Patent ID: 11911774
Assignee: nan
Field: Chemical engineering (Chemistry)
Classification: CPC B  Y | IPC B

Claim 0:
1. A carpet recycling method comprising the operations of:
preprocessing a carpet comprising fibrous carpet materials and carpet ash by:
dividing the carpet into a plurality of pieces less than nine square inches in area but greater than one square inch in area;
crushing the pieces of carpet to release crushed carpet ash from the pieces of carpet; and
performing a first separation operation to separate at least a portion of the crushed carpet ash from the pieces of carpet;

in a toroidal flow pulper, disintegrating the pieces of carpet in a quantity of liquid to form a slurry of liquid, fibrous carpet materials, and disintegrated carpet ash;
performing a second separation operation to separate at least a portion of said liquid and disintegrated carpet ash from said fibrous carpet materials;
refining the fibrous carpet materials by subjecting the fibrous carpet materials to abrasive beating in the presence of additional liquid to liberate at least a portion of the carpet ash remaining in the fibrous carpet materials following the second separation operation; and
performing a third separation operation to separate at least a portion of the additional liquid and liberated carpet ash from the fibrous carpet materials;
drying said fibrous carpet materials;
isolating at least a portion of said disintegrated carpet ash from said liquid and at least a portion of said liberated carpet ash from said additional liquid; and
drying said isolated carpet ash;
whereby a first output comprising crushed carpet ash, a second output comprising dried separated fibrous carpet materials and a third output comprising dried carpet ash are produced.