Modular Carpet Tile Backing for Moisture-Stable Installation
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Solution Overview
Problem
Conventional modular carpet systems are not able to withstand adverse installation conditions such as standing water, alkaline conditions, and high humidity, leading to loosening, buckling, shrinking, and warping.
Innovation Solution
A modular carpet system comprising dimensionally stable carpet tiles with a backing made of at least 50% amorphous polymer, such as polyvinyl butyral, and an adhesive that resists substantial loss of adhesion, including silicone-based or polyurethane-based adhesives, to maintain stability and adhesion even in adverse conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional modular carpet systems are used in adverse installation conditions, then installation flexibility is improved, but dimensional stability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the backing material by using at least 50% amorphous polymer content (such as polyvinyl butyral) instead of conventional crystalline polymers. This parameter change enables the carpet tile to resist deformation and warping in adverse conditions while maintaining installation flexibility.
Solution Approach 2:
The patent uses composite material construction with multiple layers including a face layer, a backing layer with at least 50% amorphous polymer, and optionally a primary backing layer. This composite structure provides both dimensional stability in adverse conditions and flexibility for installation.
2Ease of manufacture
If conventional adhesive is used in adverse installation conditions, then initial adhesion is achieved, but adhesion strength deteriorates over time
Solution Approach 1:
The patent changes the chemical parameters of the adhesive by selecting silicone-based or polyurethane-based adhesives with specific properties that resist degradation in adverse conditions. These adhesives maintain at least 50% of initial adhesion strength after exposure to moisture, heat, and alkaline conditions, providing long-term reliability.
3Adaptability or versatility
If carpet tiles are installed on surfaces with high moisture vapor emission, then installation versatility is improved, but carpet tile stability deteriorates
Solution Approach 1:
The patent changes the moisture resistance parameters of the backing material by using at least 50% amorphous polymer content, which inherently resists moisture vapor transmission. This enables installation on surfaces with MVER of at least 4 lb/24 hr/1000 sq. ft. while maintaining carpet tile stability and preventing warping.
4Adaptability or versatility
If carpet tiles are exposed to high alkaline conditions, then installation environment compatibility is improved, but material integrity deteriorates
Solution Approach 1:
The patent changes the chemical resistance parameters of the backing material by selecting amorphous polymers (such as polyvinyl butyral) that are inherently resistant to alkaline degradation. This maintains material integrity in environments with surface moisture pH of at least 8, preventing loosening and disintegration.
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 system remains dimensionally stable and maintains adhesion in environments with high moisture vapor emission rates, relative humidity, and alkaline conditions, preventing unwanted shifting or failure of the carpet tiles.
Implementation Method 1
the backing may comprise a polymer or polymeric material that is at least 50% amorphous, for example, polyvinyl butyral (PVB)
Implementation Method 2
an adhesive for securing the carpet tiles in a desired position (e.g., in a side-by-side relationship with other carpet tiles) on an installation surface
Data Source
AI summary
A modular carpet system includes a carpet tile and an adhesive. The carpet tile is operative for resisting deformation, even under adverse conditions. In some embodiments, the adhesive may comprise a silicone-based adhesive or a urethane-based adhesive.