Utilization Of Waste Fibers In Laminates

Abstract

The present invention provides compositions and processes wherein recycling of waste carpets and textiles is achieved by coating the individual yarn fibers with a low viscosity adhesive that is dispersed or dissolved in a suitable solvent to affect coverage of the fine fibers, and arranging the coated fibers in layers to affect the most desirable physical properties and then cured to provide a high modulus matrix for the coated fibers in the laminate structure. The fibers may be from unshredded or shredded waste carpets, shredded waste woven or non woven fabrics, fabric bits, and knitted fabrics. When the carpet is used in an as received condition, the face yarns, which may contain one or more components yarns, are coated and the carpets are arranged in a sandwich construction wherein the backings of the two carpets are placed back-to-back, e.g., (F-B-(B-F)n -B-F, (n=0 or an integer value, F=face yarn and B=backing) and then heated under applied pressure to affect a cure of the resin coating and the adhesion between carpet backing layers. The resulting laminate consists of two outer fibrous layers that contains the unmelted yarns bundles from the carpet in a high modulus matrix.