Source: http://www.freepatentsonline.com/8466205.html
Timestamp: 2018-06-19 22:20:02
Document Index: 586718303

Matched Legal Cases: ['Application No. 2007323916', 'Application No. 2007323916', 'Application No. 200780049377', 'Application No. 200780049377', 'Application No. 200780049377', 'Application No. 200780049377', 'Application No. 07854625', 'Application No. 07854625', 'Application No. 07854625', 'Application No. 07854625', 'Application No. 07854625', 'Application No. 07854625', 'Application No. 07854625', 'Application No. 2009', 'Application No. 2009', 'Application No. 200780049377', 'Application No. 60', 'Application No. 60']

Methods and systems for recycling carpet and carpets manufactured from recycled material - Columbia Insurance Company
United States Patent 8466205
Wright, Jeffrey (Cartersville, GA, US)
Ballew, Kellie (Canton, GA, US)
12/897402
139/2, 139/391, 139/399, 139/420R, 156/60, 156/72, 156/94, 428/95, 428/339, 428/364, 428/373, 521/40.5, 521/41, 521/46, 521/47, 521/48, 521/49, 524/915
521/40, 521/40.5, 521/41.42, 521/42.5, 521/43.5, 521/44, 521/44.5, 521/47, 521/48, 521/48.5, 521/49.5, 521/41, 521/46, 521/49, 528/480, 528/491, 528/495, 528/496, 528/497, 139/2, 139/391, 139/399, 139/420R, 428/85, 428/95, 428/339, 428/357, 428/364, 428/373, 428/394, 428/395, 428/396, 156/60, 156/72, 156/94, 524/915
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Amendment filed Apr. 7, 2013 with the Chinese Patent Office for Application No. 200780049377 filed Novemeber 13, 2007 (Applicant—Shaw Industries, Inc./Inventor—Wright, et al.) (pp. 1-17).
This application is a divisional of and claims the benefit of priority to U.S. patent application Ser. No. 11/939,496 filed Nov. 13, 2007 now U.S. Pat. No. 7,820,728, which application claims the benefit of priority to U.S. Provisional Patent Application No. 60/865,611 filed Nov. 13, 2006. The entire disclosures of application Ser. No. 11/939,496 and Application No. 60/865,611 are incorporated by reference herein for all purposes.
1. A method of making a carpet, comprising the steps of: providing a greige good comprised of a primary backing and a plurality of carpet fibers, the plurality of carpet fibers penetrating a bottom surface of the primary backing and protruding therefrom a top surface of the primary backing; providing an adhesive polymer composition comprising a recycled polymer composition, wherein the recycled polymer is reclaimed from a carpet by a method comprising: a) contacting a carpet with a solvent system comprising a terpene; b) dissolving at least of a portion of the polymer composition in the solvent system to provide a solution of terpene and a dissolved polymer; and c) separating terpene from the solution of terpene and the dissolved polymer to provide the reclaimed polymer composition; and applying the adhesive polymer composition to the bottom surface of the primary backing.
2. The method of claim 1, wherein the recycled polymer is a polyolefin.
3. The method of claim 2, wherein the reclaimed polyolefin composition comprises at least one of a HDPE, LDPE, LLDPE, ULDPE, VLDPE, VLLDPE, copolymer of ethylene and alpha olefin, polypropylene, copolymer of propylene and alpha olefin, copolymer of propylene and ethylene, EVA, and EMA.
4. The method of claim 1, wherein the applied adhesive composition comprises a blend of the reclaimed polyolefin composition and a virgin polyolefin composition.
5. The method of claim 4, wherein the virgin polyolefin composition comprises at least one homogenously branched ethylene polymer characterized as having a short chain branching distribution index (SCDBI) of greater than or equal to 50%.
6. The method of claim 1, wherein the applied adhesive composition substantially penetrates and substantially consolidates the fibers.
7. The method of claim 5, wherein the at least one homogeneously branched ethylene polymer is further characterized as having a single differential scanning calorimetry, DSC, melting peak between −30 and 150° C.
8. The method of claim 5, wherein the at least one homogeneously branched ethylene polymer is homogenously branched linear ethylene polymer.
9. The method of claim 1, wherein the primary backing is a woven primary backing.
10. The method of claim 1, wherein the primary backing is a nonwoven primary backing.
11. The method of claim 1, wherein the plurality of carpet fibers comprises a plurality of yarns.
12. The method of claim 1, wherein the carpet fibers are selected from a group consisting of nylon, polypropylene, polyethylene, polyester, acrylics, polyamide, wool, cotton, rayon, and combinations thereof.
13. The method of claim 1, wherein the primary backing is selected from a group consisting of nylon, polypropylene, polyethylene, polyester, acrylics, polyamide, fiberglass, wool, cotton, rayon, and combinations thereof.
14. The method of claim 1, wherein the primary backing consists essentially of a polypropylene material.
15. The method of claim 1, further comprising applying a pre-coat material to the backside of the greige good before applying the adhesive composition.
16. The method of claim 15, wherein the precoat material is selected from a group consisting of EVA hotmelt, VAE emulsion, carboxylated styrene-butadiene (XSB) latex copolymer, SBR latex, BDMMA latex, acrylic latex, acrylic copolymer, styrene copolymer, polyolefin hotmelt, polyolefin dispersion, butadiene acrylate copolymer, and combinations thereof.
17. The method of claim 1, further comprising applying a secondary backing material to a surface of the applied adhesive backing composition.
18. The method of claim 17, wherein the secondary backing material is woven.
19. The method of claim 17, wherein the secondary backing material is nonwoven.
20. The method of claim 17, wherein the secondary backing material is selected from a group consisting of polypropylene, polyethylene, and combinations thereof.
21. The method of claim 17, wherein the secondary backing material comprises at least one homogenously branched ethylene polymer characterized as having a short chain branching distribution index (SCDBI) of greater than or equal to 50%.
22. The method of claim 17, further comprising applying a pre-coat material to the backside of the greige good before applying the adhesive composition.
23. The method of claim 22, wherein the precoat material is selected from a group consisting of EVA hotmelt, VAE emulsion, carboxylated styrene-butadiene (XSB) latex copolymer, SBR latex, BDMMA latex, acrylic latex, acrylic copolymer, styrene copolymer, polyolefin hotmelt, polyolefin dispersions, butadiene acrylate copolymer, and combinations thereof.
FIG. 2a, FIG. 2b, and FIG. 2c are schematic illustrations of an exemplary multiple vessel counter flow solvent dissolution system of the present invention.
Although current 13C nuclear magnetic resonance spectroscopy cannot determine the length of a long chain branch in excess of six carbon atoms, there are other known techniques useful for determining the presence of long chain branches in ethylene polymers, including ethylene/1-octene interpolymers. Two such exemplary methods are gel permeation chromatography coupled with a low angle laser light scattering detector (GPC-LALLS) and gel permeation chromatography coupled with a differential viscometer detector (GPC-DV). The use of these techniques for long chain branch detection and the underlying theories have been well documented in the literature. See, e.g., Zimm, G. H. and Stockmayer, W. H., J. Chem. Phys., 17, 1301 (1949) and Rudin, A., Modem Methods of Polymer Characterization, John Wiley & Sons, New York (1991) pp. 103-112, the disclosures of which are incorporated herein by reference.
The dissolution step can comprise contacting the carpet with the solvent system in a single vessel maintained under desired temperature and pressure conditions as described above, for a sufficient period of time to at least substantially dissolve any terpene soluble polymers present in the carpet. However, in an alternative aspect, the dissolution step can comprise a plurality of sequential dissolution vessels in which an initial carpet feedstock is sequentially introduced into the plurality of dissolution vessels. The use of a plurality of vessels can maximize the concentration of dissolved polymer that can be achieved in a given vessel prior to devolatilization as described below. With reference to FIG. 2, an exemplary dissolution system 200 comprised of three sequential counter flow tanks is illustrated. In FIG. 2a, carpet 205 is first introduced into vessel 1 initially comprised of pure solvent, wherein a first portion of terpene soluble polymeric materials within the carpet begin to dissolve into the solvent system. Due to varying rates of dissolution associated with different materials that may be present in the carpet, the efficiency of vessel 1 in dissolving substantially all of the terpene soluble polymer may significantly decrease before the solvent reaches a maximum concentration of solubilized polymer or before substantially all of the terpene soluble polymer has been dissolved. Accordingly, after a first portion of the polymer has dissolved, the remaining carpet 205′, including non soluble material and additional terpene soluble polymer can be removed from vessel 1 and introduced into vessel 2, initially containing pure solvent. Once in vessel 2, a second portion of terpene soluble polymer will dissolve in the solvent system. However, again due to varying rates of dissolution associated with different materials that may be present in the carpet, the efficiency of vessel 2 in dissolving substantially all of the remaining terpene soluble polymer may significantly decrease before the solvent reaches a maximum concentration of solubilized polymer. Accordingly, after a second portion of the polymer has dissolved in vessel 2, the remaining carpet 205″, including non soluble material and additional terpene soluble polymer can be removed from vessel 2 and subsequently introduced into vessel 3, again initially containing pure solvent. This process can be repeated until the maximum concentration of dissolved polymer has been reached in vessel 1, at which time vessel 1 can be taken off line for subsequent devolatilization and reclamation of the dissolved polymer.
As shown in FIG. 2b, once vessel 1 has been removed, vessels 2 and 3 can each be advanced forward and a new vessel 4 containing pure solvent can be introduced into the system. The sequential dissolution process as described above can then be repeated until a maximum concentration of dissolved polymer is reached in vessel 2, at which time vessel 2 can then be taken off line for subsequent devolatilization and reclamation of the dissolved polymer. As shown, in FIG. 2c, once vessel 2 is removed, vessel three and 4 can each be advanced forward and new vessel 5 can be introduced. It should be understood that although the exemplified counter flow process is shown comprising three dissolution vessels, the process can utilize any desired number of devolatilization vessels and is not limited to the exemplified aspect.
wherein each “ ” connotes an optional bond; at least two of the optional bonds are present; R1, R1′, and R5 are independently selected from alkyl and carboxyl; R3, R4, and R7 are independently selected from hydrogen, hydroxyl, carbonyl, halogen, alkyl, alkoxyl, carboxyl, and acyl; and R6 is selected from hydrogen, hydroxyl, or oxygen. In an exemplary aspect, the terpene solvent system can comprise a terpene as set forth above, further wherein: R1 and R5 are methyl; the optional bond between C1 and C2 is present and R1′ is methylene; the optional bond between C1 and C2 is present; and wherein R3, R4, and R7 are hydrogen. In another exemplary aspect, the terpene can have the general structure set forth above wherein the optional bonds between C5 and C6 and between C6 and R6 are absent, and wherein C6 has an S configuration.
After dissolution of the polymer is at least substantially complete, the terpene solution comprising the dissolved polymer can then be conveyed to a separation station 160 whereby any undissolved components can be separated from the solvent system. For example, an initial carpet feedstock to be recycled can include, for example and not meant to be limiting, inorganic materials, such as fillers and flame retardants, and polymeric materials such as nylon faces fibers and other polymers that are not be soluble in the terpene solvent system. These materials 165 can be mechanically removed from the solution during this subsequent separation step 160. Any conventional method for removal of solids from a solution can be used. For example, non-soluble yarns and or fiber bundles can be separated by conventional filtration using for example a strainer basket or a filter bag. Non-soluble particulate solids, such as inorganic fillers and flame retardants can be recovered using techniques such as centrifugal separation, membrane filtration, vacuum belt filtration, candle tube filtration, and vibratory shear enhanced filtration process (VSEP). In an exemplary aspect, preferred equipment for separation of materials 165 includes the PANNEVIS RT-GT HGD Vacuum Belt Filter from Larox, Inc. Further, once separated, these non-soluble materials can be further processed for subsequent use in second generation carpet materials. Subsequent processing can include for example, step 167 for drying the separated non-soluble materials of any residual solvent. During this drying step 167, the residual solvent can be collected for reuse in the recycling system described herein.
According to aspects of the invention, the reclaimed polymer compositions resulting from the process described herein can exhibit physical properties that are indicative of their suitability for subsequent use in the manufacture of second generation carpets. For example, in one aspect the reclaimed polymer compositions of the present invention exhibit a melt flow rate, as measured according to ASTM D1238-04C, in the range of from 2 g/10 min to 200 g/10 min, including exemplary ratios of 10 g. 10 min, 25 g/10 min, 50 g/10 min, 75 g/10 min, 100 g/10 min, 125 g/10 min, 150 g/10 min, 175 g/10 min, and any value within a range of melt flow rates derived from any two of these values. In still other aspects, the reclaimed polymer compositions can exhibit a melt flow rates, as measured according to ASTM D1238-04C in the range of from 20 g/10 min to 100 g/10 min, including exemplary melt flow rates of 30 g/10 min, 40 g/10 min, 50 g/10 min, 60 g/10 min, 70 g/10 min, 80 g/10 min, 90 g/10 min, and any melt flow rates within a range of melt flow rates derived from any two of these values.
The face of a tufted carpet can generally be made in three ways. First, for loop pile carpet, the yarn loops formed in the tufting process are left intact. Second, for cut pile carpet, the yam loops are cut, either during tufting or after, to produce a pile of single yarn ends instead of loops. Third, some carpet styles include both loop and cut pile. One variety of this hybrid is referred to as tip-sheared carpet where loops of differing lengths are tufted followed by shearing the carpet at a height so as to produce a mix of uncut, partially cut, and completely cut loops. Alternatively, the tufting machine can be configured so as to cut only some of the loops, thereby leaving a pattern of cut and uncut loops. Whether loop, cut, or a hybrid, the yarn on the back side of the primary backing material comprises tight, unextended loops.
Alternatively, the secondary backing material can be laminated in a later step by reheating and/or remelting at least the outermost portion of the extruded layer or by a coextrusion coating technique using at least two dedicated extruders. Also, the secondary backing material can be laminated through some other means, such as by interposing a layer of a polymeric adhesive material between the adhesive backing material and the secondary backing material. Suitable polymeric adhesive materials include, but are not limited to, ethylene acrylic acid (EAA) copolymers, ionomers and maleic anhydride grafted polyethylene compositions.
(a) a melt flow ratio, I10/I2≦5.63,
i.(Mw/Mn)≦(I10/I2)−4.63,
(c) a gas extrusion rheology such that the critical shear rate at onset of surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater than the critical shear rate at the onset of surface melt fracture for a linear ethylene polymer, wherein the linear ethylene polymer has a homogeneously branched short chain branching distribution and no long chain branching, and wherein the substantially linear ethylene polymer and the linear ethylene polymer are simultaneously ethylene homopolymers or interpolymers of ethylene and at least one C3-C20 α-olefin and have the same I2 and Mw/Mn and wherein the respective critical shear rates of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melt temperature using a gas extrusion rheometer, and
(d) a single differential scanning calorimetry, DSC, melting peak between −30° C. and 150° C.
In one example, the determination of the critical shear rate in regards to melt fracture as well as other rheology properties such as “rheological processing index” (PI) can be performed using a gas extrusion rheometer (GER). One exemplary gas extrusion rheometer is described by M. Shida, R. N. Shroff and L. V. Cancio in Polymer Engineering Science Vol. 17, No. 11, p. 770 (1977), and in “Rheometers for Molten Plastics” by John Dealy, published by Van Nostrand Reinhold Co. (1982) on pp. 97-99, the disclosures of both of which are incorporated herein by reference. In one example, the GER experiments are performed at a temperature of 190° C., at nitrogen pressures between about 250 and about 5500 psig (about 1.7 and about 37.4 MPa) using a 0.0754 mm diameter, 20:1 L/D die with an entrance angle of about 180° C. For the preferred substantially linear ethylene polymers described herein, the PI is the apparent viscosity (in kpoise) of a material measured by GER at an apparent shear stress of 2.15×106 dyne/cm2 (2.19×104 kg/lm2). The substantially linear ethylene polymer for use in the invention have a PI in the range of 0.01 kpoise to 50 kpoise, preferably 15 kpoise or less. In one exemplary aspect, the substantially linear ethylene polymers used herein also have a PI less than or equal to 70 percent of the PI of a linear ethylene polymer (either a Ziegler polymerized polymer or a homogeneously branched linear polymer as described by Elston in U.S. Pat. No. 3,645,992) having an I2 and Mw/Mn each within ten percent of the substantially linear ethylene polymer.
Control 1 58.36 g/10 min
Control 2 59.89 g/10 min
Control 3 55.12 g/10 min
Control 4 48.02 g/10 min
Control 5 46.52 g/10 min
Average 53.58 g/10 min
Recovered Control Sample 1 46.52 g/10 min.
Recovered Control Sample 2 49.72 g/10 min.
Recovered Control Sample 3 47.79 g/10 min.
Recovered Control Sample 4 49.16 g/10 min.
Recovered Control Sample 5 53.11 g/10 min.
Recovered Control Sample 6 48.48 g/10 min.
Recovered Control Sample 7 51.72 g/10 min.
Recovered Control Sample 8 53.48 g/10 min.
Recovered Control Sample 9 59.68 g/10 min.
Average of Recovered Samples 1-9 51.07 g/10 min.
Sample # Starting Mass Final Mass Residual
Control 1 5.04 grams 5.04 grams 0%
Control 2 5.01 grams 5.07 grams 0.12%
Control 3 5.04 grams 5.17 grams 0.26%
Recovered Sample 1 65.79 g/10 min.
Recovered Sample 2 53.96 g/10 min.
Recovered Sample 3 46.04 g/10 min.
Recovered Sample 4 45.60 g/10 min.
Recovered Sample 5 40.74 g/10 min.
Recovered Sample 6 41.22 g/10 min.
Recovered Sample 7 40.56 g/10 min.
Recovered Sample 8 41.42 g/10 min.
Average of Recovered Samples 1-8 46.92 g/10 min.
Recovered Sample 9-A 44.38 g/10 min.
Recovered Sample 9-B 42.57 g/10 min.
Recovered Sample 9-C 44.18 g/10 min.
Recovered Sample 9-D 46.37 g/10 min.
Recovered Sample 10-A 37.44 g/10 min.
Recovered Sample 10-B 38.10 g/10 min.
Recovered Sample 10-C 38.09 g/10 min.
Recovered Sample 10-D 37.05 g/10 min.
Recovered Sample 11-A 46.18 g/10 min.
Recovered Sample 11-B 44.47 g/10 min.
Recovered Sample 11-C 41.63 g/10 min.
Recovered Sample 11-D 44.62 g/10 min.
Average of Recovered Samples 9-11 42.09 g/10 min.
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