Method and Apparatus for Recycling Carpet

Abstract

The present invention is directed to an apparatus and method for separating carpet fibers from a backing material to which said fibers are secured. The apparatus includes a belt for driving a carpet strip having one or more backings and one or more fibers secured on a face of said backing into the operative part of the device. There are a pair of rollers that are adapted to receive the carpet strip from said belt, and pass the carpet strip to a dish plate. The dish plate has an edge extending upwardly from the dish plate. The face of the carpet having the fibers contacts the edge after the carpet passes through the rollers. The edge of the blade holds the carpet presenting it to the main drum. The main drum rotates downwards and has a plurality of pins that shred the carpet backing and tear apart and free the face carpet fibers from the backing fibers. The face fibers pass to a receptacle for recycling. The torn backing fibers, being usually longer and lighter than the face fibers, remain within the pins of the drum and are transported towards the back end of the machine and fall in a different receptacle for recycling.

We claim: 
     
         1 . A method of separating the pile from the backing of a section of carpet, said method comprising:
 transporting the section of carpet upon a feed belt, with the pile contacting a surface of said feed belt, and with the backing being distally positioned with respect to said feed belt;   directing the carpet section toward a plate using a first roller and a second roller;   rotating a drum comprising a plurality of pins protruding from an outer surface thereon;   adjusting said rotating drum to be with a tip of each of said plurality of pins passing at a set distance away from a sharp edge of said plate;   passing the carpet section, from said top and bottom feed rollers, across a curved surface of said plate, and across said sharp edge of said plate;   shredding the backing of the carpet section by said pins of said rotating drum, and separating a substantial portion of the pile from the shredded backing, by said rotating pins, with said rotating pins throwing the separated pile in a first direction; and   transporting the shredded backing away from the separated pile by said pins pulling the shredded backing along a surface of said drum.   
     
     
         2 . The method according to  claim 1  further comprising adjusting the proportion of the pile being separated from the shredded backing in said first direction, by adjusting a first portion of a guide member to be closer to or farther away from said pins of said rotating drum. 
     
     
         3 . The method according to  claim 2  further comprising using a curved surface of a second portion of said guide member for guiding the shredded backing into proximity with said pins and said outer surface of said drum, for said transport therewith. 
     
     
         4 . The method according to  claim 1  further comprising removing the shredded backing from said drum using a second guide member. 
     
     
         5 . The method according to  claim 4 , further comprising receiving the shredded backing from said second guide member onto an outer surface of a rotating condenser cage, and using negative pressure within a portion of said condenser cage for sucking air through a plurality of orifices in said outer surface of said condenser cage, for carrying away crushed latex and calcium carbonate from the shredded backing. 
     
     
         6 . The method according to  claim 5  further comprising depositing the shredded backing, from said outer surface of said condenser cage when passing over a second portion of said cage, onto a transport belt. 
     
     
         7 . The method according to  claim 6  further comprising transporting the shredded backing upon said transport belt to a second receptacle, and receiving the shredded backing within said second receptacle. 
     
     
         8 . The method according to  claim 1  further comprising using a pressing roller for keeping the carpet section properly positioned on said feed belt. 
     
     
         9 . The method according to  claim 1  further comprising rotating said drum at a rate of at least 300 rpm. 
     
     
         10 . The method according to  claim 9  further comprising rotating said drum at a rate preferably in the range of 500 rpm to 600 rpm. 
     
     
         11 . The method according to  claim 1  further comprising presenting the carpet section across said sharp edge of said plate at an angle being less than 30 degrees. 
     
     
         12 . The method according to  claim 11  further comprising presenting the carpet section across said sharp edge of said plate at an angle preferably being less than 15 degrees. 
     
     
         13 . A method of separating the pile from the backing of a section of carpet, said method comprising:
 transporting the section of carpet upon a feed belt, with the pile contacting a surface of said feed belt, and with the backing being distally positioned with respect to said feed belt;   directing the carpet section toward a plate using a top feed roller and a bottom feed roller;   rotating a drum comprising a plurality of pins protruding from an outer surface thereon;   adjusting said rotating drum to be with a tip of each of said plurality of pins passing at a set distance away from a sharp edge of said plate;   passing the carpet section, from said top and bottom feed rollers, across a curved surface of said plate, and selectively presenting the carpet section across said sharp edge of said plate at an angle to said rotating drum;   pushing the backing against said sharp edge of said plate, by said pins of said rotating drum, causing shredding of the backing and separating of a substantial portion of the pile from the shredded backing, with said rotating pins throwing the separated pile in a first direction; and   transporting at least a substantial portion of the shredded backing away from the separated pile, by said pins and said outer surface of said drum pulling the shredded backing therefrom.   
     
     
         14 . The method according to  claim 13  further comprising adjusting the proportion of the pile being separated from the shredded backing in said first direction, by adjusting a first portion of a guide member to be closer to or farther away from said pins of said rotating drum. 
     
     
         15 . The method according to  claim 14  further comprising using a curved surface of a second portion of said guide member for guiding the shredded backing into proximity with said pins and said outer surface of said drum, for said transport therewith. 
     
     
         16 . The method according to  claim 15  further comprising removing the shredded backing from said drum using a second guide member. 
     
     
         17 . The method according to  claim 16 , further comprising receiving the shredded backing from said second guide member onto an outer surface of a rotating condenser cage, and using negative pressure within a portion of said condenser cage for sucking air through a plurality of orifices in said outer surface of said condenser cage, for removing particulates from the shredded backing. 
     
     
         18 . The method according to  claim 17  further comprising receiving the shredded backing, from said outer surface of said condenser cage when passing over a second portion of said cage, onto a transport belt. 
     
     
         19 . The method according to  claim 18  further comprising transporting the shredded backing upon said transport belt to a second receptacle, and receiving the shredded backing within said second receptacle. 
     
     
         20 . The method according to  claim 19  further comprising using a pressing roller for keeping the carpet section properly positioned on said feed belt. 
     
     
         21 . The method according to  claim 20  further comprising rotating said drum at a rate of at least 300 rpm. 
     
     
         22 . The method according to  claim 21  further comprising rotating said drum at a rate preferably in the range of 500 rpm to 600 rpm. 
     
     
         23 . The method according to  claim 22  further comprising presenting the carpet section across said sharp edge of said plate at an angle being less than 30 degrees. 
     
     
         24 . The method according to  claim 23  further comprising presenting the carpet section across said sharp edge of said plate at an angle preferably being less than 15 degrees.