WO2003035350A1 - A method for recycling carpet and articles made therefrom - Google Patents
A method for recycling carpet and articles made therefrom Download PDFInfo
- Publication number
- WO2003035350A1 WO2003035350A1 PCT/US2002/034053 US0234053W WO03035350A1 WO 2003035350 A1 WO2003035350 A1 WO 2003035350A1 US 0234053 W US0234053 W US 0234053W WO 03035350 A1 WO03035350 A1 WO 03035350A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- caφet
- recycle
- article
- equal
- pellets
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 47
- 238000004064 recycling Methods 0.000 title claims abstract description 18
- 239000000463 material Substances 0.000 claims abstract description 68
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 36
- 239000008188 pellet Substances 0.000 claims abstract description 35
- 239000000155 melt Substances 0.000 claims abstract description 23
- 238000002844 melting Methods 0.000 claims abstract description 10
- 230000008018 melting Effects 0.000 claims abstract description 10
- -1 polypropylene Polymers 0.000 claims description 35
- 239000000654 additive Substances 0.000 claims description 32
- 239000000203 mixture Substances 0.000 claims description 22
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 20
- 238000002386 leaching Methods 0.000 claims description 18
- 239000004743 Polypropylene Substances 0.000 claims description 17
- 229920001155 polypropylene Polymers 0.000 claims description 17
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 15
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 15
- 239000007788 liquid Substances 0.000 claims description 12
- 239000004677 Nylon Substances 0.000 claims description 11
- 230000000996 additive effect Effects 0.000 claims description 11
- 238000001125 extrusion Methods 0.000 claims description 11
- 229920001778 nylon Polymers 0.000 claims description 11
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 10
- 239000000945 filler Substances 0.000 claims description 10
- 238000001746 injection moulding Methods 0.000 claims description 9
- 239000004816 latex Substances 0.000 claims description 8
- 229920000126 latex Polymers 0.000 claims description 8
- 238000000465 moulding Methods 0.000 claims description 7
- 239000002689 soil Substances 0.000 claims description 6
- 238000000071 blow moulding Methods 0.000 claims description 5
- 238000003856 thermoforming Methods 0.000 claims description 5
- 238000002156 mixing Methods 0.000 claims description 4
- 239000011261 inert gas Substances 0.000 claims description 3
- 239000000454 talc Substances 0.000 claims description 3
- 229910052623 talc Inorganic materials 0.000 claims description 3
- 238000007664 blowing Methods 0.000 claims 1
- 239000004927 clay Substances 0.000 claims 1
- 229910052570 clay Inorganic materials 0.000 claims 1
- 229920002943 EPDM rubber Polymers 0.000 description 7
- 239000000853 adhesive Substances 0.000 description 7
- 230000001070 adhesive effect Effects 0.000 description 7
- 239000004033 plastic Substances 0.000 description 7
- 229920003023 plastic Polymers 0.000 description 7
- 239000003623 enhancer Substances 0.000 description 5
- 239000000835 fiber Substances 0.000 description 5
- 239000000047 product Substances 0.000 description 5
- 239000004609 Impact Modifier Substances 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 239000003063 flame retardant Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 3
- 229920002994 synthetic fiber Polymers 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000003292 glue Substances 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000012768 molten material Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 239000004616 structural foam Substances 0.000 description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000013022 venting Methods 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 238000012935 Averaging Methods 0.000 description 1
- 239000004604 Blowing Agent Substances 0.000 description 1
- 239000004606 Fillers/Extenders Substances 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 239000005083 Zinc sulfide Substances 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000004599 antimicrobial Substances 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- CGPRUXZTHGTMKW-UHFFFAOYSA-N ethene;ethyl prop-2-enoate Chemical class C=C.CCOC(=O)C=C CGPRUXZTHGTMKW-UHFFFAOYSA-N 0.000 description 1
- 229920006244 ethylene-ethyl acrylate Polymers 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000012760 heat stabilizer Substances 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 239000004005 microsphere Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
- 239000002071 nanotube Substances 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000005453 pelletization Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 230000000135 prohibitive effect Effects 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000012958 reprocessing Methods 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 229910052984 zinc sulfide Inorganic materials 0.000 description 1
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
- B29B17/0042—Recovery 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
- B29B17/0036—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting of large particles, e.g. beads, granules, pellets, flakes, slices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/05—Filamentary, e.g. strands
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/04—Particle-shaped
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/285—Feeding the extrusion material to the extruder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/285—Feeding the extrusion material to the extruder
- B29C48/288—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
- B29C48/2886—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/285—Feeding the extrusion material to the extruder
- B29C48/297—Feeding the extrusion material to the extruder at several locations, e.g. using several hoppers or using a separate additive feeding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/345—Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/76—Venting, drying means; Degassing means
- B29C48/762—Vapour stripping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING 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
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/10—Polymers of propylene
- B29K2023/12—PP, i.e. polypropylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING 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
- B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/251—Particles, powder or granules
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
- B29K2105/256—Sheets, plates, blanks or films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/26—Scrap or recycled material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING 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
- B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
- B29K2705/02—Aluminium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/732—Floor coverings
- B29L2031/7322—Carpets
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
Definitions
- This disclosure relates to making plastic articles, and especially relates to recycling carpet.
- carpet is currently manufactured from a number of different synthetic materials that have varying physical and chemical characteristics.
- conventional carpet materials typically include several layers.
- the simplest types of carpet might have fibrous pile (e.g., nylon, PET, or polypropylene) fused directly to a thermoplastic, typically polyolef ⁇ n, backing.
- a secondary binder or substrate layer a reinforcing web material through which the pile is attached, and/or separate glue that is used to anchor the pile to the backing.
- the glue can be, for example, styrene-butadiene rubber, applied as a latex, filled with an inorganic filler such as calcium carbonate.
- the method for recycling ca ⁇ et comprises: melting recycle ca ⁇ et; reducing a water content of the recycle ca ⁇ et to less than or equal to about 0.5 wt%, based upon the total weight of the recycle ca ⁇ et and the water, to form a melt ribbon; and forming pellets from the extruded melt ribbon.
- FIG. 1 is a schematic depicting the ca ⁇ et recycling method.
- Recycled ca ⁇ et can be converted into a material suitable for use, for example, in blow molding, and even for use in injection molding.
- the ca ⁇ et can be employed to form various articles, including, but not limited to, leaching chamber(s), e.g., for dispersing liquids in soil, of the type having a hollow interior with open ends and an open bottom enabling passage of liquids therethrough; endplate(s) for use with a leaching chamber for dispersing liquids in soil, of the type having a hollow interior with open ends, and sidewalls with perforations enabling passage of liquids therethrough, and wherein the endplate comprises an inner wall and an outer wall defining a central portion having an interior channel and optionally at least one connector capable of engaging an edge of a leaching chamber, with physical contact with both an inner surface and an outer surface of the leaching chamber; pallets; and the like.
- leaching chamber(s) e.g., for dispersing liquids in soil, of the type having a hollow interior with open ends and
- FIG. 1 depicts the overall method and apparatus used to recycle ca ⁇ et.
- ca ⁇ et typically in the form of a ca ⁇ et bale 1
- a shredder 2 where the bulk ca ⁇ et sample is shredded.
- the resulting ca ⁇ et strips are then fed from the shredder onto a conveyer 3 that conveys the ca ⁇ et strips to a continuous mixer 5 via a hopper 4.
- the continuous mixer 5 melts the ca ⁇ et strips and reduces any moisture therein to produce a melted ca ⁇ et. From the continuous mixer 5, the melted ca ⁇ et passes through a feed throat 7 and into an extrusion device 6.
- the melted ca ⁇ et and additives are further mixed and melted to form a melted material.
- the melted material then passes to an extruder die head 10 and into a pelletizer 11.
- the pelletizer 11 creates pellets that pass from the pelletizer 11 via additional conveyer 12 into pellet bin 13 for later use, such as in injection molding.
- the ca ⁇ et can comprise any available main material (e.g., poly(ethylene terephthalate) (PET), polypropylene, nylon ca ⁇ et, and the like), with any pile weight.
- PET poly(ethylene terephthalate)
- PET polypropylene
- nylon ca ⁇ et nylon ca ⁇ et
- a post-consumer or used ca ⁇ et is employed for reasons of economy, availability, and environmental considerations; although, non-used ca ⁇ et, such as ca ⁇ et unacceptable for sale, trim scrap from production of the ca ⁇ et, or ca ⁇ et returned by the purchaser, may also be used.
- the ca ⁇ et may be in any number of physical conditions including soiled, wet, dyed, treated for stain resistance, and the like, as well as combinations comprising at least one of the foregoing conditions.
- the ca ⁇ et is in the form of bales that can comprise any number of different types of PET, polypropylene, or nylon ca ⁇ ets, e.g., different ca ⁇ et origins, physical properties, chemical properties, and the like.
- the ca ⁇ et can be unseparated, i.e., ca ⁇ et that has not been modified to remove or separate out one or more of the primary components (pile, backing, adhesive, etc.) from the ca ⁇ et prior to processing.
- an unseparated bulk ca ⁇ et sample is preferred, separated ca ⁇ et, or portions thereof can be employed in the present process. In other words, if the backing, for example, has been reclaimed in another process, the pile and other remaining ca ⁇ et components can be employed.
- the ca ⁇ et will comprise pile, a backing, an adhesive, and a filler.
- the pile and the backing often comprises a thermoplastic material, such as a polyolefin, polyester, polypropylene, nylon, and the like, as well as combinations comprising at least one of the foregoing materials.
- the adhesive typically employed to adhere the pile to the backing typically comprises a latex material, other adhesives, and the like. Some possible adhesives include styrene-butadiene rubber (SBR), acrylate resins, polyvinyl acetate, and the like, as well as combinations comprising at least one of the foregoing adhesives.
- the filler comprises calcium carbonate.
- a ca ⁇ et can comprise a main material and optionally, latex, flame retardants, additives, and the like.
- the ca ⁇ et comprises greater than or equal to about 50 weight percent (wt%) of the main material (e.g., PET, polypropylene, nylon, or the like), with greater than or equal to about 70 wt% main material preferred, and greater than or equal to about 80 wt% main material more preferred, based on the total weight of the ca ⁇ et excluding water weight.
- the ca ⁇ et typically also comprises greater than or equal to about 5 wt% latex material, may comprise up to about 20 wt% or so of a flame retardant, and may comprise about 0.5 wt% to about 10 wt% calcium carbonate.
- a ca ⁇ et comprises, about 80 wt% to about 85 wt% main material (e.g., PET, polypropylene, nylon, or the like), about 10 wt% to about 15 wt% latex material, and less than or equal to about 10 wt% calcium carbonate, based on the total weight of the ca ⁇ et excluding water weight.
- main material e.g., PET, polypropylene, nylon, or the like
- 10 wt% to about 15 wt% latex material e.g., polypropylene, nylon, or the like
- less than or equal to about 10 wt% calcium carbonate based on the total weight of the ca ⁇ et excluding water weight.
- various additives can be added to the ca ⁇ et. The amounts and types of additives employed are based upon the composition of the ca ⁇ et.
- one or more bales, from a truck load of ca ⁇ et bales are tested for composition utilizing a spectrometer to determine composition, and melt index is determined to clarify the amount of additives preferred.
- melt index is determined to clarify the amount of additives preferred.
- greater than or equal to about 0.3 wt% additives are added to the ca ⁇ et, with greater than or equal to about 0.5 wt% preferred, with greater than or equal to about 1 wt% more preferred, based upon the total weight of the ca ⁇ et and additives combined (e.g., the total combined weight).
- the additives may comprise colorants, stabilizers (e.g., light stabilizers, heat stabilizers, and others), delusterants, flame-retardants (e.g., ATH, and the like), fillers, antimicrobial agents, antistatic agents, optical brighteners, extenders, processing aids, compatibilizers, flow enhancers, mold release agents, UV absorbers, lubricants, plasticizers, pigments, dyes, blowing agents, impact modifiers, and other additives that impart desired properties to the product.
- stabilizers e.g., light stabilizers, heat stabilizers, and others
- delusterants e.g., ATH, and the like
- flame-retardants e.g., ATH, and the like
- fillers e.g., antimicrobial agents, antistatic agents, optical brighteners, extenders, processing aids, compatibilizers, flow enhancers, mold release agents, UV absorbers, lubricants, plasticizers, pigments, dyes, blowing
- Some possible additives include impact modifiers such as olefin-containing copolymers (e.g., olefin acrylates such as ethylene ethylacrylates, and the like; olefin diene te ⁇ olymers, such as ethylene propylene dienes (EPDM), and the like), and polyolefins (e.g., polyethylene, polyethylene copolymers with alpha-olefins); and the like, as well as combinations comprising at least one of the foregoing impact modifiers, with EPDM preferred.
- olefin-containing copolymers e.g., olefin acrylates such as ethylene ethylacrylates, and the like; olefin diene te ⁇ olymers, such as ethylene propylene dienes (EPDM), and the like
- EPDM ethylene propylene dienes
- Possible flow enhancers include polyesters, e.g., poly(l,4-butylene terephthalate) (PBT), poly(propylene terephthalate) (PPT), poly(ethylene terephthalate) (PET), and the like, as well as combinations comprising at least one of the foregoing flow enhancers.
- Preferred additives comprise PET, which is usable with polypropylene and nylon at about 2 wt% to about 5 wt%, based upon the total combined weight, and EPDM, which is employed at an amount of about 5 wt% to about 10 wt% based upon the total combined weight.
- Fillers such as anhydrous aluminum silicates, mica, feldspar, clays, talc, glass (e.g., flake, fibers, microspheres, nanotubes, and the like), woUastonite, metal oxides (e.g., alumina, titanium dioxide, silica, zinc oxide, and the like), zinc sulfide, ground quartz, barium sulfate, fiberglass, and the like, as well as combinations comprising at least one of the foregoing fillers, can be employed to attain a desired thermal stability, density, stiffness, and texture.
- anhydrous aluminum silicates, mica, feldspar, clays, talc, glass e.g., flake, fibers, microspheres, nanotubes, and the like
- metal oxides e.g., alumina, titanium dioxide, silica, zinc oxide, and the like
- zinc sulfide e.g., ground quartz, barium sulfate, fiberglass, and the like, as well
- Preferred fillers include clays, talc, calcium carbonate, and combinations comprising at least one of these fillers in amounts of about 5 wt% to about 10 wt%, based upon the total combined weight.
- the amount and type of additive added to either the ca ⁇ et/ca ⁇ et strips/melted ca ⁇ et ultimately depends upon the composition of the ca ⁇ et, and the use of the product.
- the ca ⁇ et is formed into pellets that are useful in injection molding plastic articles (e.g., pallets, chambers, end-plates, and the like).
- Processing of the ca ⁇ et comprises optionally introducing the ca ⁇ et to a shredder.
- the ca ⁇ et sample is shredded to a size compatible with the other system machinery.
- the ca ⁇ et is shredded into strips of up to about 3 inches by up to about 12 inches. This is done because it is difficult to shred ca ⁇ et any finer without multiple passes through the shredder.
- the ca ⁇ et is passed through the shredder only once and some material is finely shred and some is in longer strips.
- the continuous mixer allows for the use of longer strips without plugging up the machine. Shredding it only once makes it more cost effective.
- the ca ⁇ et strips From the shredder, the ca ⁇ et strips enter a continuous mixer where the strips are preferably melted. Additionally, if the water content of the ca ⁇ et strips is greater than about 0.5 wt%, the water content is reduced to less than or equal to about 0.5 wt%, based upon the total weight of the ca ⁇ et (including the water).
- the melting and mixing can be preformed in any continuous mixer capable of attaining sufficient temperatures to melt the ca ⁇ et and vaporize and vent the water. For example, after shredding, the ca ⁇ et strips are directed to a Farrel or Technical Process & Engineering continuous mixer 5 via a conveyor 3 and hopper 4.
- the ca ⁇ et is melted and its moisture content is reduced to less than or equal to about 0.5 wt% to form melted ca ⁇ et ribbon.
- some additives are introduced at this stage as well, e.g., impact modifiers such as EPDM and the like. Due to this processing, and the reduction of water content to less than or equal to about 0.5 wt% prior to introduction to the extruder, the process allows the recycling of ca ⁇ et that can be saturated with water (e.g., that was in the rain).
- the melted ca ⁇ et is introduced to an extruder 6.
- Extruders capable of melting and mixing the melted ca ⁇ et and preferably of receiving additional components downstream of the ca ⁇ et introduction point can be employed. Possible extruders include twin and single screw extruders, as well as others.
- additive(s) may optionally be introduced to the ca ⁇ et, e.g., introduced to the strips in or prior to the mixer 5, introduced to the melted ca ⁇ et in the mixer 5 or at the melted ca ⁇ et inlet of the extruder 6, and/or downstream from the melted ca ⁇ et inlet of the extruder 6.
- the components are preferably homogenously combined to form a melted mixture.
- the melted mixture can be formed into pellets by various pelletizing operations.
- the melted mixture can pass through a die 10 and chopper (not shown).
- an underwater pelletizer 11 can be employed to form the extruded mixture into pellets.
- the pellets can be employed alone or in combination with other materials (e.g., virgin PET, polypropylene, and/or nylon) in various molding processes such as, but not limited to, blow molding, injection molding (e.g., high pressure injection, gas assist, structural foam, and the like), thermoforming (e.g., pressure forming, vacuum forming, stamping, and the like), extrusion (e.g., sheet extrusion, film extrusion, geometric shape (e.g., pipes and the like) extrusion), and the like.
- blow molding injection molding (e.g., high pressure injection, gas assist, structural foam, and the like)
- thermoforming e.g., pressure forming, vacuum forming, stamping, and the like
- extrusion e.g., sheet extrusion, film extrusion, geometric shape (e.g., pipes and the like) extrusion
- extrusion e.g., sheet extrusion, film extrusion, geometric shape (e.g., pipes and the like) ex
- each truckload has a sampling of bales of ca ⁇ et analyzed to determine it's material content, moisture levels and melt index to enable a determination of the types and amounts of additives and fillers.
- the ca ⁇ et is shredded into strips no larger than about 3 inches (7.62 centimeters (cm)) by about 12 inches (30.48 cm), and fed via a conveyer into the mixer along with flow enhancers (e.g., about 5 wt% to about 25 wt% EPDM is added, based upon the total combined weight, depending upon the ca ⁇ et composition).
- flow enhancers e.g., about 5 wt% to about 25 wt% EPDM is added, based upon the total combined weight, depending upon the ca ⁇ et composition.
- the ca ⁇ et and flow enhancers are mixed and heated to about 350°F (about 177°C) to about 450°F (about 232°C) to melt and blend the materials as well as remove moisture to less than or equal to about 0.5%.
- the melt ribbon is then fed directly into the throat of the extruder where additional additives are also optionally added.
- additional additives are also optionally added.
- about 2 wt% to about 5 wt% PET, and about 1 wt% to about 5 wt% calcium carbonate, and possibly other additives are introduced to the melt ribbon, based upon the total combined weight (inclusive of water weight).
- the extruder then blends and melts this mixture (e.g., at about 450°F (about 232°C) to about 550°F (about 288°C)) and extrudes it through a water ring pelletizer at rates typically, but not limited to, about 5,000 to about 10,000 pounds per hour (lb/hr) depending on factors including feedstock density and equipment size.
- the recycle material can then be employed in a molding process including injection molding (high pressure, gas assist, structural foam, and the like), blow molding, sheet extrusion, and the like, to form various articles. Some possible articles include, leaching chambers, pallets, endplates, as well as various other PET, polypropylene, or nylon products.
- Employing the recycle material in a molding process can comprise melting the pellets.
- the pellets can optionally be combined with virgin material(s) and/or non- ca ⁇ et originated recycled material(s) prior to, during, or after melting the pellets.
- the molten material can then be introduced into a mold having a negative of the article to be formed.
- the molten material is cooled (actively or passively) to form the article.
- a parison can be formed from the pellets and optionally combined with virgin material(s) and/or non-ca ⁇ et originated recycled material(s).
- the parison is disposed between mold halves and one end of the parison is closed. An inert gas is then blown into the parison to form a balloon and the mold halves are closed to form an article.
- Example 1 A truckload of bales of ca ⁇ et is randomly sampled (e.g., 3 bales are selected from the truckload and some material from each of the 3 bales is analyzed for material composition, content and melt index).
- the load can consist of polypropylene ca ⁇ et comprising 84 wt% polypropylene, 11 wt% latex, and the balance was calcium carbonate, with a moisture content of averaging 8 wt% and the melt index of 3.
- the bales are then shredded to allow the material to be fed into the mixer.
- EPDM e.g., 10 wt% can be added to the ca ⁇ et at the feed throat of a continuous mixer.
- the material can be processed in the continuous mixer at 380°F into a homogeneous blend of ca ⁇ et and EPDM, while driving off excess water content (via converting water to steam and venting out of mixer) until residual water content is less than 0.5%.
- the blend can then be fed directly into the feed throat of an extruder along with 3 to 7 wt% PET and processed at 450°F to further mix and blend the materials for introduction to a water ring pelletizer for conversion to pellets.
- Example 2 An endplate for use with a leaching chamber for dispersing liquids in soil, of the type having a hollow interior with open ends, and sidewalls with perforations enabling passage of liquids therethrough can be formed using the recycled ca ⁇ et.
- the recycled ca ⁇ et can be melted without separating various ca ⁇ et layers.
- Water content of the ca ⁇ et entering the continuous mixer can be up to about 10 wt%.
- the water content of the recycled ca ⁇ et is reduced to less than or equal to about 0.5 wt% within the continuous mixer, based upon the total weight of the recycle ca ⁇ et and the water, as discussed in Example 1 , to form a melt ribbon.
- the melt ribbon being properly screened for contaminant elimination, is mixed with an additive, e.g., in an extruder, kneader, or the like, to form a parison.
- the parison is disposed, e.g., extruded, between mold halves and one end of the parison is closed.
- An inert gas is then blown into the parison to form a balloon and the mold halves are closed to form the endplate.
- the endplate can comprise any appropriate endplate geometry, e.g., an inner wall and an outer wall defining a central portion having an interior channel, and at least one connector disposed about the periphery of the central portion, the connector capable of engaging the leaching chamber.
- Example 3 Leaching chamber for dispersing liquids in soil, of the type having a hollow interior with open ends and an open bottom enabling passage of liquids therethrough can be formed from the melt ribbon or the pellets of recycled ca ⁇ et.
- the recycle ca ⁇ et can be melted without separating various ca ⁇ et layers.
- the water content of the recycle ca ⁇ et can be reduced to less than or equal to about 0.5 wt%, based upon the total weight of the recycle ca ⁇ et and the water, by converting excess water to steam and venting the steam out of mixer.
- the water reduced material is then feed into an extruder.
- An additive can be mixed with the melt ribbon to form a mixture that is extruded to form pellets.
- the pellets can be heated to melting and introduced to a mold having a negative of the leaching chamber. Once the melt has cooled, actively or passively, the leaching chamber can be removed from the mold.
- Example 4 A plastic article can be produced by extruding flat sheet manufactured from melt ribbon or the pellets of recycled ca ⁇ et and then creating the article geometry through the thermoforming or stamping manufacturing process.
- the pellets can first be produced as per Example 1.
- the pellets or melt ribbon is feed through a sheet extrusion line having an extruder to melt the pellets (or ribbon), sheet die (for melt distribution to form sheet), calendaring stack (flattens, calendars, sizes sheet, initiates cooling), cooling stage (typically a water bath), and a cut-off station or take-up roll (depending on sheet thickness or end use).
- the sheet is then heated and formed by drawing (vacuum thermoforming), pushing (pressure thermoforming), or compressing (stamping) the sheet over a tool containing the negative of the plastic article geometry. Once the melt has cooled, actively or passively, the plastic article can be removed from the mold. This process can be employed to form a plastic pallet or component thereof.
- the recycle pellets formed from recycling the ca ⁇ et can be employed to form various injection molded articles, including, leaching chambers, pallets, endplates, and the like.
- the recycle pellets which may or may not comprise additives, can be combined with virgin material, such as polypropylene, high density polypropylene, PET, nylon, and the like (e.g., non-ca ⁇ et recycle).
- virgin material such as polypropylene, high density polypropylene, PET, nylon, and the like (e.g., non-ca ⁇ et recycle).
- the recycle pellets can be employed to form an article, in an amount of about 0.1 wt% to about 100 wt% recycle material (i.e., the pellet reformed into the desired article), based on the total weight of the article.
- the specific amount of the recycle material will depend upon the requirements of the actual article.
- greater than or equal to 50 wt% recycle material can be employed, with greater than or equal to about 75 wt% recycle material preferred, greater than or equal to about 90 wt% recycle material more preferred, and greater than or equal to about 95 wt% recycle material especially preferred.
- a pallet e.g., a plastic pallet
- about 5 wt% to about greater than or equal to 40 wt% recycle material can be employed.
- greater than or equal to about 10 wt% recycle material is preferred, with greater than or equal to about 15 wt% recycle material is more preferred.
- prefe ⁇ ed is less than or equal to about 30 wt% recycle material is preferred, with less than or equal to about 25 wt% recycle material more preferred.
- Injection molding of recycled polypropylene ca ⁇ et has not previously been successful due to: 1) water content of the ca ⁇ et, 2) the perceived need to produce pure polypropylene pellets, thus requiring significant separation of materials, and 3) the recycled ca ⁇ et's fractional melt index (e.g., polypropylene used to make ca ⁇ et fibers typically has a melt index of less than 2). While fractional melts are desired for some molding processes such as sheet extrusion (melt range typically from fractional up to 4), fractional melts are not desirable for blow molding (typical melt index of 2 to 6) and injection molding (typical melt index of greater than about 6).
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA 2463881 CA2463881A1 (en) | 2001-10-24 | 2002-10-24 | A method for recycling carpet and articles made therefrom |
MXPA04003786A MXPA04003786A (en) | 2001-10-24 | 2002-10-24 | A method for recycling carpet and articles made therefrom. |
EP20020784260 EP1444077A1 (en) | 2001-10-24 | 2002-10-24 | A method for recycling carpet and articles made therefrom |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US33490001P | 2001-10-24 | 2001-10-24 | |
US60/334,900 | 2001-10-24 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2003035350A1 true WO2003035350A1 (en) | 2003-05-01 |
Family
ID=23309351
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2002/034053 WO2003035350A1 (en) | 2001-10-24 | 2002-10-24 | A method for recycling carpet and articles made therefrom |
Country Status (5)
Country | Link |
---|---|
US (1) | US20030075824A1 (en) |
EP (1) | EP1444077A1 (en) |
CA (1) | CA2463881A1 (en) |
MX (1) | MXPA04003786A (en) |
WO (1) | WO2003035350A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1731283A1 (en) * | 2005-06-01 | 2006-12-13 | Infiltrator Systems, Inc. | A method for recycling carpet |
EP2174764A1 (en) * | 2008-10-10 | 2010-04-14 | Centre d'etude et de recherche pour l'automobile (CERA) | Process of manufacturing pellets from recycled materials |
GB2551559A (en) * | 2016-06-22 | 2017-12-27 | Preston Plastics Ltd | Plastic recycling |
CN110494263A (en) * | 2017-10-19 | 2019-11-22 | 艾尔思泰株式会社 | Automobile waste car cushion reuse means |
Families Citing this family (26)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6860953B1 (en) * | 1994-02-09 | 2005-03-01 | Collins & Aikman Floorcoverings, Inc. | Process for manufacturing a floor covering having a foamed backing formed from recycled polymeric material |
US6953119B1 (en) * | 2002-04-04 | 2005-10-11 | Scott Wening | System for gathering discarded post-consumer carpet, for recycling |
US7067613B2 (en) * | 2004-06-04 | 2006-06-27 | Chemical Products Corporation | Separation of polyolefins from nylons |
US20060069170A1 (en) * | 2004-09-27 | 2006-03-30 | Chemical Products Corporation | Decomposition of Polyester |
US20060070188A1 (en) * | 2004-09-27 | 2006-04-06 | Chemical Products Corporation | Colorant Removal from Polymeric Fibers |
US20060234574A1 (en) * | 2005-03-31 | 2006-10-19 | Larry Mullinax | Floor covering product and method of making same |
WO2007075993A2 (en) * | 2005-12-21 | 2007-07-05 | Milliken & Company | Lay flat flooring products and methods |
US7875655B2 (en) * | 2006-01-20 | 2011-01-25 | Material Innovations, Llc | Carpet waste composite |
US20070212531A1 (en) * | 2006-03-07 | 2007-09-13 | Mcintyre Dan | Process for recycling fiber material and binder with novel injection mold and parts made thereby |
WO2008066751A1 (en) | 2006-11-22 | 2008-06-05 | Material Innovations, Llc. | Wood-plastic composites using recycled carpet waste and systems and methods of manufacturing |
US20080213562A1 (en) * | 2006-11-22 | 2008-09-04 | Przybylinski James P | Plastic Composites Using Recycled Carpet Waste and Systems and Methods of Recycling Carpet Waste |
US8110131B1 (en) * | 2006-12-06 | 2012-02-07 | Dell Orco Sergio | Carpet reclamation system |
US7501159B1 (en) | 2007-07-23 | 2009-03-10 | James Gilstrap | Use of carpet scraps to improve paint coating durability |
US7514026B1 (en) * | 2007-11-30 | 2009-04-07 | Dzs, Llc. | Method for recycling floor coverings |
JP4386457B2 (en) * | 2007-12-14 | 2009-12-16 | 住友ゴム工業株式会社 | Artificial turf structure, artificial turf facility using artificial turf structure, and method for recycling artificial turf structure |
BRPI0922481A2 (en) * | 2008-12-19 | 2018-06-05 | Fiber Composites Llc | wood-plastic composites using ionomer capstocks and manufacturing methods |
US20100273001A1 (en) * | 2009-04-22 | 2010-10-28 | Keating Joseph Z | Method of Recycling Carpet Components and Carpet Components formed Therefrom |
US8360348B2 (en) | 2010-08-12 | 2013-01-29 | Frank Levy | Method and apparatus for recycling carpet |
US8870104B2 (en) | 2011-01-13 | 2014-10-28 | Frank Levy | Method for separating carpet fibers |
US20120282409A1 (en) * | 2011-05-03 | 2012-11-08 | Emerson Climate Technologies, Inc. | Recycled nylon materials for use in refrigeration systems |
US20130227880A1 (en) * | 2012-03-05 | 2013-09-05 | Att Southern, Inc. | Recycled plastic composite composition |
US20190184619A1 (en) * | 2017-12-15 | 2019-06-20 | GM Global Technology Operations LLC | Long fiber reinforced thermoplastic filament |
CN110733144B (en) * | 2019-10-29 | 2021-05-28 | 常州中科绿塑环保科技有限公司 | Melting granulation process for recycling plastic foam |
ES2790498B2 (en) * | 2020-07-16 | 2023-02-20 | Sports & Landscape S L | RECYCLING PROCEDURE FOR ARTIFICIAL GRASS AND RECYCLED ARTIFICIAL GRASS PRODUCT |
US11572646B2 (en) | 2020-11-18 | 2023-02-07 | Material Innovations Llc | Composite building materials and methods of manufacture |
CN114505322B (en) * | 2022-01-18 | 2023-09-26 | 河南车邦汽车用品制造有限公司 | Blanket leftover material recycling system and method |
Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4003408A (en) * | 1974-02-26 | 1977-01-18 | George C. Ballas, trustee | Underground irrigation porous pipe |
US4517316A (en) * | 1984-01-24 | 1985-05-14 | Dasurat Enterprises Pte Ltd. | Porous irrigation pipe prepared from particulate elastomer and thermoplastic binder containing controlled moisture content |
DE3610822A1 (en) * | 1986-04-01 | 1987-10-08 | Erwin Moeck | Process for producing pallets |
JPH05287139A (en) * | 1992-04-14 | 1993-11-02 | Teijin Ltd | Production of thermoplastic resin composition |
DE4311708A1 (en) * | 1993-04-08 | 1994-10-13 | Dlw Ag | Process for recycling bonded fabrics containing plastic, and also the recycled material obtainable thereby and use thereof |
US5591802A (en) * | 1993-03-25 | 1997-01-07 | David; Donald J. | Thermoplastic composition and method for producing thermoplastic composition by melt blending carpet |
DE19540366A1 (en) * | 1995-10-30 | 1997-05-15 | Dieter Prof Dr Ing Wuestenberg | Recycling used thermoplastic carpets to form a regranulated sec. fibre reinforced plastic composite prod. |
US5859071A (en) * | 1996-04-15 | 1999-01-12 | Lear Corporation | Recycling of carpet scrap |
US6241168B1 (en) * | 1999-06-10 | 2001-06-05 | Lear Corporation | Recycling of carpet scrap and compositions employing ultralow density polyethylene (ULDPE) |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS5876577A (en) * | 1981-10-26 | 1983-05-09 | 日石三菱株式会社 | Carpet backing composition |
US5236645A (en) * | 1990-09-21 | 1993-08-17 | Basf Corporation | Addition of additives to polymeric materials |
US5417167A (en) * | 1993-03-03 | 1995-05-23 | Salflex Polymers Ltd. | Plastic pallet |
EP0719301B1 (en) * | 1993-08-30 | 2001-06-20 | Masland Industries, Inc. | Recycling of carpet scrap |
JPH10506136A (en) * | 1994-09-23 | 1998-06-16 | チバ スペシャルティ ケミカルズ ホールディング インコーポレーテッド | Stabilized recycled plastic |
US6076993A (en) * | 1997-06-16 | 2000-06-20 | Psa, Inc. | Leaching chamber |
US5951712A (en) * | 1996-12-31 | 1999-09-14 | Campbell; Jerome | Method for plastic waste reclamation and product produced thereby |
US6140463A (en) * | 1997-02-18 | 2000-10-31 | Stefandl; Roland E. | Process for recycling and recovery of purified nylon polymer |
US6182913B1 (en) * | 1999-01-25 | 2001-02-06 | Interface, Inc. | Method and apparatus for reclaiming carpet components |
-
2002
- 2002-10-24 WO PCT/US2002/034053 patent/WO2003035350A1/en not_active Application Discontinuation
- 2002-10-24 MX MXPA04003786A patent/MXPA04003786A/en unknown
- 2002-10-24 EP EP20020784260 patent/EP1444077A1/en not_active Withdrawn
- 2002-10-24 CA CA 2463881 patent/CA2463881A1/en not_active Abandoned
- 2002-10-24 US US10/279,443 patent/US20030075824A1/en not_active Abandoned
Patent Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4003408A (en) * | 1974-02-26 | 1977-01-18 | George C. Ballas, trustee | Underground irrigation porous pipe |
US4517316A (en) * | 1984-01-24 | 1985-05-14 | Dasurat Enterprises Pte Ltd. | Porous irrigation pipe prepared from particulate elastomer and thermoplastic binder containing controlled moisture content |
DE3610822A1 (en) * | 1986-04-01 | 1987-10-08 | Erwin Moeck | Process for producing pallets |
JPH05287139A (en) * | 1992-04-14 | 1993-11-02 | Teijin Ltd | Production of thermoplastic resin composition |
US5591802A (en) * | 1993-03-25 | 1997-01-07 | David; Donald J. | Thermoplastic composition and method for producing thermoplastic composition by melt blending carpet |
DE4311708A1 (en) * | 1993-04-08 | 1994-10-13 | Dlw Ag | Process for recycling bonded fabrics containing plastic, and also the recycled material obtainable thereby and use thereof |
DE19540366A1 (en) * | 1995-10-30 | 1997-05-15 | Dieter Prof Dr Ing Wuestenberg | Recycling used thermoplastic carpets to form a regranulated sec. fibre reinforced plastic composite prod. |
US5859071A (en) * | 1996-04-15 | 1999-01-12 | Lear Corporation | Recycling of carpet scrap |
US6241168B1 (en) * | 1999-06-10 | 2001-06-05 | Lear Corporation | Recycling of carpet scrap and compositions employing ultralow density polyethylene (ULDPE) |
Non-Patent Citations (1)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 018, no. 082 (C - 1164) 10 February 1994 (1994-02-10) * |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1731283A1 (en) * | 2005-06-01 | 2006-12-13 | Infiltrator Systems, Inc. | A method for recycling carpet |
EP2174764A1 (en) * | 2008-10-10 | 2010-04-14 | Centre d'etude et de recherche pour l'automobile (CERA) | Process of manufacturing pellets from recycled materials |
FR2936973A1 (en) * | 2008-10-10 | 2010-04-16 | Cera | PROCESS FOR MAKING A GRANULE FROM RECYCLING |
GB2551559A (en) * | 2016-06-22 | 2017-12-27 | Preston Plastics Ltd | Plastic recycling |
CN110494263A (en) * | 2017-10-19 | 2019-11-22 | 艾尔思泰株式会社 | Automobile waste car cushion reuse means |
Also Published As
Publication number | Publication date |
---|---|
MXPA04003786A (en) | 2005-04-08 |
CA2463881A1 (en) | 2003-05-01 |
US20030075824A1 (en) | 2003-04-24 |
EP1444077A1 (en) | 2004-08-11 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20030075824A1 (en) | Method for recycling carpet and articles made therefrom | |
US20050206029A1 (en) | Method for recycling carpet and articles made therefrom | |
Turku et al. | Characterization of wood plastic composites manufactured from recycled plastic blends | |
US6723424B2 (en) | Product and process for producing a molded product from recycled carpet waste | |
US7022751B2 (en) | Composite plastic materials produced from waste materials and method of producing same | |
JP4006076B2 (en) | Manufacturing method of molded products made from plastic waste | |
EP0695614B1 (en) | Process and apparatus for extruding mixtures of thermoplastic and thermoset materials and products made therefrom | |
EP0593589B1 (en) | Method for preparation of composite materials | |
US5951940A (en) | Method of recycling post-consumer plastic waste | |
US20140220280A1 (en) | Process of recycling plastics, products and applications thereof | |
EP0692356A2 (en) | Method for preparing automobile shredder residue - synthetic plastic material composite | |
JP2006502888A (en) | Article comprising a fiber reinforced thermoplastic polymer composition | |
US20200307060A1 (en) | Apparatus for recycling waste automobile floor mat | |
HU225951B1 (en) | Method for processing of polymer wasts to obtain matrix material; the matrix material and the composite material | |
AU2002348047A1 (en) | A method for recycling carpet and articles made therefrom | |
DE19830913A1 (en) | Recycling and preparation of plastics involving heat treating and crosslinking | |
KR101619141B1 (en) | A method of manufacturing a fuel-saving a sewer pipe filling wall with the waste plastic | |
KR0153321B1 (en) | Manufacturing method of recycled board utilized used-carpet and carpet scrap | |
MXPA06001344A (en) | Method for recycling carpet and articles made therefrom | |
KR19990049341A (en) | Manufacturing method of recycled resin using peroxide | |
JP4125942B2 (en) | Mixed material using plastic waste, manufacturing apparatus thereof, and manufacturing method thereof | |
CN1146395A (en) | Plastic material made from waste material and method | |
WO2004041495A1 (en) | Low shear pelletization method and apparatus therefor | |
EP4292790A1 (en) | Method for obtaining a recycled material from multilayer pet containers and recycled material obtained using same | |
JPH10272629A (en) | Manufacture of fiber reinforced thermoplastic resin reclaimed articles |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AK | Designated states |
Kind code of ref document: A1 Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NO NZ OM PH PL PT RO RU SD SE SG SI SK SL TJ TM TN TR TT TZ UA UG US UZ VN YU ZA ZM ZW |
|
AL | Designated countries for regional patents |
Kind code of ref document: A1 Designated state(s): GH GM KE LS MW MZ SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR IE IT LU MC NL PT SE SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG |
|
121 | Ep: the epo has been informed by wipo that ep was designated in this application | ||
WWE | Wipo information: entry into national phase |
Ref document number: 2463881 Country of ref document: CA |
|
WWE | Wipo information: entry into national phase |
Ref document number: 532336 Country of ref document: NZ |
|
WWE | Wipo information: entry into national phase |
Ref document number: 200402991 Country of ref document: ZA |
|
WWE | Wipo information: entry into national phase |
Ref document number: PA/a/2004/003786 Country of ref document: MX |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2002784260 Country of ref document: EP |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2002348047 Country of ref document: AU |
|
WWP | Wipo information: published in national office |
Ref document number: 2002784260 Country of ref document: EP |
|
WWW | Wipo information: withdrawn in national office |
Ref document number: 2002784260 Country of ref document: EP |
|
NENP | Non-entry into the national phase |
Ref country code: JP |
|
WWW | Wipo information: withdrawn in national office |
Country of ref document: JP |