Apparatus and process for separating carpet fibers

Abstract

Apparatus for separating components of post-consumer carpet—pile, adhesive, and primary/secondary backings—may initially comprise spectrographic face fiber identification. Separating substantial portions of pile from backing comprises feeding carpeting into a rotating pinned drum, with separated pile U's dropping, while a residual composition, being primarily backing, travels with the drum, to be separated therefrom using vacuum pressure, with the composite backing being sent to a press. Vacuum pressure delivers the separated U's to a spinning perforated squirrel cage to remove dislodged pieces of adhesive, by vacuum pressure applied to an interior top portion of the cage to draw pieces therein. Rotating the perforated squirrel cage, which is sealed on the exterior using a belt, permits the U's to drop into a hopper. A mesh shaker box vibrates to separate any remaining backing from the pile U's. Hammers in a fibermill remove remaining adhesive attached to the separated pile U fiber.

1 . A carpet recycling process, for use in separating carpet pile U fiber, adhesive, and backing fiber of post-consumer carpet, said carpet recycling process comprising:
 rotating a pinned drum;   feeding post-consumer carpet into said rotating pinned drum and substantially separating pile and backing by shredding therein;   shaking a mesh pen for separating remaining backing from separated pile;   rotating hammers in a fibermill to crush adhesive remaining on separated pile;   removing crushed adhesive through a fibermill grate; and   vacuuming pile out through a fibermill opening.   
     
     
         2 . A carpet recycling process according to  claim 1  further comprising rotating a perforated squirrel cage for separating dislodged pieces of adhesive and dust from pile. 
     
     
         3 . A carpet recycling process according to  claim 2  further comprising drawing said dislodged pieces of adhesive into a partitioned interior upper portion of said perforated squirrel cage by applying vacuum pressure therein, and sealing an exterior upper portion of said rotating perforated squirrel cage. 
     
     
         4 . A carpet recycling process according to  claim 3  further comprising storing separated pile in a hopper, and limiting pile in said shaker mesh by rotating a paddle wheel to drop pile from said hopper onto a weigh pan, and weighing a preset amount of pile for processing in said mesh pen using said weigh pan. 
     
     
         5 . A carpet recycling process according to  claim 4  further comprising rotating a mesh door on said mesh pen and releasing remaining backing, and deflecting said remaining backing into a conduit. 
     
     
         6 . A carpet recycling process according to  claim 5  further comprising regulating an amount of said pile to be processed by said fibermill using a star valve, said star valve metering an amount to be processed by said fibermill for each fibermill cycle. 
     
     
         7 . A carpet recycling process according to  claim 6  further comprising identifying a pile fiber type using a sensor, said sensor being capable of performing spectrographic analysis. 
     
     
         8 . A carpet recycling process according to  claim 7  further comprising shaking and pushing pile in a cylinder by rotating a spoked shaft therein, and vacuuming loosened adhesive out from a grate. 
     
     
         9 . A carpet recycling process according to  claim 8  further comprising one or more of baling, pelletizing, or agglomerating separated pile and separated backing. 
     
     
         10 . A carpet recycling apparatus, for use in separating pile, backing, and adhesive of post-consumer carpet, said apparatus comprising:
 a first stage apparatus, said first stage apparatus being for use in mechanically separating a substantial portion of pile fibers from backing, said first stage apparatus comprising:
 a drum, said drum being cylindrical and being mounted to permit rotation about an axis of said drum; said drum comprising a plurality of pins protruding outward; 
 a feed dish, said feed dish being curved and having a first end and a second end, said second end terminating in an edge being proximate to said drum; 
 a feed roller; 
 a guide member, said guide member comprising a plurality of perforations, said guide member terminating in proximity to a chute; 
 a vacuum, said vacuum providing negative pressure in said chute; and 
   wherein rotation of said drum causes said plurality of pins to rotate and successively be in proximity to said sharp edge of said feed dish to accomplish said carpet recycling.   
     
     
         11 . A carpet recycling apparatus according to  claim 10  wherein said plurality of pins protruding outward from said cylindrical surface of said drum are generally equally spaced circumferentially about said cylindrical outer surface and generally equally spaced laterally across said cylindrical outer surface. 
     
     
         12 . A carpet recycling apparatus according to  claim 11  further comprising a pile rejecting plate, said pile rejecting plate being in close proximity to said pins of said drum. 
     
     
         13 . A carpet recycling apparatus according to  claim 12  further comprises a sensor, said sensor being capable of performing spectrographic analysis to identify polymer molecules. 
     
     
         14 . A carpet recycling apparatus according to  claim 13  wherein said sensor is capable of performing spectrographic analysis comprising one or more of: infrared reflectance; and Raman scattering. 
     
     
         15 . A carpet recycling apparatus according to  claim 14  wherein said second end of said feed dish comprises curvature having a tangency being approximately tangent to a cylindrical surface formed by said plurality of pins. 
     
     
         16 . A carpet recycling apparatus according to  claim 15  wherein said first stage apparatus further comprises a feed belt rotatably supported by first and second belt support rollers; a pressing roller, and a bottom feed roller, said pressing roller being positioned proximate to an end of said feed belt above said second belt support roller. 
     
     
         17 . A carpet recycling apparatus according to  claim 16  further comprising a willow cleaner, said willow cleaner comprising a cylindrical chamber having a rotatable shaft with a series of spokes being spirally positioned along said shaft. 
     
     
         18 . A carpet recycling apparatus according to  claim 10  further comprising a second stage apparatus, said second stage apparatus being for use in mechanically separating remaining backing fibers and remaining adhesive from pile, said second stage apparatus comprising:
 a housing; said housing comprising an inlet conduit; 
 a shaker pen, for use in separating backing fiber from pile, said shaker pen comprising: 
 one or more walls forming a top opening and a bottom opening, at least said bottom opening of said shaker pen comprising a mesh, said bottom mesh being pivotable, said shaker pen comprising at least one top receiving door for covering said top opening; and 
 wherein when said at least one top door is closed, shaking of said shaker pen causes separation of said pile from said backing fiber. 
 
     
     
         19 . A carpet recycling apparatus according to  claim 18  further comprising a first condensing apparatus, said first condensing apparatus being positioned to receive said fiber from said inlet conduit, and being for use in removing dislodged pieces of adhesive, said condensing apparatus comprising:
 a belt, said belt being mounted upon a first roller and a second roller to be oriented approximately in a vertical direction; said belt being substantially sealed relative to said housing; 
 a drive motor; said drive motor driving said first roller to rotate and cause corresponding rotation of said belt; 
 a perforated squirrel cage, said squirrel cage being rotatably mounted in said housing to rotate about a segregation plate, an interior of said squirrel cage being sealed by said segregation plate to form an upper portion and a lower portion; 
 a flexible seal plate, said flexible seal plate sealing a first exterior side of said squirrel cage; said exterior of said squirrel cage being divided into a corresponding upper portion and lower portion by said flexible seal plate and by a second side of said squirrel cage being sealed by contact with said vertically mounted belt; and 
 said vacuum creating negative pressure in said interior upper portion of said squirrel cage; and wherein said drive motor causes rotation of said squirrel cage corresponding to rotation of said belt; 
 
     
     
         20 . A carpet recycling apparatus according to  claim 19  further comprising a deflector plate, said deflector plate being mounted to said housing to be pivotable between first and second positions; said deflector plate when in said first position sloping toward a first opening in a bottom of said housing while simultaneously blocking a second opening therein; said deflector plate when in said second position sloping toward said second opening while simultaneously blocking said first opening; and
 wherein when said at least one top door is closed, shaking of said shaker pen causes said separated pile to fall through said mesh and be deflected by said deflector plate in a first direction; and wherein when said shaking of said shaker pen stops, said pivotable mesh pivots open to permit said backing fiber to drop and be deflected by said deflector plate in a second direction. 
 
     
     
         21 . A carpet recycling apparatus according to  claim 20  further comprising a weigh pan. 
     
     
         22 . A carpet recycling apparatus according to  claim 21  wherein said second stage further comprises a hopper section and one or more paddle wheels, said one or more paddle wheels controlling access to said weight pan from said hopper section. 
     
     
         23 . A carpet recycling apparatus according to  claim 22  wherein said one or more walls of said shaker pen comprises a box. 
     
     
         24 . A carpet recycling apparatus according to  claim 23  wherein said belt being generally sealed relative to said housing is by a flexible upper seal plate and by a flexible lower seal plate. 
     
     
         25 . A carpet recycling apparatus according to  claim 18  further comprising a third stage apparatus, for use in mechanically separating a substantial portion of remaining adhesive from pile, said third stage apparatus comprising:
 a housing; said housing comprising an inlet conduit; 
 a star valve, said star valve accomplishing volumetric measuring; and 
 a fibermill; said fibermill comprising one or more hammers, a bottom grill, and a dispatch opening; said fibermill further comprising an upper opening into an exit conduit, said conduit being connected to said vacuum, said vacuum selectively creating negative pressure in said exit conduit. 
 
     
     
         26 . A carpet recycling apparatus according to  claim 25  further comprising a first condensing apparatus, said first condensing apparatus being positioned to receive said fiber from said inlet conduit of said second stage, and being for use in removing dislodged pieces of adhesive, said condensing apparatus comprising:
 a belt, said belt being mounted upon a first roller and a second roller to be oriented approximately in a vertical direction; said belt being substantially sealed relative to said housing; 
 a drive motor; said drive motor driving said first roller to rotate and cause corresponding rotation of said belt; 
 a perforated squirrel cage, said squirrel cage being rotatably mounted in said housing to rotate about a segregation plate, an interior of said squirrel cage being sealed by said segregation plate to form an upper portion and a lower portion; 
 a flexible seal plate, said flexible seal plate sealing a first exterior side of said squirrel cage; said exterior of said squirrel cage being divided into a corresponding upper portion and lower portion by said flexible seal plate and by a second side of said squirrel cage being sealed by contact with said vertically mounted belt; and 
 said vacuum creating negative pressure in said interior upper portion of said squirrel cage; and wherein said drive motor causes rotation of said squirrel cage corresponding to rotation of said belt; 
 
     
     
         27 . A carpet recycling apparatus according to  claim 26  further comprising a second condensing apparatus; said second condensing apparatus being for use in separating pile from dislodged pieces of adhesive, and being positioned to receive said fiber from said inlet conduit of said third stage. 
     
     
         28 . A carpet recycling apparatus according to  claim 27  further comprising a hopper section; and
 wherein said star valve controls access to said fibermill from said hopper based upon said volumetric measurement.