Textile backing formed from recycled materials

1. A method of making a textile backing from post-consumer textile backing waste and post-industrial polymeric waste, the method comprising:

forming the post-consumer textile backing waste, wherein forming the post-consumer textile backing waste comprises

shredding post-consumer textile waste, wherein the post-consumer textile waste comprises fibers joined to post-consumer backing, the post-consumer backing comprising compounded polyvinyl chloride, and wherein shredding the post-consumer textile waste at least partially separates the fibers from the post-consumer backing, and

removing at least about 80% of the fibers from the shredded post-consumer textile waste to form the post-consumer textile backing waste, so that the post-consumer textile backing waste comprises at least about 80% compounded polyvinyl chloride, wherein the post-consumer textile backing waste is in a shredded condition;

processing the post-industrial polymeric waste, the post-industrial polymeric waste comprising up to 100 wt % compounded polyvinyl chloride;

delivering the post-consumer textile backing waste in the shredded condition to an extruder, wherein the post-consumer textile backing waste is delivered to the extruder in the shredded condition without being granulated or densified;

extruding a mixture comprising from about 1 to about 3% blowing agent and from about 97 to about 99% combined polymeric waste, wherein the combined polymeric waste comprises from about 40 to about 100 wt % of the post-consumer textile backing waste and from 0 to about 60 wt % of the processed post-industrial polymeric waste; and

heating the extruded mixture to a temperature above an activation temperature of the blowing agent to form the textile backing.

2. The method of claim 1 , wherein removing at least about 80% of the fibers from the shredded post-consumer textile waste to form the post-consumer textile backing waste comprises removing at least about 85% of the fibers, so that the post-consumer textile backing waste comprises at least about 85% compounded polyvinyl chloride.

3. The method of claim 1 , wherein removing at least about 80% of the fibers from the shredded post-consumer textile waste to form the post-consumer textile backing waste comprises removing at least about 90% of the fibers, so that the post-consumer textile backing waste comprises at least about 90% compounded polyvinyl chloride.

4. The method of claim 1 , wherein removing at least about 80% of the fibers from the shredded post-consumer textile waste to form the post-consumer textile backing waste comprises removing at least about 95% of the fibers, so that the post-consumer textile backing waste comprises at least about 95% compounded polyvinyl chloride.

5. The method of claim 1 , further comprising calendaring the extruded mixture.

6. The method of claim 1 , wherein the mixture comprises from about 55 to about 98 wt % post-consumer textile backing waste, from 0 to about 45 wt % post-industrial polymeric waste, and about 2 wt % blowing agent.

7. The method of claim 1 , wherein the mixture comprises from about 59 to about 98 wt % post-consumer textile backing waste, from 0 to about 39 wt % post-industrial polymeric waste, and about 2 wt % blowing agent.

8. The method of claim 1 , wherein the mixture comprises less than about 39 wt % post-industrial polymeric waste.

9. The method of claim 1 , wherein the mixture comprises at least about 59 wt % post-consumer textile backing waste.

10. The method of claim 1 , wherein the mixture comprises about 59 wt % post-consumer textile backing waste, about 39 wt % post-industrial polymeric waste, and about 2 wt % blowing agent.

11. The method of claim 1 , wherein the post-consumer textile backing waste comprises at least about 85 wt % post-consumer backing.

12. The method of claim 1 , wherein the post-consumer textile backing waste comprises at least about 90 wt % post-consumer backing.

13. The method of claim 1 , wherein the post-consumer textile backing waste comprises greater than about 95 wt % post-consumer backing.

14. The method of claim 1 , wherein the post-consumer textile waste comprises at least one of carpet and carpet tiles.

15. The method of claim 1 , wherein the post-industrial polymeric waste comprises at least one of pool liner, meat wrap, and automotive scrap.

16. The method of claim 1 , wherein the processing of the post-industrial polymeric waste comprises at least one of shredding, chopping, grinding, compacting, granulating, and pelletizing the post-industrial polymeric waste.

17. The method of claim 1 , wherein the textile backing comprises a carpet backing.

18. A method of making a textile backing, the method comprising:

forming post-consumer textile backing waste, wherein forming the post-consumer textile backing waste comprises

shredding post-consumer textile waste, wherein the post-consumer textile waste comprises fibers joined to post-consumer backing, the post-consumer backing comprising compounded polyvinyl chloride, and wherein shredding the post-consumer textile waste at least partially separates the fibers from the post-consumer backing, and

removing at least about 90% of the fibers from the shredded post-consumer textile waste to form the post-consumer textile backing waste, so that the post-consumer textile backing waste comprises at least about 90% compounded polyvinyl chloride, wherein the post-consumer textile backing waste is in a shredded condition;

separately densifying post-industrial polymeric waste, the post-industrial polymeric waste comprising up to 100 wt % compounded polyvinyl chloride, wherein densifying the post-industrial polymeric waste comprises at least one of compacting and pelletizing the post-industrial polymeric waste;

delivering the post-consumer textile backing waste in the shredded condition, the densified post-industrial polymeric waste, and a blowing agent to an extruder to form a textile backing composition, wherein the post-consumer textile backing waste is delivered to the extruder in the shredded condition without being granulated or densified;

extruding the textile backing composition; and

activating the blowing agent to form the textile backing.

19. A method of making a textile backing, the method comprising:

shredding post-consumer textile waste, wherein the post-consumer textile waste comprises fibers joined to post-consumer backing, the post-consumer backing comprising compounded polyvinyl chloride, and wherein shredding the post-consumer textile waste at least partially separates the fibers from the post-consumer backing, and

removing at least about 85% of the fibers from the shredded post-consumer textile waste to form post-consumer textile backing waste, so that the post-consumer textile backing waste comprises at least about 85% compounded polyvinyl chloride;

delivering the shredded post-consumer textile backing waste to an extruder, wherein the post-consumer textile backing waste is delivered to the extruder in the shredded condition without being granulated or densified;

extruding a mixture comprising from about 1 to about 3% blowing agent and at least about 85% compounded polyvinyl chloride from the shredded post-consumer textile backing waste; and

activating the blowing agent to form the textile backing.