Solvent-Based Floor Covering Recycling Process
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Solution Overview
Problem
Current recycling methods for floor coverings, such as carpets and artificial turf, face challenges in achieving complete material recycling due to the non-reversible hardening of latex and polyurethane coatings, leading to partial recyclability and the need for economic and efficient processes that can separate and recover pure plastic components.
Innovation Solution
A solvent-based recycling process utilizing selective dissolution with organic solvents to separate polyolefin waxes and higher molecular weight polymers, allowing for the recovery of pure material components with minimal cross-contamination, particularly using metallocene-produced polyolefin waxes and halogen-free hydrocarbons as solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If latex or polyurethane coating is used to integrate yarn into carrier, then the coating provides binding function, but the non-reversible hardening prevents complete material recycling
Solution Approach 1:
The patent changes the chemical parameter of the coating material from conventional latex/polyurethane to polyolefin wax, which has different solubility characteristics. This parameter change enables the coating to be dissolved by organic solvents like xylenes, making the entire floor covering construction recyclable while maintaining the binding function during use.
Solution Approach 2:
The patent introduces polyolefin wax as an intermediary coating material that serves as a bridge between the yarn and carrier, providing binding functionality while being soluble in organic solvents. This intermediary material enables both the mechanical binding function and the chemical recyclability that previous coating materials could not achieve simultaneously.
2Device complexity
If mechanical separation processes are used for recycling, then the process is simple, but pure plastic separation cannot be achieved satisfactorily
Solution Approach 1:
The patent replaces the mechanical separation system with a chemical dissolution system. Instead of using complex mechanical means to physically separate mixed plastics, the invention uses organic solvents to selectively dissolve the polyolefin wax coating and associated plastics, achieving pure separation through chemical affinity differences.
Solution Approach 2:
The patent changes the separation mechanism from mechanical to chemical by utilizing the solubility parameter of polyolefin wax in organic solvents. This parameter change allows for high-purity plastic separation because the dissolution process selectively targets specific polymer types based on their chemical properties rather than physical characteristics.
3Loss of substance
If downcycling methods like regranulation are used, then material recycling is achieved, but materials cannot be used in their original form
Solution Approach 1:
The patent extracts the polyolefin wax coating material from the floor covering construction using organic solvents, separating it from the yarn and carrier. This extraction process recovers the coating material in pure form, enabling it to be reused as a coating material in new floor coverings rather than being downcycled into lower-quality applications.
Solution Approach 2:
The patent implements a recovery system where the polyolefin wax coating is dissolved, separated, and recovered in pure form. This recovered material can then be reused for its original purpose as a coating material, maintaining its high-value application rather than being discarded into lower-quality uses like infill or heavy layers.
4Use of energy by moving object
If incineration is used for energy recovery, then energy is recovered and landfilling is avoided, but material recycling opportunities are lost
Solution Approach 1:
The patent performs preliminary separation of the polyolefin wax coating from the floor covering construction before any energy recovery or disposal processes. By dissolving and recovering the coating material in pure form first, the invention enables subsequent material recycling applications, preventing the need to choose between energy recovery and material recycling.
Solution Approach 2:
The patent segments the floor covering construction into separable components through selective dissolution of the polyolefin wax coating. This segmentation allows the coating material to be recovered separately for material recycling, while the remaining yarn and carrier components can be processed for energy recovery or other applications, enabling both material and energy value capture.
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
This process achieves high-quality separation of mixed plastics, removing additives and achieving material recovery with minimal impact on mechanical properties, enabling the reuse of recovered materials in their original form with high purity and efficiency.
Implementation Method 1
A solvent-based recycling process utilizing selective dissolution with organic solvents to separate polyolefin waxes and higher molecular weight polymers
Implementation Method 2
allowing for the recovery of pure material components with minimal cross-contamination
Data Source
AI summary
The invention relates to a solvent-based separation method for the total material recycling of materials used in nonwoven, woven, and tufted wares into the individual material components thereof sorted by type. At least one of the materials contains a polyolefin wax. As a solvent and/or swelling agent, halogen-free, aliphatic hydrocarbons or aromatic hydrocarbons or a mixture of one or several of said solvents are used.