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US 2011/0257345 A1Published application
Method of separating and cleaning of post consumer carpet face yarn from carpet backing and yarn product produced therefrom
AssigneeUniversal Fibers, Inc.
InventorsGeorge T. Hoover, JR., Milton K. Roark, Brendan F. McSheehy, JR., Mathew B. Studholme
Life of this patent
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Abstract
A process for producing a synthetic fiber composition with reclaimed post consumer carpet yarn, wherein face yarn is shaved from post consumer carpet using a shaving device to provide shaved face yarn, the shaved face yarn is reduced in size, contaminants are removed using mechanical screeners, the shaved face yarn is melt filtered, and spun into fiber.
Claims20
A process for producing a synthetic fiber from reclaimed post-consumer carpet yarn, the process comprising:
- a. shaving face yarn from post-consumer carpet by use of a shaving device to provide a shaved face yarn,
- b. reducing the sizes of said shaved face yarn,
- c. feeding said shaved face yarn from step (b) to a mechanical screener to produce a mechanically-screened face yarn,
- d. melt filtering said mechanically-screened face yarn to form a melt-filtered face yarn, and
- e. spinning said melt-filtered face yarn to form a synthetic fiber.
2 more elements
A synthetic fiber composition comprising a blend of:
- a) at least 2 wt % of a recycled fiber-forming thermoplastic resin from reclaimed post consumer carpet yarn;
- and
- b) a virgin fiber-forming thermoplastic resin,
- wherein said blend provides a pressure rise of 0.6 psi/gm or less when said blend (i) contains 2 wt % of said recycled fiber forming thermoplastic resin and (ii) is subjected to a melt filter test using a Dutch twilled weave filter screen of 80×700 nominal mesh count using a pilot-scale single screw extruder.
1 more element
Dependencies are inferred from the claim text.