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.
Claims30
A composite building material comprising:
- a first layer comprising a first carpet waste, a first binding agent, and an inorganic filler in addition to any filler present in the first carpet waste;
- and
- a second layer disposed on the first layer, the second layer comprising a second carpet waste, a second binding agent, and a colorant.
A method of manufacturing a composite building material, the method comprising the steps of:
- forming a first mat comprising a first carpet waste, a first binding agent, and an inorganic filler in addition to any filler present in the first carpet waste;
- forming a second mat on the first mat, the second mat comprising a second carpet waste, a second binding agent, and a colorant;
- and
- heating and pressing the first mat and the second mat together to form the composite building material.
A composite building material comprising:
- a processed carpet waste comprising at least one of polyester and sisal;
- and
- a binding agent in intimate association with the processed carpet waste,
- wherein at least one of (i) the processed carpet waste comprises a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste, and (ii) the composite building material comprises an inorganic filler in addition to any filler present within the carpet waste and any synthetic fiber filler.
A method of producing a composite building material, the method comprising the steps of:
- providing a processed carpet waste comprising at least one of polyester and sisal;
- mixing the processed carpet waste with a binding agent to produce a carpet waste mixture;
- and
- heating and pressing the carpet waste mixture to form the composite building material,
- wherein at least one of (i) the processed carpet waste comprises a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste, and (ii) mixing the processed carpet waste comprises adding an inorganic filler to the carpet waste mixture, the added inorganic filler being present in the carpet waste mixture in addition to any filler present within the carpet waste and any synthetic fiber filler.
Dependencies are inferred from the claim text.