Carpet tiles and systems and methods of making same
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Solution Overview
Problem
Existing carpet tiles are stiff due to heavy backings, difficult to cut, and costly to produce, with current manufacturing methods requiring multiple applications of backing adhesive and limited by narrow-width backing equipment.
Innovation Solution
A carpet tile design featuring a greige good with a primary backing component and fibers, an adhesive layer with an adhesive composition and a reinforcement material partially embedded within it, and a secondary backing material co-laminated with the reinforcement material onto the adhesive composition, allowing for easier production and reduced costs.
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 the carpet tiles become stiff and difficult to cut
Solution Approach 1:
The patent employs a composite backing structure consisting of a lightweight foam backing material combined with a discrete reinforcement material (such as scrim or mesh) embedded within an adhesive layer. This composite approach provides dimensional stability through the reinforcement material while the foam backing maintains flexibility and ease of cutting, resolving the contradiction between stability and ease of operation.
Solution Approach 2:
The reinforcement material is strategically placed only where needed for dimensional stability - embedded within the adhesive layer at the backing interface - rather than using heavy backing throughout the entire carpet tile. This localized reinforcement provides stability where required while keeping the overall structure lightweight and easy to cut.
2Strength
If multiple applications of backing adhesive are required, then bonding strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the reinforcement material and multiple adhesive applications into a single integrated adhesive layer. The reinforcement material is embedded within this unified layer, allowing the adhesive to be applied in one continuous operation rather than requiring separate applications, thus maintaining bonding strength while simplifying the manufacturing process.
Solution Approach 2:
The adhesive layer is formulated as a composite material containing both adhesive composition and reinforcement material in a single layer structure. This composite adhesive layer provides the bonding strength of multiple adhesive applications while being applied as a single layer, reducing manufacturing complexity.
3Stability of the object's composition
If reinforcement material is fully embedded within adhesive layers, then dimensional stability is improved, but adhesive material consumption increases
Solution Approach 1:
The patent employs partial embedding of the reinforcement material within the adhesive layer, where the reinforcement material extends beyond the adhesive layer boundaries. This partial embedding approach provides sufficient dimensional stability through the embedded portion while reducing adhesive material consumption compared to complete embedding, as adhesive is only applied where needed for bonding.
4Adaptability or versatility
If narrow-width backing equipment is used, then manufacturing flexibility is maintained, but productivity is reduced
Solution Approach 1:
The patent changes the physical parameters of the adhesive layer by creating a thinner, more concentrated adhesive structure with reinforcement material embedded within it. This allows the adhesive layer to be applied more efficiently on backing equipment, potentially enabling wider width application and faster production speeds while maintaining the flexibility to adapt to different manufacturing configurations.
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 new carpet tile construction is easier to produce, reduces material costs, and allows for more competitive pricing while maintaining stability and durability, as the reinforcement material enhances dimensional stability and the adhesive layer ensures strong bonding between layers.
Implementation Method 1
The reinforcement material has 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
The secondary backing material is adhered to the primary backing component by contact with the second surface of the adhesive layer
Data Source
Figure 1
Figure 2
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 secondarv 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.