Universal Floor Covering Backing for Dimensional Stability
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Solution Overview
Problem
Existing textile floor coverings, such as broadloom and modular carpets, face issues with stability, particularly in the machine direction, due to inherent instability of tufted yarns and shrinkage of primary backing substrates, and the complexity and cost of multiple backing layers and preformed reinforcement layers, making it difficult to recycle and manufacture dimensionally stable products.
Innovation Solution
A manufacturing method that includes a tufted textile substrate with a primary backing substrate and a wet-laid continuous overlapping reinforcement layer of fibers aligned parallel to the machine direction, using a controlled application of adhesive and reinforcement fibers to provide dimensional stability, simplify manufacturing processes, and allow for recycling by separating adhesive from reinforcement fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple backing layers and preformed reinforcement layers are used to improve dimensional stability, then stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the reinforcement layer and backing layer into a single integrated wet-laid nonwoven structure. The reinforcement fibers are embedded within the adhesive matrix during the wet-laid forming process, creating a unified composite material that provides both structural support and dimensional stability without requiring separate backing layers.
Solution Approach 2:
The invention uses a composite material consisting of reinforcement fibers embedded in an adhesive matrix to create a wet-laid nonwoven backing. This composite structure integrates the functions of multiple traditional layers into a single material system that provides dimensional stability while simplifying the overall construction.
2Stability of the object's composition
If multiple backing layers and disparate materials are used to improve dimensional stability, then stability is improved, but ease of manufacture and recyclability worsen
Solution Approach 1:
The patent employs a homogeneous material composition where reinforcement fibers and adhesive form a unified wet-laid nonwoven structure. This homogeneity allows the entire backing layer to be processed and recycled as a single material system, eliminating the need to separate multiple disparate layers and materials.
Solution Approach 2:
The integrated wet-laid nonwoven structure enables easier recovery and recycling of materials. The uniform composition allows for more efficient material separation and recovery processes compared to multi-layer constructions with disparate materials, facilitating sustainable manufacturing practices.
3Stability of the object's composition
If traditional multi-layer construction is used to improve dimensional stability, then stability is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the reinforcement and backing functions into a single wet-laid nonwoven layer, eliminating the need for multiple separate layers and the associated manufacturing steps. This consolidation reduces material costs, processing time, and manufacturing complexity while maintaining dimensional stability.
Solution Approach 2:
The use of a composite wet-laid nonwoven material provides dimensional stability in a cost-effective manner. By integrating reinforcement fibers within the adhesive matrix during a single manufacturing process, the invention avoids the costs associated with producing and assembling multiple separate layers.
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 method results in a dimensionally stable floor covering that reduces manufacturing costs, simplifies installation, and enables recycling, while eliminating the need for pre-formed reinforcement layers and traditional installation methods, providing enhanced stability and flexibility for both broadloom and modular products.
Implementation Method 1
forming a wet-laid continuous overlapping reinforcement layer of fibers that is substantially parallel to the machine direction
Implementation Method 2
using a controlled application of adhesive and reinforcement fibers to provide dimensional stability
Data Source
AI summary
A dimensionally stable universal floor covering includes a tufted textile having stitches and a reinforcement layer operatively connected to the stitches to provide dimensional stability for the entire floor covering. The reinforcement layer is made of fibers that are initially contained within a composition of adhesive and fibers. Mixing of the adhesive/fibers composition and/or injection of compressed air, assists in preparing the adhesive and fiber composition to be in the preferred condition and position prior to the forming of the reinforcement layer. Multiple sources of pressure, including vacuum, are applied in a controlled manner for moving the adhesive and fiber composition to form a reinforcement layer of fibers that is operatively connected to the stitches and/or to form a layer of fibers and adhesive that is contained within the stitches. The universal floor covering is selectively cut and transported in a roll for installation, and it can be conveniently recycled if necessary.