# US 2014/0151924 A1 · Cycle time reduction masterbatches and their use in thermoplastic compounds > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0151924 A1 - Document ID: US20140151924A1 - Status: Published application - Kind: A1 - Application number: 14/002,629 - Filed: 2012-03-01 - Published: 2014-06-05 - Earliest claimed: 2011-03-04 - Assignees: Revolutionary Plastics, LLC; PolyOne Corporation - Inventors: Jack R. Prince; Jason D. Piunti - Web page: https://patentgrep.com/patent/US20140151924A1 ## CPC - C08L 23/06: Polyethylene - B29C 43/24: Calendering - B29C 45/0013: {using fillers dispersed in the moulding material, e.g. metal particles} - B29C 48/001: {Combinations of extrusion moulding with other shaping operations} - B29C 48/022: {characterised by the choice of material} - C08J 3/226: {using a polymer as a carrier} - B29C 48/03: characterised by the shape of the extruded material at extrusion - B29C 48/07: Flat, e.g. panels - B29C 48/08: flexible, e.g. films - B29C 48/09: Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - 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) - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) ## Abstract A masterbatch for a thermoplastic compound is disclosed, comprising fly ash and/or cinders and a carrier thermoplastic resin, compatible with or the same as the thermoplastic resin used in the compound. The amount of fly ash and/or cinders comprises at least 50 percent by weight of the masterbatch. Presence of the fly ash and/or cinders can reduce cycle time for molding of the compound into a plastic article by from about 5 percent to about 30 percent merely because of the presence of the fly ash and/or cinders. ## Claims ### Claim 1 A masterbatch for thermoplastic compounds of a first thermoplastic resin, comprising: (a) fly ash and/or cinders and (b) a second thermoplastic resin, compatible with or the same as the first thermoplastic resin, to serve as a carrier for the fly ash and/or cinders, wherein the fly ash and/or cinders comprises at least 50 percent by weight of the masterbatch. ### Claim 2 (depends on 1) The masterbatch of claim 1, wherein the first thermoplastic resin and the second thermoplastic resin are selected from the group consisting of polyolefins, polyamides, polyesters, poly (meth)acrylates, polycarbonates, poly(vinyl halides), polyvinyl alcohols, polynitriles, polyacetals, polyimides, polyarylketones, polyetherketones, polyhydroxyalkanoates, polycaprolactones, polystyrenes, polyurethanes, polysulfones, polyphenylene oxides, polyphenylene sulfides, polyacetates, liquid crystal polymers, fluoropolymers, ionomeric polymers, and copolymers of any of them and combinations of any two or more of them. ### Claim 3 (depends on 1) The masterbatch of claim 1, wherein the fly ash and/or cinders has a melting point or greater than about 1090° C.; a specific gravity of from about 2.2 to about 2.8; less than 100 parts per million of lead, hexavalent chromium, mercury or cadmium, a moisture content of 1% or less; a polycyclic aromatic hydrocarbon content of less than about 200 parts per million; a crystalline silica content of below about 0.5%; and a particle size range in which about 85% of the particles fall within 0.2 μm-280 μm, and remainder are less than about 850 μm. ### Claim 4 (depends on 1) The masterbatch of claim 1, wherein the masterbatch further comprises adhesion promoters; biocides, anti-fogging agents; anti-static agents; bonding, blowing and foaming agents; dispersants; fillers and extenders; fire and flame retardants and smoke suppresants; impact modifiers; initiators; lubricants; micas; pigments, colorants and dyes; plasticizers; processing aids; release agents; silanes, titanates and zirconates; slip and anti-blocking agents; stabilizers; stearates; ultraviolet light absorbers; viscosity regulators; or waxes; or combinations of them. ### Claim 5 (depends on 1) The masterbatch of claim 1, wherein the fly ash and/or cinders comprises from about 72 to about 90 weight percent of the masterbatch. ### Claim 6 (depends on 3) The masterbatch of claim 3, wherein the fly ash and/or cinders comprises from about 72 to about 90 weight percent of the masterbatch. ### Claim 7 (depends on 1) The masterbatch of claim 1 mixed with the first thermoplastic resin to form a thermoplastic compound. ### Claim 8 (depends on 1) A compound comprising the masterbatch of claim 1 and the first thermoplastic resin. ### Claim 9 (depends on 8) The compound of claim 8, in the shape of a molded plastic article, an extruded plastic article, or a calendered plastic article. ### Claim 10 (depends on 1) A method of using the masterbatch of claim 1, comprising the steps of: (a) melt-mixing the masterbatch and the first thermoplastic resin reshaping by extrusion, molding, or calendering a mixture of; and (b) reshaping the compound to form a plastic article, wherein the masterbatch has a weight percent in the plastic article ranging from about 1 to about 65 weight percent, and wherein the fly ash and/or cinders has a weight percent in the plastic article ranging from about 1 to about 58 weight percent. ### Claim 11 (depends on 10) The method of claim 10, wherein the reshaping step comprises four substeps of: (1) injecting the compound into a mold; (2) holding the compound in the mold to form the plastic article in the shape of the mold; (3) cooling the plastic article to permit the plastic article to be released from the mold while retaining shape of the mold; and (4) ejecting the plastic article, wherein time between commencement of the injecting substep (1) and commencement of the ejecting substep (4) is one cycle time, and wherein the cycle time of the compound is reduced from about 5 percent to about 30 percent for a plastic article of the compound as compared with a cycle time between commencement of substep (1) and commencement of substep (4) for a plastic article of the first thermoplastic resin. ### Claim 12 (depends on 11) The method of claim 11, wherein the first thermoplastic resin comprises polyethylene and the second thermoplastic resin comprises polyethylene, and wherein the cycle time of the compound is about 14 percent faster than the cycle time of the first thermoplastic resin. ### Claim 13 (depends on 11) The method of claim 11, wherein the plastic article is a core section about which a capstock section is also molded. ### Claim 14 (depends on 1) A molded plastic article made by the method of claim 1. ### Claim 15 (depends on 10) An extruded plastic article made by the method of claim 10. ### Claim 16 (depends on 10) A calendered plastic article made by the method of claim 10.