TECHNOLOGY DESCRIPTION
The national carpet recycling rate is substantially lower than the amount produced, creating large amounts of carpet waste. This leads to conceiving a method to continuously produce recycled carpet composites. A machine combines carpet and plastic together through compressive force, producing a composite material that shows properties acceptable for light structural applications. This machine deploys a pusher system that contains the carpet HDPE (High-Density Polyethylene) in an air tight, low oxygen environment. The hot plastic and carpet are forced through a steel compression zone that can use isostatic or hydrostatic compression as means of forcing these materials together. The carpet backing remains intact throughout to carry tension and contribute toughness to the resulting composite. As the composite is pushed through the hydrostatic compression zone, any pressure present is released through a pumping motion. The composite is motivated through the hot zone using asymmetric triangular teeth or an inclined corrugated surface as the system is isostatically pressed and decompressed. An advantage of this process is the heating is done over a short period of time, avoiding full degradation of the carpet during infiltration of the HDPE into the tufts. The composite is then pushed through a 90 degree turn, helping to motivate the material through the process. The recycled material produced from this process could be offered as an alternative to wood for many applications, such as wood pallets, due to the robust material properties shown by the composite.
KEY WORDS
plastic wood, recycled carpet, polyethylene
POTENTIAL APPLICATIONS
The ways in which this product can be used are as a plastic alternative to wood as a structural product, useful for creating pallets, crates, and modern-day construction. Due to its polymer attributes, it has a greater resistance to biofouling than its wood counterparts, providing a longer lifespan when exposed to the elements. Target markets would include the same use cases as other plastic products.
Plastic pallets, plastic crates
ADVANTAGES
- Robust material properties acceptable for light structural applications
- Resistant to biofouling
- High value application for low recycle rate materials
TECHNOLOGY READINESS
Lab prototype available.