# US 2019/0315019 A1 · Method for recycling high-density polyethylene (hdpe) material by thermofusion and recycled hdpe products

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- Number: US 2019/0315019 A1
- Document ID: US20190315019A1
- Status: Published application
- Kind: A1
- Application number: 16/341,802
- Filed: 2017-10-13
- Published: 2019-10-17
- Earliest claimed: 2016-10-14
- Assignees: Sociedad Comercial Harut SPA
- Applicants: Sociedad Comercial Harut SPA
- Inventors: Gabriel Ignacio BARAHONA OSORIO; Silvia Montserrat BRUNA PAEZ
- Web page: https://patentgrep.com/patent/US20190315019A1

## CPC

- B29B 17/0042: {for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic}
- B29B 17/04: Disintegrating plastics, {e.g. by milling}(B29B9/02, B29B11/02, B29B13/10, {B29B17/02} take precedence)
- B29B 9/02: by dividing preformed material
- B29B 17/02: Separating plastics from other materials
- B29B 17/0412: {to large particles, e.g. beads, granules, flakes, slices}
- B29C 51/002: {characterised by the choice of material}
- B29C 51/264: {Auxiliary operations prior to the thermoforming operation, e.g. cutting (B29C51/42, B29C51/46 take precedence)}
- B29C 70/58: comprising fillers only {, e.g. particles, powder, beads, flakes, spheres (B29C70/025 takes precedence, agglomerating hollow spheres to produce synthetic foam B29C70/66; compounding ingredients per se C08K)}
- C08J 11/06: without chemical reactions
- B29B 2017/0289: {Washing the materials in liquids}
- B29B 2017/0468: {Crushing, i.e. disintegrating into small particles}
- B29C 43/02: of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)}
- B29K 2023/065: {HDPE, i.e. high density polyethylene}
- B29K 2105/26: Scrap {or recycled material}
- B29L 2031/712: {Containers; Packaging elements or accessories, Packages (closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418)}
- C08L 2207/062: HDPE
- Y02W 30/62: Plastics recycling; Rubber recycling
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- 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)
- 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
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

The present invention relates to a process for recycling waste high density polyethylene (HDPE) materials, which is carried out by thermofusion. Through this recycling process, products having particular qualities are obtained, and laminated products or products in the form of a molded block may be obtained. Said products, in addition to representing a benefit for the environment, exhibit particularities that make them different from virgin raw material products and recycled products, representing a surprising and unexpected technical advantage over those currently available.

## Claims

### Claim 1

A process for recycling high density polyethylene (HDPE) materials by thermofusion, comprising the steps of:
crushing waste HDPE containers;
storing crushed material in maxi sacks;
pouring the crushed material into a wash container;
washing the crushed material with a biodegradable degreaser;
rinsing the crushed material with pure water;
storing clean crushed material in maxi sacks;
pouring the clean and dry, crushed material into a thermofusion furnace;
boiling, by thermofusion, the material under specific conditions;
removing the thermo-fused product from the thermofusion furnace;
pressing the thermo-fused material; and
extracting the molded product.

### Claim 2 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein, for crushing step, the waste HDPE are place in a chipping machine.

### Claim 3 (depends on 2)

The process for recycling high density polyethylene (HDPE) materials, according to claim 2, wherein the materials are crushed until reaching an approximate dimension from 1×1 cm to 10×10 cm.

### Claim 4 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein each maxi-sack may hold up to one ton of crushed material.

### Claim 5 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein, in the crushed material washing step, the biodegradable degreaser used is neutral and washing time is extended from 10 to 14 minutes.

### Claim 6 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein the rinsing step lasts 1 to 3 minutes.

### Claim 7 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein the drying step is carried out by means of an industrial filter acting as a dryer, whose motor rotates at a speed equivalent to 80 km/h.

### Claim 8 (depends on 7)

The process for recycling high density polyethylene (HDPE) materials, according to claim 7, wherein the drying step lasts between 1 and 3 minutes.

### Claim 9 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein the quantity of crushed, clean and dry that is poured into the thermofusion furnace will depend on the type of product to be obtained.

### Claim 10 (depends on 9)

The process for recycling high density polyethylene (HDPE) materials, according to claim 9, wherein, to obtained laminated products, the same quantity of crushed material required as that of the end product to be obtained.

### Claim 11 (depends on 9)

The process for recycling high density polyethylene (HDPE) materials, according to claim 9, wherein, to obtain block-shaped products or of a particular shape, a third part of the quantity of crushed material required is poured, to obtained the desired end product.

### Claim 12 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein if a gas-burned thermofusion furnace is used at the boiling step, said furnace must remain on for approximately one hour before introducing the crushed material.

### Claim 13 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein if an electric thermofusion furnace is used in the boiling step, said furnace must be turned on a half hour before the crushed material is poured into it.

### Claim 14 (depends on 12, 13)

The process for recycling high density polyethylene (HDPE) materials, according to claims 12 or 13, wherein the thermofusion furnace chamber must reach a temperature between 150° C. and 158° C. when pouring the crushed material.

### Claim 15 (depends on 10)

The process for recycling high density polyethylene (HDPE) materials, according to claim 10, wherein, to produce a laminated product, the crushed material is poured into the furnace mold in one go, and after one minute, the temperature of the furnace raises to 170° C., during the following seven minutes, said temperature fluctuates between 170° C. and 180° C., and, finally, the laminated product is taken out of the furnace.

### Claim 16 (depends on 11)

The process for recycling high density polyethylene (HDPE) materials, according to claim 11, wherein, to produce a block product, the crushed material is poured, separately, into three equal parts of crushed material, each of said parts at a specific time.

### Claim 17 (depends on 16)

The process for recycling high density polyethylene (HDPE) materials, according to claim 16, wherein the first layer of material, equivalent to one third of the amount estimated by product, stays in the furnace for 8 minutes, the second layer is poured in the same mold containing the first layer and is thermo-fused for 4 minutes, and, then, the third layer is poured, which is left to thermo-fuse for 3 minutes.

### Claim 18 (depends on 17)

The process for recycling high density polyethylene (HDPE) materials, according to claim 17, wherein the furnace temperatures corresponding to each of the time periods are handled such that that, after one minute, the furnace temperature rises to 170° C.; in the second and third variation, equivalent to pouring two and three thirds of the material, the temperature is not modified and will range between 170° C. and 180° C.

### Claim 19 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein, once the thermo-fused product is removed from the furnace, said furnace is left open for 10 seconds, the temperature decreasing to a range from 150° C. to 158° C., being, in this way, able to start a new process.

### Claim 20 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein the pressing of the thermo-fused product is carried out in a hydraulic press.

### Claim 21 (depends on 20)

The process for recycling high density polyethylene (HDPE) materials, according to claim 20, wherein the thermo-fused product, after leaving the furnace, does not take more than 10 seconds to be moved to the hydraulic press.

### Claim 22 (depends on 20)

The process for recycling high density polyethylene (HDPE) materials, according to claim 20, wherein the laminated thermos-fused product is pressed for 5 seconds.

### Claim 23 (depends on 22)

The process for recycling high density polyethylene (HDPE) materials, according to claim 22, wherein the laminated thermo-fused product, after being pressed, is hooked on the press “T's” and submerged in cold water, at a temperature close to 5° C., for a period between 3 and 5 minutes, the mold being finally opened and the laminated product being removed.

### Claim 24 (depends on 20)

The process for recycling high density polyethylene (HDPE) materials, according to claim 20, wherein the thermo-fused block product is pressed for 60 seconds.

### Claim 25 (depends on 24)

The process for recycling high density polyethylene (HDPE) materials, according to claim 24, wherein the block thermo-fused product, after being pressed, is hooked on the mold faces and submerged in cold water, at a temperature close to 5° C., for a period between 5 and 10 minutes, the mold being finally opened that the block product being removed.

### Claim 26 (depends on 1)

The process for recycling high density polyethylene (HDPE) materials, according to claim 1, wherein the waste HDPE materials may be containers, sheets or meshes.

### Claim 27

A planchette-shaped laminated product that is made from a waste HDPE material having an upper surface and an opposite bottom surface.

### Claim 28 (depends on 27)

A planchette-shaped laminated product, according to claim 27, wherein both surfaces are smooth.

### Claim 29 (depends on 27)

A planchette-shaped laminated product, according to claim 27, wherein at least one of its surfaces is textured.

### Claim 30 (depends on 27)

A planchette-shaped laminated product, according to claim 27, wherein its length and width will range from 5 cm and 2,000 cm.

### Claim 31 (depends on 30)

A planchette-shaped laminated product, according to claim 30, wherein its length and width are 60 cm by 60 cm.

### Claim 32 (depends on 27)

A planchette-shaped laminated product, according to claim 27, wherein it is of a single color.

### Claim 33 (depends on 27)

A planchette-shaped laminated product, according to claim 27, wherein it is multicolored.

### Claim 34 (depends on 27)

A planchette-shaped laminated product, according to claim 27, wherein it has veins of different colors.

### Claim 35 (depends on 27)

A laminated product, according to claim 27, wherein it is made from a recycled HDPE material and may have different regular and/or irregular surfaces.

### Claim 36 (depends on 1)

A recycled HDPE product, wherein it is made following the thermofusion recycling process as disclosed in claim 1.