Carpet backing layer composition
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Solution Overview
Problem
Conventional carpet backing layers face issues with dimensional stability due to atmospheric fluctuations and are negatively affected by the addition of fillers, which influence flexibility and processing performance, leading to adhesion problems and degradation during high-temperature processing.
Innovation Solution
A carpet backing layer composition comprising between 10% to 50% semi-crystalline polyolefin and up to 90% inorganic filler with a volume median particle diameter of 10 μm or more, along with processing additives like waxes and tackifiers, to achieve a heat of fusion within specific temperature ranges, ensuring dimensional stability and improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fillers are added to carpet backing layers, then cost is reduced and fire resistance is improved, but flexibility deteriorates and adhesion problems occur
Solution Approach 1:
The patent changes the particle size parameter of fillers to D50≥10μm and controls the filler content at ≤90% by weight, which resolves the contradiction between fire resistance and flexibility by selecting optimal parameter ranges that satisfy both requirements
Solution Approach 2:
The patent creates a composite material system combining polyolefin resin with specific fillers (calcium carbonate, magnesium hydroxide, talc, etc.) in controlled proportions, achieving both fire resistance and flexibility through proper material composition
2Quantity of substance
If high filler content is used, then cost is reduced, but processing performance deteriorates and degradation occurs during high-temperature processing
Solution Approach 1:
The patent specifies D50≥10μm for filler particles and limits filler content to ≤90% by weight, which prevents processing degradation while maintaining high filler content for cost reduction
Solution Approach 2:
The patent uses inexpensive inorganic fillers like calcium carbonate and magnesium hydroxide that provide fire resistance and cost benefits without compromising processing when used within the specified parameter ranges
3Ease of operation
If conventional polyolefin compositions are used, then adhesion is achieved, but dimensional stability deteriorates under atmospheric fluctuations
Solution Approach 1:
The patent creates a composite formulation combining polyolefin resin with specific fillers (calcium carbonate, magnesium hydroxide, talc, silica) in controlled proportions, achieving both adhesion and dimensional stability through synergistic material composition
Solution Approach 2:
The patent controls filler particle size (D50≥10μm) and content (≤90% by weight) to prevent dimensional instability while maintaining adhesion properties
4Shape
If filler particle size is reduced, then surface finish is improved, but processing difficulty increases and local overheating occurs
Solution Approach 1:
The patent optimizes filler particle size to D50≥10μm, which balances surface finish quality with processing ease by preventing local overheating and degradation while maintaining acceptable surface appearance
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 solution provides a carpet backing layer with enhanced dimensional stability, preventing curling under varying temperature and humidity conditions, while maintaining processing ease and adhesion properties.
Implementation Method 1
a carpet backing layer comprising a semi-crystalline polyolefin or a blend of semi-crystalline polyolefins
Implementation Method 2
the heat of fusion within the temperature range of from 10 to 40° C. (ΔH10→40° C.) is less than 12.5%, preferably less than 10%, more preferably less than 5% of the heat of fusion within the temperature range of from 10 to 170° C. (ΔH10→170° C.)
Data Source
AI summary
The present invention relates to a carpet backing layer composition, comprising: —100 parts by weight of a polyolefins or a blend of polyolefins and optionally a blend of oils, wax and tackifiers, said polyolefin or polyolefin blend comprising at least 0% by weight of (co)polymerized C3-C8 alfa-olefins—between 100 and 900 parts by weight of one or more inorganic filler(s) characterized by a volume median particle diameter (D50) comprised between 10 and 1000 μm; —the backing layer composition having a heat of fusion within the temperature range of from 10 to 40° C. (ΔH10→40° C.) that is less than 12.5% of the heat of fusion of the backing layer within the temperature range of from 10 to 170° C. (ΔH10→170° C.), the heat of fusion being measured by Differential Scanning calorimetry. The invention further relates to a carpet comprising a carpet backing layer obtained from the carpet backing layer composition and a method for the preparation of the carpet.