# US 2013/0154157 A1 · Novel material and process of manufacture > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0154157 A1 - Document ID: US20130154157A1 - Status: Published application - Kind: A1 - Application number: 13/812,748 - Filed: 2011-07-27 - Published: 2013-06-20 - Earliest claimed: 2010-07-27 - Inventors: Gary Thompson - Web page: https://patentgrep.com/patent/US20130154157A1 ## CPC - B29C 43/18: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} - B29C 43/003: {characterised by the choice of material} - B29C 43/02: of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)} - E04B 2/06: using elements having specially-designed means for stabilising the position - E04B 2/12: using elements having a general shape differing from that of a parallelepiped - B29K 2105/16: Fillers - B29K 2709/08: Glass - E04B 2002/0206: {of rectangular shape} - E04B 2002/0219: {of pyramidal shape} - E04B 2002/023: {with rabbets, e.g. stepped} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A process for manufacturing a material including glass in particulate form and plastic, comprises the steps of heating the glass in particulate form and/or the plastic to a threshold temperature sufficient to change the state of the plastic from a solid to a viscous liquid, mixing together the glass and plastic to form a mixture, pressing the mixture into a desired shape and curing the pressed mixture. ## Claims ### Claim 1 A process for manufacturing a material including glass in particulate form and plastic, the process comprising the steps of: i. Heating the plastic to a threshold temperature sufficient to change the state of the plastic from a solid to a viscous liquid; ii. Mixing together the glass and plastic to form a mixture; iii. Pressing the mixture into a desired shape; iv. Curing the pressed mixture. ### Claim 2 (depends on 1) A process according to claim 1, wherein the threshold temperature is between 230 C and 250 C. ### Claim 3 (depends on 1) A process according to claim 1, wherein the method comprises one of the following steps: heating the glass heated to the threshold temperature and mixing the heated glass with plastic at room temperature; heating the plastic to the threshold temperature and mixing the heated plastic with glass at room temperature; and heating the plastic to the threshold temperature and mixing the heated plastic with glass heated above room temperature up to the threshold temperature. ### Claim 4 (depends on 1) A process according to claim 1, wherein one of the plastic and the glass is added gradually to the other as mixing proceeds. ### Claim 5 (depends on 1) A process according to claim 1, comprising the further step of heating the glass and plastic mixture to maintain the temperature of the mixture at the threshold temperature. ### Claim 6 (depends on 1) A process according to claim 1, wherein during the mixing step the mixture is maintained at the threshold temperature by a heating means associated with the mixing vessel. ### Claim 7 (depends on 1) A process according to claim 1, wherein the step of exerting pressure on the mixture takes place in one of a press a mould or a die. ### Claim 8 (depends on 7) A process according to claim 7, wherein pressure is exerted on the material is in the range of 5-11 Newtons/mm2. ### Claim 9 (depends on 8) A process according to claim 8, wherein the pressure exerted on the material is in the range of 5 to 8 Newtons/mm2. ### Claim 10 (depends on 8) A process according to claim 8, wherein the pressure exerted on the material is in the range 8 to 9.6 Newtons/mm2. ### Claim 11 (depends on 8) A process according to claim 8, wherein the pressure exerted on the material is in the range 9.6 to 11 Newtons/mm2. ### Claim 12 (depends on 7) A process according to claim 7, wherein the pressure is exerted on the material for a period of between 15 and 60 seconds. ### Claim 13 (depends on 12) A process according to claim 12, wherein the pressure is exerted on the material for a period of approximately 30 seconds. ### Claim 14 (depends on 7) A process according to claim 7, comprising the step of heating the mixture, the computer including one of a press, a mould and a die. ### Claim 15 (depends on 1) A process according to claim 1, wherein the mixture comprises glass in the range of 65% to 90% and plastic in the range 35% to 15% by weight. ### Claim 16 (depends on 15) A process according to claim 15, wherein the mixture comprises substantially 70% glass and substantially 30% plastic. ### Claim 17 (depends on 1) A process according to claim 1, wherein the glass comprises recycled glass cullet. ### Claim 18 (depends on 1) A process according to claim 1, wherein the glass particles are in the range of 6 mm down to dust. ### Claim 19 (depends on 1) A process according to claim 1, including the step of coating the glass particles are coated in calcium carbonate. ### Claim 20 (depends on 19) A process according to claim 19, including the step of coating the glass particles in calcium carbonate to a thickness of 0.04 micron. ### Claim 21 (depends on 1) A process according to claim 1, wherein the plastic is polyethylene. ### Claim 22 (depends on 1) A process according to claim 1, including the further step of quenching the material post heating. ### Claim 23 (depends on 1) A process according to claim 1, including the step of laying a mesh substrate into the mixture prior to pressing thereof. ### Claim 24 (canceled) ### Claim 25 (canceled) ### Claim 26 (canceled) ### Claim 27 (canceled)