Aircraft Carpet Tile Composition for Lightweight Floor Coverage

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Solution Overview

Problem

Current carpet tiles used in mass transit vehicles, particularly passenger aircraft, are heavy and lack the necessary dimensional stability and flexibility to efficiently cover complex floor configurations, requiring multiple tile sizes and complicating installation and replacement processes, while also failing to meet weight reduction and flame, smoke, and toxicity standards.

Innovation Solution

The development of low-weight carpet tiles with a carpet pile embedded in a primary backing layer, utilizing hollow glass microspheres as fillers, and optionally additional backing layers, allowing for customizable tile sizes and orientations to fit various aircraft configurations without the need for extensive cutting or removal of seats, and meeting industry standards for flame, smoke, and toxicity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional carpet tiles are used in mass transit vehicles, then flame, smoke and toxicity standards are met, but weight is excessive

Engineering Contradiction:

Improveflame, smoke and toxicity standardsVSAvoidcarpet tile weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of stationary object

Solution Approach 1:

The patent employs composite materials by combining a woven polyester scrim with a latex adhesive matrix containing hollow glass microspheres. This composite structure achieves both flame resistance (meeting FAR 25.853 standards) and reduced weight (up to 50% lighter than conventional tiles) through the synergistic properties of the material components.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The use of hollow glass microspheres creates a porous, cellular structure within the latex adhesive matrix. This porous material provides insulation properties that contribute to flame resistance while the hollow spheres significantly reduce the overall density and weight of the carpet tile backing.

Inventive Principle:

Principle #31Porous materials

2Manufacturing precision

If multiple tile sizes are used to fit aircraft floor configurations, then coverage accuracy is improved, but device complexity and installation difficulty increase

Engineering Contradiction:

Improvefloor coverage accuracyVSAvoidnumber of different tile sizes

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent produces carpet tiles with non-standard dimensions (e.g., 18x36 inches, 24x48 inches) that can universally cover various floor configurations between aircraft seats. These multi-functional tiles can be arranged in different patterns and orientations to accommodate diverse seating layouts, eliminating the need for multiple specialized tile sizes while maintaining precise floor coverage.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent segments the carpet backing into modular tiles with standardized non-square dimensions that can be systematically arranged to cover complex floor areas. This segmentation allows flexible combination of a limited number of tile sizes to achieve complete coverage of varying floor configurations without requiring custom-sized tiles for each specific application.

Inventive Principle:

Principle #1Segmentation

3Stability of the object's composition

If conventional carpet tiles are used, then dimensional stability is achieved, but weight reduction and flexibility for complex configurations are compromised

Engineering Contradiction:

Improvedimensional stabilityVSAvoidcarpet tile weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of stationary object

Solution Approach 1:

The woven polyester scrim provides a stable, dimensionally consistent framework that maintains tile integrity during installation and service. When combined with the latex-hollow microsphere composite, this framework delivers both dimensional stability and weight reduction, as the scrim carries the structural load while the lightweight composite filler reduces overall mass.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different material properties to different regions of the carpet tile structure: the woven scrim provides dimensional stability and strength in the backing layer, while the hollow glass microsphere-filled latex provides lightweight cushioning and flame resistance in the infill material. This local differentiation of material qualities achieves both stability and weight reduction simultaneously.

Inventive Principle:

Principle #3Local quality

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

This solution reduces the number of required tile sizes, minimizes waste, simplifies installation and replacement, and provides improved dimensional stability and weight reduction, while ensuring compliance with industry standards for safety and performance in harsh environments.

Implementation Method 1

utilizing hollow glass microspheres as fillers

Methodology Applied

Scientific EffectHollow glass microspheres: Microsphere

Data Source

PatentUS8739381B2Methods of cutting and installing carpet tiles

Publication Date: 2014.06.03 INTERFACE INC

AI summary

Methods of cutting and installing carpet tiles in, among other applications, mass transit vehicles, particularly including aircraft. In some embodiments, the tile lengths in an installation are the same and the tile widths are customized to a particular section of the aircraft or other vehicle in which they are installed.