David A Murdock

US Patent:

7923477, Apr 12, 2011

Filed:

Aug 29, 2007

Appl. No.:

11/846865

Inventors:

David E. Murdock - Dublin OH, US
Douglas Mancosh - Warwick RI, US
James P. Przybylinski - St. Helena CA, US

Assignee:

Material Innovations LLC - Providence RI

International Classification:

C08J 11/04

US Classification:

521 405, 521 47, 521 48, 521 498

Abstract:

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.

US Patent:

8278365, Oct 2, 2012

Filed:

Mar 22, 2011

Appl. No.:

13/053837

Inventors:

David E. Murdock - Dublin OH, US
Douglas Mancosh - Warwick RI, US
James P. Przybylinski - St. Helena CA, US

Assignee:

Material Innovations LLC - Providence RI

International Classification:

C08J 11/04

US Classification:

521 405, 521 48, 521 498

Abstract:

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.

US Patent:

20030214067, Nov 20, 2003

Filed:

Apr 29, 2003

Appl. No.:

10/257234

Inventors:

David Murdock - Dublin OH, US
Dale Snead - Yardley PA, US
Darrell Dardenne - St Agustine FL, US
Ian Mills - Westerly RI, US

International Classification:

B29C047/76

US Classification:

264/102000, 264/349000, 425/208000, 425/209000, 425/377000, 425/812000

Abstract:

The invention is extrusion equipment and a process. The extrusion equipment links two extruders () together. The first extruder () is, desirably, a counter-rotating twin screw extruder. The first extruder () receives organic filler, preferably wood particles or fiber, having a variable moisture content. Moisture is withdrawn from the extruder barrel. A polymer is fed from a second extruder () into the barrel of the first extruder () after the polymer is heated, mixed, and melted in the second extruder (). The second extruder () can be a single screw or twin screw extruder. The combined mixture of organic filler and polymer is further mixed alone or with optional additives. The mixture is vacuum vented to remove moisture and volatiles and then extruded through a die. Additional processing steps are optional depending upon the extruded product or profile being produced.

US Patent:

20130102707, Apr 25, 2013

Filed:

Aug 29, 2012

Appl. No.:

13/597481

Inventors:

David E. Murdock - Dublin OH, US
Douglas Mancosh - Warwick RI, US
James P. Przybylinski - St. Helena CA, US

International Classification:

C08L 97/02
B02C 19/18

US Classification:

524 14, 241 23

Abstract:

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.

US Patent:

20140251545, Sep 11, 2014

Filed:

Mar 10, 2014

Appl. No.:

14/202824

Inventors:

Blake Burich - Dublin OH, US
David Murdock - Dublin OH, US

International Classification:

B29B 17/02

US Classification:

156701, 264138

Abstract:

A process and method for recycling carpet is disclosed. The process and method involves the liberation and separation of desirable carpet face fibers from the carpet backing materials. The present invention eliminates face fiber shearing. In the present process, the secondary layer of the carpet backing is removed either manually or mechanically. Then, the bottom of the primary backing layer of the carpet with the bottom of the face fiber “U's” exposed, is mechanically grip-abraded by a rubber material. The grip-abrasion of the rubber or rubber-like material across the bottom of the primary carpet backing layer loosens the glue and grips and pulls the face fiber from the primary backing without destructing primary or secondary backing. The liberation and separation of face fibers from the backing materials using this method produces the highest yield of usable materials compared to any other method. It not only separates the entire face fiber for recycling, but it also allows the backing material to be recycled since it is not contaminated with face fibers.