Carpet waste composite

Abstract

A composite material produced from carpet waste and a binding agent, in intimate association, which material includes 25% and 99% carpet waste and between 1 and 25% binding agent. A method for manufacturing the composite material is also disclosed.

Description

DESCRIPTION OF DRAWINGS

FIG. 1 is a flow chart depicting the types of size reduction equipment and the variety of size reduction procedures depending on the final carpet waste material form required for the process equipment.

FIG. 2 depicts steps for coating the carpet waste material with the bonding agent and subsequent forming process.

FIG. 3 depicts steps for finishing the composite board product.

Claims

1. A composite material comprising carpet waste and a binding agent in intimate association, said material comprising between 25% and 99% carpet waste and between 1 and 25% binding agent.

2. The composite material of claim 1 wherein the sum of the carpet waste and the binding agent are between 50% and 99% of the total material.

3. The composite material of claim 1 wherein the material comprises from 0-50% natural fibers.

4. The composite material of claim 1 wherein the material comprises from 0-50% man made fiber fibers.

5. The composite material of claim 1 further comprising oriented fiberglass.

6. The composite material of claim 1 further comprising at least one inorganic filler.

7. The composite material of claim 6 wherein the inorganic filler comprises calcium carbonate, silica or both.

8. The composite material of claim 1, wherein the carpet waste includes all carpet components substantially without segregation from one another.

9. The composite material of claim 8, wherein the carpet waste comprises carpet backing in an amount equal to at least 10% of the composite material, by weight.

10. The composite material of claim 1, wherein the carpet waste comprises at least two different carpet face polymers.

11. The composite material of claim 10, wherein the carpet face polymers include one or more of: nylon, polyester, polypropylene and wool.

12. The composite material of claim 1 in which the binding agent comprises one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF).

13. The material of claim 12 in which the binding agent is MDI.

14. The composite material of claim 1, wherein the modulus of elasticity of the composite material is at least 55000 PSI by ASTM test D790.

15. The composite material of claim 1, wherein the modulus of elasticity of the composite material is at least 100,000 PSI by ASTM test D790.

16. The composite material of claim 1, wherein the modulus of rupture of the composite material is at least 600 PSI by ASTM D790.

17. The composite material of claim 1 or claim 14, wherein the modulus of rupture of the composite material is between 1000 and 2500 PSI by ASTM D790.

18. The composite material of claim 1, wherein density of the composite material is at least 30 pounds per ft3.

19. The composite material of claim 18, wherein density of the composite material is from 40-80 pounds per ft3.

20. A method of manufacturing a composite material comprising a) providing carpet waste;b) preparing the carpet waste by subjecting it to size-reduction treatment;c) combining the size-reduced carpet waste with a binder;d) subjecting the binder/carpet waste combination to pressure and elevated temperature in a confined geometry to produce a composite structure comprising carpet waste and a binding agent in intimate association, said material comprising between 25% and 99% carpet waste and between 1 and 25% binding agent.

21. The method of claim 20 in which step b) comprises one or more of the following processes: chopping; shredding; grinding; contaminant separating, palletizing agglomerating, pulverizing; fine grinding and fiberizing the carpet waste.

22. The method of claim 21 in which the carpet waste granules are subjected to spinning and are forced under pressure through orifices sized and configured to densify the material.

23. The method of claim 20 in which the carpet waste and binder are combined in a drum to coat the waste with binder.

24. The method of claim 20 the binder is MDI and the carpet waste and MDI are combined in a drum.

25. The method of claim 20 in which the binder/carpet waste combination is subjected to heat and pressure in a continuous belted press or in a stationary press.

26. The method of claim 20 further comprising applying a further layer to a surface of the composite sheet of step e).

27. The composite material of claim 1 further comprising a further layer on the surface.

28. The method of claim 26 or the composite material of claim 27 in which the further layer is a laminated layer or a foil-transfer layer.

29. The method of claim 26 or the composite material of claim 27 in which the further layer is a paint, a stain or a polymeric compound.

30. The method of claim 26 or the composite material of claim 27 in which the further layer is molded or embossed to create a patterned surface on the composite material.

31. The method of claim 26 or the composite material of claim 27 in which the further layer is a wood veneer, a synthetic veneer, or a polymeric sheet.

32. The method of claim 26 or the or the composite material of claim 27 in which the further layer is a foil or film laminate.

33. The method of claim 26 further comprising preparing a surface of the composite material and subjecting a surface of the material to mechanical or chemical preparation, followed by foil or film lamination of the further layer.

34. The method of claim 26 or the or the composite material of claim 27 in which the further layer is a hot-stamped layer.

35. The method of claim 26 or the or the composite material of claim 27 in which the composite material is thermoformed into a desired shape.

36. The method of claim 26 or the or the composite material of claim 27 in which the further layer is a foil or film laminate.

37. The method of claim 26 or the or the composite material of claim 27 in which at least one layer of the composite material is sanded.