Recyclable Single Polymer Floorcovering Article

Abstract

This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.

What is claimed is: 
     
         1 . A process for recycling a floor covering article comprising substantially 100% polyester material, said process comprising the steps of:
 (a) providing a floorcovering article comprised of substantially 100% polyester material;   (b) breaking down the floorcovering article into smaller pieces;   (c) feeding the floorcovering article into an agglomerator for further size reduction;   (d) heating the floorcovering article of step “c” to drive off moisture and preheat the material;   (e) transferring the floorcovering article of step “d” into an extruder to create a polyester polymer melt;   (f) subjecting the polyester melt material to vacuum pressure;   (g) filtering the polyester melt material;   (h) pelletizing the polyester melt material to form a pelletized polyester material; and   (i) incorporating the pelletized polyester material in a new polyester-containing article.   
     
     
         2 . The process of  claim 1 , wherein the recycling process is achieved by melt processing. 
     
     
         3 . The process of  claim 1 , wherein the process of breaking down the floorcovering article is achieved by shredding. 
     
     
         4 . The process of  claim 1 , wherein the new polyester-containing article is selected from the group consisting of fiber, yarn, film, and articles incorporating fiber, yarn or film. 
     
     
         5 . The process of  claim 1 , wherein the new polyester-containing article is a thermoplastic material. 
     
     
         6 . The process of  claim 1 , wherein the extruder is a twin screw extruder. 
     
     
         7 . The process of  claim 1 , wherein the pelletized polyester material is further processed in a reactor under heat and high vacuum to solid state polymerize the material and increase the molecular weight and intrinsic viscosity. 
     
     
         8 . A depolymerization process for recycling a floor covering article comprising substantially 100% polyester material, said process comprising the steps of:
 (a) providing a floorcovering article comprised of substantially 100% polyester material;   (b) breaking down the floorcovering article into smaller pieces;   (c) feeding the material into a bath solution that optionally contains at least one catalyst;   (d) subjecting the material in the bath solution to heat and pressure to form polyester monomer material;   (e) polymerizing the polyester monomer material to form polyester polymer material; and   (f) incorporating the polyester material in a new polyester-containing article.   
     
     
         9 . The process of  claim 8 , wherein depolymerization is achieved via methanolysis. 
     
     
         10 . The process of  claim 8 , wherein depolymerization is achieved via glycolysis. 
     
     
         11 . The process of  claim 8 , wherein depolymerization is achieved via hydrolysis. 
     
     
         12 . A process for recycling a polyester floorcovering article comprising the steps of:
 (a) providing a floorcovering article comprised of substantially 100% polyester material;   (b) breaking down the floorcovering article into smaller pieces;   (c) feeding the smaller pieces of the floorcovering article into a plast agglomerator;   (d) heating the floorcovering article by friction to just below the melting temperature of the article;   (e) forcing the floorcovering article of step “d” through a die;   (f) cutting the floorcovering article of step “e” into granules with a high bulk density; and   (g) using the granules as a feedstock for other processes to make polyester articles.   
     
     
         13 . A process for recycling a polyester floorcovering article comprising the steps of:
 (a) providing a floorcovering article comprised of substantially 100% polyester material;   (b) marking the floorcovering article with a resin identification code according to ASTM D7611/D7611M;   (c) placing the floorcovering article in a recycle bin according to the resin identification code present on the floorcovering article; and   (d) allowing the floorcovering article to be recycled for use in new products.