Disclosed are continuous compression molding processes for producing a flexible polyurethane foam laminate and laminates produced thereby, which may be suitable for use, for example, as a carpet underlayment.

Devices, systems and methods for the recycling and recovery of carpet are disclosed herein, including devices, systems and methods for disassembling or deconstructing carpet into the various components that make up the carpet, by abrasive removal and separation of the components.

Methods, compositions, single phase aqueous solutions, process mixtures, and kits are provided relating to recycling a fibrous surface covering, e.g., carpet, using a single-phase aqueous solution. For example, a method of recycling a fibrous surface covering may include providing the single phase aqueous solution. The single phase aqueous solution may include water and a surfactant composition. The method may include providing the fibrous surface covering. The fibrous surface covering may include: a fibrous surface layer; a first backing coupled to the fibrous surface layer; and a binder coupled to one or more of the first backing and the fibrous surface layer. The method may include contacting the single phase aqueous solution and the fibrous surface covering to form a process mixture under conditions effective to provide a recycled portion of the fibrous surface covering.

Methods and apparatus for treating a mixture of fiber and granules are provided. The method includes passing the mixture through a friction zone comprising a conveyor belt that moves mixture and a friction device comprising a stationary surface in contact with a surface of the mixture. The method includes applying pressure to the mixture with the friction device to generate friction such that at least 5% of the fiber in the mixture is rotated. The method includes forming an agglomerate that is larger than the granules in the mixture.

Methods of amending soil to improve porosity and reduce compaction are provided. The method includes providing a carpet product. The method further includes separating the carpet product into fiber and granules. The method also includes adding the granules to the soil. The method can also include impacting the carpet product with a rotary impact separator. The method can also include impacting the carpet product with a hammer mill.

A method for making a yoga towel includes a step of preparing a towel with multiple apertures defined therethrough, a resilient plate placed on the towel; a step of placing the towel and the resilient plate between a top mold and a bottom mold which has cavities defined therethrough; a step of heating and softening the resilient plate and matching the top mold to the bottom mold, and a step of vacuuming to suck the softened resilient plate to form anti-slip protrusions on the second face of the towel via the apertures. The anti-slip protrusions are integrally formed with the towel and have elasticity.

Various embodiments are directed to an airline carpet kit comprising a plurality of carpet components collectively forming a substantially continuous floor covering, for example, for use within an aircraft interior. Each of the plurality of carpet components comprises a tufted carpet backing having a plurality of carpet tufts extending from a back surface of the carpet backing and above a top surface of the carpet backing; and an edge strip comprising an amorphous plastic material, wherein the edge strip extends around a lateral edge of the carpet backing between a base portion embedded within a back surface of the carpet backing and an edge surface defining a perimeter edge of the carpet component. The edge surface of a first carpet component abuts an edge surface of an adjacent second carpet component to form an at least substantially continuous floor covering for an aircraft interior.

A composite floor comprises a coextrusion layer compression moulded using a coextrusion process. The layer comprises a first stone-plastic layer, a stone-plastic foaming layer, and a second stone-plastic layer sequentially arranged from top to bottom. The stone-plastic foaming layer is used as the main material layer, which reduces a whole weight of the floor; and the first stone-plastic layer and the second stone-plastic layer are arranged at two sides of the stone-plastic foaming layer, respectively, so that the composite floor is more stable. It is more environmentally friendly and simple in manufacturing to use the coextrusion process for compression moulding by avoiding bonding using glue. Use of the coextrusion process makes various layers bond more compact, with little delamination and warpage due to effect of environmental changes. The composite floor has a low expansion rate and shrinkage rate, excellent in performance and long in service life.

A process for separation and recovery of waste carpet components, wherein waste carpets are predominantly composed of a face fiber material, a backing material and an adhesive coating which includes latex and filler. Virtually all of the filler, i.e. calcium carbonate, is removed prior to fine grinding and passing the mixture to a high speed centrifuge for separation of the face fiber material from the backing material. A high friction washer is disclosed which separates the face giver material, the backing material and the adhesive coating. The fine grinding of the material to be recycled may be done only once before passing the mixture to the centrifuge by which the loss of the fiber material is highly reduced before its separation into face fiber and backing material and also the life time of the fine grinder and the centrifuge can be prolonged.

The present invention pertains to a method to manufacture a textile product comprising a first sheet having a width and a length, and polymer yarns fastened to this sheet to form a pile thereon, the method comprising providing the sheet, stitching the polymer yarns through the sheet to form the pile on a first surface of the sheet and loops of the yarns at a second surface of the sheet, transporting the sheet in a direction parallel to its length along a heating element, the heating element being directed to the second surface of the sheet, heating the second surface with the heating element to at least partly melt the loops of the yarns to fasten the yarns to the sheet, wherein the method comprises transporting the sheet in contact with the heating element, wherein the heating element is a stationary rigid plate-like element having a width corresponding to the width of the sheet, and a length that extends parallel to the length of the sheet, the plate being curved in its length direction, wherein the outer circumference of the plate is contacted with the sheet. The invention also pertains to a method to use a textile product obtained with the new method and a device for applying the said method.