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US 9,724,852 B1Granted
High density composites comprising reclaimed carpet material
AssigneeColumbia Insurance Company
InventorsJohn J. M. Rees, Gregory Fowler
Life of this patent
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Abstract
Disclosed are methods for utilizing reclaimed carpet materials in the manufacture of high density composites. Also disclosed are products manufactured by the disclosed methods.
Claims18
A method of making a composite from reclaimed carpet material, comprising:
- providing a composite layer of reclaimed carpet material and low melt thermoplastic binder resin;
- heating the composite layer at a temperature sufficient to melt the thermoplastic binder resin;
- subjecting the heated composite layer to pressure sufficient to substantially consolidate the melted binder and reclaimed carpet material and to form a composite having a desired density and thickness;
- and
- cooling the formed composite having the desired density and thickness;
- wherein the reclaimed carpet material comprises a population of reclaimed carpet fibers having non-uniform linear fiber densities;
- and
- wherein the formed composite has a density of from 30 to 100 pounds per cubic foot.
5 more elements
A method of making a flooring underlayment, comprising:
- providing a composite layer of reclaimed carpet material, wherein the reclaimed carpet material comprises a population of reclaimed carpet fibers having non-uniform linear fiber densities, and wherein a portion of the reclaimed carpet material comprises polypropylene;
- heating the composite layer at a temperature sufficient to melt at least a portion of the polypropylene;
- subjecting the heated composite layer to pressure sufficient to substantially consolidate the melted polypropylene and reclaimed carpet material and to form a composite underlayment having a desired density and thickness;
- and
- cooling the formed composite underlayment;
- wherein the formed composite has a density of from 30 to 100 pounds per cubic foot.
3 more elements
Dependencies are inferred from the claim text.