Carpet end molding

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Solution Overview

Problem

Existing carpet treads for stairs often loosen from the stair surface due to weak bonding between different materials, leading to compromised stability and appearance, and increased maintenance needs.

Innovation Solution

A method of forming a molded tread by sandwiching a molding agent between two materials and curing it to create a predefined geometric shape that conforms to the stair edge, ensuring a uniform and secure attachment without exposing the molding agent to the stair surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If carpet treads are mounted using adhesive or non-slip backing to each stair, then the carpet can cover the stair surface, but the treads may loosen from the stair compromising stability and appearance

Engineering Contradiction:

Improvestability of carpet tread attachmentVSAvoidbonding strength between materials

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines multiple materials (carpet, adhesive layer, rigid reinforcement material) into a single integrated tread structure. The rigid material is embedded within the carpet layers, creating a unified component that maintains its shape and bonding strength, preventing the carpet from loosening while preserving stability and appearance.

Inventive Principle:

Principle #5Merging (Combining)

2Shape

If a molding agent is applied to form geometric shapes at carpet ends, then the carpet can conform to surface geometry, but the molding agent may be exposed to the stair surface creating an uneven appearance

Engineering Contradiction:

Improvegeometric configuration of carpet endVSAvoiduniformity of material surface

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The molding agent is nested or sandwiched between layers of carpet material. The carpet layers are positioned over the molding agent, encapsulating it within the structure. This allows the molding agent to form the desired geometric shape at the carpet end while remaining hidden from view, maintaining a uniform and clean appearance.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 enhances the adherence of carpet treads to stair surfaces, reducing the risk of loosening and improving both appearance and safety by maintaining a consistent, uniform material surface, thus preventing slips and falls.

Implementation Method 1

persistently maintaining the predefined geometric shape by curing the molding agent

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS20210362384A1Carpet end molding

Publication Date: 2021.11.25 OAK VALLEY DESIGNS INC

AI summary

In one embodiment, a method of forming a product used in covering an edge, comprising: providing a molding agent between a first surface of a first material and a second surface of a second material; forming, at one end portion corresponding to each of the first material and the second material and the molding agent, a predefined geometric shape that is different than an opposing end of each of the first material and the second material; and persistently maintaining the predefined geometric shape by curing the molding agent.