Carpet waste composite
A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.
1. A composite building material, comprising:
a first layer comprising a carpet waste, a first binding agent, and an inorganic filler in addition to any filler present in the carpet waste; and
a second layer disposed on the first layer and comprising natural fibers and a second binding agent.
2. The composite building material of claim 1 , wherein the first binding agent comprises methylenediphenyldiisocyanate (MDI).
3. The composite building material of claim 1 , wherein the first binding agent comprises a product of a reaction involving methylenediphenyldiisocyanate (MDI).
4. The composite building material of claim 1 , wherein the second binding agent comprises phenol formaldehyde (PF).
5. The composite building material of claim 1 , wherein the second binding agent comprises a product of a reaction involving phenol formaldehyde (PF).
6. The composite building material of claim 1 , wherein the carpet waste comprises carpet fibers having a length from about 0.25 inches to about 1.0 inch.
7. The composite building material of claim 1 , wherein the carpet waste comprises carpet fibers having a length of about 1.0 inch.
8. The composite building material of claim 1 , further comprising at least one of a patterned surface, a cover layer, or a sanded surface.
9. The composite building material of claim 8 , wherein the patterned surface comprises at least one of a molded surface, an embossed surface, a colored surface, or a wood grain pattern.
10. The composite building material of claim 8 , wherein the cover layer comprises a coating selected from the group consisting of primers, paints, stains, polyurethane, and acrylic.
11. The composite building material of claim 1 , further comprising at least one of a molded patterned surface, an embossed patterned surface, or a hot-stamped layer.
12. The composite building material of claim 1 , further comprising fiberglass.
13. The composite building material of claim 1 , wherein the composite building material comprises polypropylene.
14. The composite building material of claim 1 , further comprising a third layer disposed on an opposite side of the first layer and comprising natural fibers and the second binding agent.
15. A method of manufacturing a composite building material, the method comprising the steps of:
forming a first layer comprising a carpet waste, a first binding agent, and an inorganic filler in addition to any filler present in the carpet waste;
applying a second layer to the first layer, the second layer comprising natural fibers and a second binding agent; and
heating and pressing the first layer and the second layer together to form the composite building material.
16. The method of claim 15 , wherein the first binding agent comprises methylenediphenyldiisocyanate (MDI).
17. The method of claim 15 , wherein the second binding agent comprises phenol formaldehyde (PF).
18. The method of claim 15 , wherein the carpet waste comprises carpet fibers having a length of about 1.0 inch.
19. The method of claim 15 , further comprising adding at least one of a patterned surface, a cover layer, or a sanded surface to the composite building material.
20. The method of claim 19 , wherein the patterned surface comprises at least one of a molded surface, an embossed surface, a colored surface, or a wood grain pattern.
21. The method of claim 15 , further comprising adding at least one of a molded patterned surface, an embossed patterned surface, or a hot-stamped layer to the composite building material.
22. The method of claim 15 , wherein forming the first layer comprises adding fiberglass.
23. The method of claim 15 , further comprising applying a third layer to an opposite side of the first layer, the third layer comprising natural fibers and the second binding agent.