RECOVERY

TECHNICAL FIELD

[0001] The present disclosure relates generally to the recycling and recovery of carpet. Certain embodiments relate more specifically to devices, systems, and methods employing tension and abrasion to break-down carpet into its component materials.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002] The written disclosure herein describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to certain of such illustrative embodiments that are depicted in the figures, in which:

[0003] FIG. 1 A is a cross sectional view of an exemplary loop pile carpet that may be processed by the methods and systems disclosed in the present invention. This cross sectional view illustrates the loop pile face fibers punched into and protruding from the primary backing, and a secondary backing that is attached to the primary backing.

[0004] FIG. 1 B is a cross sectional illustration of the secondary backing separated from the primary backing and face fibers of the loop pile carpet of FIG. 1 A.

[0005] FIG. 1 C is a cross sectional illustration of the primary backing separated from the face fibers of the loop pile carpet of FIG. 1 A and FIG. 1 B.

[0006] FIG. 2 is a schematic illustration of an exemplary method for separating the secondary backing from the primary backing and face fibers of a loop pile carpet.

As shown in FIG. 2, the loop pile carpet is immersed face fiber down in a heated water bath to loosen the secondary backing. As the carpet exits the water bath, residual water is removed and the secondary backing separated from the primary backing. [0007] FIG. 3 is a side view of a carpet recycling system as described herein. FIG. 3 illustrates a downward-facing loop pile carpet (less the secondary backing) fed through three clamping mechanisms (a rear clamp, a middle clamp and a front clamp).

[0008] FIG. 4 is a side view of the carpet recycling system illustrated in FIG. 3, showing an downward-facing loop pile carpet (less the secondary backing) that is clamped in place by the eccentric and stationary shafts of the front and middle clamps.

[0009] FIG. 5 is a side view of the carpet recycling system illustrated in FIG. 4, showing the front clamp forcibly moving away from middle clamp to tear or break the primary backing of the loop pile carpet (less the secondary backing) to allow the loop pile face fibers to separate from the primary backing. Upon tearing the primary backing, the middle clamp is loosened and the rear clamp is positioned as far back on the carpet piece or pieces as their overall length will allow.

[0010] FIG. 6 is a side view of the carpet recycling system illustrated in FIG. 5, showing a front clamp that is repositioned to allow the first end of the face fiber to pull through the front clamp. The primary backing attached to the first end of the face fiber is removed.

[0011] FIG. 7 is a side view of the carpet recycling system illustrated in FIG. 6 that shows two parallel, opposing abrasive pads positioned between the front and middle clamps with the abrasive surfaces facing each other. The loop pile face fiber is held in tension between the two abrasive surfaces. The front clamp concentrates its clamping force on the loop pile face fiber (free of primary backing), while the rear clamp holds the end portion of the carpet stationary and the middle clamp is released to allow the loop pile face fiber to pull through it as the face fiber is guided through the opposing abrasive pads.

[0012] FIG. 8 is a side view of an exemplary carpet recycling system illustrated in FIG. 7, showing two abrasive pads being activated to clean residual materials (e.g., adhesive and filler materials) that may be adhered to or embedded in the loop pile face fibers as the front clamp rotates to separate the loop pile face fibers from the primary backing.

[0013] FIG. 9 is a side view of an exemplary carpet recycling system, illustrating a downward-facing loop pile carpet (less the secondary backing) fed through two clamping mechanisms (a front clamp and a rear clamp).

[0014] FIG. 10 is a side view of the carpet recycling system illustrated in FIG. 9, showing a downward-facing loop pile carpet (less the secondary backing) that is clamped in place by the eccentric and stationary shafts of the front and rear clamps.

[0015] FIG. 1 1 is a side view of the carpet recycling system illustrated in FIG. 10, showing the front clamp forcibly moving away from the rear clamp to tear or break the primary backing of the loop pile carpet (less the secondary backing) to allow the loop pile face fibers to separate from the primary backing.

[0016] FIG. 12 is a side view of the carpet recycling system illustrated in FIG. 1 1 , showing the loop pile face fiber pulled through the front clamp as the primary backing attached to the first end of the loop pile face fiber is removed.

[0017] FIG. 13 is a side view of the carpet recycling system illustrated in FIG. 12 that shows two parallel, opposing abrasive pads positioned between the front and rear clamps with the abrasive surfaces facing each other. The loop pile face fiber is held in tension between the two abrasive surfaces. [0018] FIG. 14 is a side view of the carpet recycling system illustrated in FIG. 13 that shows two abrasive pads being activated to clean residual materials (e.g., adhesive and filler materials) that may be adhered to or embedded in the loop pile face fibers as the front clamp rotates to separate the loop pile face fibers from the primary backing.

[0019] FIG. 15 is a section view of an exemplary set of two abrasive pads with abrasive surfaces facing each other. The bottom abrasive pad is held stationary as the top abrasive pad simultaneously applies pressure perpendicular to the abrasive surfaces and moves parallel to the bottom abrasive pad to remove adhesive and filler materials from the loop pile face fibers.

[0020] FIG. 16 is a schematic illustration of an embodiment of the carpet recycling systems according to the present description.

[0021] FIG. 17 is a flowchart illustrating an embodiment of the methods for carpet recycling described herein.

DETAILED DESCRIPTION

[0022] Devices, systems, and methods for recycling carpet are described herein. The methods, systems and devices disclosed are suited to breaking down loop pile carpet 50 into components that have significant value as recycled materials. The methods described herein include separation of the secondary carpet backing 40 from the primary carpet backing 30, applying sufficient tension to the carpet 50 to separate the face fibers 25 from the primary backing 30, and abrasively cleaning the face fibers 25 after they are removed from the primary backing 30 to remove residual materials such as adhesive 70 and filler 60 materials adhered to or embedded in the face fibers 25. For example, in certain embodiments, the methods for recycling loop pile carpet 50 as described herein include the following: (i) processing the carpet 50 to remove the secondary backing 40 from the primary backing 30; (ii) subjecting the primary backing 30 containing the face fibers 25 to a breaking force, which causes the separation of the face fibers 25 from the primary backing 30 at a first end of the carpet 50; (iii) subjecting the separated face fibers 25 to a continuous force, causing the face fibers 25 to be pulled as continuous fibers from the primary backing 30; and (iv) abrasively removing residual adhesive 70 and filler 60 materials from the continuous face fibers 25 after the face fibers 25 are pulled free of the primary backing 30.

[0023] FIG. 1A illustrates a cross sectional view of an exemplary loop pile carpet 50 that can be processed by the devices, methods and systems described in the present invention for recycling carpet. Shown in FIG. 1A are loop pile face fibers 25, primary backing 30, and secondary backing 40. Loop pile carpet 50 may include a plurality of loop pile face fibers 25 punched into and protruding from the top surface of the primary backing 30. A secondary backing 40 may be connected to the primary backing 30 using adhesive 70 and filler 60 materials to form the backside of the loop pile carpet 50. FIG. 1 B illustrates a cross sectional view of a loop pile carpet 50 that has the secondary backing 40 separated from the primary backing 30 and loop pile face fibers 25. FIG. 1 C illustrates a cross sectional view of a loop pile carpet 50 (less the secondary backing 40) that has the primary backing 30 separated from the loop pile face fibers 25.

[0024] The terms "face fiber" and "face fibers" refer to fibers or yarns made of any one of a number of types of materials such as acrylics, nylons, polypropylene, polyethylene, polyamides, polyesters, wool, cotton, rayon, and the like, that are or can be used to form the pile 25 of a loop pile carpet 50. [0025] The terms "primary backing" and "primary backings" are used herein to refer to a woven or non-woven fabric made of one or more natural or synthetic fibers or yarns such as wool, polypropylene, polyethylene, ethylene-propylene copolymers, polyesters, rayon, fiberglass, and the like. The face fibers 25 of the loop pile carpet 50 are punched into and affixed to the primary backing 30.

[0026] The terms "secondary backing" and "secondary backings" are used herein to refer to woven or non-woven fabrics made of one or more natural or synthetic fibers or yarns such as wool, polypropylene, polyethylene, ethylene-propylene copolymers, polyesters, rayon, polyvinyl chloride (PVC), jute, and the like. The secondary backing 40 is generally affixed or adhered to the primary backing 30.

[0027] The terms "filler" and "fillers" are used herein to refer to substances such as calcium carbonate, calcium sulfite, glass, coal fly ash, bauxite, and the like, which are suitable for use in the manufacture of carpets 50.

[0028] The terms "adhesive" and "adhesives" are used herein to refer to substances such as latex, and the like, which are suitable for use in the manufacture of carpets 50.

[0029] The methods described herein comprise breaking down carpet 50 into its primary components. As used herein, "primary component" refers to any of the face fiber 25, the primary backing 30, and the secondary backing 40. The secondary backing 40 may be removed by any suitable technique or process, leaving the primary backing 30 with the face fibers 25 included therein. The primary backing 30 including the face fibers 25 is subjected to a tensile breaking force to separate the face fiber 25 from the primary backing 30 at a first end. The breaking force is applied in a direction such that, upon separating the face fiber 25 from the primary backing 30, application of a continuous force will result in separation of the face fiber 25 from the primary backing 30 as continuous fibers. Any suitable mechanisms can be employed to apply the breaking force and the continuous force. For example, the carpet 50 (less secondary backing 40) may be positioned within three clamping mechanisms, such that the first and second ends of the carpet 50 may be positioned within a front clamp 1 10 and a rear clamp 210, respectively, and a middle clamp 120 may be positioned between the front 1 10 and rear clamps 210. Once positioned within the three clamping mechanisms, the front clamp 1 10 holding the first end of the carpet 50 can be pulled away from the middle clamp 120 with sufficient force (a breaking force) to cause the face fiber 25 to begin to separate from the first end of the carpet 50. The middle clamp 120 holds the carpet 50 in place as the front clamp 1 10 pulls the first end of the carpet 50 away from the middle clamp 120, so as to concentrate the initial pull in a relatively small area of the carpet 50, which minimizes and/or prevents breaking in other areas of the carpet 50. In one embodiment, the front clamp 1 10 is connected to a mechanical actuator that can be activated to apply a breaking force to the primary backing 30 including the face fibers 25. Examples of mechanical actuators that may be used include, but are not limited to, hydraulic and pneumatic actuators, electrical motors, and the like. The clamping mechanisms can be any suitable mechanism, such as roll clamps, bar clamps, v-clamps, and the like. Additionally, in certain embodiments, the clamping mechanisms may be mounted to moveable carriages, and the breaking force may be applied by one or more actuators acting against the one or more moveable carriages in a manner that distances the first end of the carpet 50 away from the second end of the carpet 50.

[0030] Once the face fiber 25 begins to separate, the face fibers 25 are subjected to a continuous force that pulls the face fibers 25 from the primary backing 30 from the first end of the carpet 50. As the continuous force is applied, the face fibers 25 are removed from the primary backing 30 as continuous fibers and in a progressive fashion from the first end of the carpet 50 to the second end. The continuous force is a tensile force and can be applied using any suitable mechanism. The continuous force may be varied depending on the nature of the face fiber 25 or primary backing 30, but it is sufficient to remove the face fiber 25 from the primary backing 30, while being low enough to allow removal of the face fibers as continuous fibers (i.e., face fibers 25 are removed and collected in a continuous manner without breaking). In some embodiment, the front clamp 1 10 is configured to rotate and apply a continuous force and collect the continuous face fibers 25, as the face fibers 25 wind around the front clamp 1 10. In other embodiments, the front clamp 1 10 may be mounted on a long rail system or a similar device configured for use in this context to pull the continuous face fibers 25 away from the rear clamp 210, which may eliminate the need to stop and cut loose the primary backing 30 after application of the breaking force, and may reduce or eliminate the need for cutting the continuous face fiber 25 that is wound around the front clamp 1 10.

[0031] With loop pile carpet 50, as the face fibers 25 are pulled from the primary backing 30, they may include residual adhesive 70 and filler 60 materials. The residual materials are impurities that can limit the utility and value of the recycled face fiber 25 material unless they are removed. To address this concern, the methods described herein include a step wherein the residual adhesive 70 and filler 60 materials are removed from the face fibers 25 by abrasion prior to collection. The term "abrasion" refers to any technique, process, or technology involving the application of an abrasive to the surface of a material with a mechanical force sufficient to abrade, grind, strip, pull or otherwise remove the designated material. For purposes of the present disclosure, "abrasion" includes any sanding or grinding technique, process, or technology suitable for use in the methods described herein for removing residual adhesive 70 and filler 60 materials from face fibers 25 separated from the carpet 50 being recycled. In certain embodiments, abrasion as contemplated for the methods described herein can be carried out using an orbital sander, circular sander, reciprocating sander, drum sander, high pressure water spray, belt sanding or grinding mechanism, and the like. The abrasive material 420 may be a suitable, commercially available abrasive product, such as, sand paper, sanding cloth, carbide grit, diamond grit, zirconium grit, abrasive cloth, hook and loop roll abrasive, high pressure liquid (such as, for example, water and abrasive solutions and suspensions) and the like. Abrasion of the face fibers 25 is carried out in a manner that removes residual adhesive 70 and filler 60 materials from the face fibers 25 without abrading the face fibers 25 to such an extent that they are cut or break as the continuous force is applied.

[0032] In some embodiments, the carpet 50 to be recycled may be cleaned or remediated prior to breaking down the carpet 50 into its primary components. In further embodiments, the carpet 50 is sized and/or sorted prior to deconstruction. For example, in some embodiments, the carpet 50 may be graded according to the nature of the face fiber 25 as part of the recycling process. Grading the carpet 50 in this manner facilitates collection of specific face fiber 25 and primary backing 30 materials for recycling. For example, a system for carrying out the methods described herein may be dedicated to recycling carpets 50 having a certain type or class of face fibers 25. Alternatively, a single system may be used for recycling carpets 50 having any type of face fiber 25, but the carpets 50 may be graded, grouped, and processed according to face fiber 25 type so that different types of face fibers 25 can be collected with little or no contamination with face fibers 25 of a different material.

[0033] In certain embodiments, the materials forming the primary components may be further processed to facilitate their sale, transportation or use as post- consumer recycled materials. For instance, the materials may be washed, or otherwise cleaned, densified, baled, pelletized, etc. Moreover, in some embodiments, once separated from the carpet 50, the primary component materials may be handled or processed to isolate or produce secondary component materials. For example, the secondary backing 40 may include secondary backing fiber 42, adhesive 70, and filler 60 materials, and once separated from the carpet 50, the material forming the secondary backing 40 may be collected and processed in a manner that allows collection of one or more secondary component materials (e.g., one or more of the secondary backing fiber 42, adhesive 70, or filler 60 materials recovered from the secondary backing 40). Therefore, in certain embodiments of the methods described herein, the material recovered from the secondary backing 40 is processed to separate and collect one, or more, or each of the adhesive 70, filler 60, and secondary backing fiber 42 materials used in the secondary backing 40.

[0034] FIG. 17 is a flowchart schematically illustrating an embodiment of the methods for recycling carpet 50 as described herein. The method may start with inspection of the carpet 50 to determine if a hazardous contaminant, such as, for example, asbestos, is present. If a hazardous material is present, steps are taken to abate the hazardous material and properly dispose of the carpet 50 without further processing. If a hazardous material is not present, the carpet 50 may be checked for other non-hazardous contaminants and cleaned if necessary. If the carpet 50 is cleaned to remove contaminants, the carpet 50 may be re-inspected after cleaning to ensure that all contaminants are sufficiently removed before further processing.

[0035] Once it is confirmed that the carpet 50 is free of hazardous material and sufficiently clean, the face fiber 25 type of the carpet 50 may be determined so as to properly sort the carpet 50 for further processing with other like carpets 50. The face fiber 25 type of the carpet 50 may be determined using commercially available tools and systems such as a micro-fiber carpet analyzer, such as a Polychromix Phazir™ analyzer, and the like. Once sorted according to the type of face fiber 25, the carpet 50 may then be measured and combined according to size in preparation for separation of the secondary backing 40 and removal of the face fibers 25 from the primary backing 30 (represented by "sort, size, and combine"). In some embodiments, the loop pile carpets 50 may be trimmed parallel to the loop pile face fibers 25 to dimensions suitable for processing by the methods and systems described herein (included in the step represented by "sort, size, and combine").

[0036] The secondary backing 40 is removed from the carpet 50, and the carpet 50 is loaded in clamping mechanisms (represented by "load and clamp carpet in system"), such as clamps positioned on moveable carriages as described herein, and a breaking force is applied, which stretches the carpet 50, breaks the primary backing 30 at a first end of the carpet 50 and causes separation of a first end of the face fibers 25 from the primary backing 30. A continuous force is then applied to effect removal of face fibers 25 as continuous fibers 25 from the primary backing 30, and after the face fibers 25 are pulled away from the primary backing 30, the residual adhesive 70 and filler 60 materials are removed by abrasion (represented by "abrasively remove adhesive and filler materials from fibers") prior to collection. [0037] The secondary backing 40 can be removed from the carpet 50 using any suitable means or process. An embodiment of a process suited to remove the secondary backing 40 is schematically illustrated in FIG. 2. With reference to FIG. 2, the carpet is treated with or submerged in a heated water bath 80, which serves to loosen the bond between the secondary backing 40 and the primary backing 30. Once treated with heated water, pressure may be applied to the carpet 50 (such as by passing the carpet 50 through a set of rollers 90) to remove residual water from the carpet 50 before removing the secondary backing 40. The secondary backing 40 may then be removed by applying a force sufficient to pull the secondary backing 40 from the primary backing 30 containing the face fibers 25. In another embodiment, the secondary backing 40 may separated from the primary backing 30 and face fibers 25 through abrasive removal as described in U.S. Provisional Application No. 61/528,569, which is incorporated by reference herein.

[0038] With the secondary backing 40 removed, the face fiber 25 can be removed from the primary backing 30 using any mechanism or system suited for carrying out the methods described herein. An embodiment of a system suited to carrying out the methods of the present description is illustrated in FIG. 3 - FIG. 8. FIG. 3 is a side view of an exemplary carpet recycling system, illustrating a downward-facing loop pile carpet 50 (less the secondary backing 40) that is fed through three clamping mechanisms (front clamp 1 10, middle clamp 120, and rear clamp 210). The front 1 10 and middle 120 clamps may be mounted to a moveable front carriage 100. The front clamp 1 10 may be mounted to a mechanical actuator (not shown), which can be activated to apply a breaking force that stretches and ultimately breaks the carpet 50 (less secondary backing 40) and pulls a first end of the face fibers 25 from the primary backing 30. The mechanical actuator described herein may include, but is not limited to, hydraulic and pneumatic actuators, electrical motors, and any other device capable of applying a breaking force to the primary backing 30 and face fibers 25. The front clamp 1 10, middle clamp 120, and rear clamp 210 may each be composed of an eccentric shaft 130 and a stationary shaft 140. When the end portion of the loop pile carpet 50 is fed through the rear clamp 210, the carpet 50 is stopped and securely clamped in the rear clamp 210. The rear clamp 210 may be mounted to a moveable rear carriage 200 that can be moved toward and away from the moveable front carriage 100. If necessary, the rear carriage 200 may move forward until the rear carriage 200 is sufficiently close to the front carriage 100 for the carpet 50 to pass through the front clamp 1 10. One or both of the front 100 and rear carriages 200 can be displaced relative to the other in order to accommodate varying lengths of carpet 50. In some embodiments, the front 100 and rear carriages 200 may be mounted or otherwise connected to a frame or a main carriage assembly 330.

[0039] FIG. 4 is a side view of the carpet recycling system illustrated in FIG. 3, with the carpet 50 (less secondary backing 40) clamped in place by the front and middle eccentric 130 and stationary shafts 140. As shown in FIG. 4, the eccentric shaft 130 of the front 1 10 and middle clamps 120 may be rotated to secure the loop pile face fibers 25 and primary backing 30 between the eccentric 130 and stationary shafts 140. The eccentric shafts 130 may be rotated around a fixed axis 132 to allow a machined slot 134 of the eccentric shaft 130 to clamp the carpet 50 (less the secondary backing 40) against the corresponding stationary shaft 140.

[0040] As shown in FIG. 5, once the carpet 50 is loaded into the front 1 10 and middle 120 clamps, the front clamp 1 10 is displaced away from the middle clamp 120 such that the carpet 50 is stretched and a breaking force (represented by the illustrated arrow) sufficient to tear the primary backing 30 and pull a first end of the face fibers 25 from the primary backing 30 is applied. In the embodiment illustrated in FIG. 5, the middle clamp 120 remains stationary as the front clamp 1 10 is displaced away from the middle clamp 120 applying a force on the loop pile carpet 50 sufficient to tear the primary backing 30 and to separate the loop pile face fibers 25. Once the primary backing 30 is torn, the middle clamp 120 is loosened and the rear clamp 210 is positioned as far back on the carpet 50 as their overall length would allow. In an alternative embodiment, the moveable front carriage 100 remains stationary as the moveable rear carriage 200 moves away from the front carriage 100, which applies a force on the loop pile carpet 50 (less the secondary backing 40) sufficient to tear the primary backing 30 and separate the loop pile face fibers 25. The rear clamp 210 mounted to the moveable rear carriage 200 may be displaced relative to the moveable front carriage 100, such that the initial pull by the rear clamp 210 to break the primary backing 30 may be concentrated within a small section of the carpet 50 (less secondary backing 40), which prevents or reduces the likelihood of breaking in other areas of the carpet 50 (less secondary backing 40). In certain embodiments, a guide 300 may be provided to help maintain the horizontal positioning of the carpet 50 and separated face fibers 25 within the front clamp 1 10. The guide 300 may be an ultra-high-molecular-weight (UHMW) polyethylene guide bar, rod, roller or any suitable mechanism configured for use in this context.

[0041] The breaking force necessary to tear the primary backing 30 and separate the loop pile face fibers 25 may be applied by means known to one of skill in the art. In one embodiment, the carriage to which the front clamp 1 10 is mounted may be operatively associated with the carriage to which the rear clamp 210 is mounted by one or more mechanical actuators (not shown). Mechanical actuators suited to the methods and systems described herein include, hydraulic and pneumatic actuators, electrical motors, and the like. In another embodiment, instead of forcibly tearing the primary backing 30, a hot cutting instrument may be used to selectively cut the primary backing 30 without compromising or substantially compromising the face fiber 25.

[0042] Once the face fibers 25 are pulled free of the primary backing 30, the front clamp 1 10 may be disengaged or opened, and repositioned such that a first end of the face fibers 25 can be pulled through the front clamp 1 10, and the portion of the primary backing 30 attached to the first end of the face fibers 25 is removed. The piece of primary backing 30 attached to the first end of the face fibers 25 can be cut and removed using any suitable cutting instrument (illustrated as knife 320). Once the first end of the face fibers 25 is pulled through the front clamp 1 10, the front clamp 1 10 can then be reengaged, locking the face fibers 25 into the clamp 1 10. FIG. 6 shows the front clamp 1 10 reengaged with the separated face fibers 25 locked into the front clamp 1 10 and in preparation for application of the continuous force to remove the remaining lengths of the face fibers 25 from the primary backing 30. If desired, the middle clamp 120 may be released and the rear carriage 200 may be moved away from the front carriage 100 until the face fiber 25 is held in tension by the front 1 10 and rear clamps 210.

[0043] As shown in FIG. 7, embodiments of a system for recycling carpet according to the methods described herein may include an abrasive mechanism positioned between the front 1 10 and middle 120 clamps. To apply a continuous force for removing the remaining lengths of the face fibers 25 from the primary backing 30, the front clamp 1 10 may concentrate its clamping force on the loop pile face fiber 25 (free of primary backing 30) while the rear clamp 210 holds the end portion of the carpet 50 stationary. The middle clamp 120 may be disengaged or opened to allow the face fiber 25 to pull through, as the face fiber 25 is guided through the abrasive mechanism 410. The abrasive mechanism shown in FIG. 7 includes two parallel abrasive pads 410 having opposing abrasive surfaces 420. The face fiber 25 separated from the primary backing 30 passes between the abrasive pads 410 and in contact with the abrasive surfaces 420. As the face fiber 25 is pulled through the opposing abrasive surfaces 420, residual materials (e.g., residual adhesive 70 and filler 60 materials) are abraded and removed. In one embodiment, a guide 300 may be positioned between the front clamp 1 10 and the abrasive pads 410 to keep the face fiber 25 aligned with the abrasive surfaces 420 of the abrasive pads 410. In one embodiment, the abrasive pads 410 may be replaced with other suitable abrasive means, such as, but not limited to, abrasive drums, abrasive belts, abrasive blasting equipment, high pressure water spray, and other suitable mechanism configured for use in this context.

[0044] FIG. 8 illustrates the system shown in FIG. 7 with the abrasive pads 410 activated to remove residual adhesive 70 and filler 60 materials embedded in the separated face fiber 25. Additionally, FIG. 8 illustrates the collection of the separated and abrasively cleaned face fiber 25 by the front clamp 1 10. In the embodiment shown in FIG. 8, the front clamp 1 10 is configured to rotate about an axis to apply a continuous force that pulls the face fibers 25 from the primary backing 30 in a continuous manner. As the front clamp 1 10 rotates, the face fibers 25 are wound around and gathered by the front clamp 1 10. After all the loop pile face fibers 25 have been removed from the primary backing 30 back to the rear clamp 210, the rear clamp 210 may be disengaged or opened and the carriages adjusted to allow more carpet 50 to be pulled through and the process repeated, or the remaining primary backing 30 may be removed and collected from the rear clamp 210. Similarly, the gathered face fibers 25 are cut from the front clamp 1 10 and collected. If needed, the primary backing 30 and face fiber 25 materials can be subjected to further process steps to facilitate sale, transportation, or use of such materials. For example, in one embodiment the separated face fibers 25 are delivered to a conventional washing system for final cleaning before being sent to be densified, pelletized, baled or otherwise processed. The primary backing 30 material, now free of the face fiber 25, may be subjected to similar post-collection processing.

[0045] Another embodiment of a system suited to carrying out the methods of the present description is illustrated in FIGS. 9 - 14. FIG. 9 is a side view of an exemplary carpet recycling system, illustrating a downward-facing loop pile carpet 50 (less the secondary backing 40) that is fed through two clamping mechanisms (front clamp 1 10 and rear clamp 210). The front clamp 1 10 and rear clamp 210 may be mounted to moveable front 100 and rear 200 carriages, respectively. One or both of the front 100 and rear 200 carriages can be displaced relative to the other in order to apply a breaking force, which stretches and ultimately breaks the carpet 50 (less the secondary backing 40) and pulls a first end of the face fibers 25 from the primary backing 30. The front clamp 1 10 and rear clamp 210 may each be composed of an eccentric shaft 130 and a stationary shaft 140. When the end portion of the loop pile carpet 50 (less the secondary backing 40) is fed through the rear clamp 210, the carpet 50 (less the secondary backing 40) is stopped and securely clamped in the rear clamp 210. If necessary, the rear clamp 210 may move forward until the rear clamp 210 is sufficiently close to the front clamp 1 10 for the carpet 50 (less the secondary backing 40) to pass through the front clamp 1 10. One or both of the front 1 10 and rear clamps 210 can be displaced relative to the other in order to accommodate varying lengths of carpet 50. In certain embodiments, the front 1 10 and rear clamps 210 or the front 100 and rear carriages 200 may be mounted or otherwise connected to a frame or a main carriage assembly 330.

[0046] FIG. 10 is a side view of the carpet recycling system illustrated in FIG. 9, with the carpet 50 (less the secondary backing 40) clamped in place by the front and rear eccentric 130 and stationary shafts 140. As shown in FIG. 10, the eccentric shaft 130 of the front 1 10 and rear clamps 210 may be rotated to secure the loop pile face fibers 25 and primary backing 30 between the eccentric 130 and stationary shafts 140. The eccentric shafts 130 may be rotated around a fixed axis 132 to allow a machined slot 134 of the eccentric shaft 130 to clamp the carpet 50 against the corresponding stationary shaft 140.

[0047] As shown in FIG. 1 1 , once the carpet 50 (less the secondary backing 40) is loaded into the front 1 10 and rear 210 clamps, the front clamp 1 10 is displaced away from the rear clamp 210 such that the carpet 50 (less the secondary backing 40) is stretched and a breaking force (represented by the illustrated arrow) sufficient to tear the primary backing 30 and pull a first end of the face fibers 25 from the primary backing 30 is applied. In the embodiment illustrated in FIG. 1 1 , the rear clamp 210 remains stationary as the front clamp 1 10 is displaced away from the rear clamp 210, applying a force on the loop pile carpet 50 (less the secondary backing 40) sufficient to tear the primary backing 30 and to separate the loop pile face fibers 25. The front clamp 1 10 may be displaced relative to the rear clamp 210, such that the initial pull by the front clamp 1 10 to break the primary backing 30 may be concentrated within a small section of the carpet 50 (less the secondary backing 40), which prevents or reduces the likelihood of breaking in other areas of the carpet 50 (less the secondary backing 40). Once the primary backing 30 is torn, the front clamp 1 10 is loosened and the rear clamp 210 is positioned as far back on the carpet 50 (less the secondary backing 40) as their overall length would allow. In another embodiment, the front clamp 1 10 remains stationary as the rear clamp 210 moves away from the front clamp 1 10, which applies a force on the loop pile carpet 50 (less the secondary backing 40) sufficient to tear the primary backing 30 and to separate the loop pile face fibers 25. The rear clamp 210 may be displaced relative to the front clamp 1 10, such that the initial pull by the rear clamp 210 to break the primary backing 30 may be concentrated within a small section of the carpet 50 (less the secondary backing 40), which prevents or reduces the likelihood of breaking in other areas of the carpet 50 (less the secondary backing 40). In some embodiments, a guide 300 may be used to help maintain the horizontal positioning of the carpet 50 and separated face fibers 25 within the front clamp 1 10.

[0048] Once the face fibers 25 are pulled free of the primary backing 30, the front clamp 1 10 may be disengaged or opened, and repositioned such that a first end of the face fibers 25 can be pulled through the front clamp 1 10, and the portion of the primary backing 30 attached to the first end of the face fibers 25 is removed. Once the first end of the face fibers 25 is pulled through the front clamp 1 10, the front clamp 1 10 can then be reengaged, locking the face fibers 25 into the clamp 1 10. FIG. 12 shows the front clamp 1 10 reengaged with the separated face fibers 25 locked into the front clamp 1 10 and in preparation for application of the continuous force to remove the remaining lengths of the face fibers 25 from the primary backing 30. If desired, the rear clamp 210 may be moved away from the front clamp 1 10 until the face fiber 25 is held in tension by the front 1 10 and rear clamps 210. [0049] As illustrated in FIG. 13, embodiments of a system for recycling carpet according to the methods described herein may include an abrasive mechanism positioned between the front 1 10 and rear 210 clamps. To apply a continuous force for removing the remaining lengths of the face fibers 25 from the primary backing 30, the front clamp 1 10 may concentrate its clamping force on the loop pile face fiber 25 (free of primary backing 30) while the rear clamp 210 holds the end portion of the carpet 50 stationary. The abrasive mechanism shown in FIG. 13 includes two parallel abrasive pads 410 having opposing abrasive surfaces 420. The face fiber 25 separated from the primary backing 30 passes between the abrasive pads 410 and in contact with the abrasive surfaces 420. As the face fiber 25 is pulled through the opposing abrasive surfaces 420, residual adhesive 70 and filler 60 materials are abrasively removed. In some embodiments, a guide 300 may be positioned between the front clamp 1 10 and the abrasive pads 410 to keep the face fiber 25 aligned with the abrasive surfaces 420 of the abrasive pads 410.

[0050] FIG. 14 illustrates the system shown in FIG. 13 with the abrasive pads 410 activated to remove residual adhesive 70 and filler 60 materials embedded in the separated face fiber 25. FIG. 14 also illustrates the collection of the separated and abrasively cleaned face fiber 25 by the front clamp 1 10. In the embodiment shown in FIG. 14, the front clamp 1 10 is configured to rotate about an axis to apply a continuous force that pulls the face fibers 25 from the primary backing 30 in a continuous manner. As the front clamp 1 10 rotates, the face fibers 25 are wound around and gathered by the front clamp 1 10. After all the loop pile face fibers 25 have been removed from the primary backing 30 back to the rear clamp 210, the rear clamp 210 may be disengaged or opened and the carriages adjusted to allow more carpet 50 to be pulled through and the process repeated, or the remaining primary backing 30 may be removed and collected from the rear clamp 210. Similarly, the gathered face fibers 25 are cut from the front clamp 1 10 and collected.

[0051] Though the abrasive mechanisms shown in FIG. 8 and FIG. 14 are configured such that the opposing abrasive pads 410 move relative to one another and to the separated face fibers 25, an alternative embodiment is shown in FIG. 15. In particular, as illustrated in FIG. 15, the abrasive mechanism may be configured such that only a top or a bottom pad moves relative to the other pad and to the separated face fibers 25. The residual materials (e.g., residual adhesive 70 and filler 60 materials) adhered to or embedded in the face fibers 25 are also shown in FIG. 15. A force (represented by the downward arrow) perpendicular to the direction of movement of the face fibers 25 is applied to ensure that the face fibers 25 come in contact with the abrasive material 420 included on the abrasive pads 410. In certain embodiments, at least one of the opposing abrasive pads 410 moves relative to the other abrasive pad 410 and the separated face fibers 25. Such movement facilitates contact between all sides of the face fibers 25 and the abrasive pads 410 as the face fibers 25 move through the abrasive pads 410. Though shown as individual pads 410 in the figures provided herein, the abrasive pads 410 can take on any configuration suited to the systems and methods described herein. Moreover, the force applied through the abrasive pads 410, the size and rate of movement of the abrasive pads 410, and the nature of the abrasive material 420 used with the abrasive pads 410 can be adjusted to facilitate removal of the residual materials without breaking the separated face fibers 25. The size and characteristics of the abrasive pads 410 and associated mechanisms for driving one or both of the abrasive pads 410 can be adjusted according to the nature of the face fiber 25. [0052] FIG. 16 is a schematic illustration of an exemplary carpet recycling system according to the present invention that is used to separate loop pile carpet 50 into its individual components of a secondary backing 40, a primary backing 30, and loop pile face fibers 25. As shown in FIG. 16, the secondary backing 40 of the loop pile carpet 50 is removed before feeding the carpet 50 (less the secondary backing 40) through the carpet recycling system to separate the loop pile face fibers 25 from the primary backing 30. The face fibers 25 are then removed from the primary backing 30 and collected as described herein. At this point, the primary backing 30 is essentially free of secondary backing 40 material and face fiber 25 material. The primary backing 30 material can then be collected, and, if desired, the collected primary backing 30 and face fiber 25 materials can be further processed to facilitate their sale, transportation, or use.

[0053] Though the system illustrated in FIG. 16 is just one embodiment of a system suited for recycling carpet according to the present description, FIG. 16, highlights that the methods described herein not only break carpet 50 down into the materials forming the primary carpet components, but the methods described herein additionally allow the collection of the materials forming each of the primary components as discrete products. The materials collected include little cross contamination. For example, because the adhesive 70 and filler 60 residues are abrasively removed as the face fibers 25 are pulled from the primary backing 30, the face fibers 25 collected include very little material from the secondary backing 40 and very little to no material from the primary backing 30. Additionally, the recovered primary backing 30 material includes little to no face fiber 25 or secondary backing 40 material. Each of the discrete products produced by the methods and systems described herein can, themselves, be sold, transported and use with little to no additional processing.

[0054] Any methods disclosed herein comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified.

[0055] The materials recovered using the methods, systems and devices described herein can be used for any purpose suited to the material recovered. Because the methods described herein facilitate the removal and isolation of individual components of the carpet being recycled, the methods reduce the amount of additional processing required to prepare the materials for commercial sale and use as recycled materials for any one of a variety of applications. In some embodiments, where the primary components used to construct the carpet are fabricated from synthetic yarns or fibers that exhibit lipophilic properties, the materials generated from the methods and systems described herein are well suited for use in the recovery, clean-up and recycling of liquid hydrocarbons and organic liquids. Examples of suitable fibers exhibiting lipophilic properties suitable for recovery, clean-up and recycling of liquid hydrocarbons and organic liquids include synthetic fibers, such as polymer fibers. These polymer fibers may be formed from one or more of nylon, polyester, olefin, or acrylic polymers.

[0056] With reference, for example, to FIG. 16, where any of the primary backing 30, the secondary backing 40 or the face fibers 25 are formed of a lipophilic material, the recovered lipophilic material may be used to form absorbent booms, pads, or filling suited for the recovery, clean-up and recycling of liquid hydrocarbons and organic liquids. In most carpet manufactured, at least one of the primary components is formed using a synthetic yarn or fiber. For example, the yarns used in forming the secondary 40 and primary 30 backings are often made of polypropylene (an olefin polymer). Additionally the face fiber 25 material is typically one of polypropylene, nylon, polyester, and the like. In one example, because the primary backing 30 recovered using the systems and methods described herein is often preserved substantially intact, the recovered primary backing 30 may be sewn or otherwise formed into the exterior netting of a mat, pad, or boom, with the exterior netting formed by the recovered primary backing 30 material being filled with one or more of recovered face fiber, recovered secondary backing 40 fiber, and recovered primary backing 30 fibers. In specific embodiments, such a mat, pad or boom, would be configured to allow water to pass through while liquid hydrocarbon or liquid organic material contained in the water is collected in the matrix formed by the recovered lipophilic fiber material. Examples of mats, pads, and booms which may be constructed using the materials recovered from the methods and systems described herein are shown, for instance, in U.S. Patents numbered 3,565,257, 3,667,608, 3,679,058, 3,968,041 , 5,165,821 , 5,580,185, 5,679,247, 6,143,172, 6,743,367, the entire contents of which are herein incorporated by reference.

[0057] Throughout this specification, any reference to "one embodiment," "an embodiment," or "the embodiment" means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment. [0058] Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim requires more features than those expressly recited in that claim. Rather, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. It will be apparent to those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles set forth herein.