CA2637244C

CA2637244C - Carpet waste composite

Info

Publication number: CA2637244C
Application number: CA2637244A
Authority: CA
Inventors: Douglas Mancosh; James Przybylinski; David E. Murdock
Original assignee: MATERIAL INNOVATIONS LLC
Current assignee: MATERIAL INNOVATIONS LLC
Priority date: 2006-01-20
Filing date: 2007-01-11
Publication date: 2016-08-23
Anticipated expiration: 2027-01-11
Also published as: US7923477B2; CA2933740A1; US20080064794A1; US20110097552A1; US10294666B2; WO2007084822A2; US20070173551A1; US8455558B2; US8278365B2; US20210254336A1; US7875655B2; CA2933740C; US20150024171A1; TW200738456A; CN101405318A; CA2637244A1; US20170260746A1; US20130102707A1; US20110229691A1; CN101405318B

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

CARPET WASTE COMPOSITE
BACKGROUND
The general field of this invention is natural and manmade fiber composites which are used in various industrial and consumer applications.
Natural and manmade fiber composites can be used in building construction, industrial applications, consumer goods, automotive products, and other industries requiring moisture or thermal resistance with various physical properties, such as low moisture absorbance and low thermal distortion. The ability to build composites of this nature, while controlling physical properties such as strength, stiffness, ductility, impact resistance, and hardness, opens a variety of application opportunities.
Additionally, there is growing pressure to re-utilize waste streams which are high in volume and low in degradability. In particular the manufacture, installation, use and (eventually) replacement of floor covering products, especially carpeting, produces a large amount of waste product. Carpet waste from new carpet production, post-consumer landfill or other used carpet applications is a several billion pound-per-year waste problem. The industry generally uses the term "selvedge" for waste material generated during the manufacturing process while other forms of manufacturing and installation waste are sometimes termed "scrap". We use the term carpet waste to cover all types of waste produced by the manufacture, installation, use and replacement of floor covering products.
Often, carpet waste is not recycled, but rather is disposed of by land-filling or burning.
SUMMARY
We have discovered a composite material produced from carpet waste and a binding agent.
The first aspect of this invention is a process for converting carpet waste with or without additional fibers and/or fillers and combining it with binding agents to produce a composite material. More specifically the invention is its general form features a composite material comprising carpet waste and a binding agent in intimate association, where the composite material includes between 25% and 99% carpet waste and between 1 and 25%
binding agent.
In accordance with one aspect of the invention, there is provided a composite material comprising: carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties;
an added inorganic filler; and a binding agent in intimate association, the composite material comprising between 25% and 99% carpet waste and between 1% and 25% binding agent, wherein (i) the binding agent comprises one or more of methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and (ii) the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.
Preferably, the sum of the carpet waste and the binding agent are between 50%
and 99% of the total material, and the composite material also includes from 0-50%
natural fibers or manmade fiber fibers (such as oriented fiberglass), or a combination of manmade and natural fibers. The composite material may also include at least one inorganic filler such as calcium carbonate or silica. Additionally, the composite material may also include special additives that result in favorable physical property attributes. Flame retardants and/or mold inhibitors an be added at levels of 0-25% (preferably levels of 0-10%) of the total material.
Flame retardants that could be used, but are no limited to, are Occidental's Dechlorane Plus, Ferro's Pyrochek 68PB, and Great Lakes P0-64P. The flame retardants may or may not also require a Sb302 synergizer to be used. Mold Inhibitors that could be used at the same levels, include but are no limited to, are Zinc Borate and Rohm & Haas Vinyzene mold inhibitor.
Scientifically, the carpet waste includes all carpet components substantially without segregation from one another. For example, the carpet waste comprises carpet backing in an amount equal to at least 10% (by weight) of the composite material and/or it comprises carpet face polymers, such as nylon, polyester, polypropylene and wool.
Also preferably, the modulus of elasticity of the composite material is at least 55,000 PSI by ASTEM test D790, more preferably at least 100,000 PSI by ASTEM test D790.
Preferably the modulus of rupture of the composite material is at least 600 PSI by ASTM

2 D790, more preferably between 1000 and 2500 PSI by ASTEM D790. Preferably the density of the composite material is at least 30 pounds per ft3.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of:
methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and d) subjecting the carpet waste, inorganic filler and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25%
and 99% carpet waste and between 1% and 25% binding agent, wherein the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.
Preferably the size reduction step comprises one or more of the following processes:
chopping; shredding; grinding; contaminant separating; palletizing;
agglomerating;
pulverizing; fine grinding; and/or fiberizing the carpet waste. (For example, the carpet waste and configured to densify the material.) The size-reduced carpet waste and binder are combined in a drum to coast the waste with binder. The binder/carpet waste combination is subjected to heat and pressure in a continuous belted press or in a stationary press.
Optionally, a further layer is applied to a surface of the composite sheet thus manufactured, for example, the further layer is a laminated layer or a foil-transfer layer, or the further layer is a paint, a stain or a polymeric compound. The further layer may be molded or embossed to create a patterned surface on the composite material.
Optionally, the further layer may be a wood veneer, a synthetic veneer, and/or a polymeric sheet. The surface of the composite material is prepared by means of mechanical or chemical methods,

3 followed by foil or film lamination of the further layer. The further layer may include a hot-stamped layer.
The composite material thus formed maybe thermoformed into a desired shape.
The further layers may be a foil or film laminate.
At least one layer of the composite material may be sanded.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25%
and 99% carpet waste and between 1% and 25% binding agent; and e) applying a layer to a surface of the composite material, wherein the layer is molded or embossed to create a patterned surface on the composite material.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler , and binding agent in intimate association, the composite material comprising between 25%
and 99% carpet waste and between 1% and 25% binding agent; and e) applying a layer to a surface of the composite material, wherein the layer comprises a foil or film laminate.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing the 3a carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25%
and 99% carpet waste and between 1% and 25% binding agent; e) preparing the surface of the composite material and subjecting the surface of the composite material to mechanical or chemical preparation; and applying a layer to a surface of the composite material, wherein the layer comprises a foil or film laminate.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25%
and 99% carpet waste and between 1% and 25% binding agent; and e) applying a layer to a surface of the composite material, wherein the layer comprises a hot-stamped layer.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, 3b and binding agent in intimate association, the composite material comprising between 25%
and 99% carpet waste and between 1% and 25% binding agent; and e) applying a layer to a surface of the composite material, wherein at least one of the layer and the surface is sanded.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment comprising one or more of: chopping; shredding; grinding; contaminant separating; pelletizing;
agglomerating;
pulverizing; fine grinding; and fiberizing; and spinning and forcing the carpet waste under pressure through orifices sized and configured to densify the size-reduced carpet waste; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25% and 99% carpet waste and between 1% and 25% binding agent.
In accordance with another aspect of the invention, there is provided a composite material comprising: carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added inorganic filler; a binding agent in intimate association with the carpet waste, wherein the binding agent comprises one or more of methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF);
and a layer on a surface of the composite material, wherein (i) the layer is molded or embossed to create a patterned surface on the composite material, (ii) the composite material comprises between 25% and 99% carpet waste and between 1% and 25% binding agent, and (iii) the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.
In accordance with another aspect of the invention, there is provided a composite material comprising: carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added 3c inorganic filler; a binding agent in intimate association with the carpet waste, wherein the binding agent comprises one or more of methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF);
and a layer on a surface of the composite material, wherein (i) the layer comprises a foil or film laminate, (ii) the composite material comprises between 25% and 99%
carpet waste and between 1% and 25% binding agent, and (iii) the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.
In accordance with another aspect of the invention, there is provided a composite material comprising: carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added inorganic filler; a binding agent in intimate association with the carpet waste, wherein the binding agent comprises one or more of methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF);
and a layer on a surface of the composite material, wherein (i) the layer comprises a hot-stamped layer, (ii) the composite material comprises between 25% and 99%
carpet waste and between 1% and 25% binding agent, and (iii) the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.
In accordance with another aspect of the invention, there is provided a composite material comprising: carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added inorganic filler; a binding agent in intimate association with the carpet waste, wherein the binding agent comprises one or more of methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF);
and a layer on a surface of the composite material, wherein (i) at least one of the layer and the surface is sanded, (ii) the composite material comprises between 25% and 99% carpet waste and between 1% and 25% binding agent; and (iii) the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.
In accordance with another aspect of the invention, there is provided a composite adapted for use as a building material, the composite comprising: processed carpet waste, wherein the processed carpet waste comprises (i) a reduced amount of inorganic filler present 3d within an unprocessed carpet waste; and (ii) a melted polypropylene and an unmelted nylon;
an added inorganic filler; and between about 2% and about 10% binding agent by weight of the composite.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite adapted for use as a building material, the method comprising the steps of: applying heat and pressure to a processed carpet waste, an added inorganic filler, and a binding agent to form the composite at a temperature and for a time period sufficient to melt a plurality of materials comprising the processed carpet waste; and cooling the composite while applying pressure to the composite.
In accordance with another aspect of the invention, there is provided a method of manufacturing a composite adapted for use as a building material, the method comprising the steps of: applying heat and pressure to a processed carpet waste, an added inorganic filler, and a binding agent to form the composite material; and cooling the composite material while applying pressure to the composite material; wherein the step of applying heat and pressure occurs in a first cycle press, and wherein the step of cooling the composite while applying pressure occurs in a second cycle press.
In accordance with another aspect of invention, there is provided a method of manufacturing a composite adapted for use as a building material, the method comprising the steps of: processing a carpet waste to obtain a processed carpet waste;
applying heat and pressure to the processed carpet waste, an added inorganic filler, and a binding agent to form the composite; and actively cooling the composite while applying pressure to the composite, wherein the composite is cooled under pressure for a time period and to a reduced temperature sufficient to reduce warping of the composite.
In accordance with another aspect of invention, there is provided a composite building material comprising: a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste; and a binding agent in intimate association with the processed carpet waste.
3e In accordance with another aspect of invention, there is provided a method of producing a composite building material, the method comprising the steps of:
providing a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste; mixing the processed carpet waste with a binding agent to produce a carpet waste mixture; and heating and pressing the carpet waste mixture to form the composite building material.
In accordance with another aspect of invention, there is provided a composite building material comprising: a carpet waste; an inorganic filler in addition to any filler present within the carpet waste and any synthetic fiber filler; and a binding agent in intimate association with the carpet waste and the inorganic filler.
In accordance with another aspect of invention, there is provided a method of producing a composite building material, the method comprising the steps of:
providing a carpet waste; providing an inorganic filler, wherein the inorganic filler is in addition to any filler present within the carpet waste and any synthetic fiber filler; mixing the carpet waste and the inorganic filler with a binding agent to produce a carpet waste mixture;
and heating and pressing the carpet waste mixture to form the composite building material.
In accordance with another aspect of invention, there is provided a composite building material comprising: a sheet having a first exterior surface and a second exterior surface defining a thickness, the sheet comprising a substantially homogeneous mixture from the first surface across the thickness to the second surface, the sheet comprising: a carpet waste; an added inorganic filler; and a binding agent in intimate association with the carpet waste and the added inorganic filler, wherein at least one of the first exterior surface and the second exterior surface comprises at least one surface feature selected from the group consisting of a molded patterned surface, an embossed patterned surface, and a hot-stamped layer.
In accordance with another aspect of invention, there is provided a method of producing a composite building material, the method comprising: providing a carpet waste;
providing an inorganic filler; mixing the carpet waste and the inorganic filler with a binding agent to produce a carpet waste mixture; and heating and pressing the carpet waste mixture to 3f form the composite building material comprising a sheet having a first exterior surface and a second exterior surface defining a thickness, the sheet comprising a substantially homogeneous mixture from the first surface across the thickness to the second surface, wherein at least one of the first exterior surface and the second exterior surface comprises at least one surface feature selected from the group consisting of a molded patterned surface, an embossed patterned surface, and a hot-stamped layer.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
Fig. 1 is 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.
3g DETAILED DESCRIPT/ON
A. generic coniposition of the carpet :waste-product prodoced by the invention Niat:erial.DeSeri,ption Per .cent of material in composition Carpet: Waste. 25%-- 00%
Binding Agents 25%
Wood or. nattiral ..fibers,..$yhthetic fibers;
Inorganic Hers., Reinforcing fillers.
Flame Retardants 1.5 MOld Inhibitors 0%.- 2.5%
There.oN two .bitSiØ $ttP$ in the production:.of 'composite matetial...frOm.
Carpet waSte, 20FgshoWs the types ö.equipinea.and the variety Of proceduresde.pending on the final formreqiiired filr the Process. Equipment. The .final. limn may :also be dependent on the .desired finishedeothpotiite:prOduet and physiettl properties tö beattaineki th the proeeSS.
FirSt,.:the carpet waste iS.proe.es.sed as deseribed below th rt...duce its size, Thert::the .size,reduce.d carpet sv4SIV isMiX:ea with a binder to producematerial that is subjected to 25. temperature::ahdlor presS tireõ by a...panel/shed% o aid process,. to yìeld. eorpposite material.
Below we describe both.Steps in cletail. We then describe post-mantifacture treat-items lbr. the composite:material.
carpet Waste Size Reduction The carpet µAtaste isMade 'UP of selvedge,. post-industrial earpetwaste, post-consuma. w.aste 3t. carpet, or waste .earpet. recianned from landfills. These materials, Will he in baled form to begin the sizeredoetiOnphaseof the pTe-procosing, The Wes: y4ry in :si..4e .bot usually represent about 1000.11). to .2000 The first .step is to rednee the Wage to a manageable size.for.the rosteltheptoetss.
Either acc.,)mhination of 4 shreddertehopper and..grinder,:or, a.risajor capacity .grintier is :used 35.
to:process.the .materials to smalla: sizes. Thethreddedehopper svill reduce:
the .selvedge or carpet. t.x'aste to Chunks .approximately three.ineh.es Square (3"
The.Shr Oda-xi material then passes.through a .giiiider ss, hi h. further reduces .the.::ckinni,,-s fiber than/aerial wi a

4 diameter of the fibers similar to the (lin-inter of the original carpet fibers and a lenzth of about 4" to I ".
The waste optionally can be run through a separator which acts as a hammer tnilUcyclone to remove the dirt from the carpet waste. In this step some of the carpet backing containing inorganic fillers may also be removed. The slightly size reduced material, due to the hammer mill effect, is ready 'for the next step, the agglomeration process. The dirt and. carpet basking materials that have been removed from the small chunks are then disposed:
The fiber fluff, regardless of the use of the separator or not, optionally can be blended with other materials such as wood or natural fibers, synthetic fibers (i.e. fiberglass), inorganic fillers, other reinforcing fillers, flame retardants and mold inhibitors. The fiber fluff material or the blended material is then. conveyed to the agglomeration step.
The agglomeration of the above materials occurs inside the agglomerator. The materials enter a horizontal drum containing a revolving rotor. The rotor is shaped so as to force the fiber fluff or blends against the drum wall. The drum wall is pertbratal so that, as the rotor forces the contained materials against the perforated wall., the material is forced through the perforations fomiing strands of a fixed diameter. Oivthe outside of the drum are stationary knives which cut the strands into a fixed length. During this process the material is. heated by friction to a temperature that remains below the melting point of the. highest melting point material in the blend., The temperature is controlled by the speed of the rOtor, 26 the diameter of the perforations, and the thickness of the drum wall.
The granules that are formed in the agglomeration step are cylindrical in shape and approximately 1/8 inch in diameter and. 1/8 to 'A inch long. The diameter and length of the granules can be changed by changing the diameter of the holes in the drum wall and/or changing the speed of the knives rotation. Because the granules are hot when they are formed and cut to length som.e ofthe granules are stuck to one. -another.
Therefore., for better Size consistency, the pinnies next pass through a grinder which breaks the granules away from each other. This grinder step may also be used to reduce the size of the granules.
The granules may be. further reduced in size by a pulverizer. If the final desired dimension is less than 1/8 inch the pulverizer is used to reduce the particle size to 8-16 36 mesh. 'This is the equivalent of 0.04 inch to 0,10 inch.
()lie last optional step may now be performed, to fiberize the granules or the pulverized particles. The fiberizing is a mechanical roughing of the surface so that the

5 surfaee takes on a "fuzz." like characteristic. This can be an important final preparation for the composite product process described below in the Process Description. The material, whether granule or pulverized particle, whether fiberized or not, is now sent cin to the composite production process.
An alternative method for initial size reduction is to use a major capacity grinder :NW& reduces the carpet waste to -fibers approximately 'A inc.h to 1 inch in length arid approximately 1/32 inch to 1/8 inch in diameter. These random sized fibers are ready for the agglomeration process or for alternative actions not requiring aulomeration.
Regardless of the process direction, the next step is to pass the material through a separator. This is the same equipment and effect as described above. As above, this is an -16 o.ptional step in the material preparation phase being described here.
The fibers may now go through the agglomeration process in the exact same manner as described above, or the fibers may pass directly to the fiberizer equipment Again the fiberizer acts to change the surface characteristics of the fibers giving them a "fuzz" surface with greater surface area and a different bulk density. The fiber-I:zing step may not be required for all end uses of -the composite products.
Whether the fibers :have been tiberized or not, they will pass through a blender where wood or natural fibers, synthetic fibers (i.e. fiberglass), inorganic fillers, mineral fillers (if any), flame retardants, and mold inhibit-ors may be added. Once the blending of the fibers and added materials is complete, the blend is ready for the composite product Process.
The composite product compoSition is controlled by controlling the above steps.
Sigfificantly, it typically is not necessary to separate or classic), the various materials contained in selvedge or carpet waste. Most carpet surface materials are nylons, polyester, polypropylene, or wool. The backing material is usually polypropylene and/or highly filled aa -synthetic. latex. These materials exhibit considerably different physical properties and processing properties. The entire waste product may be used regardless of the differences in the materials. However, if desired, the carpet waste can be separated by face fiber type -and.
processed, For example, a panel -can be made of 100% Nylon -6 face fiber carpet waste. A
panel can also be made by blending different face fiber carpet waste together at a. controlled aa ratio of each type to create a panel. For example, a panel could be made of 50% Polyester face fiber carpet waste and 50% Polypropylene face fiber carpet waste.

6 The -waste carpet, having been made into an agglomerate, a fiberized agglommte, a pulverized agglomerate, or a fiberizal, pulverized agglomerate, becomes the base material for the composite product. Waste fiber or fiberized waste fiber may also be used to Manufacture a composite product. The whole range of materials in carpet waste may be part of the composition.
The other major part of the coMposition is a binding -agent. The binding.
function can be aecomplished using methylenediphenyldiisoeyanate (MDT), urea formaldehyde (H), MelaritirIC urea formaldehyde (MIN), phenol formaldehyde (p) or a combination thereof Other binders may be used depending on factors such as compatibility, cost and environmental issues. The binding agent acts .as a glue for the fibers or agglomerated materials to give -the basis -air the composite products. The ratio of the "binding agent to the fibers or particles is a determinant in the physical properties attained in the Process.
Further, the physical propertiesare modified by the use of wood and natural fibers, synthetic fibers, inorganic fillers, reinforcing fillers, flame retardants and mold inhibitors.
The binding agent and carpet waste materials -comprise at least 50% of the composition and may make up 100% of the final product. The binding agent content is between and 25% iCtlAing the remainder of the material to be carpet waste and added materials. The added materials, wood and natural fibers, synthetic fibers, inorganic fillets, reinforcing tillers,. flame retardants, and mold inhibitors may make up to 50%
of the total composition. However, the basic material is usually a 9:1 ratio of carpet waste to binding 26 agent with any added materials being around 25% of the carpet wastaibinding agent content.
In summary, the composition of carpet waste and binding agent (with or without additive materials) can be used to make a wide range of composite products.
The carpet waste includes all of the carpet product including all the different- types of face fibers and the carpet backing.
Coating the Carpet Waste Material with the Binding Agent The carpet waste material may have the form of granules (pellets or particles)., or of the fibrous waste material or fiberized versions of-the granules or fibrous material. The carpet waste materials are generally loaded into a large rotating drum or a drum With 35- rotating mixing blades or a resination blow line. Other -materials such as natural fiber fillers, inorganic fillers, flame retardants, and mold inhibitors may be loaded with the carpet waste material. If the material is loaded into a drum, then water and/or a binding 'agent are

7 sprayed out of the head inside of the drum to thoroughly coat the materials.
While the drum andfor blad.es are spinning and causing the-material held within to become evenly distributed, the spray head is releasing a fine mist of water or binding agent. This results in a thoroughly coated material. Water is usually sprayed into the: drum to achieve a desired moisture content for the material and prepare the material for the binding agent. The binding agent is usually sprayed after the water to. make sure that it reacts and thoroughly coats the material in the drum. For the resination blow line method, the material is blown throug,,h a tube that has Water and binding agent-introduced into it. The blowing action cause the air to become turbulent which allows the water and binding agent to evenly coat the material. The binding agent is applied in this. manner to the granules or fibers at a is concentration of I% to 25% of the total weight of the granules-plus any other additives.
(Throughout the description, the terms granules or fibers CM include additives in addition to the carpet waste.) The binding agent. adheres to the granules and fibers, giving each granule or fiber a binding agent surface coating. The binding agent dries rapidly under ambient conditions, allowing the granules or fibers to continue-to flow without adhering to one another. The granules or fibers with the binding agent coating then pass-on to the next step in the-process which is the preparation of the carpet. waste composite material for the Board.
Preparing for the Board Forming Process The binding agent coated composite material is conveyed to the Mat Forming Station which includes conveyors, metering scales, spreader heads and a control management system. The mat forming station employs spreading equipment to distribute the composite material onto a forming belt so that the spread material becomes a mat which has a uniform thickness, width and density. Board properties are mainly determined by the shape of the carpet waste composite particles/fibers and bytheir position in the formed MAL
For this reason the spreading equipment is finely-tuned to product the proper shape and size of the mat. The Forming station can distribute more than one type of material for a multi-layered board. For example, the spre,ader head in the forming station coulki spread a mat of fibers on the forming belt, then a second spreader bead could spread a mat of pellets on top of the fibers, then a third spread head could spread a top layer of fibers onto the pellets.
Many different combinations of materials can be spread onto the forming belt to make various types of boards. The number of layers per board can be varied also.
For example,

8 Ward cohld 17.)eiliaptifaagred to have CV fther.Skins 4nd tufffrerOass.. core or a board .could bemanuractured to have CW.pellet skins, CW:fiberunderlayets and a CNN' pellet care.
A.fterthernat is spread :formed, therm/ming belt theri 'transports then-tat:into the.pre-heater.
or.:directlyitlto .a Pre-Press. The .pre-heater continuously .transft,Ts thernatand subjects the.
c..'ompostte material to mierowaves orinjeets hot air.andiorsteam into.thernat before it o enters :the Board :Forming process, The teinpurature of blot is. 40/m.0d from...about.65.7F
t.o.about 20Ø'17 before entering the .board forming process. This :rapid .heat transfer to die carpet waStel is' accomplished.by microwaves or by the injection of a steainfait mix (mast . air) alternately from either surface into the tmat. The. steam :condenses ths process, transferring the heat into. the. mat Thepre-heater may :also pre-presS. or conipress. the.
'15 Material before it enters the .'.:board %fining process. The heated mat:is:then tram4ffedby an intermediate 'belt conveyor tp.tbe:corapre.ssion section of the itifeed..end of a eohtinuous:
fell press or into.'a .eycle press.. which is the ...beginning fthe board,forming.. process.
If acyCle. Or :Stationary press is .used.. instead of:a continuous. roll pre.s.s,. theh. pre-:heating of the .mat is.. usually skipped and steam injection .may be AISCd during the sheeting:
process n thc eyck.press or the steam injeetion can be .skipped..
The Board FOnhingproct.'ss. employs a Cycle:Press or C.ontinuous Roll. Press:.
.Both.
types of equipment .u.se. Rre.,$swe and temperature to fortha board, ..panel or sheet limn the Carpet Waste..C'otroositelgaterial. that is coated with a 'binding :agent:
The. Cycle presa.rnay 'have single of inulti4laYlight openings. The .comNsite.
25 material is transferred into the cyelepress where it is:sabjected.to temperature ..and pressure from::a top .and 'bottorn platen that condenseStheinat to a determined hcìght atid .allows the binding agcnt..reaction. to take placebandingtheniat together to forni.a:Boa.ni. 'The :mat :Tnay have..stearn injected through it. vhìe :in theeyele presstoensure a thorough heating and bonding Of the composite matetial.. The ..platens may have a pattern engraved into them to.
.give the.boards..surface:a. structured. pattcni. The..Cyclepre.ss ma.y also use a cooling .cycle to ..reduce the temp.eratureof the board before it exits the press:
Carpet Waste: tottipoSite boards have been rhanufactuml using a. cycle press.
The operat.ing conditions.and...%.....ttings ,tr.e shown in chart l. attached ret , The.continuousloll.press is A double ..belted press .Capable of Maintaining a..range.of as. temperatures and pressures on the. Mat to allow the..bincling.ageht reaction to take binding the:I/lat.:together. `rhepreferred type. of belt:tbr the .continuous roll press is made of steel but other materials :may be used. The press has the :capability of fondling temperatures.
g:

= of 5F 1.0 .5.50*.F. to aliow the heat. to .transfer throughout the mat, Siatilarly. varying pressures are use to squeeze .the granule layer Or the fiber mat to the desired thickness ,and density:of the final produet.
The continuous :roll press consists of a press .strueture.which takt;%:up. the :horizontal forceS resulting from the. belt .tensioning.. There are any frame :units:
%hose:number 714) depends on.thelength.of the:press and .pressure that is :needed..
Cylinders are used.fin. the :exertion Of pressure :arranged ..at the frame units in. variouseombinations, a.eertain number of.which are suitable :for opening. the press; There are top .and bottom heated platens which The roller rods and belts travel. over. The presshas on infeedheadio vide the :roller rods, belts and mat to be pressed. The .roller rods:: are .located between the heated platens and the beitS Menial IS lotatal betWeenthe to bts odrums :are .100ted at cad end Of the press for the belts to travel ...tround. Drum scrapers are used to. keep the mat between the belts: A release .aRetainay bosprayed.onto the.belts to keep:thernitt .froin Sticking to the belts :and exit .the press. A control system regulates the operation tif the press such as the speed ofthe belts,. temperature, pressure, thickness of the mat, etc.
20 The co/Ai:Trams. toll press transfers heat to the binding agent-coated COmivsite Material, The heat activates the hiding agent coating or materials. Which are then pressed ...to a lesser thiCkness by tho.eontinuouslymovinibelts.
As.:60.material names betWeeti the beltS through the infeed .SeetiOn., the -thickness dimension is reduced as well AS
.eputibually heated The temperature of. the bilidi:Og.agt.Tit-coeted granules or Me :binding 25. agent-OEUCd:liberS:.is. Inaintairm4:.above the activation.
4.,.triperaturo of the binding agent.
Under the pressure :oftheplatenS Which are Set at a: predetomined height,: the gratitlaS or fiber$: adhere: to each other fmaing a continuous. Sheet prodUct, This :final thickness determines the.density:i)fthe material as well.: The .density is determined by the initial thickness oldie tin-bondtx1 mat entering the continuouspress and the lin&
thickness as. the 30. uewly -firmed. composite: product ailing the press.
lf the temperature :Of thecontinuotts press belts or 'stationary press tens are heated pp: to C or abOve, o thitibut. dense outer siri can be fOrtned in the panel. This otttO
.skin can. help improve physical properties in thapanel, welt as the inoduihis 0:plasticity (MOE) and themodolus ofrupture(MOR).
After the mat hits :been heated an pressed to the desired height and density in continuous press a. cooling section maybe employed to e061 the panel 'before it exits the cohtinuous.ptess: Due to the:mature:if the polynter.materi als being press ed,.cooling the to panel in the .press taRier pressure helps maintain. hoard flatness and avoid Warping. The panel is generally cooled to at least 120 'C before exiting the continuous press. A.
Stationary Press -may also tise a cooling cycle to cool the hoard before it exits the stationary press. Elowever,. this additional coolMg time creates a longer cycle tirne to create a panel.
So, a secondary stationary press may employed for cooling only. For example, a panel may lo be formed under heat and pressure in the first press, then transferred to a second stationary press to be cooled. A panel may be fomied in either type of press .and cooled in a secondary process after it exits the press.
The Board Finishing Process After the binding of the material and desired height dimension of the mat has 'be=
reached in a continuous roll press, a Board is formed which is in the shape of a continuous ribbon. 'When the ribbon. exits the press it undergoes a continuous edge trimming operation to reach the desirell width and then it is cross-cut to a pre-selected length.
The ribbon is transported through the trimming and cross-cutting operations by a roller conveyor and pinch rollers. The board that has been cut to a predetermined width and length is then transported to a cooling station. The cooling station can employ a variety of different machines such as a Star Cooler with subsequent stacking or a stacking roller conveyor. One of the most common types is the star cooler with subsequent stacking, The Star Cooler is a large diameter wheel with multiple rows of spoked arms extending from the wheel. The arms lift each Board from the conveyor and allow the Boards to rotate with the wheel and be air cooled. lf needed, the continuous roll press can have a cooling section near the exit.
This will cool the board before it exits the press eliminating the rimi ibr further cooling.
The. Board is then conveyed to a stacking operation and stored for future MC.
The Boards are TIOW ready to be shipped or they can go through a variety of decorating alternatives.
In a cycle press, the board can be manufactured to finished size or slightly oversized.
If it is oversized, then Alt cut to -finish dimensions after-it exits th.e press. The Platens in the cycle press can have a patterned surface to give the board a structured surface such BS a -wood grain pattern.
Decorating the Composite Product As the comrx}site product exits the Process as described above, it may be of varying thicknesses from less than 1/8 inch up to 2 inches. Since the last step in the Process is the cutting. to length of the composite product, the tirst step in finishing the product is cutting to final width. Figure 3 shows the finishing and decorating steps that May he employed following cutting to final width.
The composite product can. now be molded to change the profile to take on the Shape required in the finished product. The molding is done on a cutting machine of different io designs. The most common of which is the rotating knives device. This machine allows for the setting of the knife bladt.s to adjust the cut to the desired profile.
Another common device is the router which cuts a specific. groove or peeves (routs) into thesurface of the composite product The router has the same effect as the molder in that it changes the initial profile out of the Process into the -desired profile required for the. final product.
The prOfile may alSo be changed using thermolonning methods. In this ease the composite product is placed in a mold of the desired profile and with heat and pressure the product takes on the shape of the mold. This profile change-01.1bn an -additional decorating capability in that the desimd color andlor pattern may be on a transfer .foil placed in the mold. With the application of the heat and pressure during the process, the color -and/or ;.?0 pattern are. transferred from the carrier foil to the composite product.
Thus at the end of the them-noibrming process, the composite product has the desired profile and also the desired decoration.
The composite product may be embossed after the Process. The embossing is aceoinplished with an embossing plate or roll. The plate or roll has the pattan to be 25 transferred to the product on the surface of the plate or roll. 'rills surface is heated to a temperature that will --soften the surface of the compositeprodoct.. Then the plate or roll is pressed on to the surface of the product to give the desired pattern transfer.
As the surface of the -composite product cools, the embossed pattern becomes fixed on the surface of the composite product. The embossed composite product is now ready to be coated;
or if no 30 mating is required for the end-use product, it is ready fir paekaging.
All composite products that will be -decorated pass through the sander the equipment described above). This smoothing of the surface prepares the product for coating;, transfers, and. laminating.
The sanded or embossed composite product may be coated with primers, finish 36 paints, or stains. The ;application of the coatings employs the various, conventional spray techniques using exhaust systems to remove the excess spray and solvents.
Either penetrating or film-forming coatings are applicable, and the choice is dependent on the desired finished product appearance and application.
The sanded composite product can also act as a core to which decorative and protective layer(s) may be hot stamped from a foil or film or lamina led, to achieve the improved physical and visual enhancement over the current inventions.
The composite product may be decorated using transfer foils. Once again the product requires sanding to smooth the surface. An adhesive layer is applied to die profile using a conventional application technique. The transfer foil has the desired color and/or pattern on a polymeric substrate. The foil is brought into contact with the surface of the product using stamping equipment designed for the specific application. Using heat arid pressure the color and/or pattern are transferred from the foil to the product. The heat required for the transfer activates an adhesive layer on the surface of the profile ensuring bonding of the decoration to the profile. With the color and/or pattern now on the composite product, the spent foil is then collected for disposal; and the finished product has the desired decorated effect.
Another decorating method which may be employed is lamination. Several materials may be used as the laminate surface, such as, wood veneers, synthetic veneers, foils, films, and polymeric sheets.
The application of rigid laminates like wood veneers is done using conventional laminating equipment. Generally, an adhesive system (either a wet adhesive system or a hot-melt adhesive system) employing a primer and an adhesive is applied to the substrate. The rigid surface laminate is then laid on to the substrate and temperature and pressure are applied. After the temperature-pressure step the laminated product is then set for a fixed period of time to allow the adhesive system to cure. In tie case of the composite product, the composite product is the substrate. The adhesive system, usually a hot-melt adhesive, is applied to the composite product. The rigid veneer is the placed on the adhesive layer forming a sandwich of composite product, adhesive, and rigid laminate. The sandwich is then pressed to secure the bond of the laminate to the composite product. After curing the laminated product" with the desired decorative appearance is ready for packing, Another laminating technique used with the composite product is toil laminating. This technique can be referred to as wrapping wherein the composite product profile is wrapped in the decorative foil. After the composite product profile has been sanded the profile passes through a wrapping device. This device lakes the foil wrap from a coil then applies the adhesive (and primer, if required) to the foil. In a continuous process the foil wrap is then passed over the composite product profile. Using a series of rollers, the foil wrap is shaped to the composite product profile. The foil wrap may incorporate in addition to its decorative elements an integral topcoat material for physical property enhancement. This integrated element may be polyurethane, acrylic, or other protective materials. If, however, the foil wrap integrates only the decorative dements, then the wrapped composite product will require a topcoat for certain applications.
If the end-use product application requires significant surface property enhancements, such as abrasion resistance, a topcoat may be added to the decorating process.
The topcoat cars be polyurethane, acrylic, or other protective material that, will impart better physical properties to the surface of the wrapped finished product. The topcoat may be spray applied or hot melt applied. If spray applied, the wrapped composite product will pass through a spray applicator and then may or may not pass through a curing device such as ultra- violet radiation. If the topcoat is hot melt applied, then a layer of polyurethane is applied to flat surfaces of the decorated composite product. The cure process for this type of material is time dependent and could take several days depending on the hot melt topcoat chosen for a specific end-use application for the completed finished product.
A number of embodiments have been described. Nevertheless, it will be understood that various modifications may he made thereto. The invention, rather, is defined by the claims.

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Claims

WHAT IS CLAIMED IS:

1 . A composite building material comprising: a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste; and a binding agent in intimate association with the processed carpet waste.

2. The composite building material of claim 1, wherein the processed carpet waste comprises melted polypropylene fibers and unmelted polyester fibers.

3. The composite building material of claim 1, wherein the processed carpet waste comprises face fibers consisting essentially of a material selected from the group consisting of polyester, nylon, and polypropylene.

4. The composite building material of claim 1, further comprising an exposed patterned surface on at least a portion thereof, the exposed patterned surface comprising at least one of an embossed surface and a colored surface.

5. The composite building material of claim 1, further comprising a coating, the coating comprising a material selected from the group consisting of a primer, a paint, and a stain.

6. A method of producing a composite building material, the method comprising the steps of: providing a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste; mixing the processed carpet waste with a binding agent to produce a carpet waste mixture; and heating and pressing the carpet waste mixture to form the composite building material.

7. The method of claim 6, wherein the processed carpet waste comprises unmelted polyester fibers and melted polypropylene fibers.

8. The method of claim 6, wherein the processed carpet waste comprises face fibers consisting essentially of a material selected from the group consisting of polyester, nylon, and polypropylene.

9. The method of claim 6, further comprising forming a patterned surface on at least a portion of the composite building material, the patterned surface comprising at least one of an embossed surface and a colored surface.

10. The method of claim 6, further comprising applying a coating, the coating comprising a material selected from the group consisting of a primer, a paint, and a stain.

11. The method of claim 6, further comprising modifying a cross-sectional profile of the composite building material using at least one of thermoforming, embossing, and cutting.

12. The composite building material of claim 1, further comprising an additional inorganic filler relative to an amount present in the processed carpet waste.

13. The composite building material of claim 1, further comprising a natural fiber filler.

14. The method of claim 6, further comprising providing an additional inorganic filler relative to an amount present in the processed carpet waste , wherein the mixing step comprises mixing the processed carpet waste and the additional inorganic filler with the binding agent to produce the carpet waste mixture.

1 5 . The method of claim 6, further comprising adding a natural fiber filler to the carpet waste mixture.

16. The composite building material of claim 1, further comprising a sheet having a first exterior surface and a second exterior surface defining a thickness, the sheet comprising a substantially homogeneous mixture from the first surface across the thickness to the second surface.

17. The method of claim 6, wherein heating and pressing comprises forming the composite building material into a sheet having a first exterior surface and a second exterior surface defining a thickness, the sheet comprising a substantially homogeneous mixture from the first surface across the thickness to the second surface.

18. The composite building material of claim 1, further comprising synthetic fiber filler in intimate association with the binding agent.

19. The method of claim 6, further comprising adding synthetic fiber filler to the carpet waste mixture.

20. The composite building material of claim 1, characterized by an absence of synthetic fiber filler.

21. The method of claim 6, wherein the composite building material is characterized by an absence of synthetic fiber filler.

22. The composite building material of claim 1, further comprising a surface feature selected from the group consisting of a foil laminate, a film laminate, a sanded surface, a primer, a paint, and a stain.

23. The method of claim 6, wherein the composite building material further comprises a surface treatment selected from the group consisting of a foil laminate, a film laminate, a sanded surface, a primer, a paint, and a stain.

24. The composite building material of claim 1, wherein the processed carpet waste comprises a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties.

25. The composite building material of claim 1, wherein the composite building material comprises between 25% and 99% processed carpet waste and between 1% and 25% binding agent.

26. The composite building material of claim 1, wherein the binding agent comprises one or more of methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF).

27. The composite building material of claim 1, wherein the composite building material comprises fibers consisting essentially of a highest melting point fiber of the processed carpet waste.

28. The composite building material of claim 1, wherein a combination of the processed carpet waste and the binding agent is present in the composite building material in an amount from 50% to 99% of the composite building material.

29. The composite building material of claim 1, wherein the composite building material comprises from 0% to 50% man-made fiber fibers.

30. The composite building material of claim 1, further comprising oriented fiberglass.

31. The composite building material of claim 12, wherein the additional inorganic filler comprises calcium carbonate, silica or both.

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

33. The composite building material of claim 1, wherein the processed carpet waste comprises carpet backing in an amount equal to at least 10% of the composite building material, by weight.

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

35. The composite building material of claim 34, wherein the carpet face polymers include one or more of: nylon, polyester, polypropylene and wool.

36. The composite building material of claim 1, wherein the binding agent is methylenediphenyldiisocyanate (MDI).

37. The composite building material of claim 1, wherein the composite building material has a modulus of elasticity of at least 55000 PSI by ASTM
test D790.

38. The composite building material of claim 1, wherein the composite building material has a modulus of elasticity of at least 100,000 PSI by ASTM
test D790.

39. The composite building material of claim 1, wherein the composite building material has a modulus of rupture of at least 600 PSI by ASTM D790.

40. The composite building material of claim 1, wherein the composite building material has a modulus of rupture of between 1000 and 2500 PSI by ASTM
D790.

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

42. The composite building material of claim 1, wherein a density of the composite building material is from 40-80 pounds per ft3.

43. The composite building material of claim 1, further comprising a layer on a surface of the composite building material.

44. The composite building material of claim 43, wherein the layer is molded or embossed to create a patterned surface on the composite building material.

45. The composite building material of claim 43, wherein the layer comprises a laminate layer discrete from the processed carpet waste and the binding agent.

46. The composite building material of claim 43, wherein the layer comprises a foil or film laminate.

47. The composite building material of claim 43, wherein the layer comprises a hot-stamped layer.

48. The composite building material of claim 43, wherein at least one of the layer and the surface is sanded.

49. The composite building material of claim 12, wherein the composite building material comprises up to about 50% of the additional inorganic filler.

50. The composite building material of claim 1, wherein the binding agent is present in the composite building material in an amount from about 2% to about 10%, by weight of the composite building material.

51. The composite building material of claim 1, wherein the composite building material comprises about 5% binding agent, by weight of the composite building material.

52. The composite building material of claim 1, wherein the processed carpet waste comprises a material selected from the group consisting of wool, nylon, polyester, polypropylene, and combinations thereof

53. The composite building material of claim 1, further comprising an additive selected from the group consisting of a fiberglass, a mold inhibitor, and combinations thereof.

54. The composite building material of claim 1, wherein the processed carpet waste comprises at least one of post-industrial waste carpet and post-consumer waste carpet.

55. The composite building material of claim 1, wherein the processed carpet waste comprises at least one of a pelletized carpet waste and a fiber carpet waste.

56. The composite building material of claim 1, further comprising sisal.

57. The method of claim 6, wherein the processed carpet waste comprises a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties.

58. The method of claim 6, further comprising preparing the processed carpet waste by subjecting the unprocessed carpet waste to size-reduction treatment comprising one or more of: chopping; shredding; grinding; contaminant separating;
pelletizing; agglomerating; pulverizing; fine grinding and fiberizing the unprocessed carpet waste.

59. The method of claim 6, wherein the binding agent comprises one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF).

60. The method of claim 6, wherein the composite building material comprises between 25% and 99% processed carpet waste and between 1% and 25%
binding agent.

61. The method of claim 6, wherein the composite building material comprises fibers consisting essentially of a highest melting point fiber of the processed carpet waste.

62. The method of claim 6, wherein the processed carpet waste comprises granules that are subjected to spinning and are forced under pressure through orifices sized and configured to densify the processed carpet waste.

63. The method of claim 6, wherein the mixing step comprises combining the processed carpet waste and the binding agent in a drum to coat the processed carpet waste with the binding agent.

64. The method of claim 6, wherein the binding agent is methylenediphenyldiisocyanate (MDI).

65. The method of claim 6, wherein heating and pressing comprises subjecting the carpet waste mixture to heat and pressure in a continuous belted press or in a stationary press.

66. The method of claim 6, further comprising applying a layer to a surface of the composite building material.

67. The method of claim 66, wherein the layer is a laminated layer or a foil-transfer layer.

68. The method of claim 66, wherein the layer is a paint, a stain or a polymeric compound.

69. The method of claim 66, wherein the layer is molded or embossed to create a patterned surface on the composite building material.

70. The method of claim 66, wherein the layer is a wood veneer, a synthetic veneer, or a polymeric sheet.

71. The method of claim 66, wherein the layer comprises a foil or film laminate.

72. The method of claim 66, further comprising preparing the surface of the composite building material and subjecting the surface of the composite building material to mechanical or chemical preparation.

73. The method of claim 66, wherein the layer comprises a hot-stamped layer.

74. The method of claim 66, wherein at least one of the layer and the surface is sanded.

75. The method of claim 66, wherein the layer is discrete from the processed carpet waste and the binding agent.

76. The method of claim 6, further comprising thermoforming the composite building material into a desired shape.

77. The method of claim 6, further comprising pressing at least one of a plate or a roll onto the composite building material to form a patterned surface on the composite building material.

78. The method of claim 6, further comprising hot-stamping the surface of the composite building material.

79. The method of claim 6, further comprising embossing a surface of the composite building material.

80. The method of claim 6, further comprising cooling the composite building material.

81. The method of claim 6, wherein heating and pressing comprises melting a plurality of materials comprising the processed carpet waste.

82. The method of claim 6, further comprising cooling the composite while applying pressure to the composite.

83. The method of claim 82 wherein (i) heating and pressing occurs in a first cycle press, and (ii) cooling while applying pressure occurs in a second cycle press.

84. The method of claim 82, wherein (i) heating and pressing occurs in a first cycle press, and (ii) cooling while applying pressure occurs in the first cycle press.

85. The method of claim 6, wherein heating and pressing heats the composite building material to a temperature of about 65 °F to about 550 °F.

86. The method of claim 6, wherein the processed carpet waste comprises unmelted processed carpet waste.

87. The method of claim 6, wherein the composite building material comprises about 90% to about 98% processed carpet waste, by weight.

88. The method of claim 6, wherein the composite building material comprises about 95% processed carpet waste, by weight.

89. A composite building material manufactured according to the process of claim 6.

90. The method of claim 6, wherein the processed carpet waste comprises fibers comprising at least one of polypropylene, nylon, and polyester.

91. The method of claim 6, wherein heating and pressing comprises applying heat and pressure to the carpet waste mixture to form the composite building material at a temperature and for a time period sufficient to melt substantially all materials comprising the processed carpet waste.

92. The method of claim 6, further comprising actively cooling the composite building material while applying pressure to the composite building material, wherein the composite building material is cooled under pressure for a time period and to a reduced temperature sufficient to reduce warping of the composite.

93. The method of claim 92, wherein the step of actively cooling the composite while applying pressure cools the composite to a temperature of about 120 °C.

94. The method of claim 6, wherein the carpet waste mixture comprises sisal.