CA2133303A1 - Improved carpet reclamation process - Google Patents

Improved carpet reclamation process

Info

Publication number
CA2133303A1
CA2133303A1 CA 2133303 CA2133303A CA2133303A1 CA 2133303 A1 CA2133303 A1 CA 2133303A1 CA 2133303 CA2133303 CA 2133303 CA 2133303 A CA2133303 A CA 2133303A CA 2133303 A1 CA2133303 A1 CA 2133303A1
Authority
CA
Canada
Prior art keywords
carpet
backing
pile
binder
set forth
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA 2133303
Other languages
French (fr)
Inventor
Peter Michael Ramsden
Roger Joseph Goulet
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Monsanto Co
Original Assignee
Monsanto Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Monsanto Co filed Critical Monsanto Co
Priority to CA 2133303 priority Critical patent/CA2133303A1/en
Priority to AU37241/95A priority patent/AU3724195A/en
Priority to CA 2201375 priority patent/CA2201375C/en
Priority to PCT/US1995/012186 priority patent/WO1996010054A1/en
Priority to US08/817,402 priority patent/US5916410A/en
Publication of CA2133303A1 publication Critical patent/CA2133303A1/en
Priority to US08/825,204 priority patent/US6379489B1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02Separating plastics from other materials
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00Recovery or working-up of waste materials
    • C08J11/04Recovery or working-up of waste materials of polymers
    • C08J11/06Recovery or working-up of waste materials of polymers without chemical reactions
    • C08J11/08Recovery or working-up of waste materials of polymers without chemical reactions using selective solvents for polymer components
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04Disintegrating plastics, e.g. by milling
    • B29B2017/0424Specific disintegrating techniques; devices therefor
    • B29B2017/0428Jets of high pressure fluid
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/732Floor coverings
    • B29L2031/7322Carpets
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/62Plastics recycling; Rubber recycling

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Organic Chemistry (AREA)
  • Sustainable Development (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)

Abstract

The process involves the reclamation of base materials from carpet. The reclamation is achieved by numerous steps, one important step which is to provide a water soluble and environmentally friendly solvent for dissolving the binder material conventionally associated with carpets. The use of such a water soluble solvent not only provides for a clean reclamation process but additionally substantially reduces the amount of mechanical agitation and other processing to which the carpet must be subjected. The process results in a substantially clean and expedited reclamation process which further provides a recycling feature for recycling the water soluble solvent.

Description

2133~03 IMPROVED CARPET RECLANATION PROCESS
The present invention is directed to an improved process for carpet reclamation and more particularly, the process is directed to the use of a water soluble solvent for dissolving binder material conventionally associated with carpet in order to expedite and simplify the reclamation process.

Other reclamation processes have been previously proposed in the art, typical of which is the process indicated in U.S.
Patent No. 5,230,473, issued to Hagguist et al., July 27, 1993.

In the Hagguist et al. method, apart from introductory steps which involve screening the carpet, and preliminary loop cutting and other processing, the removal of the secondary backing involves a whole series of steps. This additionally is the situation when the binder material is to be removed from the primary backing.

In greater detail, and with respect to the removal of the secondary backing from the carpet, the carpet must be initially exposed to fluids under pressure for loosening and debonding the latex binder from the secondary backing. The next step includes passing the remaining material onto a further processing stage where the secondary backing is mechanically treated with rotating mechanical impingement devices on both sides of the carpet. It is the mechanical arrangement that results in the removal of the secondary backing. At this time, the binder system is still substantially intact.

In order to remove the binder material, the remaining carpet structure must be passed to yet another stage where there is included a plurality of rotating brushes as well as rotating high pressure nozzle heads. This, as indicated by the patentees, ~1333~3 results in the gradual loosening and removal of the binder system from the primary backing.

In view of the teachings of this reference, it is clear that the method is dependent on the use of mechanical means for the removal of not only the secondary backing, but further the removal of the latex binder conventionally positioned between the secondary backing and the primary backing.

As with all multiple step processes, there are the concomitant disadvantages which include increased production time, the use of a greater number of moving parts, possibly the requirement for a larger labour force as well as a general impediment to a high efficiency process capable of processing, for example, millions of square meters of carpet.

In view of what has been proposed in the prior art set forth above, there clearly exists a need for a high efficiency method of reclaiming base components of a carpet quickly and without the use of toxic contaminants or multiple stage processes.

One aspect of the present invention is directed to satisfying the above need and according to one aspect of one embodiment of the present invention, there is provided a process for reclaiming carpet components, the carpet including backing material, binder material and carpet pile, the process comprising the steps of: contacting the carpet with a solution for dissolving the binder; dissolving the binder from the carpet to provide backing and pile devoid of the binder; and separating the pile from the backing.

As an attendant advantage, the process according to the present invention employs a non-toxic environmentally friendly 2133~03 water soluble solvent as a preferred solvent, an example of which may be a suitable member of the dimethyl ester solvents. Other suitable solvent compounds include non-toxic members selected from the polar and non-polar solvents capable of dissolving the binder, including, for example, GreensolvTM, SantosolTM, etc. In order to further enhance the dissolution of the binder, additional chemicals may be added in the system including, for example, surface active agents to enhance the wettability of the backing material of the carpet. In addition, thickeners may be added to control the flow and adhesive properties of the solvent.

Conveniently, the process permits the reuse and recycle of the pile material into critical end uses requiring a high degree of product purity such as, for example, carpet fibers, plastic pellets and other materials. Once the dissolution of the latex binder is complete, the separation of the base components of the carpet may be achieved by making use of mechanical means, fluid means including air and liquid flow, vacuum means or by manual means.
According to a further aspect of the present invention, there is provided in a process for reclaiming materials from a carpet having backing material, binder material and carpet pile, the improvement comprising: contacting the carpet with a solution for dissolving the binder; dissolving the binder; and separating the backing and the pile.

Any residual solvent present on the individual base components of the carpet may be removed by simply washing the components and this may additionally include pressurized washing making use of a suitable washing agent.

According to yet another aspect of one embodiment of the 2133~

present invention there is provided a system for reclaiming carpet components, the carpet including backing material, binding material and carpet pile, the system including: advancing means for advancing the carpet to a solvent application means; solvent application means for applying solvent to the carpet to dissolve the binder material; and collection means for collecting separated backing material and carpet pile.

It will be readily appreciated that the process as set forth herein is clearly applicable to all carpet types including, for example, standard carpet with primary and second backing, or with foam secondary backing.

Having thus generally described the invention, reference lS will now be made to the accompanying drawings illustrating preferred embodiments and in which:
Figures 1 and 2 illustrate various types of carpeting in cross-section; and Figure 3 is a schematic illustration of the process according to one embodiment of the present invention.

Similar numerals in the Figures denote similar elements.

Referring now to the drawings, Figures 1 and 2 illustrate cross-sectional view of typical carpet varieties. In Figure 1, the carpet 10 includes a primary backing 12 within which is disposed carpet pile 14. The carpet pile 14 being fixedly secured with binder 16, typically latex binder. A secondary backing 18 is additionally provided.
Figure 2 illustrates a second type where in the binder material comprises a foam material 20 and further does not include a secondary backing.
2 1 ~

It will be appreciated by those skilled in the art that further types of carpeting may be processed according to the invention.

Prior to the onset of the process, the carpet remnants will be screened for processing suitability. The use of visual inspection, metal detectors, etc., may be employed to this end.
Further, the carpet may be preconditioned with, for example, a surface active agent or other compound(s) to enhance the processing.

Turning to Figure 3, which illustrates a schematic illustration of the process according to one embodiment of the invention, in the carpeting material of Figure 1, a first roller 30 advances the carpet material to a first pair of liquid nip rollers 32 and 34. Rollers 32 and 34 include the water soluble solvent for application onto the secondary backing 18 of the carpet 10. The solvent may optionally be heated to accelerate the dissolution. A further set of rollers 36 and 3B further enhance the application of the binder dissolving solvent through the secondary backing into the binder material of the carpet.

The carpet is then passed between two star wheels 40 and 42 which mechanically loosen the secondary backing from the carpet passing therethrough. At this point, the secondary backing is effectively removed from the carpet and to this end, an abrasive roll 44 is provided and further acts on a smooth roll 46 to remove the secondary backing from the carpet. The removed secondary backing may be passed on through rollers 48 and 50 to a high pressure wash, globally denoted by numeral 52, optionally dried by pressure rollers 54 and 56 and collected on a spool 58 for subsequent usage.

21~3~

Once the secondary backing 18 has been completely removed, the primary backing 12, together with the pile 14 and binder 16, are further treated with the solvent using a nip roller arrangement 60 and 62 in a similar manner as set forth with respect to nips 32 and 34. After a suitable dwell time, the remaining material is subjected to a high pressure wash at 64 water in order to remove any residual binder from the primary backing along with any remaining solvent. After entering the washing cycle 64, the primary backing and carpet pile is then dried in a drying cycle at 66 using any suitable means for effectively drying, e.g. forced hot air.

In order to remove the carpet pile 14 from the primary backing 12, once dried, the primary backing and carpet pile are passed into contact over a source of vacuum. In the embodiment shown, this is an inverted vacuum plate 68 which pulls the carpet pile 14 of the primary backing 12 for subsequent collection as generally indicated by the arrow 70 in Figure 3. Any remaining particles of binder 16 are then dropped into a collection unit (not shown). The separated primary backing 12 is then optionally washed and passed on to a collection spool, the latter steps not being schematically illustrated in Figure 3.

As further steps, the solvent may be applied pressurably to the carpet. Further, the carpet may be passed through the system a second time, when required.

In addition to the above, the spent solvent may be reused by recycling the same subsequent to filtering the spent solution.
Further, the solvent may be purified by distillation or other well known chemical purification techniques.

Other solvents may be combined with the dissolving solvent 21~3~0S3 to enhance dissolution of the binder.

Although embodiments of the invention have been described in detail herein, it will be appreciated by those skilled in the art that numerous modifications may be made to the invention without departing from the intended scope of the invention.

Claims (22)

1. A process for reclaiming carpet components, said carpet including backing material, binder material and carpet pile, said process comprising the steps of:
contacting said carpet with a solution for dissolving said binder;
dissolving said binder from said carpet to provide backing and pile subsequently devoid of said binder; and separating said pile from said backing.
2. The process as set forth in claim 1, further including the step of segregating said pile and said backing.
3. The process as set forth in claim 2, further including the step of washing said pile and said backing to remove residual solution.
4. The process as set forth in claim 3, further including the step of filtering said solution to remove dissolved binder.
5. The process as set forth in claim 4, further including the step of reintroducing filtered solution in said contacting step.
6. The process as set forth in claim 5, further including the step of recontacting said pile and backing of said solution to remove any residual binder.
7. The process as set forth in claim 1, further including the step of adding a surface active agent to said solution to enhance wettability of said solution.
8. The process as set forth in claim 6, further including the step of heating said solution to enhance dissolution of said binder.
9. The process as set forth in claim 1, wherein said contacting step includes contacting said carpet with said solution under pressure.
10. In a process for reclaiming materials from a carpet having backing material, binder material and carpet pile, the improvement comprising:
contacting said carpet with a solution for dissolving said binder;
dissolving said binder; and separating said backing and said pile.
11. The process as set forth in claim 10, wherein said carpet includes primary and secondary backing.
12. The process as set forth in claim 11, further including the step of washing removed secondary binder.
13. The process as set forth in claim 12, further including the step of washing primary backing of said carpet containing said pile.
14. The process as set froth in claim 13, further including the step of drying said primary backing and containing said carpet pile.
15. The process as set forth in claim 14, further including the step of contacting said primary backing containing said carpet pile with vacuum means to remove said carpet pile from said primary backing.
16. The process as set forth in claim 15, further including the step of collecting primary backing material.
17. The use of an environmentally friendly binder solvent for separating a secondary backing from a carpet.
18. The use of water soluble solvent for separating a secondary backing from a carpet.
19. The use of a dimethyl ester solvent for dissolving a secondary backing of a carpet.
20. A system for reclaiming carpet components, said carpet including backing material, binding material and carpet pile, said system including:
advancing means for advancing said carpet to a solvent application means;
solvent application means for applying solvent to said carpet to dissolve said binder material; and collection means for collecting separated backing material and carpet pile.
21. The system as set forth in claim 20, wherein said solvent application means comprises roller means.
22. The system as set forth in claim 21, wherein said collection means includes means for retaining separated backing and vacuum means for collecting carpet pile.
CA 2133303 1994-09-26 1994-09-29 Improved carpet reclamation process Abandoned CA2133303A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
CA 2133303 CA2133303A1 (en) 1994-09-29 1994-09-29 Improved carpet reclamation process
AU37241/95A AU3724195A (en) 1994-09-29 1995-09-26 Improved carpet reclamation process
CA 2201375 CA2201375C (en) 1994-09-29 1995-09-26 Improved carpet reclamation process
PCT/US1995/012186 WO1996010054A1 (en) 1994-09-29 1995-09-26 Improved carpet reclamation process
US08/817,402 US5916410A (en) 1994-09-29 1995-09-26 Carpet reclamation process
US08/825,204 US6379489B1 (en) 1994-09-26 1997-03-27 Carpet reclamation process

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA 2133303 CA2133303A1 (en) 1994-09-29 1994-09-29 Improved carpet reclamation process

Publications (1)

Publication Number Publication Date
CA2133303A1 true CA2133303A1 (en) 1996-03-30

Family

ID=4154431

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2133303 Abandoned CA2133303A1 (en) 1994-09-26 1994-09-29 Improved carpet reclamation process

Country Status (3)

Country Link
AU (1) AU3724195A (en)
CA (1) CA2133303A1 (en)
WO (1) WO1996010054A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19636847A1 (en) * 1996-09-11 1998-04-16 Matthias Dipl Ing Knirsch Recovery of materials from carpetings
CN108789936A (en) * 2018-05-21 2018-11-13 广德天运新技术股份有限公司 A kind of processing method of sound-proof material offal

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5227085A (en) * 1992-02-03 1993-07-13 Motsenbocker Gregg A Water-based cleaner containing TSP, EDTA, ethylene glycol butyl ether, and acetone
US5230473A (en) * 1992-04-13 1993-07-27 Hagguist James A E Carpet reclaimer

Also Published As

Publication number Publication date
WO1996010054A1 (en) 1996-04-04
AU3724195A (en) 1996-04-19

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Legal Events

Date Code Title Description
EEER Examination request
FZDE Discontinued
FZDE Discontinued

Effective date: 20050623