Recycled materials strengthening process, system, and products

Abstract

A method of forming a reinforced building product from garbage, comprising the steps of sorting garbage, shredding plastics within the garbage, shredding fibers within the garbage, heating the shredded plastics, forming a slurry from the plastics and fibers, disposing the slurry within an extrusion cavity, extruding the fluid through a venturi, and allowing the extruded materials to cool. Garbage is separated into plastics, fibers, and other materials. Plastics are shredded to facilitate melting. Fibers are shredded to macroscopic lengths no greater than a maximum internal diameter of a venturi. The plastics are melted. The melted plastics are mixed with fibers and other material to form a slurry that is extruded from a cavity through a venturi, thereby causing significant alignment of the shredded fibers within the slurry in an outer region of the extruded slurry. Cooled, there is reinforced building material.

1 . A method of forming a reinforced building product from garbage, comprising the steps of:
 sorting the garbage by separating the garbage into plastics, fibers, and other materials;   shredding the plastics to a size configured to facilitate melting;   shredding the fibers to macroscopic lengths no greater than a maximum internal diameter of a venturi;   heating the plastics to a temperature sufficient to substantially melt the plastic;   forming a slurry by mixing the heated plastic and the fibers;   disposing the slurry within an extrusion cavity, wherein the extrusion cavity includes an extrusion piston and the venturi;   extruding the slurry through the venturi by actuating the extrusion piston, thereby causing significant alignment of the shredded fibers within the slurry in an outer region of the extruded slurry; and   allowing the extruded slurry to cool and harden, thereby forming reinforced building product material.   
     
     
         2 . The method of  claim 1 , further comprising:
 sorting the other materials into fillers and unusables;   shredding the fillers; and   mixing the fillers with the heated plastic and the fibers.   
     
     
         3 . The method of  claim 2 , wherein the fillers, heated plastic, and fibers are mixed according to the following ranges:
 from about 30 percent to about 60 percent of heated plastic;   from about 0 percent to about 35 percent of fibers; and   from about 30 percent to about 60 percent of fillers.   
     
     
         4 . The method of  claim 1 , further comprising sanitizing the fibers. 
     
     
         5 . The method of  claim 1 , wherein the venturi is a pipe venturi configured to produce hollow reinforced building product material. 
     
     
         6 . The method of  claim 1 , further comprising cutting the reinforced building product material to a desired length. 
     
     
         7 . The method of  claim 2 , further comprising sanitizing the fibers and the fillers. 
     
     
         8 . The method of  claim 1 , further comprising repeating the method a second time using the reinforced building product material resultant from a first time as a core upon which to form a layer of reinforced building product material disposed thereupon by a pipe extruder including a pipe venturi. 
     
     
         9 . The method of  claim 1 , wherein the fibers comprise metal wires. 
     
     
         10 . An apparatus for producing reinforced building material, comprising:
 a sorter configured to sort garbage into plastics, fibers, filler, and unusable materials;   a shredder configured to receive materials from the sorter and to shred plastics and filler to a fine consistency and fibers to lengths from about ⅛ inches to about 1 inch;   a mixer configured to receive and mix shredded garbage;   a heater configured to melt shredded plastic;   an extruder in fluid communication with the mixer and configured to extrude fluid received from the mixer;   a controller configured to control the mixer and the extruder, wherein the mixer is configured to mix plastic, filler, and fibers;   a venturi in fluid communication with the extruder configured to cause substantial alignment of shredded fibers in an outer region within a fluid being extruded through the venturi; and   a cooling system configured to cool fluid after it is extruded through the venturi.   
     
     
         11 . The apparatus of  claim 10 , further comprising a sanitizer configured to heat fillers and fibers to a sufficient temperature for a sufficient duration to sanitize the fillers and fibers. 
     
     
         12 . The apparatus of  claim 10 , wherein the venturi is a pipe venturi configured to produce hollow reinforced building product material. 
     
     
         13 . The apparatus of  claim 10 , wherein the shredder is configured to receive metal wire and to cut metal wire to lengths of about ⅛ of an inch to about 1 inch. 
     
     
         14 . The apparatus of  claim 10 , wherein the apparatus is configured to receive reinforced building material from a second apparatus and coat the reinforced building material of the second apparatus. 
     
     
         15 . The apparatus of  claim 10 , wherein the heater is configured to melt plastics with a melting point greater than about 500 degrees Fahrenheit. 
     
     
         16 . The apparatus of  claim 10 , further comprising a cutter configured to cut extruded and cooled materials. 
     
     
         17 . A reinforced building material, comprising:
 about 30 percent to about 60 percent plastics;   about 0 percent to about 35 percent filler material; and   about 30 percent to about 60 percent macroscopic fibers, wherein the macroscopic fibers are substantially aligned perpendicular to an outer surface of the reinforced building material in an outer region.   
     
     
         18 . The reinforced building material of  claim 17 , wherein the macroscopic fibers comprise metal wires. 
     
     
         19 . The reinforced building material of  claim 17 , further comprising a hollow core substantially central to the reinforced building material and extending laterally therethrough, thereby forming a reinforced pipe. 
     
     
         20 . The reinforced building material of  claim 17 , further comprising a second outer layer wherein the macroscopic fibers are substantially aligned perpendicular to an outer surface of the reinforced building material in a second outer region of the second outer layer.