MXPA99000439A - Process to make products from recycled material containing plasti - Google Patents

Abstract

The present invention relates to a process for producing a composite product having a predetermined shape, the process which is characterized by subjecting a mixture of particles of thermoplastic material and waste particles or filler material to a mixing operation of a high intensity such which raises the temperature of the particles of thermoplastic material and the particles of waste or filler material through the interaction of particles until the particles of thermoplastic material reach a molten state which causes the molten plastic to coat and bond with the particles hot waste or filler material to form a hot mass of waste particles or filler material that are coated with and bonded by the thermoplastic material and then with the thermoplastic material in the molten state, compress the hot mass to force the thermoplastic material within any interstices and irregularities of the waste particles or filler material as they form the hot mass to a desired product form to produce, upon cooling thereof, a compacted composite product in which the waste or filler particles are encapsulated by the material thermoplastic

Description

PROCESS FOR MAKING PRODUCTS FROM RECI CLADO MATERIAL CONTAINING PLASTICS FIELD OF THE I NVENTION The invention particularly relates to products of the type that are currently formed with wood or use wood, plywood or other board or the like as the support or base substructure.

BACKGROUND OF THE INVENTION At present there are a large number of products that are formed of wood or use wood, plywood or the like as a structural component, substructure or base, to provide the required physical properties such as stress or structural strength, rigidity idez and the form to which surface joints, covers or coatings can be screwed, nailed, stuck or otherwise held, applied or joined. Typical examples include insulated steel doors that use a wooden perimeter frame to which the steel sheet is applied on opposite sides of the same and the frame is then lowered with foamed insulation. Other examples include wooden door profiles and window frames whose exposed surfaces can be painted, covered or veneered, for example, with plastic or aluminum, or wood veneer door panels used in folding or revolving doors for garages or for truck doors or other vehicles and the like. With such current products, the physical properties of the components or substructures available are relatively limited being determined by the selection of wood, plywood or other board that is produced by conventional manufacturing processes. In addition the substantial waste of the wood by splintering, warping or by virtue of imperfections that occur in manufacturing processes, and frequently the final product is subjected to water absorption, warpage, delamination and erosion. In addition, if other more conventional regular shapes of such materials, such as square or rectangular, are required for final use, such shapes must be manufactured by sawing, cutting and / or assembling individual parts and securing them with nails, screws or other means of subject Composite materials that can be molded or processed into products have been proposed. For example, United States Patent 5,075, 157, issued December 24, 1991, describes the production of a product in which the residual plastic material containing some thermoplastic material is shredded, ground and homogenized in flow powder free that is then heated by subjecting it to a temperature below the softening temperature of the plastic. The heated free-flowing powder is then dry blended with filler material which is preferably heated or pretreated, for example with chemicals. The dry mix is compression molded at elevated temperatures and pressures. United States Patent 4, 003,866, issued January 18, 1997, discloses a construction material comprising a plastic component containing a thermoplastic resin and a filler component. These components are mixed together under the application of heat. To improve the adhesion between the plastic material and the filler material, such as wood waste, the particles of the filler material before being mixed with the plastic are previously coated by the application of thermal agitation with the polyethylene or polypropylene wax that it has a molecular weight from 1000 to 10000, a high molecular weight thermo-fluid polymer, or a silicate coating material. Such prior art materials that involve the different stages of mixing, heating and coating are relatively expensive in their production and it is difficult to achieve an adequate bonding ratio between the plastic and the filler.

BRIEF DESCRI PCIÓ N DE LA I NVENC ION The present invention is directed to providing very low cost and very durable products of composite material having superior qualities. According to the invention such composite products are prepared by first subjecting a mixture of thermoplastic particles and waste particles or filler material to a high intensity mixing operation to frictionally heat the particles to bring the thermoplastic particles to a molten state for moistening and adhering to and coating or substantially coating or encapsulating the hot waste or filler particles by joining them. The hot mix is then subjected to a compression molding operation to compress the coated waste or filler particles together to force the thermoplastic material into the interstices and irregularities of the waste filler particles to ensure encapsulation while a bond is made. of high resistance between the particles. In the cooling and hardening of thermoplastic material, a compact, dense composite product of the desired shape having a very high internal bond is created. The particles of the thermoplastic material and the waste or filler material used to produce composite products of the invention can vary in size from a powder to particles of a size of about 1 cm. These particles can be prepared as necessary by shredding, milling or the like. The high-intensity mixing of the selected mixture of thermoplastic and waste or resin particle material can be carried out by introducing the mixture into a high intensity batch mixer in which the rotating blades rotate at high rotation speeds of the order of about 20 meters per second inside a cylindrical chamber drive the particles in collision with each other and the wall of the mixer. This bombardment action not only affects the narrow mixing of the particles but elevates their temperature through a thermo-kinetic effect or internal friction healing. As the mixing continues, the thermoplastic particles soften first and then reach a molten state where they melt and wet and adhere to the hot or unmelted solid particles so that the hot solid particles are coated and bonded by the molten thermoplastic material. . The hot coated bonded waster or the filler particles are then subjected to a compaction pressure in a compression molding step wherein the molten thermoplastic material is forced into the fibers, pores, slits or irregularities of the filler or filler particles depending of its nature to lock these particles in the thermoplastic material ensuring its complete encapsulation and increasing or improving the bond between such captured or locked particles. The result of the compression molding step is the production of a product formed of densely compacted particulate material encapsulated and held in an extremely strong bond by the thermoplastic material. By preparing composite molded products as mentioned above, useful composite products, components or substructures can be prepared using as much as 10% by weight of thermoplastic material, the remainder being waste, recycled or particulate material from the filler. Further, according to the invention, such composite components or substructures may be incorporated into a thermoplastic product in which the component or substructure carries or is used to hold a covering or covering covering of at least a portion of the surface thereof. Because the function of the thermoplastic material is to encapsulate and join the waste or particles of the filler, the invention allows the effective use of waste or recycled thermoplastic materials, such as low, medium and high density reprocessed polyethylene, polypropylene, polyethylene. , terephthalate (PET), nylon, PVC, ABS, and other thermoplastic material ground as sources of thermoplastic material. The particle material that can be used advantageously as fillers are fibrous materials, such as wood sawdust, pieces of ground wood, ground cloth, paper, glass fibers and thermocrafted reprocessing materials. Other examples of particulate material that are useful as fillers are waste materials such as ash dust, baking powder, ground peanut shells, rice husks or corn husks. It will also be understood that many other particle materials such as rubber particles, metal, sand, concrete or the like can also be used. Therefore, it will be appreciated that the invention allows the production of highly useful products while the same time significant environmental benefits are achieved through the use of waste material that would otherwise have to be dislodged from a suitable site. It will be understood that different mixtures of particle material can be used as desired or required. For example, the inclusion of fibrous particle material provides good control of the expansion properties of the molded composite product, component or substructure, a need where the final composite product such as a door frame or panel whose shape and size is controlled by the substructure that It is exposed to a wide range of temperatures during the year. Again, the use of particle material such as ash dust, glass particles, kiln dust imparts strength and rigidity to the composite product of which the base forms. The thermoplastic binder is also preferably a recycled thermoplastic such as PVC or one of the polyethylenes or a mixture of recycled thermoplastic materials whose melting points are relatively similar. In this manner, the entire substance can comprise recycled or waste materials molded into a highly useful compacted structural component that exhibits the selected physical properties. It will be understood that a component will be free from water absorption, warping, chipping or otherwise deterioration during its intended use. The amount of thermoplastic binder per weight of the molded product, component or substructure may vary from about 10% to about 90% by weight with the encapsulated particle material varying from about 90% to about 10% by weight of the product depending on its use final. For most uses, the thermoplastic binder comprises from about 40% to 60% by weight and the physical property that controls the particle material from about 60% to about 40% by weight of the molded product. Because the preparation of the molded product, composite or substructure is a molding, it will be understood that it can be produced in a very wide range of forms without having to be manufactured in a way that can be used for, or as a basis for, a variety of very wide. Examples of such products using the invention include insulated steel doors, door frame profiles, window frame profiles, rotating door panels, folding door panels for buildings and vehicles, or other products where the shape and physical characteristics of the final product are important. Further, it will be understood that insofar as the tightly bonded, compacted nature of the product, structural component or substructure forms a firm solid structure, and the encapsulation of the particle material by thermoplastic binder renders it impervious to moisture, insects, erosion and the like, in so much so that at the same time it locks in the waste or the particles of the filling through its encapsulation so that they are evicted environmentally safe and effective in so far as they serve a very useful purpose. It will be understood the composite molded products, components or substructures prepared as set out above can be easily perforated, cut or machined and will easily accept and retain nails, screws, staples or other fasteners. The surface coverage or other exterior joints can also be easily bonded to it using commercial industrial adhesives. Also, with proper preparation of the surface of such molded composite products, they can be painted if desired.BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an exploded perspective view showing the components of a composite steel door having as a substructure a compression molded composite frame prepared in accordance with the invention. Figure 2 is a cross section of the line 2-2 of Figure 1. Figure 3 is a cross section of a finished door showing the interior filled with an insulating material. Figure 4 is a cross-sectional view separated through one of the vertical edges of the door that has been slotted to receive a plastic lid. Figure 5 is a perspective view illustrating the molding operation in which a thermoplastic binder ribbon heated to a viscous state that can flow molten and contains hot or substantially coated or encapsulated particulate filler material is deposited in a mold ready for compression. Figure 6 is a section on line 6-6 of Figure 5. Figure 7 is a cross-sectional view showing the application of pressure to compact the material located within the mold cavity and secure the encapsulation of the waste or filler particles. Figure 8 is a view similar to Figure 7 showing the substructure material after it has been compacted. Figure 9 is a perspective view illustrating the assembly of a composite panel comprising a substructure molded by compression in the form of a frame ready to be inserted between the cover sheets or panels. Figure 10 illustrates a substitute frame for that shown in Figure 9 in which the frame comes in two sections.

Figure 11 is a cross-sectional view of the assembled panel of Figure 9 and showing the introduction of the insulating foam into the interior thereof. Figure 12 is a cross-sectional view of a typical window profile comprising a compression molded substructure in which the exposed surfaces are covered with bonded facing. Figure 13 is a view similar to Figure 12 although it shows a typical door frame profile. Figure 14 is a perspective view illustrating the assembly of a composite door frame in which the components have been prepared in accordance with the invention. Figure 15 is a perspective view of a truck illustrating a folding rear door formed of a series of panels that may be hinged in any desired manner (the hinges are not shown). Figure 16 is a sectional view on line 16-16 of Figure 15 showing the compression molded substructure for which a cover or covering covering the edge and outer surfaces of the substructure has been attached. Figure 17 is a view similar to Figure 16 although it shows the fully coated substructure. Figure 18 is a rear end view of a truck of the type using a pair of vertically hinged revolving doors. Figure 19 is a cross-sectional view on line 19-19 of Figure 18 showing the composite structure of the door panel according to the invention with the door panel in this example being completely coated or coated.

DETAILED DESCRIPTION ACCORDING TO THE PREFERRED MODALITIES OF THE PRESENT INVENTION The steel door assembly 50 illustrated in Figure 1 is simply an example of a product according to the invention using a composite substructure prepared according to the invention. As illustrated, the door is formed of a frame 1 comprising a compression molding of encapsulated particle material and joined by a thermoplastic binder produced according to the invention. This frame forms the substructure to which the steel cover plates 2 are secured by any suitable means such as nails, screws, industrial glues. When assembled, the hollow interior of the frame can be filled with insulating material 3 such as foamed polyurethane that can be introduced into the interior of a frame through a hole 4 illustrated in Figure 1 punched through the frame which is further provided. with purging holes 5 to allow air to escape from inside the frame during the foaming operation.

As the substructure involved, which is the frame 1 in the figure, according to the invention is resistant to paint applications without an appropriate surface treatment or preparation, the exposed vertical edges of the substructure frame can be slotted as in 6 for receiving and retaining a plastic edge cover 7. As illustrated in Figure 1, the frame 1 is provided with an inward projection 8 which coincides with a hole 9 in the front cover plate or panel 12 for mounting the handle of door or knob and the associated locking mechanism (not shown). Figure 5 shows the mold 10 for molding the frame 1 comprising a channel 1 corresponding to the shape of the frame 1 and within this channel a load is located in the form of a ribbon 12 of molten composite produced in a mixer of high density and forced out of the nozzle 13 either by screw feeding or ram ejection from the feeder 14 which is urged to move around the channel 11 as it supplies its power through any suitable means, preferably a robotic device (not shown) ). As explained, the material forming the molten charge 12 is prepared by selecting a mixture of thermoplastic particles and waste filler material which may in this case be wood, flour or sawdust. The mixture is then introduced into a high intensity batch mixer in which the blades rotate in the cylindrical mixing chamber and produce rotation speeds which can be of the order of about 20 meters per second and drive the particles in collisions against each other. others and the wall of the cylindrical mixer. This action ensures the complete and narrow mixing of the particles which raises its temperature through the thermokinetic effect or internal friction heating. As the mixing continues, the thermoplastic particles, or at least those with lower melting temperatures, are first softened around the temperature of about 160 to 170 ° C depending on the plastic involved. Upon further mixing, the softened thermoplastic particles are brought to a molten state at a temperature of about 200 to 230 ° C, wet or coated or adhered to the solid non-molten particles so that the hot solid particles are bonded and encapsulated or at less substantially encapsulated by the molten thermoplastic material. Figure 6 which is a cross section showing the molten charge or tape after it has been placed in channel 1 1 and fixed in the channel diagrammatically illustrates the molten thermoplastic material 15 and the particle material in 16. Figure 7 shows the press platen 17 lowered to apply pressure to the molten charge 12 to compact it into a dense mass as illustrated in Figure 8. The subjecting of the load 12 to the compaction pressure in the compression molding step, as shown in FIG. He explained, it produces a dense and strong structural component or substructure of encapsulated particle material held in a high strength joint and having the desired determined shape. The selection of the particle material 16 and the ratio of the thermoplastic material will depend on the final use of the door 50. When the door will be exposed to substantial temperature changes, the particle or filler waste preferably comprises, at least in part , a fibrous material such as sawdust, or fabric or paper particles. The thermoplastic material 15 preferably comprises recycled PVC or polyethylene and the weight ratio would preferably be in the order of about 305 to 60% particle material with the remainder being the thermoplastic binder material or mainly thermoplastic binder together with some additional particle material such as polvillo of ashes or kiln dust added to impart hardness and strength. It will be appreciated that because the frame or substructure in the example of the steel door involves encapsulated particle material and attached in a compact mass, not only achieves the ability to use waste particles that would otherwise pose a waste problem but to use them in a very advantageous and safe way to control or define the physical properties of the substructure. At the same time, since the function of the thermoplastic binder is to encapsulate and agglutinate the particulate material, the recycled thermoplastics can be used advantageously instead of being discarded as waste so that the entire substructure can be entirely of waste materials or recycled so that they can be produced at a very low cost. From an environmental point of view, it will be appreciated that it is not necessary to cut trees to have access to wood fibers that may have the form of sawdust or ground splintered wood or other waste wood that can serve as the particle material. In addition, it will be appreciated that the basic form of the product within which the composite component or substructure is incorporated is or can be determined by the shape of a composite component or substructure that can be molded in such form without having to be manufactured. On the other hand, the molded composite product or substructure can be easily perforated, cut and machined ready for the assembly or joining of the materials to be held in this manner by conventional fasteners or industrial glues. It will also be understood that the molded composite component or substructure can be coated or coated with a cover layer for example of rubber or latex by dripping or other similar process or, if its surface was prepared, it can be painted, dyed or have patterns applied to the same With the particulate material encapsulated by compression and strongly bonded by the thermoplastic material during compression molding, as explained, a wide range of waste or filler particle materials can be advantageously employed. The recycled or reprocessed thermoplastic materials whose melting point is above the thermoplastic material which is heated to a molten state in the molding process to form the binder can serve as a solid material or useful filler particles. Also useful are reprocessed or recycled thermosettable plastic particles. In the fibrous group of useful particles, ground waste wood together with sawdust, ground cloth, paper give expansion control and for the hardness short fine glass fibers are useful. Other typical waste particle materials that give structural strength include ash dust, kiln dust, ground peanut shells, ground rice husks or ground corn husks. Without intending to limit the invention, other useful particulate materials include sand, concrete particles, metal particles, and rubber particles. It is also understood that any of the combinations of the different particle materials can be used to select the required properties of the structural component or substructure according to the nature and use of the final composite product for which the substructure forms the base. As mentioned, examples of recycled plastics that can be used as the thermoplastic binder include low, medium and high density reprocessed polyethylene, polypropylene, polyethylene terephthalate (PET), nylon, ABS, and PVC. Figure 9 again illustrates the use of the component or substructure 18 prepared as described above in the form of a rectangular frame to form a composite product comprising an insulated panel 19. In this case, the substructure frame 18 is inserted between a a pair of cover or liner plates 20 which are screwed, nailed or otherwise secured to the frame 18 and the inner l filled with a foamed insulation 21 as in the case of the steel door 50. The cover plates 20 may be of a suitable material that would include steel, aluminum or plastic coating. While the substructure 18 is conveniently a complete frame, it will be appreciated that the substructure may be formed of individual parts such as sections of half frame 22 shown in Figure 10. Again the selection of the particle material will depend on the end use of the panel and also of the properties of the material forming the cover plates or coating 20 with fibrous particles which are useful for expansion control and such particles as ash dust which are useful for hardness. Figure 12 illustrates a composite component or substructure 23 produced as described above that has been compression molded in the form of a window frame profile with exposed surfaces having a coating 24 of plastic or metal secured thereto. In Figure 13, the compression molded composite or the substructure 25 is in the form of a door frame profile having a cover 26 in the form of plastic or metal secured to the exposed surfaces thereof. The selection of the particle material of the substructures 23 and 25 in the form of the window or door frame profiles respectively is selected for its end-use application. When they are to be used in locations undergoing wide temperature changes, the particulate material preferably includes a significant proportion of fibrous particles of up to the order of 30% 40% by weight of the substructure. While fully manufactured composite products such as door 50 or panel 19 may have the composite substructure or molded frame as a complete unit frequently the composite compression molding of the invention may simply be a component for assembly with other components molded by compression. For example, when frames such as the door or window frames of Figures 13 and 12 respectively are incorporated into the construction of a house or other building, adjustments are likely to be required. An example is the length of the side door frames or uprights indicated in 27 in Figure 14 may have to be adjusted. Therefore, these frame members are supplied for work in lengths substantially larger than the height of the door frame so that they can be cut to the proper length in place. Figure 14 illustrates the fabrication of the door frame in which the side frames or uprights 27 are secured to a threshold frame 28 and an upper frame 29. All of those frames comprise molded composite components of encapsulated particle material and bonded by a binder thermoplastic as described above. The suitable coating covering the exposed surfaces of the door frame can be secured to the substructure through the use of screws, nails or other fasteners. Additionally or alternatively, the liner can be secured by providing grooves 30 in the substructure such as those illustrated in Figure 13 and the liner can be provided with inwardly turned ends 31 as illustrated in Figure 13 for engaging in the slots 30. Alternatively the Exposed surfaces of the frames can be properly treated and painted or have a film laminate thereon. Similarly, with respect to the window profile substructure 23, the liner 24 may have inwardly turned ends 32 which engage in the slots 33 formed in the substructure 23 as illustrated in Figure 12. Another area where it is used Widely, wood as a substructure is in the construction of truck door panels where the use of a substructure of composite particle material according to the present invention provides an important saving in wood and so much that at the same time, provides improved physical properties for the doors eliminating chipping, erosion, delaminating and making doors impervious to water and insect attack. Figure 15 illustrates in diagram form a truck 34 having a collapsible rear door generally designated at 35 formed from a series of horizontal door panels 36 pivotally connected together with suitable hinged (not shown). In accordance with the present invention, those door panels 36 employ a composite substructure 37 shown in Figure 16 comprising the thermoplastically encapsulated and bonded particle material defining the shape of the panel. A liner 38 secured to the substructure 37 covering the exposed rear face of the door panel. Again, the particle material and the amount thereof will be selected to achieve the desired physical properties for the door panel 36. Through the use of recycled or waste particle material, not only can a significant reduction in cost be made to starting from the current door panels of the type illustrated by the door panel 36, but such panels using the substructure of the present invention will be substantially superior to those in use at present. While Figure 16 illustrates the substructure 37 that has been coated on the outside and the edges, the entire substructure 36 can be completely coated by the coating 39 illustrated in Figure 17.

Figure 18 illustrates another widely used door arrangement on the back of trucks such as the truck generally designated at 40. In this case, the door arrangement comprises a pair of door panels 41 secured by hinges 42 at their outer edges and placed to rotate together to join in the center where they can be secured by a suitable bolt arrangement generally designated at 43. Currently those panels 41 comprise large panels of plywood that can be covered if desired. If plywood panels such as chips or chips, as is often the case, they become waste products added to the enormous amount of wood that is involved in their production. In addition, again, such door panels are exposed to all types of weather and are subject to deterioration. By using the present invention, such door panels can be provided with enormous cost savings while eliminating the felling of many trees and at the same time improving the environment by utilizing waste or recycled materials. Thus, as illustrated in Figure 19, each of the panes 41 is formed of a substructure 44 of encapsulated particle material and bound by a thermoplastic binder provided with a coating 45 secured thereto. The liner 45 may be plastic or metal such as thin aluminum or steel cladding and, if desired, may be used to cover only the outer faces of the door panels 41. It will be understood that only a limited number of examples of products using the compression molded composite of the present invention have been illustrated and that the compression molded products, components or substructures of the invention can be advantageously employed in the manufacture of a vast number of different products. It is intended that all such products fall within the scope of the appended claims.

Claims (10)

1. A process for producing a composite product having a predetermined shape, the process which is characterized by subjecting a mixture of particles of thermoplastic material (15) and particles (16) of waste or filler material to a mixing operation of a high intensity such that it raises the temperature of the particles of thermoplastic material (15) and particles (16) through the particle interaction until the particles of thermoplastic material (15) reach a molten state which causes the molten plastic to coat and bonding with the hot particles (169) to form a hot mass of particles (16) that are coated with and bonded by the thermoplastic material (15) and then with the thermoplastic material (15) in the molten state, compress the hottest to force to the thermoplastic material (15) within any interstices and irregularities of the particles (16) insofar as they form the hottest to a desired product form to produce, upon cooling thereof, a compacted composite product in which the particles (16) are encapsulated by the thermoplastic material (15).

2. A process as claimed in claim 1, characterized in that the particles of the thermoplastic material (15) used for mixing with said waste or particulate material (16) are particles of recycled thermoplastic material.

3. A process as claimed in claim 2, characterized in that the waste or filler particles (16) comprise particles of recycled material. A process as claimed in claims 1, 2 or 3, characterized in that the particles of thermoplastic material (15) used for mixing with the waste or filler particles (16) comprise at least about 10% by weight of said particles. A process as claimed in claims 1, 2 or 3, characterized in that the particles of the thermoplastic material (15) used for mixing with the waste or filler particles (16) comprise about 30% up to 70% by weight of said particles. 6. A process as claimed in claims 1, 2 or 3, characterized in that the particles of thermoplastic material (15) used for mixing with the waste or filler particles (16) comprises approximately 40% to 60% by weight of said particles. 7. A process as claimed in claims 1, 2 or 3, characterized in that the particles of thermoplastic material (15) comprise one or more of low, medium or high density reprocessed polyethylene, polypropylene, polyethylene terephthalate, nylon , ABS or PVC. A process as claimed in any one of the preceding claims, characterized in that the waste or filler particles (16) comprise one or more of sawdust, pieces of ground wood, ground cloth, paper, glass, ash dust , furnace dust, husks or ground husks, rubber particles, metal particles, sand, concrete and thermosetting plastic material milled. A process as claimed in claims 2 to 8, characterized in that said particles of thermoplastic material (15) have a softening temperature of about 160 to 170 ° C and melt at a temperature of about 200 to 230 ° C. . A process as claimed in claim 9, characterized in that the waste or filler material (16) includes particles of thermoplastic material having a melting point of about 230 ° C. eleven . A product composed of thermoplastic material (15) and particles (16) of waste or filler characterized in that the thermoplastic material (15) is tightly bound to said particles (16) through friction heating to encapsulate and bond said particles (16), said linked encapsulated particles (16) which are compacted in a selected form for final use. 12. A composite product as claimed in claim 1, characterized in that the thermoplastic material (15) is a recycled thermoplastic material. 13. A composite product as claimed in claims 1 1 or 12, characterized in that said waste or filler material (16) comprising from about 10% to about 90% and said thermoplastic material (15) comprises from about 90% to about 10% by weight of said composite product. A composite product as claimed in claims 1 or 12, characterized in that said waste or filler material (16) comprising from about 30% to about 70% and said thermoplastic material (15) comprises from about 70% up to about 30% by weight of said composite product. 15. A composite product as claimed in claims 1 or 12, characterized in that said waste or filler material (16) comprising from about 40% to about 60% and said thermoplastic material (15) comprises from about 60% up to about 40% by weight of said composite product. 16. A composite product as claimed in any one of claims 1 to 15, characterized in that at least some of said waste or filler particles (16) are particles of recycled fibrous material. 17. A composite product as claimed in claim 17, characterized in that the recycled fibrous material (16) is selected from one or more of wood, cloth or paper. 18. A composite product as claimed in claims 12, 13, 14 or 15 characterized in that the recycled thermoplastic material (15) is selected from one or more low polyethylene. medium or high density reprocessed, polypropylene, polyethylene, polyethylene terephthalate, nylon, ABS or PVC. 19. A composite product as claimed in any one of claims 1 to 15, characterized in that the waste or particulate material (16) comprises one or more of sawdust, pieces of ground wood, ground cloth, paper, glass , dust ash, furnace dust, ground husks or husks, rubber particles, metal particles, sand, concrete particles and thermosetting plastic materials milled. 20. A composite product as claimed in any one of claims 1 1 or 19, characterized in that the product is formed in a rectangular door frame (1) to form the perimeter of a door (50) in combination with panels of cover (2) secured to each side of said frame (1) to form a door. twenty-one . A composite product as claimed in claim 26, characterized in that said frame (1) is filled with insulating material (3) between the cover panels (2). 22. A composite product as claimed in claims 20 or 21, characterized in that the cover panels (2) are steel sheets. 23. A composite product as claimed in any one of claims 1 to 19, characterized in that the product is molded to form a profiled structural component (23) (25) (37) (44) in combination with a material of cover (24) (26) (38) (45) covering surfaces of said structural component that are exposed when the structural component is incorporated in a final product. 2

4. A composite product as recited in claim 23, characterized in that the cover material (24) (26) (38) (45) is selected from plastic, steel or aluminum. SUMMARY Composite products comprising or incorporating waste compression molding or packed particles (16) encapsulated and bonded by a thermoplastic binder (15) in a compacted mass of a shape selected for final use, compression molding which is prepared by mixing The thermoplastic and waste particles or filler materials are intensively bonded together to raise their temperature to bring the thermoplastic particles to a molten state where they cover the waste or filler particles (16), and then they are compression molded. hot waste or filler particles.