Disclosed herein is a method for manufacturing a sound insulation material, a sound insulation material manufactured using this manufacturing method, and a carpet for a vehicle using the sound insulation material, and the sound insulation material is manufactured using a composite resin composition including 30 parts by weight to 70 parts by weight of aluminum oxide, 10 parts by weight to 20 parts by weight of nanoclay, 0.2 parts by weight to 0.8 parts by weight of an antioxidant, and 0.1 parts by weight to 0.5 parts by weight of a lubricant, with respect to 100 parts by weight of a base resin including PE, and the carpet for a vehicle is manufactured by coating the sound insulation material on a carpet fabric material and drying the result.

Methods for the recycling of carpet are disclosed that produce clean face fiber suitable for industrial use. The methods allow the recovery of face fiber material, for example a polyester or a polyamide, from carpets that includes a face fiber material and a backing material, and include the steps of heating the carpet to a temperature lower than the melting point of the face fiber material, but higher than the initial thermal decomposition temperature of the backing material, for a time and at a temperature sufficient to thermally decompose, pyrolyze, or oxidize at least a portion of the backing material, rendering the backing material friable, that is more friable than the untreated backing; and applying mechanical force to the carpet so as to liberate the friable backing material from the face fiber material.

Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various carpet, rug, polymeric materials and other waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like into a Clean Fuel Gas and Char source are disclosed. The invention processes the carpet, rug, polymeric material to effectively shred and/or grind the waste source, such as post-consumer carpet remnants and waste, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source. Additional waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like, are suitable for the processing of the invention disclosed.

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various carpet, rug, polymeric materials and other waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like into a Clean Fuel Gas and Char source are disclosed. The invention processes the carpet, rug, polymeric material to effectively shred and/or grind the waste source, such as post-consumer carpet remnants and waste, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source. Additional waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like, are suitable for the processing of the invention disclosed.

Compression molded composites comprising at least two compressed layers of unshredded carpet and method of making compression molded composites from unshredded carpets.

An advanced manufacturing plant and process to efficiently deconstruct and recycle post-consumer carpet primarily in an aqueous environment. The water-based technology substantially eliminates airborne particulate emissions into the workplace and the environment. It also significantly increases the quality and quantity of the resources recovered from the carpet. In addition to recycling residential carpet, it also reclaims and recycles material from commercial broadloom carpet.

A method for recovering face fiber materials and a backing material from a carpet is provided. The carpet includes the face fiber materials, the backing material, and an adhesive. The method includes applying a first mechanical force to the carpet to break a bond between the adhesive and the face fiber materials. The method includes separating at least 25% of the adhesive from the face fiber materials to form a blend of the face fiber material and the backing material. The method includes heating the blend of the face fiber material and the backing material to a temperature sufficient to melt the backing material and convert the backing material into backing droplets, the temperature less than a melting point of the face fiber materials. The method includes cooling the face fiber materials to cause the backing droplets to solidify into granules.

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

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.