Use of recycled packaging in polymer composite products
A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.
1. A method for manufacturing a polymer composite product, said method comprising:
providing an extruder;
providing recycled metalized packaging comprising:
i) at least one olefin in a total amount of 70-92% by weight; and
ii) at least one metal in a total amount of 3% up to 20% by weight;
providing an organic filler; and
extruding said recycled metalized packaging with said organic filler to form said polymer composite product comprised of said recycled metalized packaging in an amount of 20-60% by weight of said polymer composite product and said organic filler in an amount of 40-60% by weight of said polymer composite product.
2. The method of claim 1 wherein said at least one olefin is selected from the group consisting of polyethylene and polypropylene.
3. The method of claim 1 wherein said at least one olefin is polyethylene and polypropylene.
4. The method of claim 1 wherein said at least one metal comprises aluminum.
5. The method of claim 1 wherein:
said at least one olefin is selected from the group consisting of polyethylene and polypropylene; and
said at least one metal comprises aluminum.
6. The method of claim 1 wherein said polymer composite product further comprises at least one ionomer.
7. The method of claim 1 wherein said recycled metalized packaging is in an amount of 20-35% by weight of said polymer composite product.
8. The method of claim 1 further comprising, in the same step, mixing and extruding said recycled metalized packaging with said organic filler to form said polymer composite product.
9. The method of claim 1 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 1-20% by weight.
10. The method of claim 9 wherein said polyethylene terephthalate is in an amount of 5-15% by weight.
11. The method of claim 1 wherein said at least one olefin is in a total amount of 75-90% by weight.
12. The method of claim 1 wherein said at least one metal is in a total amount of 3-15% by weight.
13. The method of claim 1 wherein:
said at least one olefin is in a total amount of 75-90% by weight; and
said at least one metal is in a total amount of 3-15% by weight.
14. The method of claim 13 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 1-20% by weight.
15. The method of claim 14 wherein said polyethylene terephthalate is in an amount of 5-15% by weight.
16. The method of claim 13 wherein:
said at least one olefin is selected from the group consisting of polyethylene and polypropylene; and
said at least one metal comprises aluminum.
17. The method of claim 13 wherein said polymer composite product further comprises at least one ionomer.
18. The method of claim 13 wherein said recycled metalized packaging is in an amount of 20-35% by weight of said polymer composite product.
19. The method of claim 13 further comprising, in the same step, mixing and extruding said recycled metalized packaging with said organic filler to form said polymer composite product.
20. The method of claim 1 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 5-12% by weight.
21. The method of claim 1 wherein said at least one olefin is in a total amount of 75-85% by weight.
22. The method of claim 1 wherein said at least one metal is in a total amount of 3-12% by weight.
23. The method of claim 1 wherein:
said at least one olefin is in a total amount of 75-85% by weight; and
said at least one metal is in a total amount of 3-12% by weight.
24. The method of claim 23 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 1-20% by weight.
25. The method of claim 24 wherein said polyethylene terephthalate is in an amount of 5-12% by weight.
26. The method of claim 23 wherein:
said at least one olefin is selected from the group consisting of polyethylene and polypropylene; and
said at least one metal comprises aluminum.
27. The method of claim 13 wherein said polymer composite product further comprises at least one ionomer.
28. The method of claim 13 wherein said recycled metalized packaging is in an amount of 20-35% by weight of said polymer composite product.
29. The method of claim 23 further comprising, in the same step, mixing and extruding said recycled metalized packaging with said organic filler to form said polymer composite product.
30. The method of claim 1 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 8-12% by weight.
31. The method of claim 1 wherein said at least one metal is in a total amount of 8-12% by weight.
32. The method of claim 1 wherein:
said at least one olefin is in a total amount of 75-85% by weight; and
said at least one metal is in a total amount of 8-12% by weight.
33. The method of claim 32 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 1-20% by weight.
34. The method of claim 33 wherein said polyethylene terephthalate is in an amount of 8-12% by weight.
35. The method of claim 32 wherein:
said at least one olefin is selected from the group consisting of polyethylene and polypropylene; and
said at least one metal comprises aluminum.
36. The method of claim 32 wherein said polymer composite product further comprises at least one ionomer.
37. The method of claim 32 wherein said recycled metalized packaging is in an amount of 20-35% by weight of said polymer composite product.
38. The method of claim 32 further comprising, in the same step, mixing and extruding said recycled metalized packaging with said organic filler to form said polymer composite product.