Abstract:
A basket is made from embedded recycled container sheet. The basket includes: a side wall and a bottom, the side wall and the bottom being connected to one another in the shape of a basket with an open top, the side wall being, at least in part, a plurality of flattened recycled containers embedded therein, and each of the plurality of flattened recycled containers being visibly recognizable. In some embodiments, the basket also includes a hanging mechanism attached to at least one of the side wall and the bottom. The side wall has a footprint that may be circular, conical, oval, square, rectangular, polygonal or irregular.

Description:
BACKGROUND OF INVENTION 
       [0001]    a. Field of Invention 
         [0002]    The invention relates generally to baskets made from flattened, recycled plastic containers that are embedded in substrates that visibly display the flattened, recycled plastic containers. These products may be created by different methods, and one preferred method of producing these products involves creating sheets of plastic with embedded recycled plastic containers. The substrate plastics are clear to opaque on at least one side for displaying the recycled plastic containers therethrough. The recycled plastic containers may be sterilized and prepared prior to the embedding process. They may be sliced. e.g., vertically, and are rendered flat by any available technique, such as partial melt, steam compression or other method. When heated, the heating is such that the bottles are slightly melted to deform and fused so that original characteristics of the bottles remain visible, if somewhat obscurely, such as color, design, labels, and shape. The prepared containers (In this context, “containers” means whole or cut, but still identifiable containers.) are the placed in a molten or tacky substrate and are then topcoated with a top layer to create the finished product. The sheets may then be used to create the basket products that display the individual deformed bottles in a recognizable manner. The baskets are either molded from the embedded sheets, e.g., by compression or heat stamping, or are otherwise formed with the sheets, e.g., by cutting and heat welding the side wall(s) to the bottom. 
         [0003]    The word “basket” as used herein, refers to any type of basket that has a bottom and a side wall or side walls, such as, but not limited to waste baskets, fruit and other display baskets, plant potters and hanging baskets. 
         [0004]    b. Description of Related Art 
         [0005]    The following patents are representative of the field pertaining to creating plastic products: 
         [0006]    U.S. Pat. No. 5,468,779 to Yamamoto et al. describes a plastic material with a paint film in coarse-crushed, and a film decomposition agent, e.g. a heterocyclic compound such as imidazolek, a triazine compound such as benoguanamine, a phenylendiamine compound such as N-phenyl-N-isopropyl-p-phenylene diamine, is added to the coarse-crushed material. The mixture is then heated and kneaded to dissolve the paint film and uniformly spread the particles of the paint film in the plastic material. The physical properties and surface quality of the plastic material are substantially the same as those of the original material. 
         [0007]    U.S. Pat. No. 5,879,797 to Kim describes a novel matrix containing nephrite jade power as a main component. By using the matrix, a variety of goods in the field of medical goods, utensil goods, agricultural goods, industrial goods, fishery goods, traffic goods, transportation goods, equipment for sports, electronic instruments, precision instruments, pr the like ca be prepared. The goods made of the matrix can show excellent effects of treating pathological symptoms (headache, numb feeling, indigestion, insomnia, pr the like), removing impurities (such as heavy metals), improving the quality of water, promoting the growth of plants by virtue of the inherent properties of nephrite jade. 
         [0008]    United States Patent Publication US 2008/00200221 A1 describes systems and methods of generating a recycled output. The recycled output may include a fabric produced by fusing reclaimed plastic bags. The reclaimed plastic bags are fused together using a material manufacturing system. The system is typically configured to heat the plastic bags to a temperature wherein the plastic bags fuse together but do not completely melt. Some embodiments include the addition of different types of plastic or non-plastic materials to the recycled output. Also disclosed are systems and methods of controlling texture and patterns within the recycled output. 
         [0009]    United States Patent Publication US 2008/0145580 A1 discloses a recycled insulation material which includes plastic and/or rubber shredded or chopped up into individual pieces having random or semi-random sizes or semi-random air-pockets in between many of the individual pieces. The shredded or chopped up plastic and/or rubber pieces in combination with the air-pockets are configured to operate as an insulation filler for a variety of different panes, forms, pipes, conduits or any other item that requires insulation. 
         [0010]    United States Patent Publication US 2008/02411455 A1 relates to an encapsulated member made with open molds for forming the exterior surface of the encapsulated member, wherein the encapsulation is accomplished with at least an outer skin configuration of a plastic, metal, ceramic or other moldable material for encapsulating pre-forms, reinforcements, sheeted materials, metallic pre-forms and other core materials that can be protected from the outer elements and manufacturing considerations.  FIG. 3   c  shows and encapsulating reinforced member located within an open mold having skins thereon, and being filled in between with formable material. 
         [0011]    Notwithstanding the prior art, the present invention is neither taught nor rendered obvious thereby. 
       SUMMARY OF INVENTION 
       [0012]    The present invention is an embedded recycled container sheet basket, which comprises: a side wall and a bottom, the side wall and the bottom being connected to one another in the shape of a basket with an open top, the side wall being, at least in part, a plurality of flattened recycled containers, and each of the plurality of flattened recycled containers being visibly recognizable. The side wall has a footprint that may be circular, conical, oval, square, rectangular, polygonal or irregular. 
         [0013]    In some preferred embodiments of the present invention embedded recycled container sheet basket, the plurality of flattened recycled containers is embedded between a base substrate of plastic and a top layer of plastic. 
         [0014]    In some preferred embodiments of the present invention embedded recycled container sheet basket, the base substrate is a recycled plastic base substrate selected from the group consisting of clear plastic, opaque plastic, colored plastic and combinations thereof. 
         [0015]    In some preferred embodiments of the present invention embedded recycled container sheet basket, the top layer is a recycled plastic selected from the group consisting of clear plastic, opaque plastic and combinations thereof. 
         [0016]    In some preferred embodiments of the present invention embedded recycled container sheet basket, side wall has a top view that is selected from the group consisting of circular, square, rectangular and polygonal. 
         [0017]    In some preferred embodiments of the present invention embedded recycled container sheet basket, both the front cover and the back cover are, at least in part, a plurality of flattened recycled containers, and each of the plurality of flattened recycled containers are visibly recognizable. 
         [0018]    In some preferred embodiments of the present invention embedded recycled container sheet basket, the base substrate is a recycled plastic base substrate selected from the group consisting of clear plastic, opaque plastic, colored plastic and combinations thereof. 
         [0019]    In some preferred embodiments of the present invention embedded recycled container sheet basket, the top layer is recycled plastic selected from the group consisting of clear plastic, opaque plastic and combinations thereof. 
         [0020]    In some preferred embodiments of the present invention embedded recycled container sheet basket, the front cover and the back cover each have at least one straight edge and they are directly connected to one another at the at least one straight edge of each. 
         [0021]    In some preferred embodiments of the present invention embedded recycled container sheet basket, the basket further includes a lid. 
         [0022]    In some other preferred embodiments of the present invention embedded recycled container sheet basket, the basket includes: a side wall and a bottom, the side wall and the bottom being connected to one another in the shape of a basket with an open top, the side wall being, at least in part, a plurality of flattened recycled containers, and each of the plurality of flattened recycled containers being visibly recognizable, and further including hanging means attached to at least one of the side wall and the bottom. 
         [0023]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, the plurality of flattened recycled containers is embedded between a base substrate of plastic and a top layer of plastic. 
         [0024]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, the base substrate is a recycled plastic base substrate selected from the group consisting of clear plastic, opaque plastic, colored plastic and combinations thereof. 
         [0025]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, the top layer is a recycled plastic selected from the group consisting of clear plastic, opaque plastic and combinations thereof. 
         [0026]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, side wall has a top view that is selected from the group consisting of circular, square, rectangular and polygonal. 
         [0027]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, both the front cover and the back cover are, at least in part, a plurality of flattened recycled containers, and each of the plurality of flattened recycled containers are visibly recognizable. 
         [0028]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, the base substrate is a recycled plastic base substrate selected from the group consisting of clear plastic, opaque plastic, colored plastic and combinations thereof. 
         [0029]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, the top layer is a recycled plastic selected from the group consisting of clear plastic, opaque plastic and combinations thereof. 
         [0030]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, the front cover and the back cover each have at least one straight edge and they are directly connected to one another at the at least one straight edge of each. 
         [0031]    In some preferred embodiments of the present invention embedded recycled container sheet basket with hanging means, the basket further includes a lid. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0032]    The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the detail description serve to explain the principles of the invention. In the drawings: 
           [0033]      FIG. 1  is a schematic view of a method of producing a basket from embedded recycled container sheet according to the present invention; 
           [0034]      FIG. 2  is a schematic view of a method of producing embedded recycled container sheet basket products according to the present invention, illustrating a batch process and a continuous process; 
           [0035]      FIG. 3  is a schematic view of a method of producing an embedded recycled container sheet basket according to the present invention, illustrating processing steps for creating the product; 
           [0036]      FIG. 4  is a schematic view of a method of producing an embedded recycled container sheet basket according to the present invention, illustrating heating; 
           [0037]      FIG. 5  is a schematic view of a method of producing an embedded recycled container sheet basket according to the present invention, illustrating products created; 
           [0038]      FIG. 6  shows an oblique side view of one present invention basket created with sheet made by the method described herein; 
           [0039]      FIG. 7  illustrates an oblique side view of another basket made by the method of the present invention; and, 
           [0040]      FIG. 8  illustrates an oblique side view of a present invention basket with a hanging mechanism. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0041]    The present invention relates to a method of producing an embedded recycle sheet baskets from recycled plastic containers. The recycled plastic containers are preferably sterilized and are flattened. Flattening may be accomplished by one or more of a number or options. These include optional precutting especially vertically cutting in half, or into smaller sections, followed by soft melting, compression, hot compression, steam deforming, or steam compression such as steam calendaring. 
         [0042]    Compression and heating of the containers may be accomplished by slightly melting to deform and flatten the containers. However, the original characteristics of the bottle remain visible, if somewhat obscurely, such as color, design, labels, and shape. The deforming may be such that one will recognize the original bottle. Thus, a Pepsi bottle will be distinguishable from a ginger ale bottle which will be distinguishable from a Coke bottle. The containers may be on different sizes, shapes, colors and materials (for example, polyethylene, polypropylene, blends or other container plastics). In some cases, labels may be removed from the bottles, but in other cases, they are not removed. Preferably paper labels are not kept. If labels are removed, they may be heat fused or melted. In some cases, the bottles may be chopped, in which case, the bottles may not be as easily identifiable. 
         [0043]    In the present invention method, the plurality of empty recycled containers is flattened so that the width (thickness) is reduced by at least 80% and preferably by at least 95%. These flattened recycled plastic containers are dropped onto a base substrate and then both the containers and the bas substrate are top-coated to embed the containers. Although not essential to the present invention, when the resulting sheets are designed to be flat, sufficient top coat is applied for a self-leveling flat surface. 
         [0044]    The base substrate may be any plastic that will stick to, adhere or otherwise bond to the top coat. The base substrate and the top coat or top layer may be the same or different and are preferably recycled plastic. Polyethylene, polypropylene, polycarbonates, and other plastics and blends may be used and the base substrate may be colored, opaque, transparent, or combinations of these. The top layer must be at least partially transparent or opaque to render the embedded containers visibly recognizable. 
         [0045]    In continuous process systems, the base substrate is continuously extruded, the flattened containers are dropped or fed onto molten base substrate and the top layer is applied in molten or liquid state the continuous laminate with the cut embedded containers is cooled and for subsequent use. In other continuous processes, the base substrate could be cooled or partially cooled before the flattened containers are applied, and or the top layer could be a cooled sheet or pellets with subsequent heating or compression and heating. Likewise, batch processes may involve any of the preceding combinations but in fixed dimension molds instead of continuous flow units. The binders are made from the resulting sheets. 
         [0046]    Referring now to the drawings,  FIG. 1  is a schematic view of a method of producing an embedded recycled container sheet basket  1  from recycled plastic containers  3  according to the present invention. 
         [0047]    The method of producing the embedded recycled sheet  1  includes: (a) providing a plurality of empty, preferably cleaned, recycled plastic containers  3 ; (b) flattening and optionally pre cutting the containers  5 ; (c) providing a base substrate of plastic  7 ; (d) placing the plurality of flattened containers on the substrate  9 ; (e) applying a top layer of plastic over the containers and substrate  11  to form a sheet  11 ; and, (f) creating a basket product from the sheet so as to retain the visible display of the plurality of deformed identifiable containers  13 . 
         [0048]      FIG. 2  is a schematic view of a method of producing an embedded recycled container sheet binder  21  from recycled plastic bottles according to the present invention, illustrating a continuous process  19  and a batch process  23 . 
         [0049]    With regard to the batch process  33 , the compressed flat composite recycled bottle sheet is formed in a fixed dimension mold  25 , which may have predetermined fixed length and width dimensions or may have a non-rectangular fixed shape. 
         [0050]    With regard to the continuous process  19 , frame  27  shows that the blocks of  FIG. 1  (blocks  7 ,  9 , and  11 ) may be continuous process steps. The resulting sheet may be periodically cut and used to create basket products  29 . The embedded sheets may be vacuum molded, compression molded, cut and heat welded or otherwise formed into present invention baskets. 
         [0051]      FIG. 3  is a schematic view of a method of producing an embedded recycled container sheet basket  31  from recycled plastic containers according to the present invention. 
         [0052]    With regard to box  33 , creating the basket products from compressed flat composite recycled bottle sheets includes a processing step selected from molding, casting, cutting, machining and combinations thereof. 
         [0053]      FIG. 4  is a schematic view of a method of making an embedded recycled container sheet basket product from recycled plastic bottles according to the present invention, illustrating heating  35 . With regard to the box  37 , the heating is to a temperature sufficient to deform, partially melt and flatten the bottles, the heating is at a temperature of at least the lowest melting point of the bottles and exposure time is sufficient to deform, partially melt and flatten the bottles. With regard to box  39 , the heating is performed utilizing a method selected from the group consisting of convection, induction, microwave, ultrasonic and infrared. 
         [0054]      FIG. 5  is a schematic view of a method of producing embedded recycled container sheet basket products from recycled plastic containers according to the present invention, illustrating binder products that may be produced 41. With regard to box  43 , the product consists of a container having a bottom and at least one side wall, which includes various types of baskets, including a waste basket, a fruit basket, a planter and a gift basket. These products may have top footprints that are circular, rectangular, square, polygonal, irregular or otherwise. With regard to box  45 , the products are baskets with hangers. 
         [0055]      FIG. 6  illustrates one waste product produced by the present invention methods, namely, waste basket  50 . The basket  50  has side walls  51  and a bottom  53 , with an open top  55 . Inside walls  57  do not show recycled flattened containers as they were originally opaque base layers. 
         [0056]      FIG. 7  illustrates an oblique side view of a basket  60  made by the method of the present invention wherein a sheets according to the present invention method are created and then compression heat molded into basket  60 . Basket  60  has a circular footprint and a side wall  63  clear on its outside as well as its inside  65 , and bottom  61 . This basket  60  could be large enough to be a tall kitchen waste basket or even a 55 gallon waste basket, or small enough to be a desk basket or even a pencil holder basket. 
         [0057]      FIG. 8  illustrates an oblique side view of present invention basket  70 . Basket  70  includes a side wall  75 , a rim  77  and a bottom  79 . Rim  77  has hanger attachment orifices and two which hanger means  81  has been inserted. In this case, basket  70  is used as a planter and includes soil  71  with plant  73 , as shown. 
         [0058]    Although particular embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those particular embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.