Carpet Recycling via Toroidal Flow Pulper and Screening
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Solution Overview
Problem
Current carpet recycling methods are inefficient in separating carpet fibers from calcium carbonate backing materials, particularly when dealing with wet carpets, leading to significant material waste as they cannot handle wet conditions effectively, and often result in the discarding of a substantial portion of nylon fibers along with the backing material.
Innovation Solution
A carpet recycling process involving a toroidal flow pulper to disintegrate carpet into a slurry, followed by separation operations using screening and centrifugation to isolate fibrous materials and calcium carbonate ash, allowing for the recycling of both dry and wet carpets, and producing dried outputs of fibrous materials and ash for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional shaving methods are used to separate carpet fibers from backing, then the process is simple to operate, but only protruding fibers are reclaimed and significant nylon fibers are discarded with the backing
Solution Approach 1:
The patent applies segmentation by dividing the carpet into smaller pieces through shredding before processing. This allows the pulping process to access and separate individual fibers that would otherwise be inaccessible in intact carpet, thereby reducing fiber loss while maintaining operational simplicity
Solution Approach 2:
The patent replaces the mechanical shaving process with a chemical-pulping process using a toroidal flow pulper. This substitution enables complete fiber separation from the backing material through chemical action rather than mechanical cutting, dramatically reducing nylon fiber loss while improving reclamation efficiency
2Adaptability or versatility
If conventional recycling processes are used, then dry carpet can be processed, but wet carpet cannot be handled and must be landfilled
Solution Approach 1:
The patent applies universality by designing a recycling system that can handle both dry and wet carpet inputs through the same process flow. The toroidal flow pulper and screening system are configured to accommodate variable moisture content without requiring separate processing lines, thereby preventing material waste while expanding processing capability
Solution Approach 2:
The patent applies parameter changes by adjusting the pulping process parameters (liquid-to-carpet ratio, pulping time, screen mesh size) based on the moisture content of the input carpet. This allows the system to adapt to varying wetness levels and process both dry and wet carpet effectively, preventing landfill disposal
3Loss of substance
If centrifugation is used to separate fibers from backing, then separation is achieved, but calcium carbonate cannot be effectively separated from nylon fibers
Solution Approach 1:
The patent applies segmentation by using multiple separation stages with different screen mesh sizes. The first screen separates larger calcium carbonate particles, while subsequent screens with progressively smaller openings separate finer particles from fibers, enabling effective calcium carbonate recovery without requiring overly complex equipment
Solution Approach 2:
The patent applies dimensionality change by transitioning from a single centrifugation step to a multi-stage screening process that separates materials based on particle size dimensions. This approach effectively separates calcium carbonate from nylon fibers by progressively filtering through different mesh sizes, achieving separation without excessive device complexity
4Ease of operation
If carpet is shredded and screened to separate fibers from backing, then fibrous materials can be isolated, but the process cannot immediately process wet carpet
Solution Approach 1:
The patent applies continuity of useful action by designing a process where wet carpet is immediately fed into the toroidal flow pulper without interruption for drying. The pulping and separation processes continue uninterrupted, treating wet carpet as a valid input from the moment it enters the system, thereby eliminating drying time delays while maintaining operational simplicity
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
Enables the efficient separation and recycling of carpet fibers and calcium carbonate from the backing material, reducing waste and allowing for the reuse of these materials in new products, with the ability to handle both dry and wet carpet conditions.
Implementation Method 1
disintegrating the pieces of carpet in a quantity of liquid to form a slurry
Implementation Method 2
A first separation operation may be performed to separate at least a portion of the liquid and carpet ash from the fibrous carpet materials
Implementation Method 3
followed by separation operations using screening and centrifugation to isolate fibrous materials and calcium carbonate ash
Implementation Method 4
The fibrous carpet materials may be dried, and at least a portion of the carpet ash may be isolated from the liquid. The isolated carpet ash may be dried.
Data Source
AI summary
A carpet recycling method is disclosed. In a toroidal flow pulper, pieces of carpet are disintegrated in a quantity of liquid to form a slurry of fibrous carpet materials and carpet ash. At least a portion of the fibrous carpet materials are separated from the slurry, and the separated fibrous carpet materials are dried. At least a portion of the carpet ash is isolated from the slurry, and the isolated carpet ash is dried. Thus, a first output comprising dried separated fibrous carpet materials is produced, and a second output comprising dried carpet ash is produced.