A method for manufacturing a carpet product, and a product obtainable using this method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current carpet products made from polyester yarns lack the durability required for high-end commercial use due to low wear resistance and poor filament binding, while nylon-based products are expensive and difficult to recycle.
Innovation Solution
A method involving polyester yarns with a weight of at least 2500 Dtex and a twist level of at least 100 tpm, where the yarns are stitched through a primary backing and the locked ends are melted and solidified to connect to the backing, enhancing durability and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyester yarns are used to manufacture carpet products, then cost is reduced and recyclability is improved, but wear resistance and durability are insufficient for commercial use
Solution Approach 1:
The patent applies parameter changes by specifying polyester yarns with a weight of at least 2500 Dtex and a twist level of at least 100 tpm. These parameter modifications transform standard polyester yarns into high-durability yarns capable of withstanding commercial use conditions while maintaining recyclability and cost-effectiveness.
Solution Approach 2:
The patent utilizes phase transitions by melting the locked ends of the polyester yarns to bond them to the primary backing. This melting and solidification process creates strong adhesive bonds between the yarns and backing material, significantly improving tuft bind strength and overall durability without requiring additional adhesives.
2Reliability
If high twist level is applied to polyester yarns to improve durability, then wear resistance increases, but tuft bind strength decreases
Solution Approach 1:
The patent resolves this contradiction by utilizing the phase transition of polyester from solid to liquid state through melting. The melted locked ends of high-twist yarns are applied to the primary backing, where they solidify to form strong bonds. This process compensates for the reduced tuft bind strength inherent in high-twist yarns, achieving both wear resistance and adequate bond strength.
3Reliability
If nylon yarns are used to achieve superior wear characteristics, then durability is improved, but cost increases and recyclability becomes difficult
Solution Approach 1:
The patent applies parameter changes to polyester yarns (weight ≥2500 Dtex, twist level ≥100 tpm) to achieve wear resistance comparable to nylon. By modifying the physical parameters of polyester rather than switching to nylon, the patent maintains the cost-effectiveness and recyclability advantages of polyester while attaining the desired durability for commercial applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces a carpet product suitable for high-end commercial use, meeting European norm EN 1307:2014 + A3:2019 standards, with improved durability and recyclability, avoiding the drawbacks of nylon and previous polyester-based products.
Implementation Method 1
processing the intermediate product by feeding this product along a body having a heated surface, the back surface being contacted with the said heated surface, to melt at least a part of the polyester of the locked end of the one or more yarns
Implementation Method 2
the back surface being contacted with the said heated surface, to melt at least a part of the polyester
Implementation Method 3
cooling the molten part of the polyester to solidify this molten part of the polyester, thereby connecting the locked end of the one or more yarns to the first sheet
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
The invention pertains to a method for manufacturing carpet product comprising providing a first sheet having a front surface and a back surface, providing one or more polyester yarns having a weight of at least 2500 Dtex and a twist level of at least 100 tpm, forming a pile on the front surface of first sheet by stitching the one or more yarns through the first sheet, the one or more yarns having a free end that forms the said pile and a locked end present at the back surface of the first sheet, thereby forming an intermediate product, processing the intermediate product by feeding this product along a body having a heated surface, the back surface being contacted with the said heated surface, to melt at least a part of the polyester of the locked end of the one or more yarns, and then cooling the molten part of the polyester to solidify this molten part of the polyester, thereby connecting the locked end of the one or more yarns to the first sheet and forming the carpet product. The invention also pertains to a carpet product that is obtainable with a manufacturing method according to the invention.