Stone based copolymer substrate

A limestone based copolymer substrate, comprising

• a copolymer formed by thermodynamic combination of high-density polyethylene (HDPE) and a biopolymer, the HDPE in an amount from approximately two to twenty-five percent (2-25%) by weight of the substrate, the biopolymer being thermodynamically activated by heating to between 150 and 350 degrees F., in an amount from approximately two to twenty-five percent (2-25%) by weight of the substrate, the thermodynamic combination achieved using agitation for 1 to 4 hours at a temperature between 150 and 300 degrees F., the biopolymer being biodegradable and made from living organisms or chemically synthesized;
• a biodegradation additive in an amount from approximately three fourths of a percent to two percent (0.75-2%) by weight of the substrate within the copolymer;
• and
• calcium carbonate (CaCO3) in an amount from approximately fifty to eighty-five percent (50-85%) by weight of the substrate and varying in size generally from 1.0 to 3.0 microns that is blended with the copolymer using heated agitation at between 150 and 300 degrees F. for 1 to 4 hours thereby forming a uniform dispersion.

A process for manufacturing a high-density polyethylene substrate, comprising the steps of:

• providing high-density polyethylene;
• providing a biopolymer that is biodegradable and made from living organisms or is chemically synthesized;
• heating the high density polyethylene to form a slurry;
• thermodynamically activating the biopolymer by heating to between 150 and 350 degrees F.;
• forming a resin blend by combining:
• the heated high-density polyethylene in an amount from approximately two to twenty-five percent (2-25%) by weight of the substrate, with
• the thermodynamically activated biopolymer in an amount from approximately two to twenty-five percent (2-25%) by weight of the substrate at a temperature between 150 and 300 degrees F.;
• cohesively blending calcium carbonate (CaCO3) in an amount from approximately fifty to eighty-five percent (50-85%) by weight of the substrate with the resin blend using continuous heated agitation for 1 to 4 hours at a temperature between 150 and 300 degrees F. to obtain a cohesive blend suitable for extrusion in plastics extrusion equipment;
• adding a biodegradation additive to the cohesive blend in an amount from approximately three fourths of a percent to two percent (0.75-2%) by weight of the substrate;
• and
• forming the substrate.

A process for manufacturing a high-density polyethylene substrate comprising the steps of:

• providing high-density polyethylene;
• providing a biopolymer that is biodegradable and made from living organisms or is chemically synthesized;
• heating the high-density polyethylene to form a slurry;
• thermodynamically activating the biopolymer by heating to between 150 and 350 degrees F. and agitating for a 1 to 4 hours;
• forming a polymer resin blend by combining the high-density polyethylene slurry with the thermodynamically-activated biopolymer at between 150 and 300 degrees F. with agitation for between 1 and 4 hours, such that the resin blend is in an amount from about 4 to 50% by weight of the substrate;
• using heated agitation for 1 to 4 hours at a temperature between 150 and 300 degrees F. to obtain a cohesive blend of calcium carbonate (CaCO3) having a particle size of less than 5 microns with the resin blend to form a uniform dispersion within the resin blend;
• and
• adding a biodegradation additive in an amount from approximately 0.75 to 2% by weight of the substrate to form the substrate.