Patent Abstract:
A method an apparatus for reclaiming face fibers and polypropylene and/or polyvinyl chloride backing material from rolls and pieces of post-consumer carpet. The system includes a separator for separating the face fibers from the backing and for separating latex and carbon calcium powder from polypropylene backing. An extruder is provided for extruding the face fibers separated from the backing into extrusions, and a pelletizer pelletizes the extrusions. A roller opener opens the polypropylene backing into fibrous portions and also cleans such fibrous portions. Alternately, a granulator can be provided that chops and grinds the polypropylene or PVC backing into fragments after the separation of the face fibers from the backing. A heat source heats the PVC fragments, and also the polypropylene fragments (thereby separating the latex therefrom), and ultimately melts such fragments. Reclaimed fibers can be pelletized, made into extrusions, used in non-woven products and in other manners.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates generally to a system for reclaiming face fibers and carpet backing from post-consumer carpet. 
         [0002]    Carpet typically includes, face pile or face fiber and a backing system comprised of one or more polypropylene and/or polyvinylchloride (PVC) substrates and may have adhesive and/or latex adhesive backing for holding the face fibers in place. 
         [0003]    Carpet that has been installed and subjected to use in residential, commercial, governmental, and industrial environments may be replaced from time to time, with the installed carpet being removed and disposed of Such carpet is known in the industry as “post-consumer” carpet, as the carpet has been subjected to the wear and tear of use. Although the reasons for removing such post-consumer carpet may vary from application to application, the magnitude of post-consumer carpet disposed of on an annual basis is considerable. It is estimated that billions of pounds of such post-consumer carpet is disposed of annually, typically in landfills, resulting in a significant consumption of landfill space. Accordingly, a reduction of such carpet waste would be desirable. 
         [0004]    As such post-consumer carpet often times includes fibers, polymers, and other components that can potentially be reused, it would be desirable to have a system by which the reusable components of could be reclaimed, thereby reducing landfill deposits. In particular, it would be desirable to recycle from carpet typical constituents, such as nylon, polypropylene, carbon calcium, polyvinylchloride, PVC, etc., which, in addition to conserving landfill space would also conserve valuable natural resources and potentially provide significant cost savings. 
       SUMMARY OF THE INVENTION 
       [0005]    Generally, the present invention includes in one preferred embodiment a system for reclaiming the face fibers and polypropylene backing material from rolls and flat pieces of post-consumer carpet. The system includes a separator for separating the face fibers from the polypropylene backing and the adhesives and/or latex coating ordinarily found on such backing. An extruder extrudes the face fibers separated from the polypropylene backing into extrusions, and a pelletizer pelletizes such extrusions. In one embodiment, a granulator chops and/or grinds or otherwise reduces the polypropylene backing into small bits, fragments, or particles, or chips, after separation of the face fibers therefrom. Also, a device is provided for separating off the adhesives and/or latex and for melting the polypropylene backing, through the application of heat and compaction forces. 
         [0006]    More specifically, the present invention also includes a method and apparatus for reclaiming face fibers and polypropylene and/or polyvinyl chloride (PVC) backing from post-consumer carpet. The method may include, in one preferred embodiment, sorting rolls and/or sections of post-consumer carpet by face fiber type prior to separation of such fibers from the backing. An infrared sensor may be used for assisting in such sorting step. The impurities from the face fibers, after separation from the polypropylene backing, are preferably removed, and in one preferred embodiment, a willow cleaner is used for such removal of impurities from the polypropylene opened fibers. Further, the face fibers, after separation from the backing, and after having impurities removed therefrom, can be blended with additional fibers or constituents prior to being extruded in the extruder. 
         [0007]    With regard to the polypropylene backing and/or PVC backing, such backing, after having the face fibers separated therefrom, and being processed through a grinder, granulator, shredder, and/or a cutter, are then melted through the application of heat and pressure, is allowed to cool and harden, and is then processed into particles, fragments, or bits. These bits can be used for subsequent processing and products, and could be, for example, molded into products through injection molding, rotational molding, etc., or could be sold or reused in flakes and/or chips and/or bits or particles as a commodity for use in other manufacturing and/or commercial applications. 
         [0008]    The present invention also includes, in one embodiment, the face fibers, after separation, extrusion, and pelletization, being used in other manufacturing and/or commercial applications, such as for molding, e.g., composite molding, injection molding, rotational molding, etc., or for other manufacturing applications, such as spinning, extrusion, etc. Such pellets could also be sold on a commodity basis to industry for other manufacturing and/or commercial purposes. 
         [0009]    A preferred embodiment of a system constructed in accordance with the present invention includes a separator that separates the face fibers from the latex-coated polypropylene backing and an extruder that extrudes the face fibers into extrusions. A roller opener device opens the fibers of the backing to yield opened polypropylene portions. Alternately, a pelletizer machine pelletizes the extrusions, and a granulator chops the latex-coated polypropylene backing into particles, fragments or bits. Also, a heat source, which could be electric resistance heat, gas-fired heat or heat from another combustion source, solar heat, microwave energy, chemical reaction heat, etc., is provided that heats the bits sufficiently to generally melt the bits and sufficiently to generally separate, cook off, bake off, volatize and/or otherwise remove the latex therefrom. 
         [0010]    The present invention further contemplates alternate embodiments, specifically including baling the polypropylene backing after being opened with a roller opener and/or chopped and ground in the granulator, and then disposing of such bales in a landfill. This embodiment allows for easier material handling and lower disposal volume as compared to disposing of post-consumer carpet intact. Alternately, such bales of polypropylene, latex, and/or PVC material could be sold to subsequent converters for use in other products. 
         [0011]    In another embodiment of the present invention, such polypropylene backing material can be baled after such opening with a roller opener and/or chopping and grinding in the granulator, and then such bales subsequently opened through use of opening equipment, such as textile opening equipment, wherein such baled material is shredded, torn, and subjected to dust removal. The resulting fiber remains can be used in non-woven products, for example, singularly, or blended with other fibers, for production of non-woven products, such as insulation, sound deadening panels of other materials, batting, filler, under carpet pads, floor tiles, furniture, industrial applications such as roofing material mixed with asphalt, etc. Depending on the desired production layout, it may be possible to eliminate the baling step altogether, such that the backing with the adhesives and/or latex, after chopping and grinding, is next subjected to the opening process without the intervening baling step. 
         [0012]    The present invention also includes a roller opener for reclaiming material from carpet backing, the roller opener including an intake that receives the carpet backing and an opener roll. A plurality of working rolls are provided adjacent the opener roll and are configured for forming at least one nip zone between the working rolls and the opener roll. At least one motor drives the opener roll and the working rolls, and the opener roll and the working rolls are configured to open the carpet backing into fibrous portions in the nip zone. 
         [0013]    The roller opener may further include a conveyor and/or a suction receiver that receives and transports the fibrous portions. Additionally, an inclined conveyor may be provided that transports the carpet backing to the intake of the roller opener. 
         [0014]    Fibers can also be subjected to high pressure air, condensers, and/or a self-contained ultrasonic cleaning system which uses fluid for ultrasonically cleaning the fibers. The fibers can thereafter be subjected to drying and transported for extrusion, baling, etc. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The foregoing, as well as other objects of the present invention, will be further apparent from the following detailed description of the preferred embodiment of the invention, when taken together with the accompanying specification and the drawings, in which: 
           [0016]      FIG. 1A  is a schematic representation of a first embodiment of a carpet reclamation system constructed in accordance with the present invention illustrating carpet backing, after the fibers are separated therefrom, being fed to a granulator; 
           [0017]      FIG. 1B  is a schematic representation of a second embodiment of a carpet reclamation system constructed in accordance with the present invention illustrating carpet backing, after the fibers are separated therefrom, being fed to a roller opener machine, the output of which being fed to a conveyor; 
           [0018]      FIG. 1C  is a schematic representation of a third embodiment of a carpet reclamation system constructed in accordance with the present invention illustrating carpet backing, after the fibers are separated therefrom, being fed to a roller opener machine, the output of which being fed through ducts; 
           [0019]      FIG. 2  is a process flow diagram of a carpet reclamation system constructed in accordance with the present invention; 
           [0020]      FIG. 3A  is a side elevational view of a carpet reclamation system constructed in accordance with the present invention, wherein post-consumer carpet is fed face fiber side-down into a separator, the face fibers are separated from the backing and drawn away via suction, and the backing is drawn away by a conveyor belt; 
           [0021]      FIG. 3B  is a side elevational view of one preferred embodiment of a carpet reclamation system constructed in accordance with the present invention, wherein post-consumer carpet is fed face fiber side-down into a separator, the face fibers are separated from the backing and dropped downwardly onto a moving conveyer belt, and the backing is drawn away by a conveyor belt; 
           [0022]      FIG. 3C  is a side elevational view of one preferred embodiment of a carpet reclamation system constructed in accordance with the present invention, wherein post-consumer carpet is fed face fiber side-up into a separator, the face fibers are separated from the backing and drawn away via a conveyor belt, and the backing is drawn away by a conveyor belt; 
           [0023]      FIG. 3D  is a side elevational view of one preferred embodiment of a carpet reclamation system constructed in accordance with the present invention, wherein post-consumer carpet is fed face fiber side-up into a separator, the face fibers are separated from the backing and drawn away via a conveyor belt, and the backing is drawn away by a conveyor belt, and suction is applied to the backing carried by the conveyor belt; 
           [0024]      FIG. 3E  is a side elevational view of one preferred embodiment of a carpet reclamation system constructed in accordance with the present invention, wherein post-consumer carpet is fed face fiber side-up into a separator, the face fibers are separated from the backing and drawn away via a conveyor belt, and the backing is drawn away by a generally horizontal conveyor belt and fed to a roller opener machine; 
           [0025]      FIG. 3F  is a side elevational view of one preferred embodiment of a carpet reclamation system constructed in accordance with the present invention, wherein post-consumer carpet is fed face fiber side-up into a separator, the face fibers are separated from the backing and drawn away via a conveyor belt, and the backing is drawn away by a generally angled conveyor belt and fed to a roller opener machine; 
           [0026]      FIG. 3G  is a side elevational view of one preferred embodiment of a carpet reclamation system constructed in accordance with the present invention, wherein post-consumer carpet is fed face fiber side-up into a separator, the face fibers are separated from the backing and drawn away via a conveyor belt and then to a suction feed, and the backing is drawn away by a generally angled conveyor belt and fed to a roller opener machine; 
           [0027]      FIG. 4  is plan view of a carpet reclamation system constructed in accordance with the present invention; 
           [0028]      FIG. 5A  is a perspective view of a first embodiment of a roller opener machine constructed in accordance with the present invention having a conveyor discharge; 
           [0029]      FIG. 5B  is a perspective view of a second embodiment of a roller opener machine constructed in accordance with the present invention having a suction discharge; 
           [0030]      FIG. 6A  is a left side elevational view of the roller opener machine constructed shown in  FIG. 5A ; 
           [0031]      FIG. 6B  is a left side elevational view of the roller opener machine shown in  FIG. 5B ; 
           [0032]      FIG. 7A  is a right side elevational view of the roller opener machine shown in  FIG. 5A ; and 
           [0033]      FIG. 7B  is a right side elevational view of the roller opener machine shown in  FIG. 5B . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0034]    The foregoing, as well as other objects of the present invention, will be further apparent from the following detailed description of the preferred embodiment of the invention, when taken together with the accompanying drawings and the description which follows set forth this invention in its preferred embodiment. However, it is contemplated that persons generally familiar with fiber reclamation will be able to apply the novel characteristics of the structures illustrated and described herein in other contexts by modification of certain details. Accordingly, the drawings and description are not to be taken as restrictive on the scope of this invention, but are to be understood as broad and general teachings. 
         [0035]    Referring now to the drawings in detail, wherein like reference characters represent like elements or features throughout the various views, the carpet reclamation system of the present invention is indicated generally in the figures by reference character  10 . 
         [0036]    Turning to  FIG. 1A , one preferred embodiment of carpet reclamation system  10  is shown. Post-consumer carpet (shown in  FIG. 1A  for example purposes in the form of rolls, generally R, supported for rotation on a support), such as broadloom carpet or other carpet, is fed in the direction of arrow A 1  to a fiber separation machine, generally S. It is to be noted that in addition to post-consumer carpet in the form of rolls being fed into separation machine S, post-consumer carpet, or other carpet, in other forms, such a pieces, carpet area rugs, sections, tiles, squares, modular carpet, etc. (not shown) could also be fed into separation machine S individually manually and/or automatically. For example, modular carpet, carpet squares and/or carpet tiles could be fed into separation machine S single file, in multiple lateral and/or longitudinal rows (with respect to the direction of travel of such squares or tiles), in rows, random and/or intermittent groupings, etc. Separation machine S could be a Linta fiber separator, as manufactured by Linta Srl of Italy, although it is to be understood that other fiber separating machines could be used without departing from the disclosure of the present invention. It should be noted that carpet squares and/or tiles generally have a polyvinyl chloride (PVC) backing. 
         [0037]    In the separation machine, or separator S, the face fibers, generally F, of a length of carpet, generally C, are separated from the backing, generally B, of carpet C. Although backing B used in connection with carpet C can be of various compositions, in one preferred embodiment, backing B is polypropylene having a latex coating thereon. A length of carpet C is fed into separator S with, as shown in  FIG. 1A , the face fiber F side of carpet C facing downwardly. It is to be understood, however, that carpet C can be fed into separator S with face fiber F facing up, if desired, as shown in  FIGS. 1C and 3C  through  3 G. 
         [0038]    In one preferred embodiment, a dedusting system, generally D, ( FIG. 3C ) is provided which directs high pressure air against carpet C during the feeding of the carpet C into the separator S. 
         [0039]    A roller  16  having brushes  18  thereon which engage face fibers F of carpet C to assist in propelling carpet C beneath a guide bar  20  and onward to presentation to a circulating knife blade, generally  24 . Knife blade  24  is preferably continuously sharpened with a sharpening device (not shown) and cooled such that it does not overheat and such that it continuously presents a sharp cutting edge to sever face fibers F from backing B. As shown in  FIG. 3C , two rollers  16  with brushes  18  can be provided, if desired, with one roller being above carpet C and the other roller contacting carpet C from below. 
         [0040]    In one preferred embodiment, at least one roller has brushes and another roller  16  does not. For example, in  FIG. 3C , the roller  16  on the upper side, i.e., on the side of the fiber pile of carpet C, and could have brushes, and the roller on the bottom, or backing, side of carpet C could be a roller  16  without brushes. Alternately, this configuration could be reversed, with the brushed roller  16  being on the bottom side, and the non-brushed roller being on the upper side of carpet C. 
         [0041]    As shown in the  FIG. 1A  embodiment, after face fibers F are separated from backing B, they are sucked into a chute, or plenum,  28 , and then follow arrows A 2  to a baling operation wherein a bale press ( FIG. 4 ) is used, if desired, to form a package, or bale, of fibers, generally  32 , from fibers F. In this case, such bales  32  would subsequently be opened, i.e., the fibers removed from the bales  32 , and subjected to a suction flow, wherein the detached fibers are pulled into a hopper  36  of an extruder, generally E. Alternately, face fibers F can be separated from backing B, suctioned through chute  28 , and presented to hopper  36  without being baled in the interim, if desired. It is to be understood that packages or bales  32  could be of any desired shape and are not limited to the generally rectangular shape illustrated. 
         [0042]    Upon being fed into extruder E, fibers F are compacted and forced to flow through spinneret and/or die, generally  38 , at the outlet of extruder E, which forms extrusions, such as extruded rods, bars, etc., generally  40 , from the melted face fibers F. A cutter, and/or pelletizer, shown functionally and designated generally as P, then cuts extrusions  40  into pellets  42 . Such pellets can be used in subsequent manufacturing processes and are preferably of relatively high quality polymer, such as nylon, olefin, polyester, acrylic, etc. Such polymer pellets  42  can be used, for example, in molding operations for injection molding, composite molding, rotational molding purposes, and/or for other purposes such as being reformed into fibers through re-melting and passing through a spinneret, etc. Such pellets could also be sold and traded as a commodity on a raw material basis for use in other manufacturing, industrial, and/or commercial applications. 
         [0043]      FIG. 1A  also illustrates the separation of backing B of carpet C from face fibers F and the subsequent processing of backing B. Backing B, alter having face fibers F separated therefrom, in one embodiment may pass through a shredder, cutter, chopper, granulator, etc., referred to herein collectively as a granulator, generally G. Either polypropylene or PVC backing can by passed directly to granulator G from separator S, if desired. 
         [0044]    Granulator G includes cutters, generally  50 , which chop and/or grind backing B into flakes, chips, fragments, bits, or particles, generally  54 , which, as indicated by arrow A 3 , can be compressed and formed into bales  56  using a bale forming machine, or bale press, ( FIG. 4 ) although it is to be understood, as discussed above, that portions, fragments, bits, pieces, chips or particles  54  can by-pass the bale forming step and pass, unbaled, to an opening and dedusting step, wherein the pieces  54  are shred, torn, and/or subjected to dust removal and ultimately become fibers and/or fibrous material finding particular use as fibers to be blended in a non-woven article and/or material production line. 
         [0045]    If desired, however, after baling, pieces  54  can be sold in bale form  56  to be subsequently used in other processes and/or products, deposited in a landfill or otherwise disposed of. Even if such bales are disposed of in a landfill, the amount of landfill volume consumed by such de-fibered backing material alone, when in a compressed and/or baled configuration, would be significantly less than if such post-consumer carpet had been dumped in the landfill without performing fiber reclamation and fiber compression as contemplated by the present invention. 
         [0046]      FIG. 2  illustrates carpet reclamation system  10  in the form of a process chart. The initial step  62  includes post-consumer carpet being received by a facility. Such post-consumer carpet, as noted above, is carpet which has already been subjected to use in an installation or is otherwise not virgin carpet. Such post-consumer carpet could come from a variety of commercial, industrial, governmental, residential, etc. sources. After receipt at the facility, the post-consumer carpet is sorted in step  64  by face fiber type to facilitate fiber reclamation of similar types of face fiber during a particular batch reclamation process. As noted above, carpet typically includes, generally, face pile or face fiber and a backing system comprised of a polypropylene substrate with latex adhesive backing for holding the face fibers in place. In one preferred embodiment, carpet rolls R and/or carpet pieces are automatically transported to fiber separation machine S through use of conveyors, robots, tracks, or other suitable material handling devices. 
         [0047]    It is to be understood that step  64  could include the use of an infrared sensor (not shown), such as an infrared spectrometer, which assists in classification of the post-consumer carpet face fiber prior to reclamation. When using such a sensor, and a Fourier transform process, an infrared spectra may be produced based on a particular piece of post-consumer carpet. Such produced spectra is then compared with a library of infrared spectra of other known materials, and this comparison can ultimately yield the chemical structure of the post-consumer carpet face fiber in order to facilitate sorting thereof. For example, post-consumer carpet may be sorted by face fiber type, which could be Nylon 6, Nylon 66, polyester, polypropylene, etc. 
         [0048]    For carpet  65  having fibers wherein it is desirable and/or advantageous to separate face fibers F from backing B, such fibers F are so separated in step  66 . In the case of other carpets  66 , the fibers and backing of such carpets are opened together and dedusted in step  65   b , which could include use of roller opener  200  and/or granulator G. This combination of fibers from the backing and pile fibers may then be compressed by a press in step  65   c  and baled. Alternately, such combined hacking and pile fibers may proceed to a storage and blending box  68 . 
         [0049]    The fibers F separated from carpet  65  are dedusted and/or cleaned in step  68 , which may include use of a willow cleaner, and then are transported on to a holding and/or storage and blending box  72 . From box  72 , the fibers F may be fed in step  73  to extruder E, and then any needed components, chemicals, agents, formulations, etc. may be added in step  74  and extrusion conducted in step  76 . Subsequently, the extruded material may be cut into pellets or some other configuration in step  78 , resulting in relatively high quality polymer, which can subsequently be sold in bulk, molded, spun, etc. 
         [0050]    Alternately, after the dedusting step  68 , fibers F can be compressed into bales in step  82  and sold in the form of nylon fiber bales. It is to be understood that the bales could be of some other fiber, if desired. Also, the fibers F could be subjected to cleaning, such as by high pressure air, condensers, and/or a self-contained ultrasonic cleaning, as discussed below. 
         [0051]    Returning to the fiber separation step  66 , after fiber separation, backing B may be subjected to opening and dedusting step  65   b . The backing portions and/or fibers output from step  65   a  may then follow steps  65   b ,  65   c  and  65   d , discussed above, and/or pass to the holding and/or storage and blending box  72 . From box  72 , the backing portions and/or fibers may be formed into a web in step  86  and thermobonded in step  88  for use products such as under carpet and/or mattress insulation pads in step  90 . 
         [0052]    Alternately, from box  72 , the backing portions and/or fibers may be subjected to density compacting and melting in step  92 , and the granulated in step  94  for output as relatively low quality polymer  96  suitable for processes such as composite molding, injection molding filler, rotational molding, and/or sale as flakes. 
         [0053]    Returning to step  92 , such density compaction and melting of the backing portions (polypropylene, PVC, etc.) and/or fibers may involve use of a conglomerator, generally  97  ( FIG. 4 ), such as manufactured by Italrec Srl of Italy. During this step, the backing portions and/or fibers are heated using a heat source, which could be electric resistance heat, gas-fired heat or heat from another combustion source, solar heat, microwave energy, chemical reaction heat, etc., provided conglomerator  97  for inputting heat thereto, such heat serving to melt the material into a flowable state. The latex and other adhesive components still remaining on the material are essentially baked off, cooked off, volatized and/or otherwise removed therefrom from the heat input by the heat source, thereby purifying such material. The melted mass of material exiting conglomerator  97  is then allowed to cool and is subsequently granulated in step  94 , resulting in polymer  96 . 
         [0054]      FIG. 3A  illustrates separator S separating face fibers F from backing B of carpet C. In the embodiment illustrated in  FIG. 3A , carpet C is fed fiber side down through use of intake roller  16  having brushes  18  thereon, and also through use of a conveyor, generally  100 . As fibers F are separated from backing B, they are subjected to a suction flow downwardly through chute or plenum  28 , and carpet backing B is carried away via a conveyor  102 . 
         [0055]      FIG. 3B  illustrates an alternate embodiment separator S 1 , wherein carpet C is also fed face fiber side down. However, upon separation of face fibers F from backing B, face fibers F fall downwardly through a chute  104  via gravity and/or suction being applied thereto, and are collected on a conveyor  106  for transport away from separator S 1 . 
         [0056]      FIG. 3C  illustrates a second alternate embodiment, wherein carpet C is fed face fiber side up to separator S 2 . Rollers  16  having brushes  18  can be positioned for engaging and propelling backing B of carpet C, and/or, positioned above carpet C such that brushes  18  engage face fiber F to assist in propelling carpet C towards the cutting blade of separator S 2 . After being separated from backing B, face fibers F are carried away via a conveyor  108 , and backing B passes through a chute  110  and then engages a conveyor  112  where it is carried from separator S 2 . 
         [0057]      FIG. 3D  illustrates another alternate embodiment, wherein carpet C is also fed face fiber side up. A vacuum deduster, generally  120 , is provided to remove dust and particles from backing B as back B is transported by conveyor  112 . 
         [0058]      FIG. 3E  illustrates yet another alternate embodiment of system  10 , wherein carpet C is also fed to the separator face fiber side up. A roller opener, generally  200 , is provided which receives backing B from conveyor  112  and opens backing B into fibrous portions and simultaneously removes dust from such fibrous portions. Conveyor  112  is at approximately the same elevation as the input  202  of roller opener in this embodiment. The fibrous portions are output by roller opener  200  to a conveyor  204  for transport to further processing. 
         [0059]      FIG. 3F  illustrates still another alternate embodiment of system  10 , wherein carpet C is also fed to the separator face fiber side up. Roller opener  200  receives backing B from an upwardly inclined conveyor  208 , which in turn receives backing B from conveyor  112 . 
         [0060]      FIG. 3G  illustrates another alternate embodiment of system  10 , wherein carpet C is also fed to the separator face fiber side up. Roller opener  200  receives backing B from conveyor  208 , which in turn receives backing B from conveyor  112 . Fibers F are transported, after separation from carpet C, via a conveyor  108  to a suction input  210  and transported therefrom pneumatically by blower  212 . The fibrous portions discharged from roller opener  200  are also transported pneumatically through chute  214 . 
         [0061]      FIGS. 1B ,  1 C,  3 E,  3 F,  3 G,  4 , and  5 A through  7 B illustrate use of a roller opener device  200  in addition to, or instead of, granulator G in system  10  for processing backing B. Roller opener  200 , as shown in  FIG. 1B , is inserted in place of granulator G ( FIG. 1A ) downstream of separator S, and processes backing B into opened fibrous portions which are deposited on a conveyor. Such fibrous portions are dedusted in roller opener  200  and can be compressed into bales or transported to subsequent processing, such as for formation into a web and/or compacted and melted and ultimately formed into chips, as discussed above and as shown in  FIG. 2 . In  FIG. 1B , the input  202  of roller opener  200  is at generally the elevation of the output of backing B of separator S. 
         [0062]      FIG. 1C  illustrates another preferred embodiment of system  10 , wherein roller opener  200  is positioned at a generally lower elevation than separator S, and with carpet C being fed into separator S with the pile, or face fiber, side facing upwardly. Backing B moves generally downwardly after separation of fibers F and flows into the input  202  of roller opener. Fibrous portions of backing B are drawn or propelled outwardly by positive air flow or a vacuum being drawn through discharge chutes, or suction condensers,  206 , and, as discussed above with respect to the embodiment in  FIG. 1B , can be compressed into bales or transported for further processing. 
         [0063]      FIG. 4  illustrates the machinery and process layout of one preferred embodiment of the carpet reclamation system  10  constructed in accordance with the present invention. Process lines include a nylon extrusion and palletizing line, generally NEP, a nylon fiber press line, generally NP, an agglomeration line, generally AGG, a polypropylene and/or PVC fiber press line, generally PFP, and a nonwoven line, generally NW. 
         [0064]    Turning first to the nylon extrusion and pelletizing line NEP, carpets which have been sorted to select out those carpets with nylon pile fibers, or face fibers, are fed into the fiber separator S, and nylon face fibers separated from the carpet are pneumatically transported to a holding and/or storage and blending box, generally  130 , and then on to extruder E where they are extruded. The extrusions produced by extruder E are transported to pelletizer P, and then on to a pellet collection device  132 , where the pellets are loaded into Gaylord containers, bags, boxes, etc. for subsequent sale or use. 
         [0065]    Alternately, the fibers can also be subjected to high pressure air, condensers, and a self-contained ultrasonic cleaning system, generally U, which uses fluid for ultrasonically cleaning the fibers, the fluid having a fluid cleaning system for extracting trash and/or debris therefrom. Additionally, the fibers can thereafter be subjected to drying, which may include forced-air being directed towards the fibers and/or heat being applied to the fibers and/or centrifugal drying of the fibers. The fibers can then be transported for baling, to extruder E for extrusion, etc. 
         [0066]    Nylon fiber press line NP also receives nylon face fibers from sorted carpets, such fibers being separated from the carpets by separator S. The fibers may be transported to a self-contained ultrasonic cleaning system, generally U, and then to a deduster and fiber bale press, generally,  134  where they are dedusted and baled into bales or subsequent sale or use. Alternately, the fibers can be transported directly from separator S to deduster and fiber bale press  134 . 
         [0067]    Agglomeration line AGG includes separator S, which separates the backing from sorted carpet, the backing then proceeding to roller opener  200  (discussed in more detail below), or to granulator G, shredder, cutter, etc. (not shown in  FIG. 4 ). The backing is opened and is cleaned and/or dedusted in roller opener  200 , resulting in fibrous portions, typically polypropylene, as such material is commonly used for backing. The fibrous portions are subjected to density compaction and melting in conglomerator  97  and then to a granulator  140  for formation into chips. From granulator  140 , the chips are transported to a chip collection device  142 , where the chips are baled or loaded into Gaylord containers, bags, boxes, etc. for subsequent sale or use. 
         [0068]    Polypropylene fiber press line PPP includes roller opener  200  and condensers  206 , where the backing is opened into such fibrous portions and cleaned and/or dedusted. The fibrous portions then preferably pass to willow cleaners  136  for further cleaning and/or dedusting. Preferably, willow cleaners  136  include condensers, shakers, and also, an adjustable knife to remove more or less trash and/or debris from the fibrous portions. Ducting for pneumatic transport of the fibrous portions exiting roller opener  200  carries the fibrous portions, to a fiber press, generally  144 , where such backing fibers, typically polypropylene, are pressed and baled for subsequent sale or use in further processing operations. 
         [0069]    For reclamation of PVC backing ordinarily used on carpet squares and/or carpet tiles, such backing, once separated by separator S, may be transported to granulator G, and then to fiber press  144 , where such PVC backing fibers are pressed and baled for subsequent sale or use in further processing operations. 
         [0070]    Nonwoven line NW can find particular use for carpets that have not been sorted and/or which are not readily sortable into particular face fiber and/or backing types. Line NW includes presenting such carpets to roller opener  200  and pneumatically transporting fibrous portions containing both face fibers and backing fibers from opener  200  through condensers  206  to willow cleaners  136 , and then to storage and blending box  138  where blending of the fibrous portions may occur as desired. From storage and blending box  138 , the fibers proceed, such as by pneumatic conveyance, to a nonwoven production machine, generally  148 . 
         [0071]    Alternately, after passing through willow cleaners  136 , the fibrous portions can also be subjected to high pressure air, condensers, and a self-contained ultrasonic cleaning system U, discussed above, for extracting trash and/or debris from the fibrous portions. Additionally, the fibrous portions can thereafter be subjected to drying, which may include forced-air being directed towards the fibrous portions and/or heat being applied to the fibrous portions and/or centrifugal drying of the fibrous portions. The fibrous portions can then be transported to nonwoven production machine  148 . 
         [0072]    In one preferred embodiment of the carpet reclamation systems of the present invention reclaim, or recycle, post-consumer carpets up to 12 feet wide, and in another preferred embodiment, carpet between one foot and 10 feet wide. 
         [0073]    Turning to  FIGS. 5A through 7B , preferred embodiments of roller opener  200  are illustrated in various views. Roller opener  200  includes a frame, generally FR, having a housing, generally H, with an intake  202  which includes an intake conveyor  220  having rolls  220   a  and  220   b . A nip zone is formed at conveyor roll  220   b  and an intake roll  224  of machine  200 . Backing B from carpet C is drawn into this nip zone and is thereafter worked between a plurality of nip zones between working rolls  226   a ,  226   b ,  226   c ,  226   d , and  226   e  and a main roll  230 . 
         [0074]    As shown in  FIG. 7A , roll  226   a  is driven, together with intake roll  224 , by a motor M 1 , and roll  226   b  and roll  220   b  are driven by a motor M 2 . Rolls  226   c ,  226   d , and  226   e  are driven by motor, generally M 3 , and main roll  230  is driven by motor M 4  (FIG.  6 A). Drive members, generally  227 , such as belts, chains, gears (not shown), etc, can be used to transfer power from the motors to the respective rolls which they drive. 
         [0075]    As the backing B is transported about main roll  230  and working rolls  226   a - e , backing B is shredded and reduced to fibers and fibrous portions. Main roll  230  and working rolls  226  may include fiber engaging textures such as teeth, wire clothing, etc., as is found in textile fiber carding machines. Simultaneously, dust, dirt, debris, etc. and/or carpet backing constituents, such as carbon and calcium dust, are extracted from backing B by suction being applied to the area of rolls  226   a - e ,  230  and/or by gravity. Fibers and fibrous portions exiting the working area of rolls  226   a - e  and  230  are then allowed to fall by gravity to output conveyor  204  for transport to the various lines as discussed above, or to a collection area for storage for subsequent use and/or disposal. 
         [0076]      FIGS. 5B ,  6 B, and  7 B illustrate an alternate embodiment roller opener  200 A, which is essentially the same as roller opener  200 , except roller opener  200 A includes a pneumatic discharge for transporting fibers and fibrous portions after backing B has been worked by rolls  226   a - e  and main roll  230 . A centrifugal blower, generally  240 , is provided for suctioning off backing fibers and fibrous portions from the working area of rolls  226   a - e  and roll  230 . A suction plenum, generally  242 , is provided having suction receivers, or condensers,  206  with transitions  244  for coupling to ducts  246  to transport the fibers and fibrous portions for subsequent processing, transport, collection and/or use. 
         [0077]    From the foregoing, it can be seen that the present invention provides a system for reclaiming reusable fibers from carpets on an automated production basis. 
         [0078]    While preferred embodiments of the invention have been described using specific terms, such description is for present illustrative purposes only, and it is to be understood that changes and variations to such embodiments, including but not limited to the substitution of equivalent features or parts, and the reversal of various features thereof, may be practiced by those of ordinary skill in the art without departing from the spirit or scope of the following claims.

Technology Classification (CPC): 8