Carpet Divider System

Abstract

Methods, systems and devices to divide a layer of a first material from another material, to which is attached, are provided. Particularly, for the separation of the PVC from a modular carpet. By the use of a parallel blades mechanism that through an opposite counterpart apply at least a shear stress over the material of the modular carpet to tear the PVC layer and divide it. The carpet is preheated to facilitate the process of division and reuse of said PVC.

Claims

1. A device for dividing a layer of a first material from a layer of a second material in a composite piece, the device comprising: a pair of parallel blades separated by a predetermined separation distance, wherein said blades are movable along a cutting axis; a counterpart that is fixed respective to the blades, where said counterpart is located over the cutting axis in a parallel relation with the blades and wherein said counterpart is able to be located between and separately from said blades when said blades move along the cutting axis toward said counterpart; wherein the blades and the counterpart perform a division of the first material from the second material by applying a double shear stress over the composite piece while the blades move toward the counterpart, wherein the double shear stress includes stress applied by the blades and stress applied by the counterpart; and an outlet element coupled to each blade, wherein the outlet element includes a curved form thereby providing a known location to the layer of the first material and the layer of the second material that is under separation, wherein the known location is defined by a trajectory projected by said curved form.

2. The device of claim 1, wherein the counterpart and the blades are separated by approximately the thickness of the layer of the second material when the counterpart is between both blades.

3. The device of claim 1, wherein the counterpart has a thickness whose magnitude is directly proportional to the thickness of either the layer of the first material or the second material of the composite piece.

4.-6. (canceled)

7. The device of claim 1, wherein the blades further include heaters for heating said blades.

8. A method for dividing a layer of a first material from a layer of a second material in a composite piece, the method comprising: preheating the composite piece; placing the composite piece between a counterpart and a pair of blades with the layer of the second material facing said counterpart, wherein said blades are movable along a cutting axis by a predetermined travel distance, and wherein the counterpart, which is fixed respective to the blades, is located over the cutting axis in a parallel relation with the blades and wherein said counterpart is able to be located between and separately from said blades when said blades move along the cutting axis toward said counterpart, and wherein the composite piece is disposed over the cutting axis at a distance substantially less than half a length of said composite piece, thus defining a minor side of composite piece and a major side of composite piece; dividing, utilizing the counterpart and the pair of blades, the layer of the first material from the layer of the second material by applying a double shear stress over the composite piece while the blades move toward the counterpart until the blades have moved a travel distance that is approximately larger than a length of the minor side, wherein the double shear stress includes stress applied by the blades and stress applied by the counterpart; grasping, through a grapple mechanism, the layer of the first material that has been divided in the major side; averting, at a predetermined speed, the grapple mechanism transversely from the blades, thus separating the layer of the first material from the layer of the second material.

9. A method of claim 8, wherein the counterpart and the blades are separated by approximately the thickness of the layer of the second material when the counterpart is between both blades.

10. The method of claim 8, wherein the counterpart has a thickness whose magnitude is directly proportional to the thickness of either the layer of the first material or the second material of the composite piece.

11.-12. (canceled)

13. The method of claim 8, further including an outlet element coupled to each blade, wherein the outlet element includes a curved form thereby providing a known location to the layer of material that is under separation, wherein the known location is defined by a trajectory projected by said curved form.

14. The method of claim 8, wherein the blades further include heaters for heating said blades.

15. A system for dividing the layer of a first material from a layer of a second material in a composite piece in combination with a device for dividing a composite piece, the system comprising: a device for dividing comprising: a counterpart and a pair of blades, said blades are movable along a cutting axis by a predetermined travel distance, wherein the counterpart that is fixed respective to the blades is located over the cutting axis in a parallel relation with the blades and wherein said counterpart is able to be located between and separately from said blades when said blades move along the cutting axis toward said counterpart; and wherein the composite piece is disposed over the cutting axis between the counterpart and the pair of blades with the layer of the second material facing said counterpart at a distance substantially less than half a length of said composite piece, thus defining a minor side of composite piece and a major side of composite piece; and a grapple mechanism for holding a separated layer of the first material, wherein the grapple mechanism can move toward and away from the device for dividing at a constant speed; wherein the device for dividing divides the layer of the first material from the layer of the second material by applying a double shear stress over the composite piece while the blades move toward the counterpart until the blades have moved a travel distance that is approximately larger than a length of the minor side, wherein the double shear stress includes stress applied by the blades and stress applied by the counterpart; and wherein the grapple mechanism grasps the layer of the first material that has been divided in the major side and averts at a predetermined speed transversely from the device for dividing, thus separating the layer of the first material from the layer of the second material.

16. The system of claim 15, wherein the counterpart and the blades are separated by approximately the thickness of the layer of the second material when the counterpart is between both blades.

17. The system of claim 15, wherein the counterpart has a thickness whose magnitude is directly proportional to the thickness of either the layer of the first material or the second material of the composite piece.

18.-19. (canceled)

20. The system of claim 15, wherein the device includes an outlet element coupled to each blade, wherein the outlet element includes a curved form thereby providing a known location to the layer of material that is under separation, wherein the known location is defined by a trajectory projected by said curved form.

21. The system of claim 15, wherein the blades further include heaters for heating said blades.

22. The device of claim 7, wherein the blades are heated to a temperature of 100 C.10 C.

23. The method of claim 14, wherein the blades are heated to a temperature of 100 C.10 C.

24. The method of claim 8, wherein the method further comprises the step of heating the blades.

25. The system of claim 21, wherein the blades are heated to a temperature of 100 C.10 C.

26. The system of claim 15, wherein the system further includes heaters for heating the composite piece.

Description

DESCRIPTION OF THE FIGURES

[0023] FIG. 1 shows a cross-sectional view of a piece of carpet including a PVC layer and Nylon layer;

[0024] FIG. 2 shows a division example of the PVC from the nylon of a carpet known in the art;

[0025] FIG. 3 shows an isometric view of an embodiment of the present invention and its parts;

[0026] FIG. 4 shows a frontal view of an embodiment of the present invention;

[0027] FIG. 5 shows a force diagram, wherein a single shear stress is applied on the piece of carpet;

[0028] FIG. 6 shows a diagram of forces, where a double shear stress is applied on the piece of carpet;

[0029] FIG. 7 shows a first execution moment in an embodiment of the present invention, wherein a section of a piece of carpet is placed in the inlet zone defined by the blades and counterpart, wherein said section has a predetermined length;

[0030] FIG. 8 shows a second execution moment in an embodiment of the present invention, wherein the blades start a linear travel in order to apply the double shear stress over the piece of carpet;

[0031] FIG. 9 shows a third execution moment in an embodiment of the present invention, wherein the piece of carpet starts to be flexed as a result of the double shear stress exerted on its surface, and wherein the upper face of said piece of carpet begins to tear;

[0032] FIG. 10 shows a fourth execution moment in an embodiment of the present invention, wherein the section of side B has been obtained and the section of side A is on a known position using the outlet element, The section of carpet of side A, being in said known position, is now ready to be grasped by a grapple mechanism;

[0033] FIG. 11 shows a fifth execution moment in an embodiment of the present invention, wherein the pincer or grapple mechanism is getting closer to the side A of the section of carpet for its retention;

[0034] FIG. 12 shows a sixth execution moment in an embodiment of the present invention, wherein the pincer or grapple mechanism has already retained the side A of the PVC section;

[0035] FIG. 13 shows a seventh execution moment in an embodiment of the present invention, wherein while the pincer or grapple element is moving away, it is dividing the rest of the layer of PVC of the piece of carpet and

[0036] FIG. 14 shows a lateral view of an embodiment of the invention, wherein two sections with a corresponding length substantially equal are separated.

DETAILED DESCRIPTION OF THE INVENTION

[0037] The following description is presented to enable any person skilled in the art to make and use the embodiments, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present disclosure. Thus, the present invention is not limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

[0038] FIG. 1 shows a cross-sectional view of a composite piece that it is also called carpet or piece of carpet 10, wherein it is shown a first material layer that can be called nylon 2 and a second material layer that can be called PVC 1. A person skilled in the art could would notice that the material used to made the composite piece may vary without affecting the subject matter of the present invention. Said composite piece includes a width, a length and a thickness. In said FIG. 1 it can be noticed that the thickness of each layer is similar; however, the thickness of each layer may be different without affecting the subject matter of the present invention.

[0039] In FIG. 2 it is shown an example of the division of PVC from nylon of one piece of carpet by pulling each layer towards the opposite direction as it is known in the art, wherein in order to facilitate said pulling, the temperature of the piece of carpet is increased, that is, a preheating step is applied. However, it has been identified that this method is inefficient, since many parts of PVC (not shown in the figures) remain in the layer of nylon or vice versa.

[0040] FIG. 3 shows an isometric view of an embodiment of the present invention, wherein a device 100 is shown that includes two parallel blades 20 A and 20 B separated by a distance D. The blades 20 A and 20 B have a cutting travel towards a counterpart 22 that remains fixed respective to said blades 20 A and 20 B. At the end of the travel of the blades 20 A and 20 B, the counterpart 22 is placed within the separation D of said blades 20 A and 20 B, and wherein said blades and said counterpart are parallel disposed. The blades 20 A and 20 B have a height and a width that correspond to the height H and the width B of the counterpart 22, which also are proportional to width and length of the piece of carpet to be divided. Also, in an embodiment of the invention, the thickness of said blades depends on the thickness of each layer of the piece of carpet 10. In an embodiment of the invention, the height either of the blades 20 A and 20 B or of the counterpart 22 maintains a linear relationship with the travel or run of the blades 20 A and 20 B. The counterpart 22 has a thickness S whose dimensions depend on the piece of carpet 10. Likewise, the separation D between the blades has a magnitude that is dependent to the piece of carpet. In an embodiment of the invention, the separation distance D and the thickness S of the counterpart 22 maintain a relationship that varies according to the thickness of the nylon layer. In another embodiment of the invention, the separation distance D and the thickness S of the counterpart 22 maintain a relationship that varies according to the thickness of the PVC layer. Also, in FIG. 3 can be appreciated that any edge or end of the blades is aligned with each edge or end of the fixed counterpart. However, a person skilled in the art will notice that each alignment may vary without affecting the subject matter of the present invention.

[0041] In an embodiment of the invention, the device of the present invention includes at least one outlet element 23 A and 23 B, which is coupled to the blades 20 A and 20 B at the end of the cutting edge of said blades 20 A and 20 B, in such a way that said outlet elements 23 A and 23 B, during the division, define a known outward path for the separated material. In an embodiment of the invention, the outlet element has a curved form.

[0042] In an embodiment of the invention, the division device 100 of carpets includes an ejector or also known as drift punch 21, which is fixed respective to the movement of the blades 20 A and 20 B, wherein the drift punch 21, while the blades 20 A and 20 B return to their original position, make the waste that have remained adhered on the blades are to be taken out and then fall by gravity, i.e. the remnants are removed.

[0043] FIG. 4 shows a frontal view of the device 100 of the present invention on an initial position, wherein the distance of separation D between blades 20 A and 20 B is appreciated. Also, it is appreciated the outlet element 23 A and 23 B, the ejector or drift punch 21, as well as the angle or cutting edge of blades. In an embodiment of the invention, said angle has a dimension of 305+10. Likewise, the area which is between the blades 20 A and 20 B and the counterpart 22 is named inlet area 15, defining thus a room where the piece of carpet 10 is disposed. Furthermore, the distance of separation CA between the inner face of blade 20 A and the outer face of side A of the counterpart 22 is appreciated. In this regard, there is a separation distance CB (no shown in figures) corresponding to side B of the device 100. In an embodiment of the invention, said distances CA and CB are proportional to the thickness of the layer of nylon 2. In an embodiment of the invention, said distances CA and CB are proportional to the thickness of the layer of PVC 1.

[0044] FIG. 5 shows a diagram of forces F1 and F2 that, according to their configuration, apply a simple shear stress on a material, like a piece of carpet 10. The separation distance X between forces F1 and F2 varies according to the thickness of each layer comprising the piece of carpet, like the layer of PVC 1 and/or the layer of nylon 2, and wherein said separation distance X is lower than the thickness of the whole thickness of the piece of carpet 10. Said forces F1 and F2 once applied, with a separation distance X lower than the thickness of the piece of carpet, make the material to be bent, so after said bent at least one layer of the piece of carpet tears if said forces F1 and F2 remain applied in the same direction and sense.

[0045] FIG. 6 shows a diagram of forces F1, F2 and F3 applying a double shear stress on a material, like a piece of carpet 10, wherein the separation distance X1 and X2 between each force varies in accordance with the thickness of each layer comprising the piece of carpet, like the layer of PVC 1 and/or the layer of nylon 2. These forces F1, F2 and F3 when are applied with a separation distance X1 and X2 lower than the thickness of the piece of carpet, make the material to bend in and inverted U-form, in such a way that after the bending make at least one of the layers of the piece of carpet to tear and being separated of the other material about the same distance of travel of the forces, wherein the distance travel is also known as penetration distance or run.

[0046] FIG. 7 shows a frontal view of an embodiment of the device 100 of the present invention in a first execution moment, wherein the blades 20 A and 20 B are in an initial position aligned with the drift punch 21. The piece of carpet 10 that includes a length L of piece of carpet, is disposed in the inlet area 15, so that if said piece of carpet 10 is disposed in a different point to the middle of said length L, a minor length LB and a greater length LA are defined, as shown in FIG. 7. Underneath the blades 20 A and 20 B is the counterpart 22 in such a way that, when said blades 20 A and 20 B finish their travel to the counterpart 22 in a straight downward path, along a cutting axis, said counterpart 22 is located inside and in centered relative to the two blades 20 A and 20 B. The run or travel of the counterpart 22 inside the blades 20 A and 20 B varies according to the length of the piece of carpet 10 and its disposition in the inlet zone 15, in such a way that considering LB and LA substantially equals, a full travel division is defined and, if LB and LA are different, a partial separation of the piece of carpet is defined.

[0047] FIG. 8 shows a frontal view of an embodiment of device 100 of the present invention in a second moment, wherein the piece of carpet 10 is disposed and the blades 20 A and 20 B start their travel along the cutting axis 5. In this case, the piece of carpet is disposed with the layer of PVC 1 facing towards the blades and the layer of nylon 2 facing towards the counterpart 22. In an embodiment of the invention, the layer of PVC 1 is disposed facing towards the counterpart 22 and the layer of nylon 2 is disposed facing towards the blades 20 A and 20 B. Said piece of carpet is disposed according to a distance LB in the inlet area 15, that is, between the blades 20 A and 20 B and the counterpart 22, thus defining a first section of piece of carpet. Thus, in an embodiment of the invention, the penetration distance of the counterpart 22 inside the blades 20 A and 20 B is proportional to said distance LB.

[0048] The movement of said blades 20 A and 20 B, and the fixed counterpart 22, is represented by the application of the forces F2, F3 and F1 respectively. Each movable part performs a movement according to means already known in the art, like hydraulic pistons, electric actuators, worm screw mechanism, etc. A person skilled in the art will appreciate that the method used for applying force, and in consequence, movement to the blades and/or any movable element may vary without affecting the subject matter of the present invention. Also, the method used to hold the fixed elements respect to the movables may vary without affecting the subject matter of the present invention.

[0049] FIG. 9 shows a frontal view of an embodiment of the device 100 of the present invention in a third moment just before the breaking or tear of the layer of PVC 1 (layer that in this case is facing towards the blades), wherein the piece of carpet 10 begins to experience a double shear stress by the parallels blades 20 A and 20 B and the counterpart 22. The edge or angle that the blades have makes easier the breaking of the layer of the material mentioned. Thus, by being flexible the piece of carpet, starts to bend in the inlet zone 15 according to the downward-run of the blades. Thus, an instant later (not shown in figures) the layer of PVC 1 is broken in the zone where the double shear stress is applied, particularly at the edge of the blades 20 A and 20 B.

[0050] FIG. 10 shows a frontal view of an embodiment of device 100 of the present invention in a fourth moment, after the layer of PVC 1 has been teared starting the separation in the zone of the double shear stress, wherein the blades 20 A and 20 B continue their travel of penetration or run corresponding to a distance around or larger than LB, so that in the side A, the layer of PVC 1 is divided by the edge of the blade 20 A and directed through the outlet element 23 A towards the known position 16; and in the side B the layer of PVC 1 is separated by the edge of blade 20 B a distance around or larger than LB, so that said section LB already completely separated from the piece of carpet 10 falls by gravity in a hopper or deposit (not shown in figures). In this way, the layer of nylon 2 remains confined in the room defined by the inner surface of the blades 20 A and 20 B, and by the counterpart 22.

[0051] FIG. 11 shows a frontal view of an embodiment of the device 100 of the present invention in a fifth moment, wherein a grapple mechanism 30 is adapted to get closer and directed to the known position 16 defined by the outlet element 23 A in the side A. The grapple mechanism 30 may be comprised by a sole mechanism or a plurality of mechanisms. A person skilled in the art will notice that a grasp may be made by different methods without affecting the subject matter of the present invention.

[0052] FIG. 12 shows a frontal view of an embodiment of the device 100 of the present invention in a sixth moment, wherein said grapple mechanism 30 is located in the known position 16 and holds the section of PVC separated and also located in said known position 16.

[0053] FIG. 13 shows a frontal view of an embodiment of the device 100 of the present invention in a seventh moment, wherein said grapple mechanism 30 is moving away, thus continuing with the separation of the material, at a constant speed and/or force previously defined, which allows the repetition of the process. Said speed and/or moving-away force depends on the materials involved during the separation and on the method used for the corresponding junction. A person skilled in the art will notice that the force and speed used by the grapple mechanism 30 for approaching or moving away may be particular for each material to divide without affecting the subject matter of the present invention. Also, a person skilled in the art will notice that the means to perform said approach and/or move away are already known in the art and may vary without affecting the subject matter of the present invention.

[0054] Once the grapple mechanism 30 has been away a distance corresponding to the complete separation of the layer of PVC 1, said grapple mechanism 30 releases the section of material PVC 1 secured, in order to be deposited by gravity in a hopper or deposit.

[0055] In FIG. 14 is shown a frontal view of an embodiment of the invention, where the piece of carpet 10 is previously disposed in the inlet area 15 at the middle of its length, wherein when the travel of the blades 20 A and 20 B start, this travel is larger or equal to the half of the length of the piece of carpet 10 in such a way that at the end of said travel the piece of carpet is completely separated (no shown in the figures), i.e. the section LA and the section LB are substantially of the same length. In an embodiment of invention, this division method by full travel is applied according to the type of material, and/or composite piece, and/or according to the method of previous junction. Thus, in this embodiment of invention, the material of PVC 1 of the side A, as well the side B, at the end of the division falls by gravity in a hopper or deposit.

[0056] In an embodiment of invention, the device only includes the blade of the side A, so that it is applied a single shear stress over the carpet for its division.

[0057] In an embodiment of invention, the blades on its inside face are polished, and in an particular embodiment said internal faces have a mirror finish.

[0058] In an embodiment of invention, each one of the blades 20 A and 20 B is preheated. In a particular embodiment, the temperature of said preheating is 100 C. A person skilled in the art will appreciate that the method used for the preheating of blades 20 A and 20 B may vary without affecting the subject matter of the present invention.

[0059] In an embodiment of invention, the separation distance D of the blades vary during the division process, wherein said distance D is 0 until the blades 20 A and 20 B are close to the counterpart 22, so that around a distance equal to thickness of the layer of nylon 2 or the PVC 1, said separation distance D begins to increase until a maximum which is proportional to the thickness of said layer of nylon 2 or PVC 1. Thus, the separation distance D is variable in time during the execution of the division process.

[0060] In an embodiment of invention, instead of using the outlet element 23 A or 23 B, it is used a roller or cylinder that removes the separated material layer by rotating.

[0061] In an embodiment of invention, all the elements of the present invention are made in metal. However, a person skilled in the art will appreciated that the manufacturing material of the present invention may vary without affecting the subject matter of the present invention.

[0062] Likewise, a plurality of carpet division methods is claimed, which can be applied, either to virgin carpets, recycled and/or any composite material.

[0063] In an embodiment of the invention, an electronic identification system that previously identifies the composite material type which will be separated it's applied, so that based on said identification it is performed either a separation in accordance with the embodiment shown in FIG. 13 (by partial travel of blades and using a grapple mechanism) or a separation in accordance with the embodiment shown in FIG. 14 (by full travel of blades). In this regard, the identification of the composite material type is performed by forms and/or technologies already known in the art.

[0064] Likewise, a method is revealed, comprising:

heating the piece of carpet to a predetermined temperature through a furnace; disposing the piece in the aperture or inlet zone of the blades and counterpart by means of a mechanized line;
sliding, via a ramp, the piece on a basis that allows said piece to be disposed in a cutting position;
determining that the piece of carpet has arrived to an appropriate position of separation through a detection mean coupled to a microcontroller or microprocessor, which can be a sensor of presence, of position, of movement, etc. In one embodiment of invention, the piece of carpet is in an appropriate position by reaching a cap where a detection mean is located that activates the initial mechanism of division; launching a partial division of the carpet by starting the movement of the blades towards the counterpart so that while said movement continues towards its path, a shear stress is applied over the piece and the blades maintaining pressure on the tissue or nylon and separating the PVC by each side of the blades, wherein the travel of the blades is lower than the half of the length of the piece of carpet; approaching in the pincer or grapple mechanism to hold the end or overhang of the resulting PVC material; averting the pincer or grapple mechanism, so that by being the PVC end fasten, this PVC end pull also the remaining material of said PVC of the layer of PVC to separate it from the piece of carpet; releasing the grapple mechanism on a hopper or deposit so that the separated layer of PVC falls by gravity to it.

[0065] A method comprising:

heating the piece of carpet to a predetermined temperature through a furnace; disposing the piece in the aperture or inlet zone of the blades and counterpart by means of a mechanized line;
determining that the piece of carpet has arrived to an appropriate position of separation through a detection mean, which determines whether the piece is disposed at the half of its length. In one embodiment of invention, the piece of carpet is in an appropriate position by reaching a cap where a sensor is located that activates the initial mechanism of division; launching a full division of the carpet by starting the movement of the blades towards the counterpart so that while said movement continues towards its path, a shear stress is applied over the piece and the blades down for maintaining pressure on the tissue or nylon and separating the PVC by each side of the blades, wherein the travel of the blades is larger o equal to the half of the length of the piece of carpet;
returning the blades to their initial position.

[0066] A method to divide a layer of a first material from a second material in a composite piece, the method comprising:

preheating the composite piece; disposing the composite piece between a counterpart and a pair of blades, where said blades are movable along a cutting axis by a predetermined travel distance, and wherein the composite piece is disposed at a substantially lower distance than the half of its length, thus defining a minor side and a larger side; partially separating, using the counterpart and the pair of blades, through a shear stress over the composite piece until the blades have performed their travel, wherein the travel distance is approximately larger than the length of the minor side, holding, through the grapple mechanism, the layer of the first material which is partially separated in the larger side; averting, to a predetermined speed, the grapple mechanism thus separating the remaining of the first material from the second material.

[0067] A method to divide a layer of a first material from a second material in a composite piece, the method comprising:

preheating the composite piece; disposing the composite piece between a counterpart and a pair of blades, where said blades are movable along a cutting axis by a predetermined travel distance, and wherein the composite piece is disposed at a substantially equal distance to the half of its length;
separating, using the counterpart and the pair of blades, through a shear stress over the composite piece until the blades have performed their travel, wherein the travel distance is approximately larger than the half of the length of the composite piece.

[0068] The foregoing descriptions of various embodiments have been presented only for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention.