Carpet Reclamation System

Abstract

A method an apparatus for reclaiming face fibers and polypropylene and/or polyvinyl chloride backing material from rolls and pieces of post-consumer carpet. The system includes a separator for separating the face fibers from the backing and for separating latex and carbon calcium powder from polypropylene backing. An extruder is provided for extruding the face fibers separated from the backing into extrusions, and a pelletizer pelletizes the extrusions. A roller opener opens the polypropylene backing into fibrous portions and also cleans such fibrous portions. Alternately, a granulator can be provided that chops and grinds the polypropylene or PVC backing into fragments after the separation of the face fibers from the backing. A heat source heats the PVC fragments, and also the polypropylene fragments (thereby separating the latex therefrom), and ultimately melts such fragments. Reclaimed fibers can be pelletized, made into extrusions, used in non-woven products and in other manners.

1 - 55 . (canceled) 
     
     
         56 . An improved method for processing post-consumer carpet to recycle one or more component materials of said post consumer carpet, said method comprising:
 feeding one end of post-consumer carpet into an intake;   dedusting and cleaning of said post consumer carpet;   propelling said carpet into a separator using a first roller and a second roller;   separating face fiber of said post-consumer carpet by a circulating knife blade of said separator severing face fiber from backing material;   cleaning of said separated face fiber to extract latex and debris therefrom; and   feeding of said separated face fiber into a conglomerator for heating therein.   
     
     
         57 . An improved method for processing post-consumer carpet according to  claim 56  wherein said cleaning of said separated face fiber to extract latex and debris therefrom comprises using a self-contained fluidic ultrasonic cleaner. 
     
     
         58 . An improved method for processing post-consumer carpet according to  claim 57  wherein said heating by said conglomerator causes removal of latex and other remaining adhesive components from said separated face fiber by volatizing of said latex and other remaining adhesive components. 
     
     
         59 . An improved method for processing post-consumer carpet according to  claim 56  wherein said heating in said conglomerator comprises using a heat source comprising one or more of: electric resistance heat; heat from a combustion source; solar heat; and microwave energy. 
     
     
         60 . An improved method for processing post-consumer carpet according to  claim 56  wherein said dedusting and cleaning comprises dedusting by one or more of directing high pressure air at said carpet during said feeding by blowing air from a centrifugal blower; and
 vacuum dedusting of said post-consumer carpet. 
 
     
     
         61 . An improved method for processing post-consumer carpet according to  claim 56  wherein said cleaning of said separated face fiber comprises dedusting of said separated face fiber using a willow cleaner. 
     
     
         62 . An improved method for processing post-consumer carpet according to  claim 57  wherein said self-contained ultrasonic cleaner comprises a fluid cleaning system. 
     
     
         63 . An improved method for processing post-consumer carpet according to  claim 62  wherein said fluid cleaning system extracts dust and/or debris from said cleaning fluid. 
     
     
         64 . An improved method for processing post-consumer carpet according to  claim 57  wherein said cleaning by said self-contained fluidic ultrasonic cleaner further comprises drying of said cleaned face fiber. 
     
     
         65 . An improved method for processing post-consumer carpet according to  claim 64  wherein said drying of said cleaned face fiber comprises using one or more of: forcing air upon said cleaned face fiber; applying heat to said cleaned face fiber; and drying in a centrifugal dryer. 
     
     
         66 . An improved method for processing post-consumer carpet according to  claim 57  further comprising transporting of said cleaned face fiber pneumatically through a chute for baling of said cleaned face fibers by a baler. 
     
     
         67 . An improved method for processing post-consumer carpet according to  claim 56  further comprising:
 melting in said conglomerator of said adhesive-free face fiber into a flowable state; 
 feeding said flowable face fiber into a hopper of an extruder; 
 compacting said flowable face fiber in said extruder to force a flow of said flowable face fiber through a die for forming an extruded shape; and 
 cutting said extruded shape into pellets. 
 
     
     
         68 . An improved method for processing post-consumer carpet according to  claim 67  further comprising:
 adding one or more chemical agents to said flowable face fiber in said extruder to produce a higher quality of polymer pellets. 
 
     
     
         69 . An improved method for processing post-consumer carpet according to  claim 56  comprising carrying away of said separated backing to a shredder using a conveyor; and forming backing fragments therein by one or more of: shredding, cutting, and chopping of said backing. 
     
     
         70 . An improved method for processing post-consumer carpet according to  claim 65  comprising opening of said fragments into fibers by tearing of said fragments in an opening device; and dedusting. 
     
     
         71 . An improved method for processing post-consumer carpet according to  claim 70  comprising transporting said opened backing fibers to said conglomerator; and density compacting and melting of said torn backing fibers in said conglomerator. 
     
     
         72 . An improved method for processing post-consumer carpet according to  claim 71  wherein said comglomerator removes latex and other remaining adhesive components from said torn backing fibers by volatizing said latex and adhesive components. 
     
     
         73 . An improved method for processing post-consumer carpet according to  claim 72  comprising granulating of said adhesive-free backing to form a low quality polymer. 
     
     
         74 . An improved method for processing post-consumer carpet according to  claim 56  comprising classifying said post-consumer carpet according to chemical structure of face fiber by using an infrared spectrometer and a Fourier transform process to produce a spectra; and
 comparing said spectra of said face fiber to a library of spectra of known materials for determining said chemical structure. 
 
     
     
         75 . An improved method for processing post-consumer carpet according to  claim 56  wherein said feeding of one end of post-consumer carpet into said intake comprises feeding flat stock carpet into said intake. 
     
     
         76 . An improved method for processing post-consumer carpet according to  claim 56  further comprising supporting one or more rolls of said post consumer carpet on a support for rotation of said one or more rolls thereon to accommodate said feeding of said one end of each of said one or more rolls into said intake. 
     
     
         77 . An improved method for processing post-consumer carpet according to  claim 56  wherein said intake comprises a conveyor; and wherein said propelling using said first and second rollers comprises driving of one or more of said first and second rollers by transferring of power thereto from a motor. 
     
     
         78 . An improved method for processing post-consumer carpet according to  claim 77  wherein said feeding of said post consumer carpet into said intake comprises feeding said carpet face down; and wherein said first roller comprises a brushless roller and said second roller comprises brushes protruding therefrom, said brushless roller being above said post-consumer carpet and contacting said backing, and said second roller being below said post-consumer carpet; said brushes engaging said face fiber to cause said propelling of a portion of said roll of post-consumer carpet beneath a guide bar. 
     
     
         79 . An improved method for processing post-consumer carpet according to  claim 77  wherein said feeding of said post consumer carpet into said intake comprises feeding said carpet face up; and wherein said first roller comprises a brushless roller and said second roller comprises brushes protruding therefrom, said brushless roller being above said post-consumer carpet and contacting said backing, and said second roller being below said post-consumer carpet; said brushes engaging said face fiber to cause said propelling of a portion of said roll of post-consumer carpet beneath a guide bar. 
     
     
         80 . An improved method for processing post-consumer carpet according to  claim 56  further comprising sharpening said circulating knife blade continuously using a sharpener, to continuously present a sharp cutting edge during said severing of face fiber from backing. 
     
     
         81 . An improved method for processing post-consumer carpet according to  claim 80  further comprising cooling of said continuously sharpened circulating knife blade. 
     
     
         82 . An improved method for processing carpet to recycle one or more component materials of the carpet, said method comprising:
 feeding one end of a carpet into an intake;   dedusting and cleaning of said carpet;   propelling said carpet into a separator using a first roller and a second roller;   separating face fiber of said carpet by a circulating knife blade of said separator severing face fiber from backing;   cleaning of said separated face fiber to extract debris therefrom; and   feeding of said cleaned and separated face fiber into a conglomerator for heating therein.   
     
     
         83 . An improved method for processing carpet according to  claim 82  wherein said cleaning of said separated face fiber to extract debris therefrom comprises using a self-contained fluidic ultrasonic cleaner. 
     
     
         84 . An improved method for processing carpet according to  claim 83  wherein said heating by said conglomerator causes removal of latex and other remaining adhesive components from said separated face fiber by volatizing of said latex and other remaining adhesive components. 
     
     
         85 . An improved method for processing carpet according to  claim 84  wherein said heating in said conglomerator comprises using a heat source comprising one or more of: electric resistance heat; heat from a combustion source; solar heat; and microwave energy. 
     
     
         86 . An improved method for processing carpet according to  claim 85  further comprising:
 melting in said conglomerator of said adhesive-free face fiber into a flowable state; 
 feeding said flowable face fiber into a hopper of an extruder; 
 compacting said flowable face fiber in said extruder to force a flow of said flowable face fiber through a die for forming an extruded shape; and 
 cutting said extruded shape into pellets. 
 
     
     
         87 . An improved method for processing carpet according to  claim 86  further comprising:
 adding one or more chemical agents to said flowable face fiber in said extruder to produce a higher quality of polymer pellets. 
 
     
     
         88 . An improved method for processing carpet according to  claim 87  further comprising:
 heating in said extruder to assist said flow of said high quality polymer through said die. 
 
     
     
         89 . An improved method for processing carpet according to  claim 88  wherein said self-contained ultrasonic cleaner comprises a fluid cleaning system for extracting dust and/or debris from said cleaning fluid. 
     
     
         90 . An improved method for processing carpet according to  claim 89  wherein cleaning using said self-contained fluidic ultrasonic cleaner further comprises a drying means for drying of said fluid-cleaned face fiber. 
     
     
         91 . An improved method for processing carpet according to  claim 90  further comprising sharpening said circulating knife blade continuously using a sharpener, to continuously present a sharp cutting edge during said severing of face fiber from backing. 
     
     
         92 . An improved method for processing carpet according to  claim 91  further comprising cooling of said continuously sharpened circulating knife blade to thereby prevent overheating. 
     
     
         93 . An improved method for processing carpet according to,  claim 92  comprising:
 supporting one or more rolls of post consumer carpet on a support for rotation of said one or more rolls thereon; and 
 feeding one end of a first roll of said one or more rolls into said intake. 
 
     
     
         94 . An improved method for processing carpet according to  claim 93  wherein said intake comprises a conveyor; and wherein propelling of said carpet using said first and second rollers comprises driving of one or more of said first and second rollers by transferring of power thereto from a motor. 
     
     
         95 . An improved method for processing carpet according to  claim 94  wherein said feeding of said post consumer carpet into said intake comprises feeding said carpet face down or face up; and wherein when said carpet is fed in face down, said first roller comprises a brushless roller and said second roller comprises brushes protruding therefrom, said brushless roller being above said post-consumer carpet and contacting said backing, and said second roller being below said post-consumer carpet; said brushes engaging said face fiber to cause said propelling of a portion of said carpet. 
     
     
         96 . An improved method for processing carpet according to  claim 85  wherein said dedusting and cleaning comprises dedusting by one or more of: directing high pressure air at said carpet during said feeding by blowing air from a centrifugal blower; and vacuum dedusting of said post-consumer carpet. 
     
     
         97 . An improved method for processing carpet according to  claim 96  wherein said cleaning of said separated face fiber comprises dedusting of said separated face fiber using a willow cleaner. 
     
     
         98 . An improved method for processing carpet according to  claim 97  further comprising transporting of said cleaned face fiber pneumatically thru a chute for baling of said cleaned face fibers by a baler; and wherein said feeding of said cleaned face fiber into said conglomerator comprises feeding said bales of said face fiber into said conglomerator. 
     
     
         99 . An improved method for processing carpet according to  claim 98  comprising carrying away of said separated backing to a shredder using a conveyor; and forming backing fragments by one or more of: shredding, cutting, and chopping of said backing. 
     
     
         100 . An improved method for processing carpet according to  claim 99  comprising opening of said fragments into fibers by tearing of said fragments in an opening device; and dedusting. 
     
     
         101 . An improved method for processing carpet according to  claim 100  comprising transporting said backing fibers to said conglomerator; and density compacting and melting of said torn backing fibers in said conglomerator to remove latex and other remaining adhesive components by volatizing said adhesive components. 
     
     
         102 . An improved method for processing carpet according to  claim 101  comprising granulating of said adhesive-free backing to form a low quality polymer. 
     
     
         103 . An improved method for processing carpet according to  claim 101  comprising classifying said one or more rolls of post-consumer carpet according to chemical structure of face fiber by using an infrared spectrometer and a Fourier transform process to produce a spectra; and comparing said spectra of said face fiber to a library of spectra of known materials to identify said chemical structure. 
     
     
         104 . An improved method for processing post-consumer carpet to recycle one or more component materials of said post consumer carpet, said method comprising:
 feeding one end of post-consumer carpet into an intake;   dedusting and cleaning of said post consumer carpet;   propelling said carpet into a separator using a first roller and a second roller;   separating face fiber of said post-consumer carpet by a circulating knife blade of said separator severing face fiber from backing material; sharpening said circulating knife blade continuously using a sharpener to continuously present a sharp cutting edge for said severing; and cooling of said continuously sharpened circulating knife blade to thereby prevent overheating;   cleaning of said separated face fiber to extract latex and debris therefrom using a self-contained fluidic ultrasonic cleaner;   heating of said separated face fiber to be in a flowable state; and   extruding of said flowable face fiber in an extruder and forming of pellets therefrom.   
     
     
         105 . An improved method for processing post-consumer carpet to recycle one or more component materials of said post consumer carpet, said method comprising:
 feeding one end of post-consumer carpet into an intake;   dedusting and cleaning of said post consumer carpet;   propelling said carpet into a separator using a first roller and a second roller;   separating face fiber of said post-consumer carpet by a circulating knife blade of said separator severing face fiber from backing material;   carrying away of said separated backing to a shredder using a conveyor; and forming backing fragments by one or more of shredding, cutting, and chopping of said backing; and   opening of said fragments into fibers by tearing of said fragments in an opening device;   density compacting and melting of said torn backing fibers in a conglomerator to remove latex and other remaining adhesive components by volatizing said adhesive components; and   granulating of said adhesive-free backing to form a low quality polymer.