Continuus Materials Intellectual Property, LLC

A method for producing a composite board includes compressing and heating a composite mat between opposing hot-platens, the composite mat including plastic, cellulose, and water, applying, with the opposing hot-platens, pressure within a target pressure range to the composite mat for a first amount of time, the pressure and the first amount of time to a temperature above a boiling temperature of water at a standard atmospheric pressure without changing from a liquid state to a gaseous state, and after superheating the water, releasing the pressure of the opposing hot-platens on the composite mat, releasing the pressure causing the superheated water to change from the liquid state to the gaseous state.

A method of generating paper and plastic fragments includes measuring a moisture content of a batch of paper and plastic material, drying the batch of paper and plastic material to achieve a target moisture content, and disintegrating the batch of paper and plastic material, after drying, to form a plurality of paper and plastic fragments.

A panel including a first layer including fragments from a first blend of paper fragments of a first size and plastic fragments of a second size, a second layer including fragments from a second blend of paper fragments of a third size and plastic fragments of a fourth size, the third size being different from the first size, and the fourth size being different from the second size, and a third layer comprising fragments from the first blend. The second layer is disposed between the first layer and the third layer.

A method of manufacturing a product includes forming a first mixture of PVC fragments and cellulosic fragments, heating the first mixture at a temperature and duration sufficient to melt at least a portion of the PVC fragments, and cooling the first mixture until the melted PVC fragments resolidify.

A method may include determining a first dry mass flow rate of a wet paper material stream based on a first amount of contaminants, a first moisture content, and a first wet mass flow rate of the wet paper material stream, determining a second dry mass flow rate of a wet plastic material stream based on a second amount of contaminants, a second moisture content, and a second wet mass flow rate of the wet plastic material stream, calculating, using the first dry mass flow rate and the second dry mass flow rate, a paper/plastic ratio of a combined stream of the paper material stream and the plastic material stream, and adjusting, a flow rate of paper into the paper material stream and a flow rate of plastic into the plastic material stream such that the calculated paper/plastic ratio of the combined stream equals a target paper/plastic ratio.

A method for making a dry composite material that exhibits contraction in one or more dimensions when initially hydrated includes preparing a mixture of dry, compressible, hydrophilic polymer elements and hydrophobic, thermoplastic polymer, forming the mixture into a mat, heating the mat to a temperature that is greater than the melting-point of the hydrophobic, thermoplastic polymer such that the hydrophobic, thermoplastic polymer melts and forms a continuous phase around the compressible hydrophilic polymer elements, molding the hot mat into a desired shape, and cooling the mat to a temperature that is less than the congealing-point of the hydrophobic, thermoplastic polymer.

A coverboard panel may include a first facer layer including a non-porous synthetic polymer, a core layer, and a second facer layer, wherein the core layer is disposed between the first facer layer and the second facer layer, and wherein the coverboard panel is configured to be installed with the first facer layer bonded to a membrane.

A system for producing a composite board made of plastic and paper includes a hot press assembly. The hot press assembly includes a first heated belt configured to apply heat and pressure to a composite sandwich. The composite sandwich includes a mat comprising a mixture of paper and plastic and at least one facer positioned above or below the mat. The hot press assembly further includes a roller configured to drive the belt to move the composite sandwich through the hot press assembly and a first non-stick belt configured to separate at least a portion of the composite sandwich from the heated belt as the composite sandwich is moved through the hot press assembly.

Disclosed herein is a method of manufacturing a fragment. The method includes receiving waste materials that include paper and thermoplastic articles, refining the received waste materials to a size of about 10″ or less, processing the refined waste materials through one or more screens to generate a set of fragments having a size between about 2″ and about 10″, using a wind sifter, separating a subset of the set of fragments based on each fragment of the subset having a density below a threshold, the subset comprising paper and plastic fragments, using a near infrared sorting device, separating at least a portion of the plastic fragments from the subset, and refining the separated plastic fragments to a size of about 50 mm or less.

An insulated composite board includes a first composite board including a first layer including a plurality of cellulosic fragments and a plurality of plastic fragments and an insulation layer including a first face coupled to the first composite board, the insulation layer comprising a foam material.