US 12,441,080 B2
Carpet waste composite and method for making same
Daniel R. McIntyre, Pagosa Springs, CO (US)
Assigned to Advanced Carpet Recycling, LLC, Bedford, TX (US)
Filed by Advanced Carpet Recycling, LLC, Bedford, TX (US)
Filed on May 9, 2023, as Appl. No. 18/314,238.
Application 18/314,238 is a continuation in part of application No. 17/713,712, filed on Apr. 5, 2022, granted, now 11,648,748, issued on May 16, 2023.
Application 17/713,712 is a continuation of application No. 17/162,839, filed on Jan. 29, 2021, granted, now 11,292,230, issued on Apr. 5, 2022.
Application 17/162,839 is a continuation in part of application No. 16/774,750, filed on Jan. 28, 2020, granted, now 10,981,354, issued on Apr. 20, 2021.
Application 16/774,750 is a continuation of application No. 16/528,332, filed on Jul. 31, 2019, granted, now 10,611,121, issued on Apr. 7, 2020.
Claims priority of provisional application 63/378,388, filed on Oct. 5, 2022.
Claims priority of provisional application 62/967,893, filed on Jan. 30, 2020.
Claims priority of provisional application 62/715,401, filed on Aug. 7, 2018.
Prior Publication US 2023/0271403 A1, Aug. 31, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 5/26 (2006.01); B32B 5/02 (2006.01); B32B 5/06 (2006.01)
CPC B32B 5/26 (2013.01) [B32B 5/024 (2013.01); B32B 5/06 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method of manufacturing a composite construction material, the method comprising:
providing a plurality of cleaned, unadulterated layers of intact carpet, each of the plurality of cleaned, unadulterated layers of intact carpet having a backing side and a tufted side;
creating an initial, unfused carpet layer by placing two cleaned, unadulterated layers of intact carpet of the plurality of cleaned, unadulterated layers of intact carpet side-to-side with homogenous and adhesive contact therebetween, the homogenous and adhesive contact including an adhesive material;
applying first heat and pressure to the initial, unfused carpet layer within a first carrier having a first fixed height;
applying first cooling to the initial, unfused carpet layer to form an initial, fused carpet layer;
creating the composite construction material by iteratively adding additional layers of cleaned, unadulterated layers of intact carpet of the plurality of cleaned, unadulterated layers of intact contact carpet, each of the additional layers of cleaned, unadulterated layers of intact carpet being added side-to-side with the homogenous and adhesive contact therebetween, each of the additional layers of cleaned, unadulterated layers of intact carpet being subject to an application of second heat and pressure followed by an application of second cooling;
providing first and second plates in a sealing engagement with respective first and second surfaces of the composite construction material; and
providing a plurality of reinforcement rods traversing the composite construction material from the first plate to the second plate.