You are on page 1of 9

US 20140287144Al

(19) United States


(12) Patent Application Publication (10) Pub. No.: US 2014/0287144 A1
Burich et al.
(54)

(43) Pub. Date:

PROCESS AND METHOD FOR CELLULOSE


ACETATE MANUFACTURING WASTE

PRODUCT RECYCLING

(71) ApplicantszBlake Burich, Dublin, OH (US);

Sep. 25, 2014

Publication Classi?cation

(51)

Int- Cl
C08J 11/06

(2006.01)

(52) US. Cl.

Charles L. Putnam, Dublin, OH (US)

CPC ............ .. C08J11/06 (2013.01); C08] 2301/12

(2013.01)
(72)

Inventors: Blake Burich, Dublin, OH (US);

Charles L. Putnam, Dublin, OH (US)

USPC ........................................................ .. 427/290

(57)

ABSTRACT

The present invention is directed to processes and methods

(21) Appl' NO" 14/216165


(22) Filed_
Mar 17 2014

for recycling the waste products from the manufacture of


cellulose acetate materials, using the example of cigarette

'

'

butt manufacturing, in this case, but also applies to cellulose

Related U s A
' '

(60)

lication Data

PP

Provisional application No. 61/788,862, ?led on Mar.

15, 2013.

acetate production for other materials. Once the cellulose


acetate containing materials are processed, they may be

acceptable for use in a multitude of applications from insula


tion to reinforcements and decorative pieces.

Patent Application Publication

Sep. 25, 2014 Sheet 1 0f 6

US 2014/0287144 A1

Grinding of filter press


waste to desired size

ll
Introduction of solvent to
wet mixture

ll

Addition of binder,

colorants, UV protectant
or other desired materials

ll
Compress into mold or

desired shape

Remove any residual

" solvent in drying process

FIG1

Patent Application Publication

Sep. 25, 2014 Sheet 2 0f 6

Cutting/chopping or
crushing of CA fiber waste

to desired lengths

US 2014/0287144 A1

= Remove paper from filter

fiber materials if needed

Add at desired percentage

to other materials/plastics

Integrate into mixture

through mixing

Extrude/injection

Compress into mold or

Mold / other

desired shape

FIG2

Patent Application Publication

Sep. 25, 2014 Sheet 3 0f 6

e58
A55
AA88
3
5
Em.=m_z.zE>5.mEm2_.2\n._.

32:3821

Nod35d5%Edtwo:3mad3%nEmd$$.E5.0mu.82

mod:3Ed5%86*2623E2$6mmm<8PR6$5+n_. _ Nod.32$6m3.0mm;582mgDE_<mudRawzg+n.3_n,+2<_oc

N3N2RdcEd53Ea52so<Kim8.~%ngQd+0B:m_nE $m~NEd5d8E:.<8+253&ownm0+.<d38:a;~w&

<mIUE

US 2014/0287144 A1

Patent Application Publication

Sep. 25, 2014 Sheet 4 0f 6

US 2014/0287144 A1

Patent Application Publication

551.0

1.2
1.0

5' 0.6
g 0.4
0.2

Sep. 25, 2014 Sheet 5 0f 6

US 2014/0287144 A1

Patent Application Publication

Sep. 25, 2014 Sheet 6 0f 6

US 2014/0287144 A1

2500
T
2000

g 1500

2:
1000
>
500

<$

fg

1.6
1.4
1.2

jg 1.0

0*" $

45
40
35

3015

97 0.8

25?;

E 0.6

20 3

0.4
0.2

15
10
0

Sep. 25, 2014

US 2014/0287144 A1

PROCESS AND METHOD FOR CELLULOSE


ACETATE MANUFACTURING WASTE
PRODUCT RECYCLING
CLAIM OF PRIORITY

[0001]

This application claims priority to US. Provisional

Application Ser. No. 61/788,862 which was ?led on Mar. 15,

2013 and which is incorporated by reference.


BACKGROUND AND SUMMARY OF THE
INVENTION

[0002] Reference is made to issued US. Pat. No. 7,560,059


the contents of which are incorporated by reference as if fully
recited herein.
[0003] The present invention relates generally to the pro

proving advantages in strength while providing potential for


wall thickness reduction that would eliminate weight and
have some potentially signi?cant impact in the ability to
increase gas mileage.
[0009] This same ?ber, when prepared properly (matching
?ber length effectively with process), also creates bene?cial
?ber additives that can be encapsulated and utilized in other
products such as concrete and asphalt to not only use as a ?ller

material but also provide signi?cant advantages in strength.


Use of ?ber in plastics and other materials is not a new

concept. However, the use of this particular waste ?ber is


quite novel. The cellulose acetate ?bers can replace any ?ber
technologies available in a multitude of industries. While

encapsulation provides for retention of materials in any speci


?ed manner, the strength bene?ts provide the advantages
necessary to use the cigarette butt materials, both post-indus

cess for recycling by-products including off-quality waste


from the manufacture and testing of cellulose acetate prod
ucts such as cigarette butts, for example. More particularly,

trial and post-consumer, in this manner.

the present invention relates to a process and method for

press pads, can be ground up to smaller pieces (this can be

dealing with discarded materials from the manufacture of


cellulose acetate and cigarette butts. Focus in this application

intended application). Once ground it is then wet with acetone

[0010] In accordance with a preferred embodiment of the


invention, the ?lter press wastes, or typically referred to as
anywhere from 1/2 inch more or less in sizeidepending on

is on Post-Industrial waste but directly correlates to cleansed


Post-Consumer ?ber materials as once cleaned, they are for

to make an almost Mache out of the residual cellulose acetate

all practical purposes the same marketable material.


[0004] Cigarette ?lters are composed of a bundle of 12,000
plastic-like cellulose acetate ?bers. It can take years, for the
?bers to decay into a plastic powder that cant be seen.

cellulose may be introduced by wetting the other waste ?ber

[0005]

In the manufacturing process, there are ?lter presses

that are utilized for ?ltering wet cellulose acetate before

?nished goods are produced through a spinning process that

and the pulpous ?lm covering the press pads. Additional


materials with acetone. Colorants may then also be added to
the clear/white mixture as desired in any application. Result
ant mix is then molded and allowed to dry. Any concrete

products may be replaced with the resulting very strong and


lighter weight material that possesses R-value for insulation
applications for example. This material may have additives

evacuates the wet carrier. These ?lters are essentially fab


ric-like ?lters that contain a sandwich of pure and dry cellu

for UV protection, or coatings as desired.

lose acetate in large (approximately two foot by two foot


squares and one to three inches thick) fairly uniform pieces.
One location can produce millions of pounds of ?lter press
pad waste each year and this currently is being sent to land?ll.
[0006] Through the quality process, tow product, or the

the press pads, they can be cut in any manner to different


shapes and sizes and may even be attached together for cre

actual butt materialimade up of cellulose acetate ?ber are


determined to be off-quality and in many cases taken to land

materials can also be lique?ed with acetone (or any other


solvent one who practices in the art may select) and placed
through processes referenced in US. Pat. No. 7,560,059 and
US. Provisional Patent Application No. 61/788,862 the con
tents of which is incorporated by reference as if fully recited
herein.

?ll rather than reprocessed. This is most usually referenced as


bale material and is also being sent to land?ll.

[0007]

Quality checks for cigarette ?lters include thou

sands of tubes or rods each day. These tubes are essen

[0011]

Additionally, due to the size and strength aspects of

ating long-lasting products for decorative purposes such as


stepping stones or wall hangings
[0012]

Other ?brous tow or other waste cellulose acetate

tially paper surrounding cellulose acetate to determine ?nal

[0013]

quality of product before sending tow (cellulose acetate ?lter

to cut the ?bers into desired sizes for incorporation and encap

materials) to customers for use. The tubes are approximately


the length of a 100 cigarette and come in Western and

sulation into other products such as plastics or concrete or


other materials one may select to increase strength and or

European sizes. This material is also being land?lled.


[0008] The present invention is directed to processes and
methods for recycling the waste products from the manufac
ture of cellulose acetate materials, using the example of ciga

render lighter weight. For example, ?bers of 1 mm to 6 mm


are most desired for inclusion with Ole?n for automotive part

rette butt manufacturing, in this case, but applies to any cel


lulose acetate production for other materials also. Once the
cellulose acetate containing materials are processed, they
may be acceptable for use in a multitude of applications from
insulation to reinforcements and decorative pieces. One such
application makes any of the ?brous materials suitable for
encapsulation within plastics for use as reinforcement in

Waste ?bers may also be placed through processes

production. Larger cuts may be desired for applications such


as insulation as cellulose acetate is well known for its insu

lating characteristics.
[0014] In addition to the novel features and advantages
mentioned above, other features and advantages of the
present invention will be readily apparent from the following

descriptions and exemplary embodiments.


BRIEF DESCRIPTION OF THE DRAWINGS

automotive parts4cellulose acetate; post-industrial or post


consumer waste cut into 1 to 6 mm length has undergone

preliminary testing encapsulated in polypropylene at 10%


and 20% (30% and 40% will be tested) through extrusion and
has rendered outstanding results (as seen in FIGS. 3A-G)

[0015] FIG. 1 is a ?ow chart of an exemplary embodiment


of a process of the present invention.
[0016] FIG. 2 is a ?ow chart of an exemplary embodiment
of a process of the present invention.

Sep. 25, 2014

US 2014/0287144 A1

[0017]

FIG. 3A is a chart of the mechanical properties

showing of polypropylene (PP) at 10% and 20% encapsula


tion with cellulose acetate (CA) and with maleic anhydride

(MA).
[0018]

FIG. 3B is a bar chart showing tensile strength (TS)

in megapascals (MPa).
[0019]

FIG. 3C is a bar chart showing elongation at yield

(EAY) in percent (%).


[0020]

FIG. 3D is a bar chart showing tensile modulus

(TM) in gigapascals (GPa).


[0021]

FIG. 3E is a bar chart showing Newton inch strength

(NIS) in foot pounds per inch (ft. lb/ in).


[0022]

FIG. 3F is a bar chart showing Youngs modulus

(Y.M.) in gigapascals (GPa).


[0023]

EXAMPLE 4

[0027] Any waste ?bers, or other cellulose acetate waste


material as deemed acceptable in applications known to those
in the art are placed through a number of chosen processes to
cut the ?bers into desired sizes for incorporation into other
products such as plastics or concrete or other materials one

experienced in the art may select. For example, ?bers of 1 mm


to 6 mm are most desired for inclusion with Ole?n for auto

motive part production. Larger cuts may be desired for appli


cations such as insulation as cellulose acetate is well known

for its insulating characteristics. Residual paper from rods


may be removed through varying processes, one of which is
heat, to loosen any adhesive.

FIG. 3G is a line chart showing ?exural modulus

EXAMPLE 5

(EM) and ?exural strength in gigapascals (GPa) and mega

pascals (MPa), respectively.

[0028]

Other waste cellulose acetate materials including

?bers are lique?ed with acetone (or any other solvent one who
DETMLED[EECRHUKDJOFEXEMPLARY

practices in the art may select) and placed through processes

EMBODIMENT(S)

to introduce colorants, plasticizers or any other desired com


ponents. Mixture can then be pelletized and utilized for inj ec
tion, extrusion or other molding.

EXAMPLE 1

[0024] Filter press waste materials from cellulose acetate


manufacturing are removed from the waste stream and

ground up to any size desired. Larger particles will render a


more rough appearance while smaller particles will assist in
gaining smoothness. The resultant grind is then wet with
acetone (or another solvent know to those in the art). Addi
tional cellulose acetate may be introduced to increase integ
rity. This material can then be colored, added to with anything
that may have resultant characteristics desired, such as UV
protection, and then placed into a mold. Molding may be
improved with compression. Once allowed to cure or dry, it is
removed from the mold. Coatings may be applied as appli
cable.
EXAMPLE 2

[0025]

Press pads may be cut into any size or shape and

used for decorative purposes including stepping stones, for


example, or any other decorative or functional pieces one

experienced in the art may consider.


EXAMPLE 3

[0026] Other cellulose acetate waste materials are lique?ed


with acetone (or any other solvent one who practices in the art

may select) and placed through processes referenced in Us.


Pat. No. 7,560,059 the contents of which is incorporated by
reference as if fully recited herein.

[0029]

Any embodiment of the present invention may

include any of the optional or preferred features of the other


embodiments of the present invention. The exemplary
embodiments herein disclo sed are not intended to be exhaus
tive or to unnecessarily limit the scope of the invention. The
exemplary embodiments were chosen and described in order

to explain the principles of the present invention so that others


skilled in the art may practice the invention. Having shown
and described exemplary embodiments of the present inven
tion, those skilled in the art will realize that many variations
and modi?cations may be made to affect the described inven

tion. Many of those variations and modi?cations will provide


the same result and fall within the spirit of the claimed inven
tion. It is the intention, therefore, to limit the invention only as
indicated by the scope of the claims.
What is claimed is:
1. A process for recycling cellulose acetate waste products
from post-industrial or post-consumer materials, said process

comprising:
separating cellulose acetate ?ber materials from any other
materials in said post-industrial or post-consumer mate

rials;
cutting the ?bers to speci?ed lengths; and
incorporating and encapsulating the cellulose acetate