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US 12,441,080 B2Granted
Carpet waste composite and method for making same
AssigneeAdvanced Carpet Recycling, LLC
InventorDaniel R. McIntyre
Life of this patent
Estimating the term…
Abstract
A carpet waste composite and method for making the same are disclosed. In one embodiment of the method, cleaned, unadulterated layers of are provided. An initial, unfused carpet layer is made by placing two cleaned, unadulterated layers of carpet tufted side-to-tufted side with homogenous and adhesive contact therebetween. Heat and pressure followed by cooling are applied to furnish an initial, fused carpet layer. Carpet layers are iteratively added, as required, using heat and pressure followed by cooling to furnish a carpet waste composite. Plates are added in sealing engagement to surfaces of the composite construction material.
Claims17
A method of manufacturing a composite construction material, the method comprising:
- providing a plurality of cleaned, unadulterated layers of intact carpet, each of the plurality of cleaned, unadulterated layers of intact carpet having a backing side and a tufted side;
- creating an initial, unfused carpet layer by placing two cleaned, unadulterated layers of intact carpet of the plurality of cleaned, unadulterated layers of intact carpet side-to-side with homogenous and adhesive contact therebetween, the homogenous and adhesive contact including an adhesive material;
- applying first heat and pressure to the initial, unfused carpet layer within a first carrier having a first fixed height;
- applying first cooling to the initial, unfused carpet layer to form an initial, fused carpet layer;
- creating the composite construction material by iteratively adding additional layers of cleaned, unadulterated layers of intact carpet of the plurality of cleaned, unadulterated layers of intact contact carpet, each of the additional layers of cleaned, unadulterated layers of intact carpet being added side-to-side with the homogenous and adhesive contact therebetween, each of the additional layers of cleaned, unadulterated layers of intact carpet being subject to an application of second heat and pressure followed by an application of second cooling;
- providing first and second plates in a sealing engagement with respective first and second surfaces of the composite construction material;
- and
- providing a plurality of reinforcement rods traversing the composite construction material from the first plate to the second plate.
5 more elements
A method of manufacturing a composite construction material, the method comprising:
- providing a plurality of cleaned, unadulterated layers of intact carpet, each of the plurality of cleaned, unadulterated layers of intact carpet having a backing side and a tufted side;
- creating an initial, unfused carpet layer by placing two cleaned, unadulterated layers of intact carpet of the plurality of cleaned, unadulterated layers of intact carpet side-to-side with homogenous and adhesive contact therebetween, the homogenous and adhesive contact including an adhesive material;
- applying first heat and pressure to the initial, unfused carpet layer within a first carrier having a first fixed height;
- applying first cooling to the initial, unfused carpet layer to form an initial, fused carpet layer;
- creating the composite construction material by iteratively adding additional layers of cleaned, unadulterated layers of intact carpet of the plurality of cleaned, unadulterated layers of intact contact carpet, each of the additional layers of the cleaned, unadulterated layers of intact carpet being added side-to-side with the homogenous and adhesive contact therebetween, each of the additional layers of the cleaned, unadulterated layers of intact carpet being subject to an application of second heat and pressure followed by an application of second cooling;
- and
- providing first and second fiberglass plates in a sealing engagement with respective first and second surfaces of the composite construction material, the first and second fiberglass plates being subjacent to at least one of the additional layers of the cleaned, unadulterated layers of intact carpet.
4 more elements
A method of manufacturing a composite construction material, the method comprising:
- providing a plurality of cleaned, unadulterated layers of intact carpet, each of the plurality of cleaned, unadulterated layers of intact carpet having a backing side and a tufted side;
- creating an initial, unfused carpet layer by placing two cleaned, unadulterated layers of intact carpet of the plurality of cleaned, unadulterated layers of intact carpet side-to-side with homogenous and adhesive contact therebetween, the homogenous and adhesive contact including an adhesive material;
- applying first heat and pressure to the initial, unfused carpet layer within a first carrier having a first fixed height;
- applying first cooling to the initial, unfused carpet layer to form an initial, fused carpet layer;
- creating the composite construction material by iteratively adding additional layers of cleaned, unadulterated layers of intact carpet of the plurality of cleaned, unadulterated layers of intact contact carpet, each of the additional layers of cleaned, unadulterated layers of intact carpet being added side-to-side with the homogenous and adhesive contact therebetween, each of the additional layers of cleaned, unadulterated layers of intact carpet being subject to an application of second heat and pressure followed by an application of second cooling;
- and
- providing a trellis integrated integral to the composite construction material, the trellis including first and second plates in a sealing engagement with respective first and second surfaces of the composite construction material.
4 more elements
Dependencies are inferred from the claim text.