Carpet Tiles And Systems And Methods Of Making Same
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Solution Overview
Problem
Conventional carpet tiles with heavy backings are difficult to produce and cut, requiring multiple backing adhesive applications and being costly, necessitating a more efficient and cost-effective production method.
Innovation Solution
A carpet tile design featuring a greige good with a primary backing component, an adhesive layer containing a reinforcement material embedded within an adhesive composition, and a secondary backing material, where the reinforcement material has an open structure allowing the adhesive to flow through and embed within the composition, reducing material costs and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If heavy backings are used in carpet tiles, then dimensional stability is improved, but ease of manufacture deteriorates and cutting difficulty increases
Solution Approach 1:
The reinforcement material is made porous to allow adhesive composition to flow through it during lamination, enabling the adhesive to embed within the reinforcement material and create strong bonding without requiring heavy backings or multiple adhesive applications
Solution Approach 2:
The invention uses a composite structure combining reinforcement material with adhesive composition in a single integrated layer, eliminating the need for separate heavy backing layers while maintaining dimensional stability and simplifying the manufacturing process
2Strength
If multiple backing adhesive applications are used, then bonding strength is improved, but device complexity and production cost increase
Solution Approach 1:
The invention merges the reinforcement material and adhesive composition into a single integrated adhesive layer, allowing both reinforcement and bonding functions to be achieved in one step rather than requiring multiple separate adhesive applications
Solution Approach 2:
The porous reinforcement material allows adhesive to flow through and embed within it, creating strong mechanical interlocking and chemical bonding in a single lamination process, eliminating the need for multiple adhesive applications
3Stability of the object's composition
If heavy backings are used, then dimensional stability is improved, but productivity deteriorates due to cutting difficulty
Solution Approach 1:
The porous reinforcement material allows adhesive composition to flow through during lamination, creating strong bonding that provides dimensional stability without the need for heavy backings that are difficult to cut
Solution Approach 2:
The composite adhesive layer combining reinforcement and adhesive provides sufficient dimensional stability in a lighter construction that is easier to handle and cut, improving productivity
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 enables carpet tiles to be produced more easily and at a lower cost, with improved dimensional stability and reduced material usage, allowing for competitive pricing and efficient manufacturing on standard equipment.
Implementation Method 1
The reinforcement material can have an open structure that permits flow of the adhesive composition through the reinforcement material from the first side of the reinforcement material to the second side of the reinforcement material
Implementation Method 2
cooling the adhesive composition to define an adhesive layer in which the reinforcement material is at least partially embedded within the adhesive composition
Implementation Method 3
The secondary backing material can be adhered to the primary backing component by contact with the adhesive composition of the adhesive layer
Data Source
AI summary
A carpet tile having a greige good, an adhesive layer, and a secondary backing material. The greige good has a primary backing component and a plurality of fibers attached to the primary backing component. The adhesive layer has an adhesive composition and a reinforcement material that is at least partially embedded within the adhesive composition. The adhesive layer is applied to a back surface of the primary backing component. The secondary backing material is adhered to the primary backing component by contact with a portion of the adhesive composition that flows through the reinforcement material. The reinforcement material and the secondary backing material are co-laminated onto the adhesive composition.