Heat-Pressed Carpet Waste Composites for Landfill Diversion
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Solution Overview
Problem
There is a need for carpet waste composites that can be efficiently manufactured and utilized in industrial, construction, and consumer applications, providing tensile strength and resistance to environmental factors such as ultraviolet light and insects, while diverting carpet waste from landfills.
Innovation Solution
A method involving cleaned, unadulterated layers of carpet are placed tufted side-to-tufted side with adhesive contact, subjected to heat and pressure, followed by cooling, to create a fused carpet layer, with optional reinforcement structures, to produce a carpet waste composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If carpet waste is used to produce composites, then landfill diversion is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by controlling temperature, pressure, and time during the extrusion process to transform carpet waste into usable composite profiles. By optimizing these parameters, the process achieves effective landfill diversion while managing manufacturing complexity through systematic control of processing conditions
Solution Approach 2:
The patent creates composite materials by combining carpet waste with binding agents and other materials in an extrusion process. This composite material approach enables landfill diversion while the integrated extrusion process manages manufacturing complexity through a unified production method
2Strength
If multiple carpet layers are fused together, then composite strength is improved, but processing time increases
Solution Approach 1:
The patent implements continuous action by using an extrusion process that continuously feeds carpet waste layers and applies heat, pressure, and binding agents in a single uninterrupted operation. This achieves strong multi-layer composites while minimizing processing time through continuous manufacturing
Solution Approach 2:
The patent utilizes phase transitions by applying heat to melt thermoplastic binding agents and carpet waste materials, then cooling them to form solid fused layers. This phase change approach enables strong multi-layer bonding through controlled heating and cooling cycles in the extrusion process
3Strength
If adhesive material is used to bond carpet layers, then bonding strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies self-service by using the carpet waste materials themselves as the bonding agent through their inherent thermoplastic properties. When heated during extrusion, the carpet materials melt and bond to each other, eliminating or reducing the need for separate adhesive materials and associated 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 method enables the production of carpet waste composites with desirable properties for various applications, offering durability, abrasion resistance, and resistance to environmental factors, while diverting carpet waste from landfills.
Implementation Method 1
Heat and pressure followed by cooling are applied to furnish an initial, fused carpet layer
Implementation Method 2
Heat and pressure followed by cooling are applied to furnish an initial, fused carpet layer
Implementation Method 3
Heat and pressure followed by cooling are applied to furnish an initial, fused carpet layer
Data Source
AI summary
A carpet waste composite and method for making the same are disclosed. In one embodiment of the method, cleaned, unadulterated layers of are provided. An initial, unfused carpet layer is made by placing two cleaned, unadulterated layers of carpet tufted side-to-tufted side with homogenous and adhesive contact therebetween. Heat and pressure followed by cooling are applied to furnish an initial, fused carpet layer. Carpet layers are iteratively added, as required, using heat and pressure followed by cooling to furnish a carpet waste composite. Plates are added in sealing engagement to surfaces of the composite construction material.