Composite material and method of manufacture

Abstract

An improved composite material and method of manufacture. The improved composite material being fabricated using carpet fiber, polystyrene and polyolefin.

1 . A process for molding a composite structural object comprising: 
 a. Obtaining ingredients for the composite;    b. Mixing the ingredients;    c. Extruding the ingredients;    d. Injecting the ingredients into a mold;    e. Cooling the ingredients; and    f. Removing the structural object from the mold.    
   
   
       2 . The process of  claim 1  further comprising: drying the ingredients.  
   
   
       3 . The process of  claim 1  wherein the ingredients comprise carpet.  
   
   
       4 . The process of  claim 1  wherein the ingredients comprise carpet, polystyrene and polyolefin.  
   
   
       5 . The process of  claim 4  wherein the ingredients comprise approximately 25% to 60% carpet, approximately 5% to 15% polystyrene and approximately 25% to 70% polyolefin.  
   
   
       6 . The process of  claim 5  wherein the ingredients comprise approximately 40% carpet, approximately 10% polystyrene and approximately 50% polyolefin.  
   
   
       7 . The process of  claim 1  wherein the ingredients are heated to approximately 390° F. to 470° F. during extrusion.  
   
   
       8 . The process of  claim 7  wherein the ingredients are heated to approximately 400° F. during extrusion.  
   
   
       9 . A process for molding a composite structural member comprising: 
 a. Obtaining ingredients comprising approximately 40% carpet, approximately 10% polystyrene and approximately 50%;    b. Shredding the carpet;    c. Pelletizing the carpet;    d. Drying the carpet to a desired moisture content;    e. Mixing the ingredients;    f. Extruding the ingredients at approximately 400° F.;    g. Injecting the ingredients into a mold;    h. Cooling the ingredients; and    i. Removing the structural object from the mold.    
   
   
       10 . A composition comprising: approximately 25% to 60% carpet, approximately 5% to 15% polystyrene and approximately 25% to 70% polyolefin.  
   
   
       11 . The composition of  claim 10  comprising approximately 40% carpet, approximately 10% polystyrene and approximately 50% polyolefin.