Carpet Reclamation System Using Shearing and Solvent Separation
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Solution Overview
Problem
The recycling of carpet waste is inefficient due to the chemical and physical incompatibility of its components, leading to limited material recovery and high contamination levels, which strains landfills and requires significant virgin material usage.
Innovation Solution
A method and system for reclaiming carpet components like yarn, tufting primary and secondary backing in a continuous flow process, utilizing a shearing subsystem and sensing systems to separate and purify materials, minimizing contamination and virgin material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If manual recycling methods are used to separate carpet components, then material recovery is attempted, but contamination levels remain high and recovery efficiency is limited
Solution Approach 1:
The carpet recycling process is divided into multiple sequential separation stages: (1) initial mechanical separation of face fiber from backing, (2) chemical treatment to dissolve adhesive bonds, (3) density-based separation of backing materials, and (4) final purification steps. This multi-stage segmentation allows each component to be separated with high purity while maximizing overall material recovery
Solution Approach 2:
Chemical agents are introduced as intermediaries to facilitate separation. Specifically, solvents are used to dissolve the carboxylated styrene-butadiene latex copolymer adhesive, allowing the face fiber and backing materials to separate without direct mechanical force that would cause contamination. This intermediary chemical action enables clean separation of incompatible materials
2Manufacturing precision
If chemical agents are used to separate carpet components, then separation effectiveness improves, but chemical incompatibility causes materials to intermix and form less desirable blends
Solution Approach 1:
Different chemical treatments are applied to different regions and components of the carpet. The face fiber receives one type of chemical treatment while the backing material receives a different treatment, allowing each material to be separated and processed according to its specific properties without unwanted interactions or intermixing
Solution Approach 2:
The chemical separation process utilizes controlled changes in pH, temperature, and solvent concentration to selectively dissolve the adhesive binder at specific stages. By adjusting these parameters sequentially, the process achieves effective separation while maintaining the integrity and composition stability of each recovered material stream
3Productivity
If heat is applied to melt certain carpet materials for recycling, then material flow is improved, but heat causes unwanted dissolution and intermixing of components
Solution Approach 1:
Heat is applied periodically and selectively at specific stages of the recycling process rather than continuously. Localized heating zones are used to melt and facilitate flow of specific materials only when needed, followed by rapid cooling to prevent unwanted thermal dissolution and intermixing of heat-sensitive components
Solution Approach 2:
The process replaces thermal mechanisms with mechanical and chemical alternatives where possible. Instead of using heat to separate materials, the process employs mechanical separation devices and chemical solvents that achieve material flow and separation without thermal effects, preserving composition stability
4Measurement precision
If comprehensive separation of all carpet components is attempted, then material purity improves, but process complexity and cost increase significantly
Solution Approach 1:
The recycling process is designed as a continuous flow system where carpet waste moves sequentially through multiple separation stages without interruption. This continuous operation maintains high material purity through consistent separation conditions while avoiding the batch processing complexity and variability that would increase process complexity and operational costs
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 carpet manufacturing recommendations.
Implementation Method 1
shearing subsystem to separate and purify materials
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.