High-LRV Carpet Tile Backing for Low-Visibility Edges
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Solution Overview
Problem
Current carpet tiles with high light reflectance values above 30, especially loop pile and fibre bonded substrates, face challenges in maintaining edge visibility due to color contrast and imperfections caused by tufting and cutting processes, leading to suboptimal lighting contribution and energy efficiency in rooms.
Innovation Solution
A carpet manufacturing method involving tufting yarns onto a substrate with a pre-coat and heavy coating layer, using materials like PTT, PBT, and polyolefin-based polymers, with fillers like CaCO3, MgCO3, and ATH, to achieve a light reflectance value above 35, while ensuring dimensional stability and transparency for effective light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If loose laid carpet tiles are used with high LRV values, then light reflectance is improved, but edge visibility becomes problematic due to color contrast and cutting imperfections
Solution Approach 1:
The patent applies color matching between the backing layer and the pile yarn to reduce visual contrast at edges. Specifically, the backing layer is colored to match the pile yarn color, so that when tiles are cut and installed, the edges do not show stark color contrasts that would highlight imperfections. This allows high LRV values to be achieved while maintaining acceptable edge visibility.
Solution Approach 2:
The patent differentiates the properties of different layers of the carpet tile. The backing layer is specifically designed with color matching properties to address the edge visibility issue locally, while the pile yarn maintains high light reflectance properties. This localized quality adjustment resolves the contradiction between overall light reflectance and local edge appearance.
2Ease of operation
If minimal weight is used for carpet tiles, then ease of installation is improved, but structural stability deteriorates
Solution Approach 1:
The patent uses a composite structure combining a textile substrate with a polymer coating layer. The textile substrate provides flexibility and ease of handling for installation, while the polymer coating layer (applied to the backing) adds structural stability and dimensional stability. This composite approach allows the tile to remain lightweight yet structurally sound during and after installation.
3Illumination intensity
If high LRV values are achieved through light-colored materials, then light reflectance is improved, but stain resistance deteriorates
Solution Approach 1:
The patent changes the chemical and physical parameters of the fiber material to achieve both high light reflectance and stain resistance. Specifically, it uses solution-dyed polyester fibers with high LRV values that inherently possess good stain resistance due to the dyeing process and fiber properties. Additionally, the polymer coating on the backing provides a protective barrier that enhances stain resistance without affecting the light-colored appearance.
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 produces carpet tiles with improved light reflectance, reduced edge visibility, and enhanced stain resistance, contributing to better visual ergonomics and energy-efficient lighting plans by maintaining high LRV values and ensuring effective light transmission.
Implementation Method 1
products with higher LRV values help to reflect incoming light, either daylight or artificial, to reinforce its effect
Implementation Method 2
The carpet may for instance be laid on a transparent (for instance glass) floor, or one or more light sources may be applied under the carpet, to shine light through at least part of the carpet
Data Source
AI summary
Besides a method for manufacturing a carpet, the invention further relates to a carpet witha LRV higher than 30. In particular such carpet comprises yarns are made of PP / PA / PET / PTT / PBT, which are either white based or solution dyed based, and tufted on a white or very light woven or web substrate, such as PET and/or PP, pre-coated with a polyolefin such as HYPOD or SBR which is whitened with a filler, such as MgCO3, TiO2, ATH, and/or CaCO3, and which may comprise, in particular in the case of loose laid tiles, a secondary heavy coating consisting of a very light coloured secondary heavy coating such as a specific polyolefin, PVC, PVB, EVA or a (synthetic) bitumen, loaded with a filler pre-selected on lightness and purity as CaCO3 and/or ATH and/or specific salts, e.g. NaC1 or TiO2.