Carpet Component Recovery Process for Polymer Purification
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Solution Overview
Problem
Current carpet recycling methods are inefficient in separating and maximizing the value of individual polymer and adhesive components from carpet edge trim and whole carpet scraps, often resulting in degraded polymer properties and limited application in new products.
Innovation Solution
A comprehensive component recovery process that includes shredding, screening, granulating, centrifuge separation, and electrostatic polishing to purify polypropylene backing polymer and nylon face fibers, allowing for the creation of high-quality recycled materials that can replace virgin resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional carpet recycling methods are used, then processing simplicity is maintained, but polymer purity and quality are degraded
Solution Approach 1:
The recycling process is divided into distinct sequential stages: shredding, screening, granulating, centrifuge separation, and electrostatic polishing. Each stage targets specific separation objectives, progressively purifying the polymer components from the carpet composite material.
Solution Approach 2:
The patent introduces intermediate processing steps including screening and granulating between the initial shredding and final separation. These intermediary processes prepare the material by creating uniform granules that optimize subsequent centrifugal and electrostatic separation efficiency.
2Reliability
If simple processing methods are used, then ease of operation is maintained, but polymer property degradation occurs
Solution Approach 1:
The patent replaces conventional mechanical separation methods with centrifugal separation and electrostatic polishing. These alternative mechanisms achieve superior polymer purification without the mechanical degradation associated with traditional grinding and sorting processes.
Solution Approach 2:
The process utilizes changes in physical parameters including particle density (for centrifugal separation) and electrostatic charge (for polishing) to differentiate and separate polymer components. These parameter-based separations preserve polymer integrity while achieving high purity.
3Productivity
If conventional separation methods are used, then process simplicity is maintained, but component recovery efficiency is limited
Solution Approach 1:
The patent employs centrifugal force through rotating separators and electrostatic fields through charged plates or rollers. These pneumatic and electromagnetic fields enable efficient separation of polymer components based on their physical properties, dramatically improving recovery efficiency.
Solution Approach 2:
The process is designed to recover multiple distinct polymer components (nylon face fiber, polypropylene backing, polyester secondary backing) from the composite carpet structure. Each component is separated and recovered individually, maximizing overall productivity and material value.
4Manufacturing precision
If minimal processing is used, then energy consumption is reduced, but filler and adhesive contamination increases
Solution Approach 1:
The patent performs preliminary shredding and screening before the main separation processes. This preliminary action breaks down the carpet into manageable pieces and removes large contaminants, reducing the energy required for subsequent centrifugal and electrostatic separation while maintaining high purity outcomes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process effectively recovers purified polymer and filler components, enhancing the quality and economy of carpet recycling by reducing the need for costly additives and improving the physical properties of recycled materials.
Implementation Method 1
centrifuge separation
Implementation Method 2
electrostatic polishing
Data Source
AI summary
A component recovery process to recover one or more of the constituent components of a feed material. In one embodiment, the process is a carpet recycling process, the feed material being carpet, and the constituent components being fiber, filler and adhesive. The process can refine the polypropylene backing polymer and face fibers of post industrial edge trim selvage, whole carpet construction post industrial scraps and pieces, as well as whole carpet post consumer scraps and pieces and in particular mixtures there of. The process beneficially uses land filled edge trim and pre land filled selvage, whole carpet construction scraps and whole carpet post consumer scraps and mixtures there of for component purification.