Method and Apparatus for Purifying and Recycling Synthetic Turf

• US 20140265011A1
• Filed: 04/10/2014
• Published: 09/18/2014
• Est. Priority Date: 12/15/2008
• Status: Active Grant

• Current Assignee: APT Advanced Polymer Technology Corp.
• Original Assignee: Textile Management Associates Incorporated
• Inventors: Mashburn, Larry E., Brown, David A. Jr., Gentry, Timothy J. Sr.
• Granted Patent: US 10,086,415 B2
• Time in Patent Office: Days
• US Class Current: 264/176.1
• CPC Class Codes: B09B 3/00 Destroying solid waste or transforming solid waste into something useful or harmless
• CPC Class Codes: B29B 17/02 Separating plastics from other materials
• CPC Class Codes: B29B 17/0206 Selectively separating reinforcements from matrix material by destroying the interface bound before disintegrating the matrix to particles or powder, e.g. from tires or belts
• CPC Class Codes: B29B 2017/0217 Mechanical separating techniques; devices therefor
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/732 Floor coverings piles carpets B29L2031/7652; for vehicles B29L2031/3017
• CPC Class Codes: C08J 11/06 without chemical reactions
• CPC Class Codes: E01C 13/08 Surfaces simulating grass ; Grass-grown sports grounds grass-like surfaces for skiing E01C13/12
• CPC Class Codes: Y02W 30/62 Plastics recycling; Rubber recycling

Abstract

A method and apparatus for purifying and recycling synthetic turf are provided. The method includes removing a section of used synthetic turf, feeding the section to a rotating beater to knock sand infill loose, and passing the section through a rotating brush roll wherein a turf filament surface is directly contacted by the rotating brush roll to knock any entrained infill material loose from the section of used synthetic turf.

Claims

1. A method for purifying used synthetic turf in preparation for further recycling, wherein the used synthetic turf comprises infill including sand, the method comprising the steps of:

removing a section of used synthetic turf from an installation site, the section of used synthetic turf including residual infill including sand;

feeding the section of used synthetic turf adjacent to a rotating beater roll wherein a backing surface of the section of synthetic turf is directly contacted by the rotating beater roll to knock compacted sections of sand infill loose within the section of used synthetic turf; and

passing the section of used synthetic turf adjacent to a rotating brush roll wherein a turf filament surface is directly contacted by the rotating brush roll to knock any entrained infill material loose from the section of used synthetic turf.

2. The method of claim 1 further comprising the steps of:

channeling infill material knocked loose from the section of used synthetic turf to a first repository; and

sorting the separate components of the channeled infill.

3. The method of claim 2 further comprising the step of cutting the section of used synthetic turf into subsections of used synthetic turf, wherein the subsections of used synthetic turf further include residual infill.

4. The method of claim 3 further comprising the steps of;

channeling residual infill knocked loose from the section of used synthetic turf during the cutting step to a second repository; and

sorting the separate components of the channeled residual infill.

5. The method of claim 4 further comprising the step of grinding the subsections of used synthetic turf into used synthetic turf fibers, wherein the synthetic turf fibers further include residual infill and wherein the longest length dimension of the synthetic turf fibers is no greater than about 0.25 inches.

6. The method of claim 5 further comprising the step of sorting the separate components of the ground synthetic fibers, thereby providing sorted ground synthetic fibers.

7. The method of claim 7 further comprising the step of heating the sorted ground synthetic fibers whereby thermoplastic material included within the sorted ground synthetic fibers becomes melted, thereby densifying thermoplastic materials present within the sorted ground synthetic fibers to provide densified synthetic fibers.

8. The method of claim 7 wherein the step of heating the sorted ground synthetic fibers further comprises the step of heating the sorted ground synthetic fibers at a temperature ranging from about 250°

C. to about 350°

C. for a duration of from about 0.75 minutes to about 1.5 minutes.

9. The method of claim 7 further comprising the step of extruding the densified synthetic fibers to form a pelletized extrudate.

10. An apparatus for purifying used synthetic turf in preparation for further recycling, wherein the used synthetic turf comprises infill including sand, the apparatus comprising:

a frame;

at least one rotatable beater roll connected to the frame;

at least one rotatable brush roll connected to the frame;

a first motor connected to the beater roll for rotatably driving the beater roll;

a second motor connected to the brush roll for rotatably driving the brush roll;

a plurality of guide rolls connected to the frame for guiding a section of used synthetic turf adjacent the beater roll and the brush roll to cause removal of entrained infill;

a drive roll connected to the frame for drawing a section of used synthetic turf across the plurality of guide rolls; and

a third motor connected to the drive roll for rotatably driving the drive roll.

11. The apparatus of claim 10 further comprising:

at least one landing plate connected to the frame for catching infill material removed from used synthetic turf and directing the removed infill material to an infill repository for further sorting; and

a vibrational device connected to the landing plate to cause the landing plate to vibrate, thereby facilitating movement of removed infill material to the infill repository.

12. The apparatus of claim 11 further comprising:

a pressurized fluid container;

a tube connected to the pressurized fluid container and the frame; and

a nozzle connected to an end of the tube, wherein pressurized fluid is blown across used synthetic turf passing through the apparatus in order to facilitate removal of entrained infill.