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US 10,294,666 B2Granted
Carpet waste composite
AssigneeMaterial Innovations LLC
InventorsDavid E. Murdock, Douglas Mancosh, James P. Przybylinski
Life of this patent
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Abstract
A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.
Claims22
A composite board comprising:
- a substantially homogeneous mixture comprising a carpet waste, an inorganic filler in addition to any filler present in the carpet waste, and a binding agent;
- and
- a cover layer disposed on at least a portion of the substantially homogeneous mixture, the cover layer comprising a patterned surface.
A method of producing a composite board, the method comprising:
- providing a carpet waste;
- providing an inorganic filler, wherein the inorganic filler is in addition to any filler present within the carpet waste;
- mixing the carpet waste and the inorganic filler with a binding agent to produce a substantially homogeneous mixture;
- heating and pressing the substantially homogeneous mixture to form a composite core;
- and
- applying a cover layer to at least a portion of the composite core, the cover layer comprising a patterned surface.
3 more elements
Dependencies are inferred from the claim text.