CA2933740A1 - Carpet waste composite - Google Patents

Carpet waste composite Download PDF

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Publication number
CA2933740A1
CA2933740A1 CA2933740A CA2933740A CA2933740A1 CA 2933740 A1 CA2933740 A1 CA 2933740A1 CA 2933740 A CA2933740 A CA 2933740A CA 2933740 A CA2933740 A CA 2933740A CA 2933740 A1 CA2933740 A1 CA 2933740A1
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CA
Canada
Prior art keywords
building material
composite building
carpet waste
composite
carpet
Prior art date
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Granted
Application number
CA2933740A
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French (fr)
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CA2933740C (en
Inventor
Douglas Mancosh
James Przybylinski
David E. Murdock
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MATERIAL INNOVATIONS LLC
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MATERIAL INNOVATIONS LLC
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Priority to CA3012366A priority Critical patent/CA3012366A1/en
Publication of CA2933740A1 publication Critical patent/CA2933740A1/en
Application granted granted Critical
Publication of CA2933740C publication Critical patent/CA2933740C/en
Active legal-status Critical Current
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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B02CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02CCRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C19/00Other disintegrating devices or methods
    • B02C19/18Use of auxiliary physical effects, e.g. ultrasonics, irradiation, for disintegrating
    • B02C19/186Use of cold or heat for disintegrating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B29B17/0042Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/02Polymeric products of isocyanates or isothiocyanates of isocyanates or isothiocyanates only
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72Polyisocyanates or polyisothiocyanates
    • C08G18/74Polyisocyanates or polyisothiocyanates cyclic
    • C08G18/76Polyisocyanates or polyisothiocyanates cyclic aromatic
    • C08G18/7657Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00Recovery or working-up of waste materials
    • C08J11/04Recovery or working-up of waste materials of polymers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04Reinforcing macromolecular compounds with loose or coherent fibrous material
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L75/00Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
    • C08L75/04Polyurethanes
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00Compositions of lignin-containing materials
    • C08L97/02Lignocellulosic material, e.g. wood, straw or bagasse
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16Fillers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/26Scrap or recycled material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2711/00Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
    • B29K2711/14Wood, e.g. woodboard or fibreboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00Flat articles, e.g. films or sheets
    • B29L2007/002Panels; Plates; Sheets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/732Floor coverings
    • B29L2031/7322Carpets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2272/00Resin or rubber layer comprising scrap, waste or recycling material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00Technologies relating to chemical industry
    • Y02P20/141Feedstock
    • Y02P20/143Feedstock the feedstock being recycled material, e.g. plastics
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/62Plastics recycling; Rubber recycling
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24438Artificial wood or leather grain surface
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24612Composite web or sheet
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31551Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31551Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31554Next to second layer of polyamidoester
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/31551Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31594Next to aldehyde or ketone condensation product [phenol-aldehyde, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/31855Of addition polymer from unsaturated monomers
    • Y10T428/31935Ester, halide or nitrile of addition polymer
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/31946Next to second aldehyde or ketone condensation product
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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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 confmed 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 (MDT), 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 iriorganic 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 =
=

WO 2007/084822 " = 7CT/US2007/060381 DETAILED DESCRIPTION
A. generic composition of the carpet waste product produced by the invention 'follows:
Material De.Seription Percent of material in Composition Carpet: Waste 25% - 00%
Binding Agents 1%.- 25% =
=
Wood or natural fibers, $ynthetit fibers;
Inorganic fillers, Reinforcing fillers - 50%
nano Retardants 0% - 75%
Mold Inhibitors 0% - 25%
There are two basic steps in the production-of tOrnposite=mgerial from. carpet waste, shOWs the types of equip:neat-and the variety Of procedures depending on the final forrn required for the Process. Equipment. The final form mayalso be dependent on the desired finished compoSiteproduct and physidal properties to be attained in the process.
First, the carpet waste.4 processed as. described below to reduce its size.
Menthe :size-mimed carpet waste is mixed with a binder to produce material that is subjected in 25. .teroperatire and/or pressure, by a plinel/sheepboard =protimi. to yield composite material.
Below we describe liothSteps in detail. We (hen describe post-manufacture treatments for the composite material.
Carpet Waste Size Reduction =
The carpet waste is made up of selvedge, post-industrial carpet waste, post-consumer waste 30 carpet, or 'Wage carpet reclaimed from landfills. These materiah=i=will be in baled form to begin the size. reduction phaseof the Fe-processing. The bales- vary in size but usually represent about 1000 lb. to 2000 lb.
The first step is to reduce the wage to a manageable size for the rest of the process.
Either a combination of a shredder/chopper and grinder; or a major capacity grinder is used 35 to process.the materials to smaller sizes. The Shredder/chopper will reduce the selvedge or Carpet waste to chunks approximately three inches square (3" x 3"). The shredded material thenpasses through a Finder which =further reduces the chunks a fiber fluff material = with a
4 WO 2007/084822 ' PCT/US2007/060381 = . .
diameter of the -fibers sImilar to, the. diameter of the, original carpet fibcrs and a length of about ie. te ".
The waste optionally can be run thrOugh a-separator whiehads as a hammer millieyelone to remove the dirt from the carpet waste. In this step some Of the carpet backing containing inorganiefillers may also be removed. The slightly size reduced 1=0. material, due to the halt:mei. Mill effect, is ready Ibr the next step;
the aggleMeration process. The dirt and carpet backing materials that have beenremoved from.
the.smill .chunks are then disposed:
The fiber ling regardless of the.use of the separator ornot, optionally can be blended with other materials such as wood or natural fibers,.
syntheticibera(i:e..fiberglass), 15: inorganic .fillers, other reinforcing fillers, flame retardants. and Mold inhibitOrsõ The fiber = =
fluff material or the blended material is -then conveyed to the agglomeration-step.
The agglomeration of the above materials occurs inside the agglomerater. The materials enter a horizontal drum 'containing a revolvingrotor. Thetotor is Shaped so. tis- to force the fiber fluff or blends against the drum wall. The-drum wall is perforated so that, as 20 the rotor rorces the contained Materials against the perforated wall;
the material is forced through the perforations forming strands of a. fixed diameter- On the- eutside of the drum are stationary knives which cut the strands into a fixed length. Duringthiis process the material is. heated-by frietionto a temperature that remainshelOW &c-melting point of thehighest--mei ting point material in the blond. The temperature is controlled by the speed Of the rotor, 25 thc-.diameter of the perforations, and. the thickness of the drum wall.
The granules thatare formed in the agglomeration :Step iiretylindrieal in Shape and . .
-approximately 1/8 inch in diameter and to %inch long. The diameter and length of the granules can he changed by changing the diameter of the holes in the drum wall and/or changing the speed of the knives rotation. Bee:use-the iventiltm are hot when they are 30 lomted and tan to length some of granules are-stuck tO one another.
Therefore, for better Size consistency, the granules next pass through.a grinder which breaks the grannies 'away from each other. This grinder step may also be used to reduee the size of the granules.
The granules may be 'briber 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-8-1.6 as mesh. This is the equivalent of 0.04 inch to 0.10 inch.
One last optional step may now be performed, to fiberize the granules or the pulverized particles. The fiberizing is a mechanical roughing of the surface go that the
5 i . .
6 surface takes. on a "fuzz" like characteristic. This can be an important final preparation for the composite product procen.desetibed below in the Process Description. The material, whether granule or pulverized particle, whether fiberized or not,. is now sent .on to the, composite mduction, process.
An alternative method -for initial size reduction is to use a major capacity grinder U) which reduces the carpet waste to fibers approximately 14 inch to I inch M
length and: =
approximately 1/31 inch to 118 inch in diameter. These random sized fibers are ready for . .
the agglomeration process or for alternative. actions not requiring agglomeration.
RegardlesSof theproceas direction, the next step isio pass the material through a separator. This. isthe sameequipment and effect as described above. As above;
this is an =
optional step in the Material preparation phase being described here. The fibers may now go through the agglomeration prop* in the exact samomarmeras described above, or the fibers may pass directly to the fiberizer equipment_ Again the liferizgr acts to change the =:;
surface characteristic of the fibers giving them a "fuze suffice with .greater surface area = ==
and a different bulk density. The fiberizing step may not be required for all end uses.of the 20 eempositeproducts.
=
Whether the tiberS have been fibetized arnot,.. they will pass through ablender where wood or. funeral fibers; synthetic fibers fiberglass), inorganic filters, mineral fillers (if any), flame retardants, anttmoldinhibitors may bet added. Once the blending Of .the fibers and added matetials is complete, the blend is ready for the composite product 26 'Process, The compositepreduct.compoSition is -controlled by controlling the above steps.
Significantly, it. Opically is not necessary to separate or classify the various materials-contained in selvedge or carpetwaste. Most 'carpet surlitee materials' are nylons, polyester, polypropylene, or wool. Thetacking material is usual lypolypropylene and/or highly filled =
30 'synthetic latex. These materials exhibit considerably different physical properties and processing properties: The entire waste product may he used regardless of the differences in the 'materials. flowOet-, if desired, the 'carpet Waste can be separated by face .fiber type and =
processed. Pot exam*, a papa can be made of 100% Nylon -6 face fiber carpet waste, A
panel can also be made byblending different face 'fiber carpet waste together at a controlled :35 ratio of each type to create a panel. For example, a patio! could be made of 50% Polyester face fiber carpet waste and 50% Poly-propylene face fiber carpet waste.
.
.

WO 2007/084822 . = . PCT/US2007/060381 =
The waste carpet, havingbeen made into an agglomerate, a fiberized agglomerate, a pulverized ax-,;gicirierate, or a fiberized, palverized agglomerate,.becomes the base 'materiel .fer. the omposite=product. Waste fiber Or therize.d wage fiber may also be used to manufacture a composite product. The whole range of materials in carpet wageMay be part )-.1:the composition.
The othermajor part of the coMposition is a binding agent. The binding...function canbe accomplished using mothylenediphenytdiisocyanate (MI), urea fOnataldehyde(Uf), melamine area formaldehyde (MUF), phenol formaldehyde (PF) or acoinbination thereof. =
Other hinders may be used depending on faetorssuch as compatibility, ostand environmental issues. The binding agent acts as a .gluelor the fibers or agglomerated materials to ic the basis for the composite. Widuets..The ratio of the 'binding agent to the fibers orpattieles is a determinant in the physical properties attained in the Process..
Further, the physical propertieattre=moditiedby the .use of wotiti arid natural fibers, synthetic fibers, inorganic .fillers, reinfotoingfillers,,flarne retardants.
and meld inhibitors.
The binding agent and wpct waste materialacomprise at least 5Q% of the ixanposition and may make up 1.00% of the final products The binding agent contentia between I% and .25% leavingithe remainder of the material to be comet -waste:and added .materials. The added materials, wood and natural .fibers,. synthetic fibers:inorie.filleta = reinforcing fillers, flame retardants, and mold. inhibitofs May make uP
to 50% Oftheltital composition. However, the basic material is USually a 9!...1 ratio. ofearpet waste to binding 25. agent with any added materials being around 15% of the. carpet waste/binding agent content.
in summary, the compoSition of carpetwaste and binding agenqwith or Wi(land sedditiveinaterials) can be. Used to make a wide rangeolcommite products, The carpor.
waste includes all of the carpet product including all the different- types.
of 'face fiNta and the fourpet hacking.
= =
Coating the Carpet Waste Material with the Binding Agent The Carpet 't,,vto material mayhave the form of granules (pellets or.
particles), or of the fibrous waste material or fibcrized versions attic gentiles or fibrous material. The carpet waste materials are generally loaded into alarge rotating drum or a drum with as rotating mixing blades or a resination blow line. Other materials such as natural fiber fillersõ inorganic fillers, flame retardants, and mold inhibitors may he loaded with the carpet waste material. If the material is loaded into ttdrum, then water and/or a binding agent are '7 ==
=
=

=
6 sprayed out of the head inside of the drum to thoroughly coat the materials. While the drum and/or blades arespinning and cau4ng.thornatetiatheld within to become evenly distributed, the spray bead iSreleMing, a fine ttit of 'watepor biodingagent.
This. results-in i= = =
thoroughly coated material. Water is usually sprayed into the drum to .achieve a desired moisture content for the mate and' preparelhe Material for the binding agent.
The =
binding agent Ls Usually sprayed after the water to. make Sore that it reads and thoroughly coats the material in the drum. For theTesination blow linemighod, the material isblown through n tube that haS 'water t:md binding agent introduced into' it. The blowing action eause the air tobecoinelurbuhmt which allows the water and binding agent.to evenly coat thematerial. The bindingagent is applied. in this manner to the granules or fibers at a concentration of 1% to 25% of the total 'weight Of the grEinglea-ploOmy other additive*
. , .(Ihroughout the description, the terms granules or fibers can include .additives: in addition. to thenarpet waste). The binding:agent adheres. to thestantdes and fibers, tdvingeach =granule or fibera binding agent-Surfaee oaring. =Thdbinding.agent dries rapidly under . ===
ambient eonditipns, allowing the gawks or-fibersto continue.to now without adhering to one another. The granules or .fibers With thebinding agent coating then paSs=on to thenext.
step in theproCesa Which is the preParation of the carpet waste composite material for the .Board.
foparbig,fat Boar0õ.FOrmi4g Proms The binding agent coated composite material is conveyed to ihe Mat-Forming.
=Stationwhichineludes Conveyors, metering scales, spreader heads:.and a control Managernent System. Fheinat fanning Station employs sPreadingequipment to distribute I
the composite material onto alorraing.belt so that the spread material becomes amat which .
has a unifonn thicknesS, width and density, Board properties-Are Mainly determined by the .shopeof the:Carpet waste compositepattielesaib.ers and: by=their position in the lbrmednui.
For this reason the spreading .equipment is tinay tuned to produce the proper shape and size of the -mat. The Fortning station can distribute more than one type of material for it Multi-layered board, For example, the spreader head in the forming station .eoul4 spread a matof fibers on the-forming belt, then a-second spreader head-could .spread_ amat of pellets ontop sa of the fibers, then a third spreadhead could spread a top layer of fibers onto the pellets.
Many different combinations of materials can be spreadonto the thrilling belt to make various types of boards. The number of layers per board can be varied also.
For example, a =

=
'µ.

=
= =
beard could he manufactured to have CW fiber skins and a:fiberglass cure or a board could bemantActured to have CV.pellet skirts, CW:fiberunderlayers and u CW pellet.
cure.
Afterthe mat is spread foiled, theforining belt then 'transports ificraat MO
the .pre,hoater or-directly into a Fie-Tress. The pre-heater continuously transfers the mat and subjects the composite material to microwaves or injects hot air and/or :Steam into .thoinat before-it la enters :the Board Forming process, The temperature of the Mat is elevated from about 6PF
tryabout 2001 .before entering the hoard forming process. Thiarapid heat transfer tothO
carpet wake is accomplished by snicrowtNes or by the inieetion of:a steam/alt mhz(inbiSt =
.air..) alternately from either surface into the met The iteamoondenses during:this process, transferring. the heat into- the mat; The pre-heater may also prevresa or etnnpresS the.
Matigial bereft it enters the board forining process. Theheated India then tangle:1'1*i by an intermediate belt conveyor to the compression suction-of theitem. d. end of acentinuo.us =
rail press Or intot cycle press which is thebeginning oltheioardfonningpröeess.. =
. .
If a. cycle or stationary press is .usedinstead of tontintioni roll press, them pre-heating of the mat is usually skipped and steam injection maybe used during.
the sheeting process in the cycle. press or the steam injection can heskipped.. =
The Board Forming Process employs a cy*:131tSS or Contiuos Rog Press; .Both types of equipment ose pressure and temperature. to frm:dboard,..panel or sheet from the :Carpet Waste CompositoMaterial that is coated with a binding 'agent.
The Cycle .press -may have single or intiltklaYlight Openings. The composite 25 material is toutsfericd into the cycle press where it. is-subjectato temperaturoand pressure frem.a top and bottom platen that condenses them at to adetentrined height andelloWs.the_ binding agent-reaction. to take plec.e.bondingthe mat together to form.a:Board. Themat may have swim injected. through it while in the cycle press twensure a thorough heating and .bonding of the compoSite.matetial. The platens41.4y have a paten) engraved into them to .
give the boards surface a structured pattern. The Cycle:press may also use a cooling cycle .to =Wee the temperature of the board before it exits the press.
Carpet wasteeempoite boardShave been Maiill.factuNd usinga cycle.preSS, The.
.optrating conditions-and settings are shown in Chart I attached hereto.
, The Continuous roil press is a doubletelted press.eapable of maintaining a range of 36 temperatures and pressures on the mat to allow the binding agent reaction to take place, binding the mat together. The preferred type of belt .Thr the continuous rotl press is made of =
steel but other materials may he used. The press has the capability Of reaching temperatures ====
. =
=
WO 2007/084822 = = PCT/US2007/060381 of t55 F to 5506f to allow the. heat. to.transfer throughout therm. Similarly varying pressures- are used.to snatezethe granulelayer or the fiber that tO the desired dUcknessand density of the final product.
= -The continuons=roll press consists of a press stmetorewhich takes. up thehorizontal =
Ibtecs resulting from the belt tensioning. There Amin any frame units whose number =
19 depends on the length of the press and pressure that is. needed.
Cylinders are used .fpr the exertion cif pressurearranged at the frame units in. varionsombiliations, a certain number of whith are suitablefor opening the press. -There are. top and bottom heated platens *lila the roller rods and belts &mid over. The press .has an infeedheadlo guide thorollertOdS, belts, and mat-totepressed. The toiler rods are located between the heated platens arid the 15 bt.i181 TherliZtt is located between the two belta. -Two drums are located at each end oldie = press for the belts to travel around. Drum scrapers are used to keep the mat between the ' =
belts. A rdease.agent-maybesprayed.onto the beltsto ket41 the mitt from sticking to the be:imam! exit the press; A control sySterri regulates theoperation of the press sUeli as the speed of the belts, temperature, pressure,. thielmessof the mat, etc.
20 The continuoustollpress transfers heat to the binding agent-coated composite material The heat activates- the binding agent coating on the .materials which: are then pressecho a. lesser thiekness by thceontinuously moving 'belts. As-thematcrial moves between the:belts through the infeed .SectiOn, the-thickness dimension is reduced as well as =cominually heated. The temporatUre of the binding.agent7couted granules ortho binding . .
. .
25 agent-coated fibers, is ntaintainert.above the activation- temperature.
the: binding a$ent. =.
Under the pressure ofthe-Pratent Which are Set at a predetermined heightõthe granules or ;
OM adhere to each other-forming a continuous Sheet product. Thi$final thiekness =
determines therkatsity oldie material:as well. The -density is determined:by the. initial thickness of the un-bonded mat entering the contiiniou,s.press and the final thicluiess as the .
30 newly .formed composite product exiting the press.
lithe teniperatureof the continuous press belts or Stationary press platens are heated up to 230 'C' or above, a thin but dense outer Skin can he formed in the panel. This outer =
-skin can help improve physical properties in the panel, such as the modulus of elasticity (MOE) and the modulus of -rupture (MOrt).
=
35 Alter the mat WS been heated an4pressed to the desired height and density in a continuous press, a cooling section maybe employed to cool the panel hethre it exits the continuous press. Due to the-nature if the polymer materials being pressed,.
cooling the . .
=
=

!CT/US2007/060381 .5 panel lathe press under pressure helps maintain board :flatness and avoid warping. The ===
panel is:generally cooled to at least 120 C before exiting :the tontinuotis press. A
Stationary Press May also use a cooling cycleto cool the board before it exits the .stationary .
.
press. However, this additional tooling time creates a longer cycle :time to create a panel.
So., a secondary stationary press May employed for cooling only. For example, sa panel-May beibrined under heat and pressure in first press, then transferred to a seetind Stationary press to be cooled. A panel may be formed in either type of press and cooled in aseeondary =
process after it exits the press.
=
The Board Finishing 'Process i=lifter the binding of the material and desired height dimension of Ebel:net has httn =
reached in.a continuous roll press, a Board is formed which is in the shape of acoritinuous ribbon. When the ribbon: exits the press it undergoes -a con tinuous.edge trimming Operation =
to, reach the desired width and 'then it is cross-cut toupre-seletted length..
The ribbon is =
'transported through the trimmingand cross-cutting operations by a rollerconveyor and 26 pinch rollerS. The hoard. that has been cut to a predetermined width andlength IS then .transportedIe a Outing station. The cooling station Can employ. avariety. tyf different machines such as a Star Cooler with subsquent, stacldng or a stacking roller conveyor. One of therms; common types is the star coolerwith subsequent stackin.g The Star Cooleris large diameter wheel ,with multiple rows of spekedarrits extending from the wheel. The 25 = lift each .Board from the conveyor and allow the Boards le rotate with the wheel .and be air tooled. ifueeded, the continuous- roll press. can have aeooling section near theesit. . .
This will cool the board before it exits the press eliminating the rieedfor further cooling. =
The Board is then conveyed to a stacking operation and stored for future use., The Boards =
= now ready to be shipped or, they coup through a Variety of decorating-alternatives.
30 In a cycle press, the board can bernanufactured to finished size or Slightly overSized.
If it is oversized, then it is to finish dimensions afterit exits the press. The Platens in the press can have a patterned surface to give the board a stud:toed surface such tici wood grain pattern.
35 Decorating the Composite Product .
As the composite product exits the Process as. described. above,. it may be of varying thicknesses from less than 118 inch up to 2 inches, Since the last Step in the Process is the11 WO 2007/084822 ?CT/US2007/060381 s cutting to length of the composite product, the first step in finishing the product iseutting to final width. Figure 3. ShoWs the finiShing=and decoratingstepS that May be employed =
following cuttingto final width.
The compOsiteproduetc.art now.be.moidedto change the= Wilk to take on. the iiitipe required in the finishedproduct. The Melding is &Me on a cutting machineeldifTerent designs. The most common of which is the.rotatingbive,s-device.. This machine allows for the setting of the knife blades to adjusithe. cut to the 'desired profile.
Another common device ig the router which cuts a specific groove or greoveg (routs) into the surface of the composite product The router has the same effect as the molderin that it changes the initial profile out of the Process into the desired.protik required for ille. final product.
is The. profile May also be changed using thermoforming methods. In this case the .. composite product is placed lop mold of the desired profile and with heat and pressure the product takes on the shape ofthe Mold. This profile changeofferszti additional decorating eapab.ility.in the; the desirat color andlorptittem truty-bc on a transfer foil placed in the mold.. With the application (Idle heat and pressure during the process,' the color andfor pattern are transferred, from. the Carrier foil to the Composite product, Thus at the end Of the Abeam:forming process, the composite producthas the &Sired profile and also the desired decoration.
The composite-productinaybe embossed after the Process. The embossing is accomplished with an embossing plate or roll. The plate or minus the pattern to be 2.5 transferred lo the product On the surface of the plate or roll. This surface is heated to a.
temperature that will =.Ø11.eh the .sUrftteo (lithe eornPoslioprodtict, Then the plate or roll is =
pressed on to the surface oftheproduct to give the desired pattern transfer.
As the '.surface of the composite product cools; the embossed pattern .beoutues .fixed on the surfaceof the.
composite product.. The embossed composite product is now ready ts.) be coat*
or if no coating is required for the erickise product, it is readyfor packaging.
All composite .products that Will be decorated pass through the sander (the õ .
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 paints, Or steins.. 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 4) 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.

-CHART 1.
.
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Is .bs ii I. 1 .
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1 6t, 'I i'.I
? g 4 i I li '6- il e .f.
.
.
4 f 3.-: 1 g n. s 1 f s 1 V m 4, g '-'= ar a .s, ._ . 11 0. - . a I < fr }-=i =-.7-.2 la 1,..p u 8 i 1 i ci a _______________________________________________________________ 0...."...._"
.. Reirierks .
Fibera 116.4 10% 3 70 m1239a20.20s 560.125648 19 392 1.0 0.500 66.2 Rawl? Woodstrucbse Fatten!

Ftbers 116,4 5% 3 70 in1239a20.20s 580,125648 19 392. a 0.492 69.9 Rough Woocttreobrie Pattern -Mein 116,4 2% 3 70 if:1239626.20s 580.125648 19 392 6.5 0.504 68.0 Rough Woocilitrectee Pattern o n.) Petters -123.4 10% 5.2/ 70 rri1239a920s 500.125E148 19 392. 6 0.478 78.0 3-Layer-Viet 101a1Weighis:
Surface ko / 2.94 Layer.* 40%
.Pellets, Core Leyer = 60% w w Fibers Fibers -.3 o.
ClAt1 Anse being Pressed (German sbbr:: Pr_ 0 F 49.7 M 20 R 2.77 55 n10838109.198 .584.12sea 19 392 11.5 0.287 54.1 FL). 30Orren =
SOOrteri n.) ,....
.
:A Fibers 51.1 3% 2.9 35 rn08381119,19e 589.125348. 19 392 5.7 0.285 55.2 Tiner(Woog) Seticitat o i-, Fibers 65.3 2% 2.9 65 r:=43313019.1Q! 500,120848.
19 397, 5,7 0.291 71.2 'Fine' (Wood) Strudirre 0) Fibers 2.72/ 34aster-Risard TOW
Weigh* Siena 1 o i 3,95Layer u 40% Fibers; Core 1.eyer es 60%
0) Peres 91.0 M20 R . 56 rniZilia20.200 50;125840 .19 :302 to 0.401 58.6 Fellers 1 n.) = 114.6 10% = 68 m1238a. 20.20a 480.12584e 19 392 3.0 0.489 752 = (serne es Above) o C001 deet1 WOO Within Press used for ' .107,6 10% " 89 re1238a20.2.0S.
86042560 19 392 3.2 0.520 ' 69.0 rerneinder . .
.
. .
St. =40% Fsbers. CL = 60% Peliets Of = 215.1 10% ' 96 '38a19.19s 500.125040 19 392 0.2 0.998 682 total emiglig '6 SL. =.111, 011m6, Gt. a 91% FeliaM (or P..._ - 215.1 10% " 88 re2538.a19.160 580.125848 19 :392 12 1.020 67.7 Luiallirlights Pellets 102.3 ii7g, 6.3 70 re1232420,201 290.062024 19 392 6 0.490 68.7 Sargon+ Surface d to , Pollees 74.1 7% 5.3 50' nr12390.20.201. 290062924 19 392 6' 0.500 51.3 Stets:47r stater* .
Pelle 194.0 5% 5,34 70 m1299926.201 290.002924 19 392 '6 0.496 69.9 Smooth Swine ti . Pellets 723 ... 2% 5.63 . 50 . m1239e20201. 290.062924 19 _ 392 '6 0500 50.1 Smoot"; Surface.
to PI
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.
. .

Claims (98)

WHAT IS CLAIMED IS:
1. 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.
2. The composite building material of claim 1, wherein the carpet waste comprises melted polypropylene fibers and unmelted polyester fibers.
3. The composite building material of claim 1, wherein the 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 a natural fiber filler.
5. 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.
6. 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.
7. 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.
8. The composite building material of claim 1, further comprising synthetic fiber filler in intimate association with the binding agent.
9. The composite building material of claim 1, characterized by an absence of synthetic fiber filler.
10. 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.
11. The composite building material of claim 1, wherein the carpet waste comprises a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties.
12. The composite building material of claim 1, wherein the composite building material comprises between 25% and 99% carpet waste and between 1% and 25% binding agent.
13. 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).
14. The composite building material of claim 1, wherein the composite building material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.
15. The composite building material of claim 1, wherein the sum of the carpet waste and the binding agent is between 50% and 99% of the total material.
16. The composite building material of claim 1, wherein the composite building material comprises from 0% to 50% man-made fiber fibers.
17. The composite building material of claim 1, further comprising oriented fiberglass.
18. The composite building material of claim 1, wherein the inorganic filler comprises calcium carbonate, silica or both.
19. The composite building material of claim 1, wherein the carpet waste includes all polymeric carpet components substantially without segregation from one another.
20. The composite building material of claim 1, wherein the carpet waste comprises carpet backing in an amount equal to at least 10% of the composite building material, by weight.
21. The composite building material of claim 1, wherein the carpet waste comprises at least two different carpet face polymers.
22. The composite building material of claim 21, wherein the carpet face polymers include one or more of: nylon, polyester, polypropylene and wool.
23. The composite building material of claim 1, wherein the binding agent is MDI.
24. 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.
25. 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.
26. 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.
27. 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.
28. The composite building material of claim 1, wherein a density of the composite building material is at least 30 pounds per ft3.
29. The composite building material of claim 1, wherein a density of the composite building material is from 40-80 pounds per ft3.
30. The composite building material of claim 1, further comprising a layer on a surface of the composite building material.
31. The composite building material of claim 30, wherein the layer is molded or embossed to create a patterned surface on the composite building material.
32. The composite building material of claim 30, wherein the layer comprises a laminate layer discrete from the carpet waste and the binding agent.
33. The composite building material of claim 30, wherein the layer comprises a foil or film laminate.
34. The composite building material of claim 30, wherein the layer comprises a hot-stamped layer.
35. The composite building material of claim 30, wherein at least one of the layer and the surface is sanded.
36. The composite building material of claim 1, wherein the composite building material comprises up to about 50% of the added inorganic filler.
37. The composite building material of claim 1, wherein the carpet waste comprises a processed carpet waste comprising (i) a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste.
38. The composite building material of claim 1, wherein the carpet waste comprises melted polypropylene fibers and unmelted nylon fibers.
39. 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.
40. The composite building material of claim 1, wherein the composite building material comprises about 5% binding agent, by weight of the composite building material.
41. The composite building material of claim 1, wherein the carpet waste comprises a material selected from the group consisting of wool, nylon, polyester, polypropylene, and combinations thereof.
42. 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.
43. The composite building material of claim 1, wherein the carpet waste comprises at least one of post-industrial waste carpet and post-consumer waste carpet.
44. The composite building material of claim 1, wherein the carpet waste comprises at least one of a pelletized carpet waste and a fiber carpet waste.
45. The composite building material of claim 1, further comprising sisal.
46. 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.
47. The method of claim 46, wherein the carpet waste comprises unmelted polyester fibers and melted polypropylene fibers.
48. The method of claim 46, wherein the carpet waste comprises face fibers consisting essentially of a material selected from the group consisting of polyester, nylon, and polypropylene.
49. The method of claim 46, further comprising adding a natural fiber filler.
50. The method of claim 46, 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.
51. The method of claim 46, further comprising applying a coating on at least a portion of the composite building material, the coating comprising a material selected from the group consisting of a primer, a paint, and a stain.
52. The method of claim 46, further comprising actively cooling the composite building material under pressure.
53. The method of claim 46, further comprising modifying a cross-sectional profile of the composite building material using at least one of thermoforming, embossing, and cutting.
54. The method of claim 46, 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.
55. The method of claim 46, further comprising adding synthetic fiber filler to the carpet waste mixture.
56. The method of claim 46, wherein the composite building material is characterized by an absence of synthetic fiber filler.
57. The method of claim 46, 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.
58. The method of claim 46, wherein the carpet waste comprises a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties.
59. The method of claim 46, further comprising 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 the carpet waste.
60. The method of claim 46, wherein the binding agent comprises one or more of:
methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF).
61. The method of claim 46, wherein the composite building material comprises between 25% and 99% carpet waste and between 1% and 25% binding agent.
62. The method of claim 46, wherein the composite building material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.
63. The method of claim 46, wherein the size-reduced carpet waste comprises granules that are subjected to spinning and are forced under pressure through orifices sized and configured to densify the size-reduced carpet waste.
64. The method of claim 46, wherein the mixing step comprises combining the carpet waste, the inorganic filler, and the binding agent in a drum to coat the carpet waste and the inorganic filler with the binding agent.
65. The method of claim 46, wherein the binding agent is MDI.
66. The method of claim 46, wherein heating and pressing comprises subjecting the carpet waste mixture to heat and pressure in a continuous belted press or in a stationary press.
67. The method of claim 46, further comprising applying a layer to a surface of the composite building material.
68. The method of claim 67, wherein the layer is a laminated layer or a foil-transfer layer.
69. The method of claim 67, wherein the layer is a paint, a stain or a polymeric compound.
70. The method of claim 67, wherein the layer is molded or embossed to create a patterned surface on the composite building material.
71. The method of claim 67, wherein the layer is a wood veneer, a synthetic veneer, or a polymeric sheet.
72. The method of claim 67, wherein the layer comprises a foil or film laminate.
73. The method of claim 67, further comprising preparing the surface of the composite building material and subjecting the surface of the composite building material to mechanical or chemical preparation.
74. The method of claim 67, wherein the layer comprises a hot-stamped layer.
75. The method of claim 67, wherein at least one of the layer and the surface is sanded.
76. The method of claim 67, wherein the layer is discrete from the carpet waste and binding agent.
77. The method of claim 46, further comprising thermoforming the composite building material into a desired shape.
78. The method of claim 46, 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.
79. The method of claim 46, further comprising hot-stamping the surface of the composite building material.
80. The method of claim 46, further comprising embossing a surface of the composite building material.
81. The method of claim 46, further comprising cooling the composite building material.
82. The method of claim 46, wherein heating and pressing comprises melting a plurality of materials comprising the processed carpet waste.
83. The method of claim 46, further comprising at least one of chopping, shredding, grinding, contaminant separating, pelletizing, agglomerating, pulverizing, fine grinding, and fiberizing the carpet waste.
84. The method of claim 46, further comprising cooling the composite while applying pressure to the composite.
85. The method of claim 84, wherein (i) heating and pressing occurs in a first cycle press, and (ii) cooling while applying pressure occurs in a second cycle press.
86. The method of claim 84, wherein (i) heating and pressing occurs in a first cycle press, and (ii) cooling while applying pressure occurs in the first cycle press.
87. The method of claim 46, wherein heating and pressing heats the composite building material to a temperature of about 65 °F to about 550 °F.
88. The method of claim 46, wherein the carpet waste comprises unmelted carpet waste.
89. The method of claim 46, wherein the composite building material comprises about 90%
to about 98% carpet waste, by weight.
90. The method of claim 46, wherein the composite building material comprises about 95%
carpet waste, by weight.
91. A composite building material manufactured according to the process of claim 46.
92. The method of claim 46, wherein the carpet waste comprises fibers comprising at least one of polypropylene, nylon, and polyester.
93. The method of claim 46, wherein heating and pressing comprises applying heat and pressure to the carpet waste, the inorganic filler, and the binding agent to form the composite building material at a temperature and for a time period sufficient to melt substantially all materials comprising the carpet waste.
94. The method of claim 46, 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.
95. The method of claim 94, wherein the step of actively cooling the composite while applying pressure cools the composite to a temperature of about 120 °C.
96. The method of claim 46, wherein the carpet waste comprises a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste.
97. The method of claim 46, wherein the carpet waste comprises face fibers consisting essentially of a material selected from the group consisting of polyester, nylon, and polypropylene.
98. The method of claim 46, wherein the carpet waste mixture comprises sisal.
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US11/507,366 2006-08-21
US11/514,303 2006-08-31
US11/514,303 US7875655B2 (en) 2006-01-20 2006-08-31 Carpet waste composite
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