Synthetic wood from waste fibrous waste products

Details Synthetic wood from waste fibrous waste products Synthetic wood from waste fibrous waste products

1995-09-05

1997-05-06

Ryan, Patrick

Stock material or miscellaneous articles

Pile or nap type surface or component

Composition of pile or adhesive

428 87, 428 95, 428 96, 428190, 428198, 428362, 428370, 4283001, 525143, 525184, 525423, 525529, 524561, 524562, 427180, 427394, 156 72, 156 94, 156153, B32B 900

Patent

active

056269390

ABSTRACT:
A composition of matter and a process for the preparation thereof is disclosed for a fibrous composite (e.g., synthetic wood). The fibrous composite contains 50 to 95% by weight carpet and 5 to 50% by weight of a structural adhesive. Structural adhesives effective in this application would include phenol-formaldehyde resins, either of the resole or novalac type, phenol-formaldehyde resins that have at least one other co-monomer present, e.g., bis-phenol A, resorcinol, and other substituted phenols, urea-formaldehyde resins, melamine urea formaldehyde resins, tannin-phenol-formaldehyde resins, diisocyanate resin, epoxy resins, crosslinkable polyvinyl acetate, proteins, e.g., soy flour, blood and polyester resins. The process steps necessary for the formation of the fibrous composite would include at least the steps of shredding the carpet without component separation thereof to form carpet fibers, coating a resin on the carpet fibers to form resin coated fibers, curing the resin coated fibers under a pressure and a temperature sufficient to cure the resin and form a fibrous composite, and cooling the composite. The carpet is typically shredded to produce fibers of from 1/8 to 3/4 of an inch. In one aspect of the invention, fabric, either natural or synthetic is added to the shredded carpet.

REFERENCES:
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patent: 4845162 (1989-07-01), Schmitt et al.
patent: 5213866 (1993-05-01), Swope et al.
patent: 5234993 (1993-08-01), Huynh-Ba
patent: 5294384 (1994-03-01), David et al.

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