Carpet Reclamation Shear Subsystems for Continuous Material Separation
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Solution Overview
Problem
Current recycling methods for carpet waste are inefficient due to the chemical and physical incompatibility of its components, leading to high contamination levels and limited material reuse, resulting in a significant amount of waste being disposed of in landfills.
Innovation Solution
A system and method for reclaiming carpet components like yarn, tufting primary and secondary backing in a continuous flow process using shear subsystems to separate and recycle the materials effectively, minimizing contamination and the need for virgin materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual recycling methods are used to separate carpet components, then some material reuse is achieved, but contamination levels remain high and recycling efficiency is low
Solution Approach 1:
The carpet recycling system is divided into multiple specialized subsystems: a first shear subsystem for initial separation, a second shear subsystem for further separation, and a flake opener for final processing. Each subsystem performs a specific separation function, enabling efficient decomposition of complex carpet materials into distinct components while maintaining high purity levels.
Solution Approach 2:
The patent introduces intermediate processing stages between the input carpet waste and final recycled materials. The first shear subsystem produces intermediate separated materials that are then further processed by the second shear subsystem. This multi-stage intermediary approach allows progressive purification and contamination reduction while maintaining high recycling efficiency.
2Speed
If chemical or thermal methods are applied to separate carpet materials, then separation speed increases, but material compatibility issues cause intermixing and reduce material quality
Solution Approach 1:
The patent replaces chemical and thermal separation methods with mechanical shear subsystems. The first and second shear subsystems use mechanical shearing forces to separate carpet components based on their physical properties, achieving both high separation speed and material quality preservation without the harmful effects of chemical contamination or thermal degradation.
Solution Approach 2:
The system changes the separation parameter from chemical/thermal fields to mechanical shear force fields. By adjusting the mechanical parameters of the shear subsystems (such as shear force, speed, and configuration), the system achieves efficient separation while maintaining material integrity and avoiding intermixing of incompatible components.
3Productivity
If heat is applied to melt certain carpet materials for recycling, then processing continues, but materials intermix and form blends with less desirable properties
Solution Approach 1:
The patent substitutes thermal melting processes with mechanical shearing and flaking operations. The first shear subsystem, second shear subsystem, and flake opener collectively achieve continuous processing of carpet materials through mechanical means, preventing unwanted material intermixing while maintaining processing continuity and productivity.
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 system achieves higher efficiency in recycling carpet waste with lower contamination levels, enabling more effective reuse of materials and reducing the need for virgin materials, aligning with sustainable recycling goals.
Implementation Method 1
A first shear subsystem and a second, downstream, shear subsystem are configured for separating face materials and secondary backing materials from a primary backing material of the carpet
Data Source
AI summary
The present invention relates generally to the reclaiming of carpet waste material. More particularly, the invention relates to a method and system for reclaiming carpet components such as yarn, tufting primary, binder, and secondary backing from post industrial and post consumer carpet waste in a substantially continuous flow process.