Abstract: A process and method for recycling carpet is disclosed. The process and method involves the liberation and separation of desirable carpet face fibers from the carpet backing materials. The present invention eliminates face fiber shearing. In the present process, the secondary layer of the carpet backing is removed either manually or mechanically. Then, the bottom of the primary backing layer of the carpet with the bottom of the face fiber “U's” exposed, is mechanically grip-abraded by a rubber material. The grip-abrasion of the rubber or rubber-like material across the bottom of the primary carpet backing layer loosens the glue and grips and pulls the face fiber from the primary backing without destructing primary or secondary backing. The liberation and separation of face fibers from the backing materials using this method produces the highest yield of usable materials compared to any other method.

Abstract: 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.