Methods and systems for carpet recycling

Abstract

The present invention includes improved systems and methods for recycling one or more polymers from a carpet that has been contacted with a solvent to dissolve an adhesive carpet backing under conditions that dissolve the adhesive carpet backing to provide a reclaimed polymer composition, the improvement comprising a mechanical disruptor that both pulls and separates the polymers from the adhesive carpet backing concurrently in at least two different vectors for a time sufficient to separate the one or more polymers from the adhesive carpet backing following the step of dissolving the carpet backing with the solvent, contacting the portions of carpet, wherein the improvement provides for the complete separation of two or more polymer components, and the carpet adhesive, and the two or more polymers from the carpet are produced without substantially sheering the two or more polymers.

What is claimed is: 
     
         1 . An improved method of recycling one or more polymers from a flooring material that has been contacted with a solvent to provide a reclaimed polymer, the improvement comprising:
 cutting the flooring material into portions to provide contact between the flooring material and the solvent; and   contacting the portions of flooring material with a mechanical disruptor that both pulls and separates the one or polymers concurrently in at least two different directions for a time sufficient to separate the one or more polymers, wherein the polymers are removed from an adhesive backing of the flooring material.   
     
     
         2 . The method of  claim 1 , wherein greater than 70, 75, 80, 85, 90, 95, 96, 97, 98, or 99% of the carpet components are recycled. 
     
     
         3 . The method of  claim 1 , wherein the mechanical disruptor is defined further as comprising two or more mixing heads, blades, beaters, wisks, paddles, jets, screws, or rollers that provide the mechanical disruption in the at least two different directions. 
     
     
         4 . The method of  claim 1 , wherein the solvent is selected from at least one of a terpene solvent, a D-limonene, a pinene, an α-pinene or water. 
     
     
         5 . The method of  claim 1 , wherein the wherein the solvent is a soy based solvent. 
     
     
         6 . The method of  claim 1 , wherein the mechanical disruptor is contacted with the portions of the flooring material for a time sufficient to separate the one or more polymers without substantially sheering the one or more polymers. 
     
     
         7 . The method of  claim 1 , wherein the mechanical disruptor is contacted with the carpet components for 1 to 30, 2 to 25, 3 to 20, 4 to 15, 5 to 15, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 minutes without substantially sheering the two or more polymers. 
     
     
         8 . The method of  claim 1 , wherein the one or more polymers are selected from at least one of a HDPE, LDPE, LLDPE, ULDPE, VLDPE, VLLDPE, copolymers of ethylene and α-olefins, polypropylene, copolymers of propylene and α-olefins, copolymers of propylene and ethylene, EVA, and EMA. 
     
     
         9 . The method of  claim 1 , wherein following the separation of the one or more polymers, the one or more polymers are at least about 70% ash-free. 
     
     
         10 . The method of  claim 1 , wherein following the separation of the one or more polymers, the one or more polymers are substantially ash-free. 
     
     
         11 . A method of recycling one or more polymers from a flooring material comprising:
 subjecting a flooring material cut into portions that permit contact between the flooring material to a solvent that dissolves an adhesive backing thereof;   contacting the flooring material portions with a mechanical disruptor that both pulls and separates one or more polymers of the flooring material from the adhesive backing concurrently in at least two different directions for a time sufficient to separate the one or more polymers from the adhesive backing; and   separating any remaining adhesive away from the one or more polymers by at least one of crushing or squeezing, wherein greater than about 70% of components of the flooring material may be recycled.   
     
     
         12 . The method of  claim 11 , wherein greater than about 90% of components of the flooring material may be recycled. 
     
     
         13 . The method of  claim 11 , wherein substantially all components of the flooring material may be recycled. 
     
     
         14 . The method of  claim 11 , wherein the solvent is selected from at least one of a terpene solvent, a D-limonene, a pinene, an α-pinene or water. 
     
     
         15 . The method of  claim 11 , wherein the mechanical disruptor comprises two or more mixing heads, blades, beaters, wisks, paddles, jets, screws, or rollers that provide the mechanical disruption in the at least two different vectors. 
     
     
         16 . The method of  claim 11 , wherein the flooring material portions are contacted with the mechanical disruptor after subjecting the flooring material portions to the solvent. 
     
     
         17 . The method of  claim 11 , wherein the flooring material portions are contacted with the mechanical disruptor for about 1 to 30 minutes to separate the one or more polymers without substantially sheering the one or more polymers 
     
     
         18 . The method of  claim 11 , wherein the one or more polymers are selected from at least one of a HDPE, LDPE, LLDPE, ULDPE, VLDPE, VLLDPE, copolymers of ethylene and α-olefins, polypropylene, copolymers of propylene and α-olefins, copolymers of propylene and ethylene, EVA, and EMA. 
     
     
         19 . The method of  claim 11 , wherein following the separation of the one or more polymers, the one or more polymers are at least about 70% ash-free. 
     
     
         20 . A system for recycling one or more polymers from a flooring material cut into portions that allow contact with a solvent comprising:
 a vat or container configured to accept portions of a cut flooring material and subject the cut flooring material portions to the solvent;   a mechanical disruptor that both pulls and separates the one or more polymers from an adhesive backing concurrently in at least two different directions for a time sufficient to separate the one or more polymers from the adhesive backing following subjecting the cut flooring material portions to the solvent; and   one or more rollers configured to crush adhesive particles remaining on the one or more polymers, wherein the system achieves complete separation of the one or more polymer components and the adhesive backing without substantially sheering the one or more polymers.