WATER-RESISTANT PLYWOOD SUBSTITUTES MADE FROM RECYCLED CARPETS OR TEXTILES

WIPO Patent Application WO/2001/076869

A1

Carpet segments or other recycled materials are shredded, then layered transversely across a slow moving conveyor system, to form a wide, thick, low density belt of fibers. This fluffy belt is then compressed to generate a fibrous mat which is subsequently needle punched. A polymeric binder is then applied to the needle punched mat and the impregnated mate is compressed and the polymeric binder cured to produce a hardened wood-like product.

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Bacon, Forrest C. (7163 Washington St, SW Covington, GA, 30014, US)
Holland, Wendell R. (1404 St. Charles Court SE Conyers, GA, 30094, US)
Bacon, Jesse D. (135 Shadow Lake Drive Conyers, GA, 30094, US)

PCT/US2001/011895

October 18, 2001

April 11, 2001

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Bacon, Forrest C. (7163 Washington St, SW Covington, GA, 30014, US)
Holland, Wendell R. (1404 St. Charles Court SE Conyers, GA, 30094, US)
Bacon, Jesse D. (135 Shadow Lake Drive Conyers, GA, 30094, US)

B29C70/24; B32B5/06; B32B5/26; D04H1/46; D04H1/54; D04H1/74; D04H13/00; (IPC1-7): B32B27/00; B32B31/00

Kelly, Patrick D. (11939 Manchester, #403 St. Louis, MO, 63131, US)

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CLAIMS

1.

A method for creating a woodsubstitute material comprising recycled synthetic fibers, comprising the following steps: a. forming a compressed fibrous mat comprising recycled synthetic fibers; b. subjecting the compressed fibrous mat to a needlepunching operation, thereby creating a needlepunched fiber mat; c. contacting said needlepunched fiber mat with an adhesive capable of permeating into the fibers in said mat, and capable of chemically bonding to said fibers, and capable of hardening within said needlepunched fiber mat in a manner which can impart a woodlike hardness to the composite material formed by the adhesive and the needlepunched fiber mat; and, d. placing the needlepunched fiber mat and the adhesive compound under pressure, in a manner which causes the hardening of the composite material in a desired thickness, thereby creating an article of manufacture from said composite material which can be sawed into desired sizes and which is useful as a substitute for at least one type of wood product.

2.	The method of claim 1, wherein the needlepunched fiber mat comprises nylon fibers from discarded carpet segments.

3.	The method of claim 1, wherein the needlepunched fiber mat comprises a mixture of nylon6 fibers and nylon6,6 fibers.

4.	The method of claim 1, wherein the composite material is fabricated in sheets that are wider than about 0.6 meters.

5.	The method of claim 1, wherein the composite material is fabricated in sheets that have the same width and length as a conventional sheet of plywood.

6.	The method of claim 1, wherein the adhesive is created by mixing two chemicals that release gas bubbles when mixed.

7.	The method of claim 1, wherein the adhesive is created by mixing isocyanate and polyurethane.

8.	An article of manufacture, made by the method of Claim 1.

9.

A method for creating a woodsubstitute material comprising recycled synthetic fibers, comprising the following steps: a. forming a compressed fibrous mat comprising recycled synthetic fibers, wherein at least some of said fibers are nylon fibers, and at least some of said fibers are lowmelting fibers which have a melting temperature substantially below the melting temperature of nylon; b. subjecting the compressed fibrous mat to a needlepunching operation, thereby creating a needlepunched fiber mat; c. subjected at least one such needlepunched fiber mat to a combination of heat and pressure, under conditions which cause the lowmelting fibers within the needlepunched fiber mat to melt and bind to at least some of the nylon fibers within the needlepunched fiber mat, thereby creating a composite material; and, d. allowing the needlepunched fiber mat to cool down while it remains under pressure, in a manner which causes the hardening of the composite material in a desired thickness, thereby creating an article of manufacture from said composite material which can be sawed into desired sizes and which is useful as a substitute for at least one type of wood product.

10.	The method of claim 9, wherein the needlepunched fiber mat comprises nylon fibers from discarded carpet segments.

11.	The method of claim 9, wherein the needlepunched fiber mat comprises a mixture of nylon6 fibers and nylon6,6 fibers.

12.	The method of claim 9, wherein the composite material is fabricated in sheets that are wider than about 0.6 meters.

13.	The method of claim 9, wherein the composite material is fabricated in sheets that have the same width and length as a conventional sheet of plywood.

14.	An article of manufacture, made by the method of Claim 9.

15.	An article of manufacture suitable for use as a wood substitute, comprising a sheet of composite material consisting essentially of: (i) a needlepunched fibrous mat containing recycled synthetic fibers; and, (ii) an adhesive compound which has become bonded to said fibers.

16.	The article of manufacture of claim 15, wherein the needlepunched fiber mat comprises nylon fibers from discarded carpet segments.

17.	The article of manufacture of claim 15, wherein the needlepunched fiber mat comprises a mixture of nylon6 fibers and nylon6,6 fibers.

18.	The article of manufacture of claim 15, wherein the composite material is fabricated in sheets that are wider than about 0.6 meters.

19.	The article of manufacture of claim 15, wherein the composite material is fabricated in sheets that have the same width and length as a conventional sheet of plywood.

20.	The article of manufacture of claim 15, wherein the adhesive compound is created by mixing two chemicals that release gas bubbles when mixed.

21.	The article of manufacture of claim 15, wherein the adhesive is created by mixing isocyanate and polyurethane.

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