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.
Claims31
A composite adapted for use as a building material, the composite comprising:
- processed carpet waste, wherein the processed carpet waste comprises (i) a reduced amount of inorganic filler present within an unprocessed carpet waste, and (ii) a melted polypropylene and an unmelted nylon;
- and
- between about 2% and about 10% binding agent by weight of the composite.
A method of manufacturing a composite adapted for use as a building material, the method comprising the steps of:
- applying heat and pressure to a processed carpet waste and a binding agent to form the composite at a temperature and for a time period sufficient to melt a plurality of materials comprising the processed carpet waste;
- and
- cooling the composite while applying pressure to the composite.
A method of manufacturing a composite adapted for use as a building material, the method comprising the steps of:
- applying heat and pressure to a processed carpet waste and a binding agent to form the composite material;
- and
- cooling the composite material while applying pressure to the composite material;
- wherein the step of applying heat and pressure occurs in a first cycle press, and wherein the step of cooling the composite while applying pressure occurs in a second cycle press.
A method of manufacturing a composite adapted for use as a building material, the method comprising the steps of:
- processing a carpet waste to obtain a processed carpet waste;
- applying heat and pressure to the processed carpet waste and a binding agent to form the composite;
- and
- actively cooling the composite while applying pressure to the composite, wherein the composite is cooled under pressure for a time period and to a reduced temperature sufficient to reduce warping of the composite.
Dependencies are inferred from the claim text.