Abstract: A method is disclosed for using discarded carpet segments or other recycled textiles to make wood-like material in sheets that are comparable to plywood. The carpet segments or other recycled materials are shredded, then layered across a slow-moving conveyor to form a thick, low-density belt of fibers. This belt is compressed between rollers, and then needle-punched, using needles with surface barbs that pull fibers downward and upward. This needle-punching causes fibers inside the mat to be pulled into vertical alignment (i.e., perpendicular to the top and bottom surfaces of a horizontal mat), to form a needle-punched mat that will hold together without chemical adhesives. A binder material is then applied to at least one and possibly both surfaces of the mat, by means such as spreading or spraying a liquid binder on either or both surfaces of the mat, or stretching a continuous film of the binder material across either or both surfaces of the mat.

Abstract: Discarded or recycled carpets or other textiles can be converted into wood-like materials, in sheets comparable to plywood. The carpets or textiles are shredded, combed, and layered across a conveyor to form a low-density mat, which is compressed and needle-punched to create a cohesive but flexible mat. An adhesive is applied to at least one and preferably two or more mats, by an applicator that spreads a liquid prepolymer onto one or more surfaces of the mat(s). The mat(s) travel through a press while the adhesive cures and hardens, and the use of foaming adhesives can ensure uniform permeation through dense fiber mats. The hardened sheets can be sawed, nailed, and otherwise handled like wood, and are strong, durable, and highly resistant to damage by water or insects.

Abstract: A method is disclosed for using discarded carpet segments or other recycled textiles to make wood-like material in sheets that are comparable to plywood. The carpet segments or other recycled materials are shredded, then layered across a slow-moving conveyor to form a thick, low-density belt of fibers. This belt is compressed between rollers, and then needle-punched, using needles with surface barbs that pull fibers downward and upward. This needle-punching causes fibers inside the mat to be pulled into vertical alignment (i.e., perpendicular to the top and bottom surfaces of a horizontal mat), to form a needle-punched mat that will hold together without chemical adhesives. A binder material is then applied to at least one and possibly both surfaces of the mat, by means such as spreading or spraying a liquid binder on either or both surfaces of the mat, or stretching a continuous film of the binder material across either or both surfaces of the mat.

Abstract: A rotating claw drum for shredding discarded material (such as used carpet) is created from flat circular plates that are stacked tightly together on a driveshaft or drum, to create an impermeable drum face that prevents particulates from entering and fouling the internal mechanisms. Each flat plate is provided with at least one claw-holding slot in its outer rim; 6 to 12 slots preferably should be provided in each plate. Locking means (such as a locking bar that will pass through aligned locking notches in the slots and claws) will lock the claws in place while the drum is in use. After the drum has been stopped, a locking bar can be removed, to release a damaged claw from its slot so it can be replaced, without having to disturb any other claws.

Abstract: A method and machine are disclosed for using a cold dry abrasion step for separating segments of discarded carpet into pile material (usually nylon) and backing layers (usually polypropylene) for recycling. A preferred method of abrasion uses dry ice pellets (made of frozen carbon dioxide) which are ejected at high speed from a set of nozzles that shoot the pellets directly into an abrasion zone, as a segment of discarded carpet on a conveyor system is being stripped apart and disassembled. The dry ice pellets "freeze" the binder material (usually latex) by lowering it to a temperature that makes the binder brittle and easy to break apart. The pellets also serve as abrasive agents, in a manner comparable to sand-blasting; however, unlike sandblasting or liquid (steam or chemical) systems, the dry ice pellets evaporate (sublimate) directly into gas without going through a liquid phase, and without leaving any liquid or gritty residue.