Cast Solid Surface Materials Manufactured From Polymers and Post-Consumer Waste Glass
First Claim
Patent Images
1. A solid surface material suitable for use as a countertop, comprising:
- a) a resin; and
b) a filler including glass powder produced from a process comprising,i) supplying a stream of post-consumer waste glass containing items of non-frangible materials,ii) pulverizing the stream in a manner such that consumer waste glass in the stream is reduced to fragments of average maximum size ⅛
inch or less, while non-frangible items are not reduced to said maximum size,iii) performing a size-based separation of the reduced glass fragments from the non-frangible items,iv) washing the reduced glass fragments to separate plastic and paper fragments and organic contaminants therefrom,v) drying the washed glass fragments to a moisture content of no more than about 2% by weight,vi) grinding the dried glass fragments into a glass powder in a mill,vii) removing the glass powder,viii) returning the remaining particles to said grinding at step vi) for grinding with additional dried glass fragments received for grinding after said drying at step v), andix) repeating said removing and said returning at steps vii) and viii), respectively, for continuous manufacturer of the glass powder.
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Accused Products
Abstract
A solid surface material suitable for use as a countertop contains a resin and a filler which includes clean dry glass powder produced from unsorted post-consumer waste glass, including a substantial fraction of non-glass items. The powdered glass is used as at least a portion of the filler and/or gelling agent in lieu of or in addition to other fillers and gelling agents known in the art.
59 Citations
20 Claims
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1. A solid surface material suitable for use as a countertop, comprising:
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a) a resin; and b) a filler including glass powder produced from a process comprising, i) supplying a stream of post-consumer waste glass containing items of non-frangible materials, ii) pulverizing the stream in a manner such that consumer waste glass in the stream is reduced to fragments of average maximum size ⅛
inch or less, while non-frangible items are not reduced to said maximum size,iii) performing a size-based separation of the reduced glass fragments from the non-frangible items, iv) washing the reduced glass fragments to separate plastic and paper fragments and organic contaminants therefrom, v) drying the washed glass fragments to a moisture content of no more than about 2% by weight, vi) grinding the dried glass fragments into a glass powder in a mill, vii) removing the glass powder, viii) returning the remaining particles to said grinding at step vi) for grinding with additional dried glass fragments received for grinding after said drying at step v), and ix) repeating said removing and said returning at steps vii) and viii), respectively, for continuous manufacturer of the glass powder. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A solid surface material suitable for use as a countertop, comprising:
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a) a resin; b) a filler; and c) a gelling agent including glass powder produced from a process comprising, i) supplying a stream of post-consumer waste glass containing items of non-frangible materials, ii) pulverizing the stream in a manner such that consumer waste glass in the stream is reduced to fragments of average maximum size less than ⅛
inch, while non-frangible items are not reduced to said maximum size,iii) performing a size-based separation of the reduced glass fragments from the non-frangible items, iv) washing the reduced glass fragments to separate plastic and paper fragments and organic contaminants therefrom, v) drying the washed glass fragments to a moisture content of no more than about 2% by weight, vi) grinding the dried glass fragments into a glass powder, at least about 60% of particles of said glass powder being no more than 250 mesh particle size, wherein the grinding is performed in a mill that grinds the dried glass fragments, vii) removing the glass powder, and viii) returning the remaining particles to said grinding step for grinding with additional dried glass fragments received for grinding after said drying step in a continuous glass powder manufacturing process from a supply of a post-consumer waste glass stream. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification
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Current AssigneeEmpire Resource Recovery LLC
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Original AssigneeEmpire Resource Recovery LLC
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InventorsGrasso, Louis P. JR.
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Application NumberUS12/512,131Publication NumberTime in Patent OfficeDaysField of SearchUS Class Current523/458CPC Class CodesC04B 14/06 Quartz; SandC04B 14/22 Glass ; Devitrified glassC04B 14/28 of calciumC04B 14/285 MarbleC04B 14/305 Titanium oxide, e.g. titanatesC04B 14/306 Zirconium oxide zircon C04B...C04B 20/0076 characterised by the grain ...C04B 20/02 TreatmentC04B 20/026 Comminuting, e.g. by grindi...C04B 24/42 Organo-silicon compoundsC04B 26/06 AcrylatesC04B 26/14 Polyepoxides
