Nyloboard Building Materials

Abstract

Three new categories of building materials are discussed, all made from needle-punched mats obtained from shredded carpet: (1) "Nyloprime" is made with a two-component adhesive mixture that undergoes foaming reaction to drive the liquid through the dense fiber mat; this material can create a wood-like material in sheets, comparable to plywood or oriented strand board; (2) "Nyloflex" uses heat to soften low-melt polymers such as polypropylene, into a leather-like material; and (3) "Nyloplate" uses resins or heated compression of Nyloboard, to create a harder material that approaches a ceramic in its traits. All three forms offer several major advantages over wood products (including waterproof, bug-proof, and high strength), and can be made by placing a single additional machine at the end of a needle-punch line.