Carpet and carpet backing
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Solution Overview
Problem
Existing carpet backing systems face challenges in achieving adequate tuft bind strength, abrasion resistance, and flexibility while maintaining recyclability, with conventional latex and polyolefin-based systems having limitations such as high costs, slow production rates, and difficulties in penetration and adhesion at elevated temperatures.
Innovation Solution
The use of olefin block copolymers, particularly ethylene-based block interpolymers, as adhesive and secondary backing materials, which provide improved penetration, tuft bind strength, and abrasion resistance through extrusion coating techniques, allowing for high production rates and recyclability without segregation of carpet components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional latex or polyolefin-based backing systems are used, then adequate tuft bind strength and abrasion resistance can be achieved, but production rates are slow and costs are high
Solution Approach 1:
The patent modifies the chemical composition parameters of the backing material by using specific polyolefin polymers with controlled molecular weight, density, and comonomer content. These parameter changes enable the material to achieve adequate adhesion and tuft bind strength while allowing for faster production rates compared to conventional latex systems.
Solution Approach 2:
The invention creates a composite backing system combining polyolefin polymer with inorganic fillers (such as calcium carbonate, aluminum trihydrate, or silica) and optional organic modifiers. This composite approach maintains the flexibility and adhesion properties needed for high production rates while reducing costs and improving performance.
2Ease of manufacture
If polyolefin-based backing materials are used to reduce cost and improve recyclability, then flexibility and ease of manufacture improve, but penetration and adhesion at elevated temperatures deteriorate
Solution Approach 1:
The patent carefully selects polyolefin polymers with specific parameters including melt index (1-50 g/10min), density (0.91-0.96 g/cm³), and comonomer content (5-30 mol%). These parameter changes ensure the material maintains adequate melting point and adhesion properties at elevated temperatures while preserving flexibility and recyclability.
Solution Approach 2:
By incorporating inorganic fillers and optional organic modifiers into the polyolefin matrix, the invention creates a composite material that enhances thermal stability and adhesion performance at elevated temperatures while maintaining the base polyolefin's flexibility and recyclability advantages.
3Strength
If existing polymer systems are used to bind carpet fibers, then adequate binding strength can be achieved, but growth at elevated temperatures increases
Solution Approach 1:
The patent selects polyolefin polymers with specific molecular weight distributions, melting points, and crystallinity parameters that minimize thermal expansion and growth at elevated temperatures. The controlled comonomer content and molecular architecture ensure dimensional stability while maintaining adequate binding strength.
Solution Approach 2:
The incorporation of inorganic fillers with low thermal expansion coefficients into the polyolefin matrix creates a composite backing that resists growth and dimensional changes at elevated temperatures, while the polyolefin binder maintains adequate binding strength.
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 olefin block copolymer-based system enhances tuft bind strength, abrasion resistance, and flexibility, enabling efficient carpet production with improved recyclability and hygienic properties, while maintaining performance comparable to or exceeding incumbent latex and polyurethane systems.
Implementation Method 1
an adhesive backing material... wherein at least one of the plurality of fibers, the primary backing material, the optional precoat layer, the adhesive backing material
Implementation Method 2
at least one non-chlorinated, non-polyvinyl butyral thermoplastic polymer... having a growth tension at 40 C of less than about 25 psi
Data Source
AI summary
The present invention pertains to carpet and carpet tile. In one aspect, the carpet includes (a) a primary backing which has a face and a back surface, (b) a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed at the back surface of the primary backing, (c) an adhesive backing, (d) an optional secondary backing adjacent to the adhesive backing, and (e) at least one non-chlorinated, non-polyvinyl butyral thermoplastic polymer or composition having a specific growth tension at 40 C and a specific residual stress at 25% strain. Additional steps and procedures include washing or scouring the primary backing and fibers prior to the extrusion step, and utilizing implosion agents. The preferred olefin block copolymer are ethylene based block interpolymers. The constructions and methods described herein are particularly suited for making tufted, broad-loom carpet having improved abrasion resistance.