In this work, feasibility of recycling post-consumer carpets using a modified vacuum assistedresisted molding process into large-scale components was successfully demonstrated. The scaleup also included the incorporation of nano-clay films in the carpet composites. It is expected thatthe films will enhance the ability of the composite to withstand environmental degradation andalso serve as a fire retardant. Low-cost resins were used to fabricate the recycled carpet-basedcomposites. The scale up in terms of process was achieved by manufacturing composites withouta hot press and thereby saving additional equipment cost. Mechanical and physical propertieswere evaluated. Large-scale samples demonstrated mechanical properties that were differentfrom results from small samples. Acoustic tests indicate good sound absorption of the carpetcomposite. Cost analysis of the composite material based on the cost of the raw materials and themanufacturing process will be presented.
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