Devices, systems, and methods for recovery and recycling of carpet components

Abstract

Devices, systems and methods for the recycling and recovery of carpet are disclosed herein. Devices, systems and methods for disassembling carpet into the various components used for carpet construction by abrasive removal and separation of components are also disclosed herein.

1 . A method for carpet recycling, the method comprising:
 removing the secondary backing of the carpet with abrasion; and   removing the face fiber of the carpet with abrasion.   
     
     
         2 . A method of  claim 1 , wherein the method further comprises holding the carpet in tension. 
     
     
         3 . A method of  claim 2 , wherein the carpet is held in tension along the outer radius of a primary drum. 
     
     
         4 . A method of  claim 3 , wherein the carpet is held in tension by a force, and wherein the force applied is selected from one of the following ranges: approximately 150 to 1,500 pounds per square inch; approximately 250 to 1,500 pounds per square inch; approximately 250 to 1,250 pounds per square inch; approximately 250 to 1,000 pounds per square inch; approximately 500 to 1,500 pounds per square inch; approximately 500 to 1,250 pounds per square inch; approximately 500 to 1,000 pounds per square inch; approximately 750 to 1,500 pounds per square inch; approximately 750 to 1,250 pounds per square inch; and approximately 750 to 1,000 pounds per square inch. 
     
     
         5 . A method of  claim 4 , wherein the primary drum rotates at a speed selected from one of the following ranges: about 1 to 100 feet per minute; about 2-50 feet per minute; about 2-30 feet per minute; about 2-20 feet per minute; about 2-15 feet per minute; about 2-10 feet per minute; about 2-5 feet per minute; about 15-75 feet per minute; about 15-65 feet per minute; about 15-55 feet per minute; about 15-45 feet per minute; about 15-35 feet per minute; about 15-25 feet per minute; about 18-60 feet per minute; about 25-100 feet per minute; about 25-75 feet per minute; about 25-65 feet per minute; about 25-55 feet per minute; about 25-45 feet per minute; and about 25-35 feet per minute. 
     
     
         6 . A method of  claim 2 , wherein removing the secondary backing or the face fiber of the carpet with abrasion comprises applying at least one high speed abrasive drum against the carpet. 
     
     
         7 . A method of  claim 6 , wherein the at least one high speed abrasive drum operates at a speed selected from one of the following ranges: about 500-RPM to 10,000-RPM; about 500-RPM to 7,500-RPM; about 500-RPM to 5,000-RPM; about 500-RPM to 3,500-RPM; about 500-RPM to 2,500-RPM; about 750-RPM to 7,500-RPM; about 750-RPM to 5,000-RPM; about 750-RPM to 3,500-RPM; about 750-RPM to 2,500-RPM; about 1,000-RPM to 7,500-RPM; about 1,000-RPM to 5,000-RPM; about 1,000-RPM to 3,500-RPM; and about 1000-RPM to 2,500-RPM. 
     
     
         8 . A method of  claim 6 , wherein the at least one high speed abrasive drum applies a force of approximately 4 to 6 pounds per inch of carpet width against the carpet. 
     
     
         9 . A system for carpet recycling, the system comprising:
 a primary drum, wherein the primary drum is configured to receive a carpet disposed over the outer radius of the primary drum; and   at least one high speed abrasive drum, wherein the at least one high speed abrasive drum is configured to remove at least one of the secondary backing and the face fibers of the carpet with abrasion.   
     
     
         10 . A system of  claim 9 , wherein the at least one high speed abrasive drum comprises at least one of a first high speed abrasive drum, wherein the first high speed abrasive drum is configured to remove the secondary backing of the carpet with abrasion; and
 a second high speed abrasive drum, wherein the second high speed abrasive drum is configured to remove the face fiber of the carpet with abrasion.   
     
     
         11 . A system of  claim 10 , the primary drum comprising at least one clamping mechanism configured to secure carpet against the primary drum. 
     
     
         12 . A system of  claim 11 , wherein the primary drum rotates at approximately 2-3 RPM. 
     
     
         13 . A system of  claim 10 , the system further comprising a plurality of rollers, wherein the rollers are positioned along the outer radius of the primary drum. 
     
     
         14 . A system of  claim 11 , wherein the plurality of rollers deliver a constant force of approximately 1,000-pounds against the primary drum. 
     
     
         15 . A system of  claim 10 , wherein the at least one high speed abrasive drum further comprise a pressure-maintaining mechanism, wherein the pressure-maintaining mechanism applies a constant force on the at least one high speed abrasive drum. 
     
     
         16 . A system of  claim 15 , wherein the at least one high speed abrasive drum is fitted with an abrasive material. 
     
     
         17 . A system of  claim 16 , wherein the abrasive material comprise abrasive particles ranging from approximately 24-60 grit. 
     
     
         18 . A system of  claim 17 , wherein the at least one high speed abrasive drum spins at a speed of approximately 4,200 ft per min. 
     
     
         19 . A system of  claim 18 , wherein the at least one high speed abrasive drum applies a force of approximately 4 to 6 pounds per inch of carpet width against the carpet. 
     
     
         20 . A system of  claim 19 , the system further comprising at least one vacuum system extending towards the at least one high speed abrasive drum to collect at least one of aggregate mixture and separated face fibers. 
     
     
         21 . A system of  claim 20 , the system further comprising at least one cyclone system and at least one vibratory screen, wherein the at least one vibratory screen separates the aggregate mixture. 
     
     
         22 . A device useful in the recovery, clean-up or recycling of liquid hydrocarbons and organic liquids, the device comprising lipophilic fibers obtained from the method of  claim 1 . 
     
     
         23 . The device of  claim 22 , wherein the fibers comprise a synthetic material selected from one or more of nylon, polyester, olefin, or acrylic polymers. 
     
     
         24 . The device of  claim 22  configured as an absorbent mat, pad, boom or bale comprising a containment layer formed by a first material, wherein the first material is permeable to water and is lipophilic in nature, and a filler material, wherein the filler material is contained by or positioned within the containment layer, is also permeable to water, and is lipophilic in nature. 
     
     
         25 . The device of  claim 24 , wherein the first material is formed by selecting from fibers obtained from removing the secondary backing of a carpet with abrasion, fibers obtained from removing the face fiber of a carpet with abrasion, and fibers obtained from a primary backing of a carpet after removing the secondary backing and face fibers by abrasion. 
     
     
         26 . A method for producing a device useful in the recovery, clean-up or recycling of liquid hydrocarbons and organic liquids, the method comprising:
 providing lipophilic fibers obtained from the method of  claim 1 ;   providing a containment layer;   forming a filler material comprising the lipophilic fibers;   assembling a device comprising the filler material contained by or positioned within the containment layer, wherein the device is configured as an absorbent mat, pad, boom or bale that is permeable to and allows the passage of water, while absorbing or otherwise collecting liquid hydrocarbons and organic liquids that come in contact with the filler material.   
     
     
         27 . The method of  claim 26 , wherein providing lipophilic fibers comprises providing fibers obtained from removing the secondary backing of a carpet with abrasion. 
     
     
         28 . The method of  claim 26 , wherein providing lipophilic fibers comprises providing fibers obtained from removing the face fibers of a carpet with abrasion. 
     
     
         29 . The method of  claim 26 , wherein providing lipophilic fibers comprises providing fibers from the primary backing of a carpet after removing the secondary backing and face fibers by abrasion. 
     
     
         30 . The method of  claim 26 , wherein providing a containment layer comprises providing a containment layer comprising the lipophilic fibers obtained from a method for carpet recycling, wherein the method for carpet recycling comprises removing the secondary backing of the carpet with abrasion, and removing the face fiber of the carpet with abrasion.