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2. 发明申请

US20120031543A1 WATER-RESISTANT PLYWOOD SUBSTITUTES MADE FROM RECYCLED CARPETS OR TEXTILES 审中-公开
标题翻译：来自回收地毯或纺织品的抗水性替代品
公开(公告)号：US20120031543A1
公开(公告)日：2012-02-09
申请号：US13180142
申请日：2011-07-11
申请人： Forrest C. Bacon , Wendell R. Holland , Jesse D. Bacon
发明人： Forrest C. Bacon , Wendell R. Holland , Jesse D. Bacon
IPC分类号： B32B37/02 , B32B37/12 , B32B38/10 , B32B37/10
CPC分类号： D04H1/74 , B29C70/24 , B32B5/06 , B32B5/26 , D04H1/4274 , D04H1/46 , D04H1/488 , D04H1/54 , D04H1/64 , D04H18/02 , Y10T156/1007 , Y10T156/1015 , Y10T442/2861 , Y10T442/2893 , Y10T442/652 , Y10T442/682 , Y10T442/688
摘要： A method is disclosed for using discarded carpet segments or other recycled textiles to make wood-like material in sheets that are comparable to plywood. The carpet segments or other recycled materials are shredded, then layered across a slow-moving conveyor to form a thick, low-density belt of fibers. This belt is compressed between rollers, and then needle-punched, using needles with surface barbs that pull fibers downward and upward. This needle-punching causes fibers inside the mat to be pulled into vertical alignment (i.e., perpendicular to the top and bottom surfaces of a horizontal mat), to form a needle-punched mat that will hold together without chemical adhesives. A binder material is then applied to at least one and possibly both surfaces of the mat, by means such as spreading or spraying a liquid binder on either or both surfaces of the mat, or stretching a continuous film of the binder material across either or both surfaces of the mat. The polymer-coated fiber mat is then compressed while the binder hardens and cures, to form hardened wood-like product, in sheet form, without requiring melting of the nylon or other synthetic fibers inside the material. In an alternate embodiment, nylon fibers blended with polypropylene or other polyolefins can be heated and compressed to a temperature which (i) melts the polypropylene, causing it to act as an adhesive, and (ii) creates a “heat set” in the nylon fibers. These materials are strong, durable, highly resistant to cracking or splitting, and highly resistant to water infiltration or damage, and offer highly useful substitutes for plywood, particleboard, and other forms of wood and lumber.
摘要翻译：公开了一种使用废弃的地毯片段或其他再循环的纺织品来制造类似于胶合板的片材中的木质材料的方法。将地毯段或其他回收材料切碎，然后分层穿过缓慢移动的输送机以形成厚而低密度的纤维带。该带在辊之间被压缩，然后针刺，使用具有向下和向上的纤维的表面倒钩的针。这种针刺使得垫子内的纤维被拉入垂直对准（即垂直于水平垫的顶部和底部表面），以形成针刺垫，其将不用化学粘合剂保持在一起。然后将粘合剂材料施加到垫的至少一个且可能的两个表面上，例如通过在垫的任一表面或两个表面上铺展或喷涂液体粘合剂，或者通过两者或两者之一或两者拉伸粘合剂材料的连续膜垫的表面。然后将聚合物涂覆的纤维垫压缩，同时粘合剂硬化和固化，以片状形式形成硬化的木状产品，而不需要熔化材料内的尼龙或其它合成纤维。在另一个实施方案中，与聚丙烯或其它聚烯烃混合的尼龙纤维可被加热并压缩至（i）熔化聚丙烯导致其作为粘合剂的温度，和（ii）在尼龙中产生“热定形” 纤维。这些材料坚固耐用，耐开裂或分裂，高度耐水渗透或损坏，并为胶合板，刨花板和其他形式的木材和木材提供非常有用的替代品。

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