Laminated fabrics and protective covers with post-industrial and/or post-consumer content and methods of making laminated fabrics and protective covers with post-industrial and/or post consumer content

Abstract

A method of recycling laminated fabrics and laminated fabric products and producing new laminated fabrics and laminated fabric products includes the steps of shredding scrap or used laminated fabric material, melt separating the polymers, pelletizing the melt separated polymers, extruding the pelletized material with at least one virgin material to form a film, and laminating the film to a nonwoven material to form a new laminated fabric. The scrap or recycled laminated fabric products can include plastic/polymer materials having different melting temperatures. The new laminated fabric can be utilized to produce new products, such as protective covers.

Claims

1. A method of making a laminated fabric, including the steps of: obtaining an existing laminated fabric product, the existing laminated fabric product having a first component having a first melting point and a second component having a second melting point different from the melting point of the first component; dividing the existing laminated fabric product into two or more pieces; shredding at least some of the two or more pieces of the existing laminated fabric product to produce a shredded product; melt separating the first component from the second component in at least some of the shredded product to produce a first product stream having a majority of the first component and at least some of the second component and a second product stream having a majority of the second component; pelletizing the first product stream to produce pellets having a majority of the first component and at least some of the second component; providing at least one virgin polymer resin; forming the pellets and the at least one virgin polymer resin into a film; heating the film; providing a nonwoven material; applying adhesive to the nonwoven material; and laminating the film to the nonwoven material.

2. The method of claim 1, wherein the first component of the existing laminated fabric product and the at least one virgin polymer resin are the same material.

3. The method of claim 1, wherein the pellets and the at least one virgin polymer resin are extruded to form a cast film.

4. The method of claim 1, wherein the pellets and the at least one virgin polymer resin are extruded to form a blown film.

5. A method of making a laminated fabric, including the steps of: obtaining an existing laminated fabric product, the existing laminated fabric product having a first component having a first melting point and a second component having a second melting point different from the melting point of the first component; separating the first component of the existing laminated fabric product from the second component of the existing laminated fabric product; forming the first component of the existing laminated fabric product into pellets; providing at least one virgin polymer resin; forming the pellets and the at least one virgin polymer resin into a film; providing a nonwoven material; and laminating the film to the nonwoven material.

6. The method according to claim 5, wherein the step of separating the first component of the existing laminated fabric product from the second component of the existing laminated fabric product is performed by melt separation.

7. The method of claim 5, wherein the first component of the existing laminated fabric product and the at least one virgin polymer resin are the same material.

8. The method of claim 5, wherein the pellets and the at least one virgin polymer resin are extruded to form a cast film.

9. The method of claim 5, wherein the pellets and the at least one virgin polymer resin are extruded to form a blown film.

10. The method of claim 5, wherein the laminated fabric is heat shrinkable.

11. The method of claim 5, wherein the first component of the existing laminated fabric product is a polyethylene polymer.

12. The method of claim 5, wherein the second component of the existing laminated fabric product is PET.

13. The method of claim 5, wherein the laminated fabric is heat sealable.

14. The method of claim 5, further including the step of providing a second film and coextruding the film with the second film to form a multilayer film that is laminated to the nonwoven material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a protective cover being collected for recycling according to methods of the present invention.

(2) FIG. 2 illustrates the protective cover shown in FIG. 1 being processed according to certain steps of embodiments of the present invention to produce a pelletized material.

(3) FIG. 3 is a perspective view of the pelletized material shown in FIG. 2 being processed according to certain steps of embodiments of the present invention to form a film.

(4) FIG. 4 is a perspective view of the film shown in FIG. 3 being processed according to certain steps of embodiments of the present invention to form a laminated fabric.

(5) FIG. 5 is a perspective view of a laminated fabric according to one embodiment of the present invention.

(6) FIG. 6 is a perspective view of a new protective cover produced from a laminated fabric according to embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(7) Certain embodiments of the invention described below are illustrated in the context of laminated fabrics including a film constructed at least in part from LDPE. However, it is to be understood that reference to LDPE is for purposes of example only. The invention is equally applicable to, and embodiments of the invention encompass, processing and manufacturing laminated fabrics and products that include laminated fabrics having films constructed in whole or in part from PE and/or one or more PE copolymers other than, instead of, or in addition to LDPE.

(8) Referring to FIGS. 1-5, one embodiment of the present invention includes the following steps:

(9) Step 1—Collect material to be recycled, such as scrap laminated fabric resulting from manufacturing processes or used protective covers. For example, as shown in FIG. 1, a used protective cover 10 (such as a boat cover) can be obtained for processing according to embodiments of the present invention.

(10) Step 2—Separate PET from LDPE in the material to be recycled and pelletize the plastics. For example, as shown in FIG. 2, used protective cover 10 can be processed through a slitting or cutting apparatus 20 to produce sections 10A of used protective cover 10.

(11) Step 2a—Shredding the material to be recycled, such as, for example, processing sections 10A of used protective cover 10 through a shredder 30 to produce shredded product 10B that includes both the film component and the nonwoven component of used protective cover 10.

(12) Step 2b—Melt separate PET from LDPE in the shredded product. For example, as shown in FIG. 2, shredded product 10B can be processed through an extruder 40 to separate the PET and LDPE into a PET product stream 50 and an LDPE product stream. Note that in certain embodiments of the present invention, the PET and LDPE are completely separated to form PET product stream 50 and an LDPE product stream. In other embodiments, some LDPE, adhesive or other material may remain in PET product stream 50 and some PET, adhesive or other material may remain in the LDPE product stream. In one embodiment, 6%-12% by weight of the LDPE product stream is PET. However, a majority of PET product stream 50 is PET and a majority of the LDPE product stream is LDPE. In one embodiment, the melt separation step is performed using an Ettlinger ERF-350 Melt Filter with a 120 micron screen installed on a Next Generation Recycling Machines, Inc. (“NGR”) 85 mm Extruder. The extruder is available from Next Generation Recycling Machines, Inc. of Norcross, Ga.

(13) Step 2c—Pelletize the LDPE product stream. For example, as shown in FIG. 2, the LDPE product stream can be processed through a hot die (“HD”) pelletizer 60 to produce pellets 70. Pellets 70 are primarily LDPE, however, as noted above, because some PET may remain in the LDPE product stream, pellets 70 may be a mixture of LDPE and PET. Adhesive, color or other masterbatches, and other components of shredded product 10B may also be present in pellets 70.

(14) Step 3—Produce a film by extruding the pelletized material with virgin resin. For example, as shown in FIG. 3, pellets 70 can be combined with virgin LDPE resin to form a starting material 80 that is processed through an extruder 90 to produce a film 100. Note that in certain embodiments of the invention, one or more virgin resins may extruded with pellets 70. For example, pellets 70 can be extruded with both LDPE and LLDPE virgin resin at the same time to produce film 100.

(15) Step 4—Laminate the film to nonwoven material to form a laminated fabric. For example, as shown in FIG. 4, film 100 can be laminated to a nonwoven material 110 to produce a laminated fabric 120. In the embodiment of the invention shown in FIG. 4, this is accomplished by heating film 100 at a heating station 130, applying adhesive 140 to nonwoven material 110 at a spraying station 150, and processing film 100 and nonwoven material 110 through lamination rollers 160.

(16) In other embodiments of the invention, film 100 is coextruded with virgin film to form a multilayer film that can be laminated to nonwoven material 110 utilizing adhesive 140. For example, as shown in FIG. 5, a multilayer film 170 can be formed having one or more layers of film 100 and one or more layers of virgin film 180. Note that although layers 100 are shown as located between the two layers of virgin film 180, they can be located in any arrangement with respect to the layers of virgin film 180.

(17) In other embodiments of the invention, the layers of film 100 are coextruded with the layers of virgin film 180 to form multilayer film 170, which is then laminated to nonwoven material 110 in a single step process like that shown in FIG. 4.

(18) Step 5—Form a new protective cover. For example, laminated fabric 120 can be used to form a new protective cover, such as a boat cover 190 (FIG. 6).

(19) In one embodiment of the invention, the equipment and operating parameters that may be utilized for Step 2 above are indicated in the following table:

(20) TABLE-US-00002 TABLE 2 Reference Number LDPE Film and (Shipping Covers) PET Fibers Product Description High Temp Run Extruder Manufacturer NGR Screw Configuration (Single/Twin) single Extruder Screw Diameter 85 mm Vented (Yes/No) yes single Extruder Screw Speed 100 Extruder Workload (%) 78 Extruder Temperature 230° C. Vent Purge Pressure (PSI) minor Filter Type (ECO/ERF) ERF 350 Screen Fineness (mm) 0.125 Operating Temperature 260° C. Capacity (kg/h) 101.6 Purge Amount (kg/h) 12.7 Purge Amount (%) 12.50% Filter Inlet Pressure (kPa) 579 Filter Screen Pressure (kPa) 262 Filter Exit Pressure (kPa) 317 Filter Drum Speed (RPM) 11.4 Exit Screw/Shaft Speed (RPM) 26.7 Inlet Temperature 118° C. Outlet Temperature 119° C.

(21) It has been found that use of methods according to the present invention permits the successful manufacture of laminated fabrics and protective covers even if there is not complete separation of the LDPE from the PET. For example, in one embodiment of the invention, pelletized material that included 10% PET content, less than 2% styrene-ethylene butylene-styrene (“SEBS”) hot melt adhesive and the remainder LDPE was able to be extruded and blown to produce a film that has acceptable physical properties for use in the production of protective covers. In one embodiment of the invention, up to 50% virgin LDPE resin is used in the film. Use of 20% recycled pelletized material in the film results in a final laminated fabric that includes about 15%-16% postindustrial/postconsumer plastic by weight. The percentage can be increased further if the nonwoven utilized to make the new laminated fabric is manufactured from recycled polymers as well. For example, nonwoven material 110 could be manufactured from recycled PET. Doing so would bring the total recycled content of the final laminated fabric to about 35% by weight.

(22) Product by weight before and after recycling is described on the following table:

(23) TABLE-US-00003 TABLE 3 Initial Laminate/Cover *Weight *Weight Composition (gsm) Percent Total Weight 226 100% Film (LDPE/LLDPE) 180 79.6%  Adhesive (SEBS)  4 1.8% Nonwoven (PET)  42 18.6%  Total Recycled Resin  0 0 Recycled Weight Pellet Content Percent LDPE/LLDPE  90% Adhesive Negligible PET  10% Film w/PI and Weight PC Content Percent Recycled Resin  20% Virgin LDPE  30% Virgin LLDPE  50% Final Laminated Fabric Weight Weight Composition (gsm) Percent Total Weight 226 100% Film (LDPE/LLDPE) 180 79.6%  Adhesive (SEBS)  4 1.8% Nonwoven (PET)**  42 18.6%  Total Recycled Resin  36 16% Content in the Final Laminated Fabric** *Numbers are rounded to the nearest integer. **If the nonwoven used were 100% recycled PET, the total recycled content of the laminated fabric could be as high as 35% by weight.

(24) The example above shows that by use of melt-separation and pelletizing, two different polymer systems can be recycled together and used to produce a film that can further be laminated to form laminated fabrics and cut and sewn into covers for shipping and storage applications. In the non-limiting example provided above, the recycled content is between 10% and 35% by weight.

(25) In another embodiment of the invention, the nonwoven material utilized for the newly made laminated fabric is made from PLA polymers, which makes the laminated fabric partially biodegradable. Furthermore, because PLA can be produced from renewable plant-based resources (as opposed to fossil fuels) it can provide additional environmental benefits.

(26) Tables 4-6 disclose and describe properties of a film (Formula 1) produced without the use of recycled materials according to the present invention and two films (Formulas 2-3) according to embodiments of the present invention produced according to methods of the present invention. In the embodiments disclosed and discussed below, the films were produced on a blown film line utilizing pellets 70 according to embodiments of the present invention that contain 88% LDPE/LLDPE and 12% PET, virgin EXCEED® 1012 LLDPE (available from Exxon Mobile Corporation), and a color and additive masterbatch.

(27) TABLE-US-00004 TABLE 4 Formula 1 Formula 2 Formula 3 LLDPE 90 80 70 (1012) (wt. % 0) Master 10 10 10 Batch (wt. % 0) Pellets 70  0 10 20 (wt. % 0)

(28) Extruder and blown film line parameters for the above formulas are shown below:

(29) TABLE-US-00005 TABLE 5 Formula 1 Formula 2 Formula 3 Die Diameter (cm) 5.08 5.08 5.08 Gauge (mm) 0.127 0.127 0.127 BUR 1 1 1 Lay Flat (cm) 9.2 9.2 9.2 Extrusion rate (g/min) 21.3 21.3 21.3 Die factor (g/min/cm die 0.114 0.114 0.114 circumference) Die Gap (mm) 0.762 0.762 0.762 Target Frost Line Height (cm) 5.08 5.08 5.08 Target Line Speed (m/min) 1.22 1.22 1.22 Melt Temperature Profile (° C.) Zone 1 - Ext. 202 202 202 Zone 2 - Ext 207 207 207 Zone 3 - Ext 210 210 210 Post Extruder Temperature Profile (° C.) a. Die Zone #1-#4 210 210 210 b. Air Ring Ambient Ambient Ambient Machine Load % 46 46 47

(30) These film had the following properties:

(31) TABLE-US-00006 TABLE 6 Formula 1 Formula 2 Formula 3 Thickness 0.112 0.138 0.121 (mm) Basis Weight 96.1 91.9 89.8 (gsm) Puncture (kg) 8.39 6.26 5.26 Elmendorf 1802.24 1500.16 1960.96 Tear (grams) Machine Direction Elmendorf 1966.08 2042.88 2411.52 Tear (grams) Cross Direction Tensile 42.0 26.0 26.2 Strength (MPa) Machine Direction Tensile 40.7 22.3 23.7 Strength (MPa) Cross Direction Yield Strength 9.0 7.0 8.2 (MPa) Machine Direction Yield Strength 9.0 6.3 6.8 (MPa) Cross Direction Break 610.3 582.79 583.17 Elongation (%) Machine Direction Break 609.61 564.85 587.97 Elongation (%) Cross Direction Break Load 12.15 9.31 8.20 (kg) Machine Direction Break Load 11.78 8.01 7.39 (kg) Cross Direction 2% Modulus 130.0 109.2 139.5 (MPa) Machine Direction 2% Modulus 137.7 114.0 141.5 (MPa) Cross Direction

(32) Although the present invention has been described in detail, the same is for purposes of illustration only and is not to be taken as a limitation on the scope of the invention. Numerous modifications can be made to the embodiments described above without departing from the scope of the invention. For example, product containing polymers and materials other than those specifically discussed can be processed according to methods of the present invention to produce laminated fabrics according to embodiments of the present invention. New products other than protective coves can be produced from laminated fabrics according to the present invention. Other variations are also within the scope of the present invention.