetherketones, polyhydroxyalkanoates, polycaprolactones, polystyrenes, polyurethanes, polysulfones, polyphenylene oxides, polyphenylene sulfides, polyacetates, liquid crystal polymer fluoropolymers, ionomeric polymers, and copolymers of any of them and combinations of any two or more of them.

3. The method of claim 1 , wherein the fly ash and/or cinders has a melting point or greater than about 1090° C.; a specific gravity of from about 2.2 to about 18; less than 100 parts per million of lead, hexavalent chromium, mercury or cadmium, a moisture content of 1% or less; a polycyclic aromatic hydrocarbon content, of less than about 200 parts per million; a crystalline silica content of below about 0.5%; and a particle size range in which about 85% of the particles fall within 0.2-280 μm, and remainder are less than about 850 μm.

4. The method of claim 1 , wherein the masterbatch further comprises one or more of an adhesion promoter; a biocide, an anti-fogging agent; an anti-static agent; a bonding, blowing and/or foaming agent; a dispersant; afire and/or flame retardant; a smoke suppressant; an impact modifier; a lubricant; a mica; a pigment, colorant\s and/or dye; a plasticizer; a processing aid; a release agent; silane; titanate, zirconate; a slip and anti-blocking agent; a stabilizer; stearate; an ultraviolet light absorber; a viscosity regulator; and a wax.

5. The method of claim 1 , wherein the fly ash and/or cinders comprises from about 75 to about $5 weight percent of the masterbatch.

6. The method of claim 3 , wherein the fly ash and/or cinders comprises from about 75 to about $5 weight percent of the masterbatch.

7. The method of claim 1 wherein said fly ash and/or cinders are all sized to be less than about 850 microns and wherein said masterbatch mixed with said first thermoplastic resin to form a thermoplastic compound.

8. The method of claim 1 , wherein step (b) comprises four substeps of:

(1) injecting the compound into a mold;

(2) holding the compound in the mold to form the plastic article in the shape of the mold;

(3) cooling the plastic article to permit the plastic article to be released from the mold white retaining shape of the mold; and

(4) ejecting the plastic article,

wherein time between commencement of the injecting substep (1) and commencement of the ejecting substep (4) is one cycle time, and

wherein the cycle time of the compound is reduced from about 5 percent to about 30 percent for a plastic article of the compound as compared with a cycle time between commencement of injecting substep (I) and commencement of ejecting substep (4) for a plastic article of the first thermoplastic resin.

9. The method of claim 8 , wherein the first thermoplastic resin comprises polyethylene and the second thermoplastic resin comprises polyethylene, and wherein the cycle time of the compound is about 14 percent faster than the cycle time of the first thermoplastic resin.

10. The method of claim 8 , wherein the plastic article is a core section about which a capstock section is also molded.

11. A method of making a plastic article comprising

(a) forming a masterbatch for combining with a first thermoplastic resin, said masterbatch having:

fly ash and/or cinders comprising from about 72 to about 90 percent by weight of the masterbatch; and

a second thermoplastic resin to serve as a carrier for the fly ash and/or cinders;

(b) melt-mixing the masterbatch and the first thermoplastic resin to form a thermoplastic compound:

(c) providing a shaping machine to produce a plastic article, said shaping machine being configured to operate in a cycle that extends in time for a cycle time as the machine moves between a forming condition in which the thermoplastic compound is introduced and the plastic article formed and a removing condition in which the plastic article is removed; and

(d) introducing said thermoplastic compound into said shaping machine and operating said shaping machine in a cycle at

a first cycle time to form said plastic article, said first cycle time being faster than a second cycle time which is when said shaping machine is operated to produce a different plastic article wherein said thermoplastic compound is a resin without master batch;

wherein the masterbatch has a weight percent in the plastic article ranging from about 1 to about 65 weight percent, and wherein the fly ash and/or cinders has a weight percent in the plastic article ranging from about 1 to about 58 weight.

12. The method of claim 11 wherein the first thermoplastic resin is polyethylene and wherein said first cycle time is about 14 percent faster than said second cycle time; and wherein said fly ash and/or cinders are less than about 850 microns in particle size.

Assignments (12)