Patent ID: 6306318
Filing Date: 2001-10-23
Classification: B29C,B29K,B29L,E01C,Y10S,Y10T

Abstract:
A process of forming a molded article comprising the steps of:supplying a feed mixture to the inlet of an extruder, said feed mixture comprising carpet scrap having a fiber component and a polyvinyl chloride component, and a source of flexible polyvinyl chloride;heating said feed mixture in said extruder to a temperature sufficient to melt said polyvinyl chloride of said carpet scrap and of said polyvinyl chloride source substantially without melting said fiber component and substantially without reducing the fiber length to form a substantially uniform mixture of melted polyvinyl chloride and an unmelted fiber compound;discharging said substantially uniform mixture from said extruder and shaping and cooling said mixture to form a molded flexible article of a matrix of a substantially continuous phase of polyvinyl chloride having said unmelted fiber component dispersed therein, said matrix comprising about 5% to about 20% by weight of said fiber component and about 45% to about 85% by weight of polyvinyl chloride.