Material created from polymer and other mass which is entirely, partially or substantially composed of reclaimed mixed material

A method of forming an article of composite material, the method comprising:

• deriving a plurality of mass particles consisting of a fibrous material at least in part from recycled post-consumer materials such that the mass particles have an average particle size in the range of 1 to 50 millimeters;
• deriving a binding material consisting of a thermoplastic material at least in part from recycled post-consumer materials;
• mixing the mass particles and the binding material such that the mass particles occupy between 35% and 60% by weight of the article and the binding material occupies between 40% and 60% by weight of the article;
• heating the binding material before or during mixing such that the binding material is substantially liquified and each mass particle is substantially fully encapsulated by the liquified binding material;
• pressing the encapsulated mass particles together to form a block of material;
• and
• shaping the block of material to form the article by cutting the block of material to produce cuttings, and mixing the cuttings with the mass particles and the binding material in the formation of a second article.

A method of forming an article of composite material, the method comprising:

• deriving a plurality of mass particles consisting of a fibrous material at least in part from recycled post-consumer materials such that the mass particles have an average particle size in the range of 1 to 50 millimeters;
• deriving a binding material consisting of a thermoplastic material at least in part from recycled post-consumer materials;
• mixing the mass particles and the binding material such that the mass particles occupy between 35% and 60% by weight of the article and the binding material occupies between 40% and 60% by weight of the article;
• heating the binding material before or during mixing such that the binding material is substantially liquified and each mass particle is substantially fully encapsulated by the liquified binding material;
• pressing the encapsulated mass particles together to form a block of material;
• and
• shaping the block of material to form the article;
• before forming the block, cooling the encapsulated mass particles, transporting the encapsulated mass particles to a secondary manufacturing location, heating the encapsulated mass particles at the secondary manufacturing location, and pressing the encapsulated mass particles to form the block of material and shaping the block of material to form the article at the secondary manufacturing location.

A method of forming an article of composite material, the method comprising:

• deriving a plurality of mass particles consisting of a fibrous material at least in part from recycled post-consumer materials such that the mass particles have an average particle size in the range of 1 to 50 millimeters;
• deriving a binding material consisting of a thermoplastic material at least in part from recycled post-consumer materials;
• mixing the mass particles and the binding material such that the mass particles occupy between 35% and 60% by weight of the article and the binding material occupies between 40% and 60% by weight of the article;
• heating the binding material before or during mixing such that the binding material is substantially liquified and each mass particle is substantially fully encapsulated by the liquified binding material;
• pressing the encapsulated mass particles together to form a block of material;
• shaping the block of material to form the article;
• and
• heating the binding material during the mixing such that the binding material undergoes partial pyrolysis.

A method of forming an article of composite material, the method comprising:

• deriving a plurality of mass particles consisting of a fibrous material at least in part from recycled post-consumer materials such that the mass particles have an average particle size in the range of 1 to 50 millimeters;
• deriving a binding material consisting of a thermoplastic material at least in part from recycled post-consumer materials;
• mixing the mass particles and the binding material such that the mass particles occupy between 35% and 60% by weight of the article and the binding material occupies between 40% and 60% by weight of the article;
• heating the binding material before or during mixing such that the binding material is substantially liquified and each mass particle is substantially fully encapsulated by the liquified binding material;
• pressing the encapsulated mass particles together to form a block of material;
• and
• shaping the block of material to form the article;
• wherein an average thickness of the encapsulating binding material about the mass particles is less than the average particle size of the mass particles.

A method of forming an article of composite material, the method comprising:

• deriving a plurality of mass particles consisting of a fibrous material at least in part from recycled post-consumer materials such that the mass particles have an average particle size in the range of 1 to 50 millimeters;
• deriving a binding material consisting of a thermoplastic material at least in part from recycled post-consumer materials;
• mixing the mass particles and the binding material such that the mass particles occupy between 35% and 60% by weight of the article and the binding material occupies between 40% and 60% by weight of the article;
• heating the binding material before or during mixing such that the binding material is substantially liquified and each mass particle is substantially fully encapsulated by the liquified binding material;
• pressing the encapsulated mass particles together to form a block of material;
• and
• shaping the block of material to form the article;
• wherein the composite material of the article has a compressive strength which is greater than 1500 psi.

A method of forming an article of composite material, the method comprising:

• deriving a plurality of mass particles consisting of a fibrous material at least in part from recycled post-consumer materials such that the mass particles have an average particle size in the range of 1 to 50 millimeters;
• deriving a binding material consisting of a thermoplastic material at least in part from recycled post-consumer materials;
• mixing the mass particles and the binding material such that the mass particles occupy between 35% and 60% by weight of the article and the binding material occupies between 40% and 60% by weight of the article;
• heating the binding material before or during mixing such that the binding material is substantially liquified and each mass particle is substantially fully encapsulated by the liquified binding material;
• pressing the encapsulated mass particles together to form a block of material;
• and
• shaping the block of material to form the article;
• wherein the composite material of the article incorporates organic waste derived from the recycled post-consumer materials in which the organic waste occupies less than 3% by weight of the composite material.