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 at least one first olefin;
providing recycled metalized packaging comprising:
i) at least one second olefin in a total amount of 70-92% by weight; and
ii) at least one metal in a total amount of 1-20% by weight;
providing an organic filler; and
in the same step, mixing and extruding said at least one first olefin, said recycled metalized packaging, and said organic filler to form said polymer composite product comprised of said at least one first olefin, said recycled metalized packaging, and said organic filler;
wherein said recycled metalized packaging is in an amount of 20-60% by weight of said polymer composite product and said organic filler is in an amount of 40-60% by weight of said polymer composite product.
2. The method of claim 1 wherein said at least one first olefin is selected from the group consisting of polyethylene and polypropylene.
3. The method of claim 1 wherein said at least one second olefin is selected from the group consisting of polyethylene and polypropylene.
4. The method of claim 3 wherein said at least one second olefin is polyethylene and polypropylene.
5. The method of claim 1 wherein said at least one metal comprises aluminum.
6. The method of claim 1 wherein:
said at least one first olefin is selected from the group consisting of polyethylene and polypropylene;
said at least one second olefin is selected from the group consisting of polyethylene and polypropylene; and
said at least one metal comprises aluminum.
7. The method of claim 1 wherein said polymer composite further comprises at least one ionomer.
8. The method of claim 1 wherein said recycled metalized packaging is in an amount of 20-35% by weight of said polymer composite.
9. The method of claim 1 further comprising the step of co-extruding a cap layer on said polymer composite.
10. The method of claim 1 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 1-20% by weight.
11. The method of claim 10 wherein said polyethylene terephthalate is in an amount of 5-15% by weight.
12. The method of claim 11 wherein said at least one metal is in a total amount of 3-15% by weight.
13. A method for manufacturing a polymer composite product, said method comprising:
providing an extruder;
providing at least one first olefin;
providing recycled metalized packaging comprising:
i) at least one second olefin in a total amount of 70-92% by weight and
ii) at least one metal in a total amount of 3-15% by weight;
providing an organic filler; and
extruding said at least one first olefin, said recycled metalized packaging, and said organic filler to form said polymer composite product comprised of said at least one first olefin, said recycled metalized packaging, and said organic filler;
wherein said recycled metalized packaging is in an amount of 20-60% by weight of said polymer composite product and said organic filler is in an amount of 40-60% by weight of said polymer composite product.
14. A method for manufacturing a polymer composite product, said method comprising:
providing an extruder;
providing at least one first olefin;
providing recycled metalized packaging comprising:
i) at least one second olefin in a total amount of 70-92% by weight; and
ii) at least one metal in a total amount of 1-20% by weight;
providing an organic filler; and
in the same step, mixing and extruding said at least one first olefin, said recycled metalized packaging, and said organic filler to form said polymer composite product comprised of said at least one first olefin, said recycled metalized packaging, and said organic filler;
wherein said recycled metalized packaging is in an amount of 10-30% by weight of said polymer composite product and said organic filler is in an amount of 40-60% by weight of said polymer composite product.
15. The method of claim 14 wherein said at least one first olefin is in a total amount of 10-30% by weight of said polymer composite.
16. The method of claim 14 wherein said at least one first olefin is selected from the group consisting of polyethylene and polypropylene.
17. The method of claim 14 wherein said at least one second olefin is selected from the group consisting of polyethylene and polypropylene.
18. The method of claim 17 wherein said at least one second olefin is polyethylene and polypropylene.
19. The method of claim 14 wherein said at least one metal comprises aluminum.
20. The method of claim 14 wherein:
said at least one first olefin is selected from the group consisting of polyethylene and polypropylene;
said at least one second olefin is selected from the group consisting of polyethylene and polypropylene; and
said at least one metal comprises aluminum.
21. The method of claim 14 wherein said polymer composite further comprises at least one ionomer.
22. The method of claim 14 further comprising the step of co-extruding a cap layer on said polymer composite.
23. The method of claim 14 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 1-20% by weight.
24. The method of claim 23 wherein said polyethylene terephthalate is in an amount of 5-15% by weight.
25. The method of claim 24 wherein said at least one metal is in a total amount of 3-15% by weight.
26. A method for manufacturing a polymer composite product, said method comprising:
providing an extruder;
providing at least one first olefin;
providing recycled metalized packaging comprising:
i) at least one second olefin in a total amount of 70-92% by weight and
ii) at least one metal in a total amount of 3-15% by weight;
providing an organic filler; and
extruding said at least one first olefin, said recycled metalized packaging, and said organic filler to form said polymer composite product comprised of said at least one first olefin, said recycled metalized packaging, and said organic filler;
wherein said recycled metalized packaging is in an amount of 10-30% by weight of said polymer composite product and said organic filler is in an amount of 40-60% by weight of said polymer composite product.
27. A method for manufacturing a polymer composite product, said method comprising:
providing an extruder;
providing at least one first olefin selected from the group consisting of polyethylene and polypropylene;
providing recycled metalized packaging comprising:
i) at least one second olefin in a total amount of 70-92% by weight, said at least one second olefin selected from the group consisting of polyethylene and polypropylene; and
ii) at least one metal in a total amount of 1-20% by weight, said at least one metal comprising aluminum;
providing an organic filler; and
in the same step, mixing and extruding said at least one first olefin, said recycled metalized packaging, and said organic filler to form said polymer composite product comprised of said at least one first olefin, said recycled metalized packaging, and said organic filler;
wherein said at least one first olefin is in a total amount of 10-30% by weight of said polymer composite product, said recycled metalized packaging is in an amount of 10-30% by weight of said polymer composite product, and said organic filler is in an amount of 40-60% by weight of said polymer composite product.
28. The method of claim 27 wherein said polymer composite further comprises at least one ionomer.
29. The method of claim 27 further comprising the step of co-extruding a cap layer on said polymer composite.
30. The method of claim 27 wherein said recycled metalized packaging further comprises polyethylene terephthalate in an amount of 1-20% by weight.
31. The method of claim 30 wherein said polyethylene terephthalate is in an amount of 5-15% by weight.
32. The method of claim 31 wherein said at least one metal is in a total amount of 3-15% by weight.
33. A method for manufacturing a polymer composite product, said method comprising:
providing an extruder;
providing at least one first olefin selected from the group consisting of polyethylene and polypropylene;
providing recycled metalized packaging comprising:
i) at least one second olefin in a total amount of 70-92% by weight, said at least one second olefin selected from the group consisting of polyethylene and polypropylene; and
ii) at least one metal in a total amount of 3-15% by weight, said at least one metal comprising aluminum;
providing an organic filler; and
extruding said at least one first olefin, said recycled metalized packaging, and said organic filler to form said polymer composite product comprised of said at least one first olefin, said recycled metalized packaging, and said organic filler;
wherein said at least one first olefin is in a total amount of 10-30% by weight of said polymer composite product, said recycled metalized packaging is in an amount of 10-30% by weight of said polymer composite product, and said organic filler is in an amount of 40-60% by weight of said polymer composite product.