Field of the Invention The present invention generally relates to a method capable of producing multi-component materials via mechanical thermally controlled pulverisation of initial larger fibre reinforced materials into commercially exploitable smaller fibre containing elements. More particularly, the present invention relates to a method capable of pulverising fibre reinforced materials that can be included as a part of a materials recycling methodology that can process different sized fibre reinforced polymeric materials, such as for example fibre reinforced tyre rubber, ^• into fragments that can be utilised as precursors for industrial manufacturing processes such as for example manufacturing fibrous non-woven and/or woven materials, and it will be convenient to hereinafter disclose the invention in relation to that exemplary application. However, it is to be appreciated that the inventive method is not strictly limited to that application, and may be used in pulverising other polymeric materials such as for example conveyor belts or other fibre reinforced materials to produce precursor material for fabrication of fibrous non-woven and/or woven materials as well as for example manufacturing acoustic and/or thermal insulation materials.

Background of the Invention

The following discussion of the background to the invention is intended to facilitate an understanding of the inventive method. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application. A vehicle tyre (or tire) is a generally a circular ring shaped covering manufactured from rubber and reinforcing elements such as steel and fabric cords which is fitted over the outer circumference of a vehicle wheel. Most vehicle tyres since at least the 1960s have been made from a composite material that includes rubber reinforced with cords of polyester, steel, and/or other textile materials. Even with reinforcement, vehicle tyres have a limited life and will eventually have to be replaced. Many end-of-life tyres are shredded into pieces for processing into rudimentary relatively low-value materials or for placement into landfill as a waste product.

The inventors of the present inventive method have utilised their investigations which support the principles that the mechanical action of pulping textile reinforced polymeric material via known pulverisation devices, such as but not limited to for example a device for pulverising fibre reinforced tyre rubber segments as described in WO 2011/014902, under controlled thermal conditions will fragment the polymers and separate them from their textile reinforcing elements and at the same time enable simultaneous preparation of the separated textile reinforcing elements into a commercially useful state as multi-component material being reinforced with devulcanised rubber as precursors for utilisation in industrial processes such as for example for the manufacturing of fibrous non-woven and/or woven materials as well as for example manufacturing acoustic and/or thermal insulation materials.

Prior Art

The inventors are aware of the following closest prior art in this field:

• US 1959/2897874 - Method and apparatus of forming, processing and assembling fibres: This prior art forms fibre by projecting fibre forming mineral material by centrifugal forces into an attenuating blast wherein the material is formed into fine fibres. Compared to the present methodology, this prior art requires the more expensive fresh fibre forming mineral materials and utilises a different method of causing an attenuating blast via centrifugal forces.

• WO 2007/064728 - Surface modified bi-component polymeric fibre: This prior art forms bi-component fibres by blending a first polymer and a filler to form a composite, and co-extruding under thermal bonding conditions a second polymer and the composite to form the bi-component fibre. Compared to the present methodology, this prior art requires the more expensive method of initially blending a first polymer with a filler to form a composite which then requires co-extrusion of the composite with a second polymer.

WO 2009/135891 - Process for recycling articles based on a fibre reinforced polymer: This prior art forms fibre by recycling a fibre reinforced polymer article by dissolving the article in solvent slurry and then removing the solvent via a steam process. Compared to the present methodology, this prior art requires the more expensive method of utilising solvent slurry and then having the requirement of removing the solvent via a steam process. Further, the solvent removal process is not totally effective and the process is therefore not efficient.

US 2011/0027568 - Multi-component fibres: This prior art forms multi- component fibre by enclosing a phase change material and a viscosity modifier with a fibre forming polymer. Compared to the present methodology, this prior art requires the more expensive method of enclosing a phase change material and a viscosity modifier with a fresh fibre forming polymer.

It would therefore be desirable to provide an alternative method for the formation of multi-component precursor material that overcomes some or all of the drawbacks of the prior art. In particular there is a need for a less expensive process that overcomes the need of fresh ingredients, instead providing an environmentally sustainable commercially viable solution for recycling fibre reinforced materials into elements utilised as multi-component precursor materials for industrial processes such as for example for manufacturing fibrous non-woven and/or woven materials as well as for example manufacturing acoustic and/or thermal insulation materials.

Objectives of the Present Invention · Produce multi-component precursor material for manufacture of fibrous non-woven materials.

• Produce multi-component precursor material for manufacture of fibrous woven materials. Produce multi-component precursor material for manufacture of fibrous materials with advantageous surface characteristics such as for example surface roughness.

Produce multi-component precursor material for manufacture of fibrous materials with advantageous acoustic damping characteristics such as for example sound absorption.

Produce multi-component precursor material for manufacture of fibrous materials with advantageous phase change characteristics such as for example liquid absorption.

Produce multi-component precursor material for manufacture of fibrous materials with advantageous shock absorption characteristics such as for example damping.

Produce multi-component precursor material for manufacture of fibrous materials with advantageous thermal insulation characteristics such as for example reduced heat flow.

Produce multi-component precursor material for manufacture of fibrous materials as a viable solution for recycling fibre reinforced materials.

Summary of the Present Invention

According to the present invention, there is provided a method of a mechanical thermally controlled pulping of textile reinforced polymeric material which simultaneously fragments the polymers and separates them from their textile reinforcing elements and at the same time enables simultaneous preparation of the separated textile reinforcing elements into a commercially useful state as multi-component material being reinforced with devulcanised rubber, including:

a means for producing precursor material for manufacture of fibrous non- woven materials;

a means for producing precursor material for manufacture of fibrous woven materials;

a means for producing precursor material for manufacture of fibrous materials with advantageous surface characteristics such as for example surface roughness; a means for producing precursor material for manufacture of fibrous materials with advantageous phase change characteristics such as for example liquid absorption;

a means for producing precursor material for manufacture of fibrous materials with advantageous shock absorption characteristics such as for example damping;

a means for producing precursor material for manufacture of fibrous materials with advantageous acoustic damping characteristics such as for example sound absorption;

a means for producing precursor material for manufacture of fibrous materials with advantageous thermal insulation characteristics such as for example reduced heat flow; and

a means for producing precursor material for manufacture of fibrous materials as a viable solution for recycling fibre reinforced materials;

where in use, a device employing the mechanical action of pulping textile reinforced polymeric material via pulverisation is utilised in a thermally controlled method which simultaneously fragments the polymers and separates them from their textile reinforcing elements and also at the same time enables simultaneous preparation of the separated textile reinforcing elements into a commercially useful state as multi-component material being reinforced with devulcanised rubber.

Brief Description of the Figures Figure 1 is a scanning electron microscope view of a resultant pulverised fibre with consequential roughened surface together with adhered devulcanised rubber material (magnification x 1.79).

Figure 2 is a scanning electron microscope view of a resultant pulverised fibre with consequential roughened surface together with adhered devulcanised rubber material (magnification x 2.04). Figure 3 is a scanning electron microscope view of a resultant pulverised fibre with consequential roughened surface together with adhered devulcanised rubber material (magnification x 2.12). Figure 4 is a scanning electron microscope view of a resultant pulverised fibre with consequential roughened surface together with adhered devulcanised rubber material (magnification x 2.64).