Filler recovery processes
AssigneeMohawk Carpet Distribution, Inc.
InventorsJames A. Lindsey, Paul Meredith
Life of this patent
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Abstract
Various embodiments of the present invention generally provide processes for recovering and/or using one or more constituent components of carpeting. More specifically, various embodiments provide processes for reclaiming a filler material from carpet as well as processes for using the recovered filler material in subsequent carpet manufacturing processes. The present filler recovery processes can provide recycled filler material, which can be extracted at various stages of processing, and in different purities, depending on the subsequent need or use for the recovered filler material. In some instances, the filler recovery processes described herein can be implemented as sub-processes for recycling other carpet components.
Claims17
A recovery process for recovering filler material from carpet waste, said recovery process comprising the steps of:
- providing carpet waste that includes at least one of post-industrial carpet, carpet selvage, or post-consumer carpet;
- size-reducing the carpet waste into particulate matter comprising polymer fibers, filler material and adhesive material;
- separating the particulate matter into a first stream comprising substantially polymer fibers and a second stream comprising substantially filler material and adhesive material;
- and
- heating the second stream at a temperature that volatizes at least some of the polymer fibers remaining in the second stream to enrich the content of filler material in the second stream.
A recovery process for recovering filler material from carpet waste, said recovery process comprising the steps of:
- providing carpet waste that includes at least one of post-industrial carpet, carpet selvage, or post-consumer carpet;
- size-reducing the carpet waste into particulate matter comprising polymer fibers, filler material and adhesive material;
- screening the particulate matter to separate a first stream comprising the polymer fibers from a second stream comprising the filler material and the adhesive material;
- size-reducing the second stream using attrition methods to create size reduced particles;
- heating the size-reduced second stream to a temperature sufficient to volatize at least some of the fibers to enrich the content of filler material in the second stream thereby creating an enriched second stream;
- and
- separating the size reduced particles based on size.
Dependencies are inferred from the claim text.