Carpet waste composite

(57) Abrégé/Abstract

A composite material produced from carpet waste and a binding agent, in intimate association, which material indudes 25% and 99% carpet waste and between 1 and 25% binding agent A method for manufacturing the composite material is also disclosed.

rue Victoria · Place du Portage 1 · Gatineau, (Québec) K1AOC9 · www.opic.ic.gc.ca 50 Victoria Street · Place du Portage 1 · Gatineau, Quebec K1A0C3 · www.dpo.ic.gc.ca

Canada

CA 02933740 2016-06-20

CARPET WASTE COMPOSITE

BACKGROUND

The general field of this invention is natural and manmade fiber composites which are used in various industrial and consumer applications.

Natural and manmade fiber composites can be used in building construction, industrial applications, consumer goods, automotive products, and other industries requiring moisture or thermal resistance with various physical properties, such as low moisture absorbance and low thermal distortion. The ability to build composites of this nature, while controlling physical properties such as strength, stiffness, ductility, impact resistance, and hardness, opens a variety of application opportunities.

Additionally, there is growing pressure to re-utilize waste streams which are high in {5 volume and low in degradability. In particular the manufacture, installation, use and (eventually) replacement of floor covering products, especially carpeting, produces a large amount of waste product. Carpet waste from new carpet production, post-consumer landfill or other used carpet applications is a several billion pound-per-year waste problem. The industry generally uses the term “selvedge” for waste material generated during the manufacturing process while other forms of manufacturing and installation waste are sometimes termed “scrap”. We use the term carpet waste to cover all types of waste produced by the manufacture, installation, use and replacement of floor covering products. Often, carpet waste is not recycled, but rather is disposed of by land-filling or burning.

SUMMARY

We have discovered a composite material produced from carpet waste and a binding agent.

The first aspect of this invention is a process for converting carpet waste with or without additional fibers and/or fillers and combining it with binding agents to produce a composite material. More specifically the invention is its general form features a composite material comprising carpet waste and a binding agent in intimate association, where the

CA 02933740 2016-06-20 composite material includes between 25% and 99% carpet waste and between 1 and 25% binding agent.

In accordance with one aspect of the invention, there is provided a composite material comprising: carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added inorganic filler; and a binding agent in intimate association, die composite material comprising between 25% and 99% carpet waste and between 1% and 25% binding agent, wherein 0) the binding agent comprises one or more of methylenedipbenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and (ii) the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.

Preferably, the sum of the carpet waste and the binding agent are between 50% and 99% of the total material, and the composite material also includes from 0-50% natural fibers or manmade fiber fibers (such as oriented fiberglass), or a combination of manmade and natural fibers. The composite material may also include at least one inorganic filler such as calcium carbonate or silica. Additionally, the composite material may also include special additives that result in favorable physical property attributes. Flame retardants and/or mold inhibitors an be added at levels of 0-25% (preferably levels of 0-10%) of the total material. Flame retardants that could be used, but are no limited to, are Occidental’s Dcchlorane Plus, Ferro’s Pyrochek 68PB, and Great Lakes PO-64P. The flame retardants may or may not also require a Sb302 synergizer to be used. Mold Inhibitors that could be used at the same levels, include but are no limited to, are Zinc Borate and Rohm £ Haas Vinyzene mold inhibitor. Scientifically, the carpet waste includes all carpet components substantially without segregation from one another. For example, the carpet waste comprises carpet backing in an amount equal to at least 10% (by weight) of the composite material and/or it comprises carpet fece polymers, such as nylon, polyester, polypropylene and wool.

Also preferably, the modulus of elasticity of the composite material is at least 55,000 PSI by ASTEM test D79O, more preferably at least 100,000 PSI by ASTEM test D790. Preferably the modulus of rupture of the composite material is at least 600 PSI by ASTM

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D790, more preferably between 1000 and 2500 PSI by A STEM D790. Preferably the density of the composite material is at least 30 pounds per ft³.

In accordance with another aspect ofthe invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of:

methyfenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea 10 formaldehyde (MUF), and phenol formaldehyde (PF); and d) subjecting the carpet waste, inorganic filler and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, and binding agent in inrimntp association, the composite material comprising between 25% and 99% carpet waste and between 1% and 25% binding agent, wherein the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste. .

Preferably the size reduction step comprises one or more of the following processes: chopping; shredding; grinding; contaminant separating; palletizing; agglomerating; pulverizing; fine grinding; and/or fiberizing the carpet waste. (For example, the carpet waste and configured to density the material.)

The size-reduced carpet waste and binder are combined in a drum to coast the waste with binder. The binder/carpet waste combination is subjected to heat and pressure in a continuous belted press or in a stationary press.

Optionally, a further layer is applied to a surface of the composite sheet thus 25 manufactured, for example, the further layer is a laminated layer or a foil-transfer layer, or the further layer is a paint, a stain or a polymeric compound. The further layer may be molded or embossed to create a patterned surface on the composite material. Optionally, the further layer may be a wood veneer, a synthetic veneer, and/or a polymeric sheet. The surface of the composite material is prepared by means of mechanical or chemical methods.

CA 02933740 2016-06-20 followed by foil or film lamination of the further layer. The further layer may include a hotstamped layer.

The composite material thus formed maybe thermofonned into a desired shape. The further layers may be a foil or film laminate.

At least one layer of the composite material may be sanded.

In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing tbe carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or mote of methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the carpet waste, inorganic fillo·, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25% and 99% carpet waste and between 1% and 25% binding agent; and e) applying a layer to a surface of the composite material, wherein the layer is molded or embossed to create a patterned surface on tbe composite material.

In accordance with another aspect of Ihe invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing tbe carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting tbe carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler , and binding agent in intimate association, the composite material comprising between 25% and 99% carpet waste and between 1 % and 25% binding agent; and e) applying a layer to a surface of the composite material, wherein the layer comprises a foil or film laminate.

In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing the

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Cft 02933740 2016-06-20 caipet waste by subjecting ihe carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler end a Unding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising caipet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25% and 99% carpet waste and between 1 % and 25% binding agent; e) preparing the surface of the composite material and subjecting tbe surface ofthe composite material to mechanical or chemical preparation; and f)applying a lay» to a surface ofthe composite material, wherein the layer comprises a foil or film laminate.

In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing carpet waste; b) preparing the caipet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced caipet waste with an inorganic filler and a binding agent comprising one or more of: melhylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the caipet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising caipet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25% and 99% caipet waste and between 1% and 25% binding agent; and e) applying a layer to a surface of the composite materia), wherein the layer comprises a hot-stamped layer.

In accordance with another aspect of the invention, there is provided a method of manufacturing a composite material comprising: a) providing caipet waste; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler,

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CA 02933710 2016-06-20 and binding agent in intimate association, tbe composite material comprising between 25% and 99% carpet waste and between 1% and 25% binding agent; and e) applying a layer to a surface of the composite material, wherein at least one of the layer and the surface is sanded.

In accordance with another aspect of the invention, there is provided a method of 5 manufacturing a composite material comprising; a) providing carpet waste; b) preparing the carpet waste by subjecting the carpet waste to size-reduction treatment comprising one or more of chopping; shredding; grinding; contaminant separating; pelletizing; agglomerating; pulverizing; fine grinding; and fiberizing; and spinning and forcing the carpet waste under pressure through orifices sized and configured to densify the size-reduced carpet waste; c) combining the size-reduced carpet waste with an inorganic filler and a binding agent comprising one or more of: methylenedipbenyldiisocyanate (MOI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and d) subjecting the carpet waste, inorganic filler, and binding agent combination to pressure and elevated temperature in a confined geometry to produce a composite material comprising carpet waste, inorganic filler, and binding agent in intimate association, the composite material comprising between 25% and 99% carpet waste and between 1% and 25% binding agent.

In accordance with another aspect of the invention, there is provided a composite material comprising; carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added inorganic filler; a binding agent in intimate association with the carpet waste, wherein the binding agent comprises one or more of methylenedipheuyldiisocyariate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and a layer on a surface of the composite material, wherein (i) the layer is molded or embossed to create a patterned surface on the composite material, (ii) the composite material comprises between 25% and 99% carpet waste and between 1 % and 25% binding agent, and (iii) the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.

In accordance mth another aspect of the invention, (here is provided a composite material comprising; carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added

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ÎDorgantc filler; a binding agent in intimate association with tbe carpet waste, wherein the binding agent comprises one or more of methylenediphenyldüsocyaiiate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and a layer on a surface of the composite material, wherein (i) tbe layer comprises a foil or film laminate, (ii) the composite material comprises between 25% and 99% carpet waste and between 1% and 25% binding agent, and (iii) tbe composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.

In accordance with another aspect ofthe invention, there is provided a composite material comprising: carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added inorganic filler; a binding agent in intimate association with the carpet waste, wherein the binding agent comprises one or more of methylenediphenyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and a layer on a surface of the composite material, wherein ft) the layer comprises a hotstamped layer, (ii) the composite material comprises between 25% and 99% carpet waste and between 1% and 25% binding agent, and (iii) the composite material comprises fibers consisting essentially of a highest melting point fiber of the carpet waste.

In accordance with another aspect of the invention, there is provided a composite materia] comprising: carpet waste comprising a combination of nylon fibers, polyester fibers, and polypropylene fibers exhibiting different physical and processing properties; an added inorganic filler; a binding agent in intimate association with the carpet waste, wherein Ihe binding agent comprises one or more of methylenedipbcnyldiisocyanate (MDI), urea formaldehyde (UF), melamine urea formaldehyde (MUF), and phenol formaldehyde (PF); and a layer on a surface of the composite material, wherein (i) at least one of tbe layer and tiie surface is sanded, (ii) the composite material comprises between 25% and 99% carpet waste and between 1% and 25% binding agent; and (iii) the composite material comprises fibers consisting essentially of a highest melting point fiber of tbe carpet waste.

In accordance with another aspect of the invention, there is provided a composite adapted foT use as a building material, the composite comprising: processed carpet waste, wherein die processed carpet waste comprises (i) a reduced amount of inorganic filler present

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CA 02933740 2016-06-20 within an unprocessed carpet waste; and (ii) a melted polypropylene and an tunnelled nylon; an added inorganic filler, and between about 2% and about 10% binding agent by weight of the composite.

In accordance with another aspect ofthe invention, there is provided 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, an added inorganic filler, and a hindi ng 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. ,

In accordance with another aspect of the invention, there is provided 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, an added inorganic filler, 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 t pressure occurs in a second cycle press. '

In accordance with another aspect of invention, there is provided 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, an added inorganic filler, 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.

In accordance with another aspect of invention, there is provided a composite building material comprising: a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste; and a binding agent in intimate association with the processed carpet waste.

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Id accordance with another aspect of invention, there is provided a method of producing a composite building material, the method comprising the steps of: providing a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste; mixing the processed carpet waste with a binding agent to produce a carpet waste mixture; and healing and pressing the carpet waste mixture to form the composite building material.

In accordance with another aspect of invention, there is provided a composite building material comprising: a carpet waste; an inorganic filler in addition to any filler present within the carpet waste and any synthetic fiber filler, and a binding agent in intimate association with the carpet waste and the inorganic filler.

In accordance with another aspect of invention, there is provided a method of producing a composite building material, the method comprising the steps of: providing a carpet waste; providing an inorganic filler, wherein the inorganic filler is in addition to any filler present within the carpet waste and any synthetic fiber filler; mixing the carpet waste and the inorganic filler with a binding agent to produce a carpet waste mixture; and hearing and pressing the carpet waste mixture to form the composite building material.

In accordance with another aspect of invention, there is provided a composite building material comprising: a sheet having a first exterior surface and a secood exterior surface defining a thickness, the sheet comprising a substantially homogeneous mixture from the first surface across the thickness to the second surface, the sheet comprising: a carpet waste; an added inorganic filler; and a binding agent in intimate association with the carpet waste and the added inorganic filler, wherein at least one of the first exterior surface and the second exterior surface comprises at least one surface feature selected from the group consisting of a molded patterned surface, an embossed patterned surface, and a hot-stamped layer.

In accordance with another aspect of invention, there is provided a method of producing a composite building material, the method comprising; providing a carpet waste; providing an inorganic filler; mixing the carpet waste and the inorganic filler with a binding agent to produce a carpet waste mixture; and heating and pressing the carpet waste mixture to

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CA 02933740 2016-06-20 form the composite building material comprising a sheet having a first exterior surface and a second exterior surface defining a thickness, the sheet comprising a substantially homogeneous mixture from the first surface across the thickness to the second surface, wherein at least one of the first exterior surface and the second exterior surface comprises at least one surface feature selected from Ihe group consisting of a molded patterned surface, an embossed patterned surface, and a hot-stamped layer. '

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

¹⁰ .

DESCRIPTION OF DRAWINGS

Fig. 1 ts flow chart depicting the types of size reduction equipment and the variety of size reduction procedures depending on the final carpet waste material form required for the process equipmentFig. 2 depicts steps for coating the carpet waste material with the bonding

IS agent and subsequent forming process. '

Fig. 3 depicts steps for finishing the composite board product.

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WO 2007/084822

VCT/USM07/060381

DETAILED DESCRIPTION

Ageneflccotupuritionoftheaupet waste product produced by the invention follows:

Material Descriptfon Percent of material in compoillfon

Cerpet Waste 25% - 90% to Binding Agents I%-.25%

Wood or nature! fibers, Synthetic fibers, inorganic fillers, Reinforcing fillers 0% - 50%

Flaine Rcturduiits 0% - 25%

1.5

Mold Inhibitors 0% - 25%

There are two basic steps in the production of composite material from carpet waste.

.Fig. 1 shows the types of equipment and the variety of procedores depending on the final forat required for foe Process Bquipmuirt. The firm) fbnn may also be dependent on foe desired finished composite product and physical properties to be attained in the process.

First, the carpet waste is. processed ω described below to reduce its size. Then foe sizoreduocd carpet waste is mixed wife a binder to produce material that is subjected to temperaturo ab'd/or pressure, by a pandl/shCct/bôard process, to yidd composite mafraial.

Below wo describe both steps in detail. We then describe post-manufacture treatments for foe composite materiaÎ.

Carnet Waste Size Reduction

The carpet wusur is made up of selvedge, post-industrial carpel waste, post-consumer waste carpel, or waste carpel reclaimed from landfills. These materials will be in baled Form to begin the size reduction phase of the pre-processing. The bales vary in size but usually represent about I (W lb, to 2(100 ib.

The first step is to reduce the waste to a manageable size for foe rest of the process. Either a combi nation of u shredder/chopper imd grinder, or a major capacity grinder is used to procoss thc materials to smaller sizes. The shredd er/chopper wj li reduce foe selvedge or carpet waste fo chunks approximately three inches square (3” x 3”χ The shredded material foe» passes through a grinder which further reduces the chunks a fiber fluff material with a

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WO 2007/084822 ' PCT/US2007W60H1 dkunctcr of the fibers similar to tbe diameter ofthe original carpel fibers and a length of about >i” tc p’.

The waste optionally cm be ran through a^eparatar which acts as a banuncr milVcyçlonc to remove the dirt from the carpel waste, [n this step some ofthe carpet backing containing inorganic fillers may also be removed. Tbe Slightly Size reduced to mntcrial, due to the hammer mill effect, is ready for the next step. the agglomeration process. The dirt and carpet backing materials that have beenreutoved frora (he small chunke are then disposed.

The fiber fluff regardless of ihtuse of the separator or reof optionally can be blended with other materials such as wood or natural fibos, synthetic fibers (ie. fiberglass), inorganic fillers, other reinforcing fi]tee, flame retaritoas tod mold inhibitWs. Tbs fiber fluff material or the blended material is then conveyed to the agglomeration step.

The agglomeration of die above materials occurs inside the aggloinoratar. The materials enter a horizontal drumcortorinirigurevolvitigrotor. Tbe rittor is Striped so. ok to force tbe fiber fluff or blends 'Against the drum wall. Thedniru wall is perfumed so that, as the rotor forces die contained materials against tin: perforated wall, the material is forced through rhe perforations forming strands of a fixed diameter. On flreoutside of [he drain are stationary knives which cut the strands into a fixed length. Duringthis process die material is heated by frietiunto a teraperamre filat rCniainshcfow dtomdting point uf thehighest tneHing.ppint material in rhe blend. The temperature is controlled by d» speed of the rotor, thediameter of the perforations, and. the thidmess ofthe drum wall.

The granules that are fanned in the igglourcration step toeeyltodricaim shape ami approximately 1/S inch in diameter and 1/8 to !4inch fang. The diameter arid Içrçjth ofthe granules cun be changed by changing the diameter of (he boles in the dram wall sodfar changingthcspecd ofthe knives rotation. Because Qtc granules are hat when (hoy era formed and cut io length some ofthe granules are-stuck fa one anoflaa. Therefore, for boiler size consistency, the granules next pass through a grinder which breaks the granules away from cadi other. This grinder ilep may also be used to reduce the size ofthe granules.

The granules may be further reduced in size by a pulverizer. If the final desired dimension is Ies3 than 1/8 inch the pulverizer is used to reduce the particle sizetoK-l.ti inesh. Ibis is Ihe equivalent of 0.04 Inch to 0.10 inch.

One Iast optional step may now be pefonned, to fiberize the granules or the pulverized particles. Ibe fiberizing is a mechanical roughing of the surface so that the ί

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WO 2007/084822 ^; . PCT/US2»7/OMM1 surface takes on a “fuzz” like characteristic. This can be an important final proparaüon for the composite product process described below io tbe Process Description. The material, whether granule or pulverized particle, whether fiberized or not, is now sent an to tbe composite production process.

An aKcraative method for initial aizo reduction is to use a major capacity grinder to which reduces the carpet waste to fibers approximately U inch to 1 meh m length and:

approximately l/JJ inch to 1/9 ipch m diameter. These random sized fibers ate ready for the agglomeration process or for adteniatiré actions not requiring aggkunerotiun.

Kegprdlessof fooprocess directfort,lhé next step is to pans themsforial through a separator. This, is Ihe sameequipmari and effect as described above. As above, ibis is an optional step in the meterial preparation phascbeing described here. The fibosmaytow gi through the agglomeration process in the exact uamemanner as described above, or the fibers may pass directly lo the fiberizer equipment Again the fiberizer acts to change the surface characteristics of the fibers giving them a “fuzz” surfitoe with greater surface area arid a different bulk density. The Aberizing step may not be required for all end aScaoithe epjnposi foprodtads.

Whether the fibers have been fiberized or not,they will pass through a blendcr where wood or narural fibers, syntheticfibers (Lt fiberglass), inorganic fillers, mineral filler? (if any). Same retardan ts, and mold inhibitors may be added. Once the blending of the fibera aud added materials iff complete, the blend is ready for the composite product

Process,

The composite-productcoaipowlionis controlled hy controlling the above steps. Significantly, it typically is not necessary to separate or classify the various materials contained in sekodge-or carpet waste. Most carpet sorfiicc materials are nylons, polyester, polypropylene, or wool. Thu -backing material is usually polypropylene and/or highly filled synthetic latex. These raaicnals exhibit conriderabty different physical properties and processing properties. The entire wqste product may be used regardless of foe differences in (he materials. However, if desired, the carpet waste can be separated hy face fiber type and processed. Fur example, a panel can be made of 100% Nykm 6 face fiber carpel waste. A panel can also be made byblcnding different face fiber carpet waste together ata controlled ratio of each type io create a panel. For example, a panel could be made of 50% Polyester face fiber carpet waste arid 50% Polypropylene free fiber carpet waste.

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WO 1007/084822 f - PCTAJS2007/W0381

The-weste carpet, having been made into an agglomerate, a fiberized agglomerate, a pul vented agglomerate, or a Aborted, pulverized agglomerate, becomes the basu material for the composite-product. Waste fiber or fibfcrizrzi waite fiber may alto be used to manufacture a composite product The whole range of materials in uarpef wasteïrisy be part of the composition.

to The other major part of thu composition is a binding agent, The binding f unction can bif aceomphshed using mefoyi<mcdiphenyldritocyanate ÇMD1), urea formaldehyde (UF), melamineitraaformaldehyde fMUF), phoflof formnldébydô (PF)or aoombiruition thereof. Other bindën may he used depending on foctorasudi as compatibility, cost and Environmental issues. The binding agent acts as a glueftr be fibers Or agglomerated materials to give ifw basis for the compositeproducts. Tbe ratio of the binding itgutit to die fibers or particles is a dcienninant in the physicul properties attained in the Process.

Further, the physical properties ire modified by the use of wood and sutural fibers, synthetic fibers, inorganic filters, reinforcing fillers, ftemia naardanle and mold inhibitors.

The binding agent and carpet waste materials comprise at least 50% of the composition and mey rnokcop 100% ofthe find product. The bidding aged? contortja between 1% and 25% leaving the fcmaiiKler of the material to becarpet waste and added, materials. Hie added materials, wood and natural fibera, synthetic fibers, inorganic fillers, reinforcing filters, flame retardants, and mold inhibitors may make up to 50% of the total «imposition. However, the basic raineriol is usually a 9-1 ratio of etapet waste to binding agent writh any added materials being around 25% ofthe caipetwatfte/kinding agent content, in sianmufy, the composition of carpet waste and binding agent (with or without additive material») cun be used to moire a wide range of composite products;. Tlte carpet waste includes all of the carpet product' including all tbe different types, of fabe fibers and the oafpet backing.

Coating the Carpet Waste Material with the Blarfing Agcrit

The carpet waste material may have the form of granules (pellets or. particles), or of file fibrous waste material or fiberized versions oftlw; granules or fibrous material. The carpet waste materials arc generally loaded into a large rotating drum or a dram with rotating mixing Hades or a rcsinatipn blow fine. Other materials such as natural fiber filters, inorganic fillers, flaine retardante and mold inhihiton may be loaded with lhe carpet waste material. If foe material is loaded into a-dram, then water and/or a binding agent are

Cft 02933740 2016-06-20

W0 2007/WW Ù PCTrtJSHHWOMMl e sprayed oui of Ûk head inside af (he drum to thûrnugfaty coal the materials. While the drum and/or blades fee spinning and causingthe material hdd within to become evchty distributed, the spray head is releasing a Moe mist ofWaierqr binding agent. Thia rostlltsto a thoroughly coined material. Wafer is usually sprayed into the drum to achieve a. desired ^! moisture content for life material and prepared» material tor tbe binding agont, The binding agent ts usually sprayed after lhc water to make sore that it reacts and thoroughly coats the material in die drum. For thcTcsination blow linoinethod, the materiel tsbiown through a tube that tmwater trad binding qgenfmtroduccdinto it. The blowing action cause the air fobecoroeturbulent which allows the wafer and binding agentto evenly «oat the material. The bindingagent is applied, m (hj& manner to the granules or fibers at tt c<incenlrationofl% to 25% of the lolaj weight of Ü» granu)«plusany other additives.

(Throughoutlbe dcscriprinn, ihe tenus gratuites or Chers can include additives in addition to the CWpet waste.) The hindtng ûgcrrt adheres to (he granules and fibers, gyring each .granule or fiber a binding ijpjrrtior&ie soaring. Thotriridingagoit dries rapidly under . · ambient conditions, aflo wipgthe grapulea or fibere to continoe to flow without alhcrmg to one another. The granules Or fibers wkhfhe buidingagenteoaring Uien passonto the next stop, in the process which is fhe preparation of the earpet while composite material for the Board.

Pltepottogfer theBoardlyrmlng Process

The binding agent coated eompœite material, is«onwyed to the Mat Forming

Sutton which includes conveyors, metering scales, spreader head»' and a control i management system. 'ITiemai forming .slàiion employs spreading equipment to distribute - j die composite material opto. afonpingbelt so that (he spread material becomes a mat which ' has a uniform thickness, width and density. Board properties are wdnJy determined by fl»

3û xhape-of the carpct waste composite partfcies/fibors and bytheir position in the formed mat

For ibis reason die spreading equipment is finely timed to produce the proper shape and Site .

of file mat. The Forming Station can distribute more than -one type of material for a molrikiyered board. For example, the spreader head in the forming Nation could spnaid a matof t fibers on tbe forming belt then a second spreader head could spreadamai. of pel lets on top ί

I of the fibers, then a third spread bead could spread a top layer of fibers onto the pellets. ;

Many different combinations of materials can be spread onto the forming belttn make various types of boards, Tbe number of layers per- board can be varied also. For exanqile, a

I i

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WO 2007/084812 6 · fCT/US2007/06t)381 board could be manufactured ta baye CW fiber skins and a,fiberglass core or a board could be juanufrcniret] (o tmveCW pdlot skins, GW fiber undtrlflyere and a CW peflleC core.

Afier the mot is spread formed, thçformjng belt Ihcp trimsports thc tnal into the pre-healer or-directly into a Pre-Press. The pre-heater continuously transient the mat and subjects the composite material to microwaves or injects foot air and/oristeam into themat before it enters the Board Forming process. The temperature of the mat is dçvatcd form about 65F tp abaat 2QQ“F before entering the board forming process. ThtAiapd heat transfer tofite carpel waste is accomplished by microwaves or by the injection ofa stcnriVBrinifcr'(tni>ist aif) alternately from efthor surface into the mat The sfesneondenues juriiyj thhr process, transferring die heat into the mat. ThEpreriiea ter may also pro-press or compress the material before it enters the board forming process. Thçhealed nutria then trarcrfsrral by an intermediate bell conveyor to (he compression section of the infeed end ofa continuous red/ press or intoe cycle jmessr which is the bqptimng of the bodnkfonnbig process.

If a cycle or stationary press is used instead of à Continuous pill press, then preheating of fire mai n usually skipped and steam tnjeefron nurybeuseft Aging-thc sheeting, process ta (he cycle press Or the steam injection can be skipped.

The Board Forming Process employa a CydéPress or ConfipuQUS Roll Press. Bdfii types of equipment use pressure and temperature to form aboard, panel or Shed from the Carpet Waste CompositeMaterial that, is coated with a binding agent.

The Cycle press may turn) single or multi-daylight openings. The composite

2$ material is tiwfencd into the cycle press .where it is SUbjcctedtu temperature and pressure franva top and bottom platen (bat condenses the mat to a determined height and altowslhe binding agent-reaction (Q take place bonding the mat together to formaBoard. Thermal may havcitoaiu injected through ft while in fire cydo press to ensure a thorough heating end bonding of Ao composite material. The platens foay have a pefttaji engraved Hite them tp give the hoards surface a Structured pattern. The Cycleprcss may also use a cooling cycle lo reduce tire tempraunç-of fite board bribrc it exits the press.

Carpet was teconiposite bounlshuvo been manufactured using a cycle press. The opoating conditions and settings are shown in Chart 1 attached her®*⁰The continuous roil press is â doublc.bclted press capoble of maintaining a range of temperatures and pressures on the mat to allow the binding agent reaction to take phtec.

binding the root together. 'Πχ preferred type ofhdt for the continuous roll press is made of steel but other materials may be used. The press has the capability Of reaching temperatures of 65°F to 550°F to allow the heat to transfer throughout the mat. Similarly, varying pressures are used to squeeze the granule layer or the fiber mat to the desired thickness and density of the final product.

The continuous roll press consists of a press structure which takes up the horizontal forces resulting from the belt tensioning. There are many frame units whose number depends on the length of the press and pressure that is needed. Cy finders are used for the exertion of pressure arranged at the frame units in various combinations, a certain number of w'hich are suitable for opening the press. There are top and bottom heated platens which the roller rods and belts travel over. The press has an infeed head to guide the roller rods, belts and mat to be pressed. The roller rods are located between the heated platens and the belts. The mat is located between the two belts. Two drums are located at each end of the press for the belts to travel around. Drum scrapers are used to keep the mat between the belts. A release agent may be sprayed onto the belts to keep the mat from sticking to the belts and exit the press. A control system regulates the operation of the press such as the speed of the belts, temperature, pressure, thickness of the mat, etc.

The continuous roll press transfers heat to the binding agent-coated composite material. The heat activates the binding agent coating on the materials which are then pressed to a lesser thickness by the continuously moving belts. As the material moves between the belts through the infeed section, the thickness dimension is reduced as well as continually heated. The temperature of the binding agent-coated granules or the hinding agent-coated fibers is maintained above the activation temperature of the binding agent. Under the pressure of the platens which are set at a predetermined height, the granules or fibers adhere to each other forming a continuous sheet product. This final thickness determines the density of the material as well. The density is determined by the initial thickness of the un-bonded mat entering the continuous press and the final thickness as the newly formed composite product exiting the press.

If the temperature of the continuous press belts or stationary press platens are heated up to 446 °F or above, a thin but dense outer skin can be formed in the panel. This outer skin can help improve physical properties in the panel, such as the modulus of elasticity (MOE) and the modulus of rupture (MOR).

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After the mat has been heated and pressed to the desired height and density in a continuous press, a cooling section may be employed to cool the panel before it exits the continuous press. Due to the nature of the polymer materials being pressed, cooling the

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CA 02933740 2016-06-20

WOIM7/M482I · CT/US2M7AW«381 panel in tbe press under pressure bdpe maintain board flatness and avoid warping. The pond is gcoerotly cooled to at least Î20 “C before exiting the continuous proas. A Stationary Press may dip use a cooling cycle to cool the board before if exits the stationary press. However, this additional cooting time creates a longer cycle time to create a panel. So, a secondary atationwy press may cmploywi for cooling only. For example, a pancl may be formed under heal and pressure in die first press, that transferred to a soeopd stationary press to be cooled. A panel may be formed in cither type of press and cooled in a secondary process after it exits thepress.

The Board Finishing Process

After the binding of fhe material and desired height dinrerision of die mat. has been reached in. a continuous roU press, a Board is farmed which is in (ha shape of a continuous nhbotL When tbe libbonexhs the press ft undergoes a continuoni edge trimming openUmn iu reach foe desired width and then if is cross-cut to a pre-sdcCted length. The ribbon is transported ttuoQgh the trimming and cross-cutting Operationy by a roller-conveyor and

2û fund) rolfcm. The board that has been cut to a predetermined .width aiuUsngfo & Üwh trnrt^wrtedto a cooling station. The cooling station éat employa variety of different machines such as a Star Cooler with subsequent stacking of a stacfcing iot 1er conveyor. One of foe most common types is the star coolerwith subsequent stacking The Star Cooler Is a large diameter wheel with multiple rows of spoked pirns extending from the wheel. The arms lift cadi Board fora the conveyor and allow the Boards to rotate with (ho wheel and be air tooled. If needed, foe continuous roll press can hove a tooting section near foe exit This will cool foe board before it exits the press eliminating foe need fat farther cooling, TfaeBuanl is then conveyed to a stacking operation and stored for fifoire use. The Boards are now ready to be shipped or they can go through a variety of decorating alternatives.

® In a cycle press, foe board can be manufactured to finished size or slightly overtaxed.

Jf it is overhzod.then it is cut to finish dimensions after il exits foe press. The Platens in the cycle press can have a patterned siaface to give the board a structured surface stich as a wood grain partem.

Decorating the Composite Product

Ax foe composite product exits the Process as. described above, it may be of varying thicknesses from less than ί/B inch op to 2 inches. Since foe last Step in foe Process is the ti

CA 02933740 2016-06-20

WO za07/0S4S22 , ?CnüSMI>7rt«381 cuttingio Itstgih of ihe cumpqsitc product, Ihe first step in finishing the product is cutting to final width. Figure 3 shows the finishingnnd decorating steps ihat may be employed folluwing eutfingtQ final width.

The compositepnxlucican now he molded to change the profile to take on the shape required ia the finished'product. The ipoIdUig is dOhe on â cüifing machitieof diffèrent designs, “Ihe most common of which is the rotatinginivesdevice. This machine allows for the setting or the knife blades to adjust, fee cut to the desired profile. Anothercommon device is the rotBer which cuts à spedfic groove of grooves (routs) into the surface of the composite product The router has the same effect as file moider m feat it changes the initial profila out of the Process into thedesired profile required for the final product.

The profile may also be changed using ttwruiorormnig methods. In this case the

.. composite product is placed in g mold of die desired profile and with heat and pressure the product takes on the shape ofthe fhokf This profile change offers.ahaddilionàl decorating Crpability.in dut dus déared color end/orpaUcro maybe on a transfix foil placed is ihq mold. Wife the application offee beat ^ldpressuredaring the process, fee color widAir pattern art transferred from fee canter (nil to fee composite product. Thus at fee end of the thçrmefarrnmg process, fee composite product has ihe desired profile and also the desired decoration.

Tlie compositeproductmaybc embossed after fee Process. The embossing is accomplished with an embosring plate or roll. The plate or roll has the pattern lo be transferred to fee product On fee surfeccof fee plate*or roll. This surface is hotted to a tetnptahture feat wifi -sOflra thé SUrfeceoflhe éoraposït&pnMKicL Thai fee plate or roll is pressed on to fee surface oTftte product lo grvo fee desired paîtrait transfer. As (hesurfacc ofthc composite product coola, fee embossed pattern bcooluts fixed on fee surface of fife composite product. The embossed composite product is now ready to be ooaied; or i f do coating is required fix fee end-use product, it i$ ready fin packaging.

All composite products that will be decorated pass through the sunder (the equipment described above). This smoothing ofthc surface prepares fee product fin coating, transfers, and laminating.

The sanded or embossed composite product may be ooatud with primera, finish paints, or stains. The application of fee coatings employs fee various, cun ventional spray techniques using exhaust systems to remove fee excess spray raid solvents, iyther

Cft 02933740 2016-06-20 penetrating or film-forming coatings are applicable, and the choice is dependent on the desired finished product appearance and application.

The sanded composite product can also act as a core to which decorative and protective layerfs) may be hot stamped from a foil or film or lamina led, to achieve the improved physical and visual enhancement over the current inventions.

The composite product may be decorated using transfer foils. Once again the product requires sanding to smooth the surface. An adhesive layer is applied to die profile using a conventional application technique. The transfer foil has the desired color and/or pattern on a polymeric substrate. The foil is brought into contact with the surface of the product using stamping equipment designed for the specific application. Using heat arid pressure the color and/or pattern are transferred from the foil to the product. The heat required for the transfer activates an adhesive layer on the surface of the profile ensuring bonding of the decoration to the profile. With the color and/or pattern nowon the composite product, the spent foil is then collected for disposal; and the finished product has the desired decorated effect.

Another decorating method which may be employed is lamination. Several materials may be used as the laminate surface, such as, wood veneers, synthetic veneers, foils, films, and polymeric sheets.

The application of rigid laminates tike wood veneers is done using conventional laminating equipment. Generally, an adhesive system (either a wet adhesive system or a hot20 melt adhesive system) employing a primer and an adhesive is applied to the substrate. The rigid surface laminate is then laid on to the substrate and temperature and pressure are applied. After the temperature-pressure step the laminated product is then set for a fixed period of time to allow the adhesive system to cure. In tie case of the composite product, the composite product is the substrate. The adhesive system, usually a hot-melt adhesive, is applied to the composite product. The rigid veneer is the placed on the adhesive layer forming a sandwich of composite product, adhesive, and rigid laminate. The sandwich is then pressed to secure the bond of the laminate to the composite product. After curing the laminated product with the desired decorative appearance is ready for packing,

Another laminating technique used with the composite product is toil laminating. This technique can be referred to as wrapping wherein the composite product profile is

CA 02933740 2016-06-20 wrapped in the decorative foil. After the composite product profile has been sanded the profile passes through a wrapping device. This device lakes the foil wrap from a coil then applies the adhesive (and primer, if required) to the foil. In a continuous process the foil wrap is then passed over the composite product profile. Using a series of rollers, the foil wrap is shaped to ihe composite product profile. The foil wrap may incorporate in addition to its decorative elements an integral topcoat material for physical property enhancement. This integrated element may be polyurethane, acrylic, or other protective materials. If, however, the foil wrap integrates only the decorative dements, then the wrapped composite product will require a topcoat for certain applications.

If the end-use product application requires significant surface property enhancements, such as abrasion resistance, a topcoat may be added to the decorating process. The topcoat cars be polyurethane, acrylic, or other protective material that, will impart better physical properties to the surface of the wrapped finished product. The topcoat may be spray applied or hot melt applied. If spray applied, the wrapped composite product wilt pass through a spray applicator and then may or may not pass through a curing device such as ultra- violet radiation. If the topcoat is hot melt applied, then a layer of polyurethane is applied to flat surfaces of the decorated composite product. The cure process for this type of material is time dependent and could take several days depending on the hot melt topcoat chosen for a specific end-use application for the completed finished product.

A number of embodiments have been described. Nevertheless, it will be understood that various modifications may he made thereto. The invention, rather, is defined by the claims.

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