Solid material comminution or disintegration – Processes – By operations other than force of contact with solid surface
Reexamination Certificate
1999-01-25
2001-02-06
Husar, John M. (Department: 3725)
Solid material comminution or disintegration
Processes
By operations other than force of contact with solid surface
C241S015000, C241S020000, C241S024110, C241S024120, C241S041000, C241S065000
Reexamination Certificate
active
06182913
ABSTRACT:
TECHNICAL FIELD
This application relates to carpet recycling and, in particular, relates to reclaiming carpet components such as yarn, tufting primary and secondary backing for recycling into those same respective components.
BACKGROUND OF THE INVENTION
Tufted carpet is sold in large volumes every year, much of which is sold to replace old carpet. Most components of tufted carpet are not biodegradable and recycling used carpet has long been desirable to avoid disposal of used carpet in land fills and the like. Furthermore, because carpet is a high volume, and often, low margin, product, lowering manufacturing costs is desirable. Carpet recycling however, has often been too complicated and costly and therefore, impractical.
Carpet generally comprises yarn, a tufting primary into which the yarn is tufted, a secondary backing, and a binder, normally latex, which bonds the yam, tufting primary and secondary backing together. The yarn is typically nylon and can be in the form of cut pile or loop pile. Cut pile carpet is made of short cut lengths of yarn and loop pile carpet is made of long continuous lengths of yarn. The tufting primary is typically a thin sheet of woven polyester or polypropylene material and the secondary backing is usually jute, woven polypropylene, or polyvinylchloride (PVC) sheet.
One known method of recycling includes shredding the entire carpet and either using the shredded carpet for something other than manufacturing carpet or separating the carpet components after shredding such as in a cyclone. Another known method of recycling carpet is to simply shave the yarn off the tufting primary and secondary backing. These known methods, however, are either too complicated and expensive, or are not effective in recycling all the recyclable components of carpet.
U.S. Pat. No. 5,230,473 to Hagguist et al. discloses a system for separating the components of carpet including a combination of mechanical, hydraulic, chemical, and heating means. While this system may effectively separate carpet components, implementing it is very complicated and costly.
Accordingly, there remains a need for a relatively simple and economic system for reclaiming the components of carpet and recycling the reclaimed components back into the same components in newly manufactured carpet.
SUMMARY OF THE INVENTION
This invention satisfies the above-described need by providing a method and apparatus for reclaiming carpet components such as yarn, tufting primary, binder, and secondary backing by spraying the carpet with a high velocity water spray so as to disjoint the binder, yarn, tufting primary and secondary backing from one another, and thereafter, separating the secondary backing from the yarn and tufting primary. By disjointing the carpet components before separating the secondary backing from the yarn and tufting primary, the components of the yarn can be more easily, efficiently, and cleanly separated entirely from one another. The high velocity water spray desirably has a flow rate and velocity sufficient to break up the binder and move the tufting primary from against the secondary backing. The yarn and tufting primary can then be more easily and cleanly separated from the secondary backing.
More particularly, the method and apparatus of this invention removes water from the carpet after the carpet is disjointed with the water spray. Desirably, the system removes water from the carpet before separating the secondary backing from the yarn and tufting primary. Preferably, the method and apparatus of this invention removes water by drying the carpet such as with hot air. Separating and handling the disjointed components of the carpet is easier after drying, than when wet.
The method and apparatus of this invention desirably operate on a continuous basis by continuously conveying carpet to be recycled from a source of carpet through the high velocity water spraying and the water removal, to the separation of the components. The continuous nature of the system of this invention enhances its efficiency.
The method and apparatus of this invention desirably separates the yarn and tufting primary with a knife. More particularly, the method and apparatus of this invention bales the yarn and tufting primary and bales the secondary backing separately. Alternatively, the yarn and tufting primary can be separated and then baled separately.
The water from the water spray breaks up and washes the binder from the carpet. This invention desirably includes collecting this water and separating the binder from the water. The filtered water can be reused in the reclaiming process and the reclaimed binder can be recycled.
The method and apparatus of this invention can be used to reclaim components of both broadloom carpet and carpet tiles. When this invention recycles broadloom carpet, it preferably directs the water spray against the backing side of the carpet. When this invention recycles carpet tiles, it preferably directs the water spray at the yarn side of the carpet tile.
Therefore, an object of this invention is to provide an improved method and apparatus for reclaiming tufted carpet components.
Another object of this invention is to provide a relatively simple and economic method and apparatus for reclaiming the components of tufted carpet so that the reclaimed components can be recycled and used to make the same components in new carpet.
Other objects, features, and advantages of this invention will become apparent from the following specification, drawings and claims.
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Howe Michael A.
Locklear Samuel G.
White Samuel H.
Bindseil James J.
Husar John M.
Interface, Inc.
Kilpatrick & Stockton LLP
Pratt John S.
LandOfFree
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