Carpet Tile Multi-Layer Design for Wet Subfloor Moisture Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing carpet tiles face issues with curling, doming, mold, and mildew formation, especially on wet subfloors, which can create trip hazards and health risks.

Innovation Solution

A multi-layer carpet tile design featuring a tufted primary backing, an extruded polymer secondary backing, and a polyester cushion with a reinforcing scrim layer, which provides dimensional stability and moisture wicking properties to prevent curling and mold/mildew.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If carpet tiles are installed on wet subfloors, then installation speed is improved, but mold and mildew development occurs

Engineering Contradiction:

Improveinstallation speedVSAvoidmold and mildew development

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of moisture by incorporating hydrophilic materials (rayon, wool, cotton) that actively wick moisture away from the subfloor through capillary action. The moisture that would normally cause mold is instead channeled through designated pathways to evaporation zones at the seams, transforming the harmful moisture into a controlled drainage system that prevents mold growth while allowing rapid installation on wet subfloors

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The carpet tile incorporates porous and hydrophilic materials including rayon face yarns, wool or cotton secondary backings, and open-loop pile structures that allow moisture to pass through. These porous materials enable moisture vapor transmission and wicking, allowing the carpet to breathe and dry the subfloor rather than trapping moisture, thus preventing mold while maintaining installation speed

Inventive Principle:

Principle #31Porous materials

2Stability of the object's composition

If adhesive is used to secure carpet tiles to subfloor, then tile stability is improved, but moisture trapped under carpet worsens

Engineering Contradiction:

Improvetile stabilityVSAvoidmoisture trapping

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent applies adhesive only at specific locations (corners and center) rather than covering the entire back of the tile, creating localized bonding zones. This allows moisture to escape through the unbonded peripheral areas and maintains airflow channels at the edges, preventing moisture trapping while still providing adequate tile stability through strategic adhesive placement

Inventive Principle:

Principle #3Local quality

3Strength

If carpet layers are tightly bonded, then structural integrity is improved, but moisture vapor transmission is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidmoisture vapor transmission reduction

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent uses porous, hydrophilic materials throughout the carpet structure including rayon face yarns, open-loop pile constructions, and breathable secondary backings made of wool or cotton. These materials maintain structural integrity through their fibrous network while simultaneously providing capillary channels and open spaces that allow moisture vapor to transmit through the carpet layers, preventing moisture accumulation despite tight bonding

Inventive Principle:

Principle #31Porous materials

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 design ensures flatness, prevents curling and doming, and reduces mold and mildew growth on wet subfloors, enhancing safety and durability.

Implementation Method 1

the polyester cushion having a reinforcing scrim layer embedded within a polyester layer

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

the coated primary backing has an extruded polymer secondary backing secured thereto, and the extruded polymer secondary backing has a polyester cushion bound thereto

Methodology Applied

Scientific EffectDimensional stability:

Data Source

PatentEP3862482B1Carpet tiles for wet subfloors and methods of making the same

Publication Date: 2025.08.13 ALADDIN MANUFACTURING CORP

Figure 1
Figure 2
Figure 3

AI summary

A carpet tile and process for making the same, wherein the carpet tile comprises a facecloth having a plurality of face yarns tufted through a primary backing, an extruded polymer secondary backing layer, and a polyester cushion, comprising a reinforcing scrim layer within a polyester layer. The top surface and bottom surface of the carpet tile are defined by the facecloth and the polyester cushion, respectively. A polymer-based resin is extruded onto the facecloth to form an at least substantially uniform secondary backing layer, and the polyester cushion is laid onto the extruded polymer secondary backing layer while the extruded polymer secondary backing layer remains above a softening temperature for the resin. The entire multi-layer web is then passed through a nip to embed the reinforcing scrim layer into the extruded polymer secondary layer, and the entire web is chilled.