Fabrication of structural composites from waste carpet

Jain, Abhishek; Pandey, Gajendra; Singh, Abhishek Kumar; Rajamohan, Vasudevan; Vaidyanathan, Ranji; Singh, Raman P.

doi:10.1002/adv.20261

Cited by 30 publications

(13 citation statements)

References 4 publications

(12 reference statements)

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“…The most prominent type of household carpet is the cut-pile carpet, which is typically made of nylon or polyester yarns with a polypropylene backing (Jain, Pandey et al , 2012). In the recycling process, the upright yarns can be shaven off and recycled as a high-quality secondary material (EPA, 2009).…”

Section: Introductionmentioning

confidence: 99%

Influence of Processing Parameters and Composition on the Effective Compatibilization of Polypropylene–Poly(ethylene terephthalate) Blends

Bruggen

Koster

Picken

et al. 2016

International Polymer Processing

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The effects of the addition of different functionalized compatibilizers on toughness, morphology and rheological properties of a polypropylene (PP) -poly(ethylene terephthalate) (PET) (85-15 wt%) blend were studied. The three compatibilizers compared were: (Styrene Ethylene Butylene Styrene)-grafted-(glycidyl methacrylate); (Styrene Ethylene Butylene Styrene) -grafted -(maleic anhydryde); (polyolefin) -grafted -(glycidyl methacrylate), abbreviated to: SEBS-g-GMA, SEBS-g-MA and POE-g-GMA respectively. The effective grafting content was the same for all three compatibilizers. Before the comparison of the different compatibilizers was done, first the effects of three different processing temperatures and three different compatibilizer contents were investigated, based on the addition of SEBS-g-GMA. The compatibilization effect was significantly improved with an increase in processing temperature from 250 to 300 8C. The toughness was increased with almost a factor two and a decrease in the average domain size of the dispersed phase was observed. An increase in compatibilizer content from 0.25 to 2.5 wt% resulted in a finer dispersity as well as in a steep increase in toughness, which was noted to approach the brittle-to-ductile transition. The comparison of the three compatibilizers was subsequently done at the most promising processing temperature and content: 300 8C and 2.5 wt%. The results showed that the addition of SEBS-g-MA and POE-g-GMA had a less significant positive effect on the compatibilization compared to SEBS-g-GMA. The difference is attributed to a higher reactivity for GMA compared to MA and a higher possibility for migration towards the PP-PET interface for the SEBS chain compared to the POE chain.

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Section: Introductionmentioning

confidence: 99%

Influence of Processing Parameters and Composition on the Effective Compatibilization of Polypropylene–Poly(ethylene terephthalate) Blends

Bruggen

Koster

Picken

et al. 2016

International Polymer Processing

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“…The process was further scaled up to manufacture large scale (1 m × 1 m in size) composite panels with excellent sound absorption capabilities and mechanical properties, as reported by our previous work [8]. The present work is an extension of the works reported in [7,8], in this work we have extended the application of carpet structural composites as tooling material. The structural panels were fabricated with different low-cost room temperature cured polymer resins (epoxy, polyester, and polyurethane) infused through the nylon fibers with excellent surface quality and large sizes.…”

Section: Post-consumer Carpet Compositementioning

confidence: 74%

“…It has excellent structural performance as well as being very durable which makes post-consumer carpet a potential structural composite [6]. A novel technique has been reported in the past to recycle post-consumer waste carpet into composite panels based on a modified vacuum assisted resin transfer molding (VARTM) process [7]. The process was further scaled up to manufacture large scale (1 m × 1 m in size) composite panels with excellent sound absorption capabilities and mechanical properties, as reported by our previous work [8].…”

Section: Post-consumer Carpet Compositementioning

confidence: 99%

The Use of Recycled Carpet in Low-Cost Composite Tooling Materials

2019

Self Cite

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More than 250,000 metric tons (600 million pounds) of carpet are dumped in landfills every year. That creates a significant concern regarding environmental deterioration and economic liability. It is therefore imperative to develop sustainable post-consumer carpet-based products for high-value engineering applications such as composite tooling. To be considered as an acceptable composite tooling material, the composite needs to meet certain required properties such as a low coefficient of thermal expansion, excellent compressive properties, and high a hardness value after repeated exposure to curing cycles. The tooling composites must also exhibit the ability to endure several curing cycles, without deteriorating the mechanical properties. In the present investigation, post-consumer carpet has been recycled in the form of structural composites for tooling applications. The recycled carpet composites have been reinforced with 0.5 wt.% of graphene nanoplatelets to modify the material properties of the carpet composites. The results from compressive and hardness experiments demonstrate that the recycled carpet preserved its mechanical integrity even after several curing cycles. This indicates that recycled carpet composites have the potential to be a low-cost composite tooling alternative for the industry.

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“…Currently, almost 4-6 million tons of carpets have been discarded and become one of the largest amounts of solid wastes [8][9][10]. However, only 2% waste carpets have been recycled [11]. Waste carpets contain non-degradable petro-based materials and thus cause serious environmental pollution.…”

Section: Introductionmentioning

confidence: 99%

“…However, carpets are required to be smashed for preparation of carpet-concrete composites, leading to more energy consumption and high processing cost. Jain et al have fabricated composites using waste carpet and thermoset resins via vacuum-assisted resin transfer molding (VARTM) [11].…”

Section: Introductionmentioning

confidence: 99%

Acoustical and mechanical properties of thermoplastic composites from discarded carpets

Pan

Zhao

et al. 2016

Composites Part B: Engineering

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Without additional matrix or reinforcement, compression molded composites from waste polypropylene (PP) carpets/nylon (PA) carpets or PP carpets/polyester (PET) carpets have higher mechanical properties and sound absorption than traditional jute/PP composites. Large amount of carpets have been discarded every year, leading to waste of petro-based materials and serious environmental pollution. Fabrication of composites from discarded carpets via compression molding could save petroleum resources and alleviate environmental pressure. In this research, the compression molded composites from waste PP/PA carpets or PP/PET carpets showed good mechanical properties, sound absorption and water stability. Compared to the jute/PP composites, nylon 6,6 (PA66)/PP carpet composites had 37% and 9% higher flexural strength and impact resistance, as well as 45% and 10% higher sound absorption and water stability, indicating their potential for transportation and construction industries.

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Fabrication of structural composites from waste carpet

Cited by 30 publications

References 4 publications

Influence of Processing Parameters and Composition on the Effective Compatibilization of Polypropylene–Poly(ethylene terephthalate) Blends

Influence of Processing Parameters and Composition on the Effective Compatibilization of Polypropylene–Poly(ethylene terephthalate) Blends

The Use of Recycled Carpet in Low-Cost Composite Tooling Materials

Acoustical and mechanical properties of thermoplastic composites from discarded carpets

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