Carpet waste composite
AssigneeMaterial Innovations LLC
InventorsDavid E. Murdock, Douglas Mancosh, James P. Przybylinski
Life of this patent
Estimating the term…
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.
Claims24
A composite building material, comprising:
- a first layer comprising:
- a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste;
- and
- a first binding agent in intimate association with the processed carpet waste;
- and
- a second layer disposed on the first layer and comprising natural fibers and a second binding agent.
A method of manufacturing a composite building material, the method comprising the steps of:
- forming a first layer comprising:
- a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste;
- and
- a first binding agent in intimate association with the processed carpet waste;
- applying a second layer to the first layer, the second layer comprising natural fibers and a second binding agent;
- and
- heating and pressing the first layer and the second layer together to form the composite building material.
Dependencies are inferred from the claim text.