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US 8,017,662 B2Granted
Method of separation and cleaning of post consumer carpet face yarn from carpet backing and yarn product produced therefrom
AssigneeUniversal Fibers, Inc.
InventorsGeorge Taylor Hoover, Jr., Milton Keith Roark, Brendan Francis McSheehy, Jr., Matthew Benjamin Studholme
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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 shave face yarn is melt filtered, and then fiber spun.
Claims20
A process for producing a synthetic fiber composition, comprising
- i. shaving face yarn from post consumer carpet by use of a shaving device to provide a shaved face yarn;
- ii. reducing the sizes of said shaved face yarn;
- iii. agitating said shaved face yarn;
- iv. removing contaminants from said shaved face yarn by mechanical screening, washing, or a combination thereof;
- and
- v. melt filtering of said shaved face yarn to produce a recycled fiber-forming thermoplastic resin;
- and
- vi. blending at least 2 weight percent of said recycled fiber-forming thermoplastic resin with a virgin fiber-forming resin to form a fiber-forming blend,
- wherein
- said fiber-forming blend provides a pressure rise of 0.6 psi/gm or less when said blend (i) contains 2 weight percent 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.
7 more elements
A process for producing a synthetic fiber composition, comprising
- i. shaving face yarn comprising polyethylene terephthalate, nylon 6, or nylon 66, from post consumer carpet by use of a shaving device to provide a shaved face yarn;
- ii. reducing the sizes of said shaved face yarn;
- iii. agitating said shaved face yarn;
- iv. removing contaminants from said shaved face yarn by mechanical screening and washing;
- v. melt filtering of said shaved face yarn to produce a recycled fiber-forming thermoplastic resin;
- and
- vi. blending at least 2 weight percent of said recycled fiber-forming thermoplastic resin with a virgin fiber-forming resin comprising polyethylene terephthalate, nylon 6, or nylon 66 to form a fiber-forming blend,
- wherein
- said fiber-forming blend provides a pressure rise of 1.10 psi/gm or less when said blend (i) contains 5 weight percent 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.
6 more elements
Dependencies are inferred from the claim text.