RECYCLED COMPOSITE MATERIALS AND RELATED METHODS
Methods of producing particles of fiber and resin from fiber-resin composite materials are disclosed. The particles may be combined with a resin system and optionally combined with fillers, binders or reinforcements to produce new cured solid composite products.
1 . A method of producing particles from recycled composite materials comprising
(a) shredding composite materials to form small pieces of shredded composite materials; and
(b) grinding said small pieces of shredded composite materials to form smaller particles of composite materials.
2 . The method of claim 1 wherein said composite materials are cured or uncured fiberglass or glass fiber-reinforced plastic.
3 . The method of claim 1 wherein said composite materials are composite windmill turbine blades.
4 . The method of claim 1 further comprising using the particles to form a solid composite product.
5 . A method of forming the solid composite product according to claim 4 comprising
(a) producing particles according to the method of claim 1 ; and
(b) combining said particles with resin to form a mixture;
(c) disposing of the mixture in a form or mold; and
(d) curing the mixture to form a solid composite product.
6 . The method of claim 5 wherein said mixture further comprises binders, fillers, resins, catalysts, strengthening agents or combinations thereof before curing.
7 . The method of claim 6 wherein said wherein said mixture comprises aggregate of solid particulates.
8 . The method of claim 7 wherein said wherein said mixture comprises aggregate of solid particulates and silica.
9 . The method of claim 5 wherein said product emits no volatile organic compounds or hazardous air pollutants.
10 . A cured composite product comprising
(a) particles of composite materials according to the method of claim 1 ;
(b) aggregate; and
(c) resin;
wherein said composite product is cured.
11 . The composite product of claim 10 , wherein the resin in the cured composite product comprises less than about 30% by weight of the cured product.
12 . The composite product of claim 10 , wherein said particles of composite materials comprises about 15% by weight of the cured product.
13 . The composite product of claim 10 , wherein said product further comprises silica of about 30% by weight of the cured product.
14 . The composite product of claim 10 , wherein said aggregate comprises about 50% by weight of the cured product.
15 . The composite product of claim 10 , wherein said particles of composite material has an average fiber length of less than about one-half inch in diameter.
16 . The composite product of claim 10 , wherein said particles of composite material has an average fiber length of about one-quarter inch in diameter.
17 . The composite product of claim 10 , wherein said particles of composite material has an average fiber length of from about one-eighth inch to about one-half inch in diameter.
18 . The composite product of claim 10 , wherein said composite product withstands compressive stress of at least about 10,000 psi with a compressive strain of less than about 7%.
19 . The composite product of claim 10 , wherein the weight of said composite product increases less than about 1% after immersion in water for 24 hours.
20 . The composite product of claim 10 , wherein said product emits no volatile organic compounds or hazardous air pollutants.