Laminated Film Carpet Backing for Tuft Bind and Fluid Barrier
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Solution Overview
Problem
Conventional carpet manufacturing methods face challenges with high tuft bind strength, fluid barrier properties, and recyclability, while also being cost-effective, due to limitations in hot melt adhesive penetration and the use of significant natural gas in traditional wet coating processes.
Innovation Solution
A carpet composition comprising a greige good with a primary backing, hot melt adhesive layer encapsulating back stitches, and a laminated film providing fluid barrier properties, which enhances tuft bind strength and recyclability while reducing costs by eliminating the need for oven heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hot melt adhesive is used alone, then cost is reduced and footprint is minimized, but tuft bind strength is insufficient and fluid barrier properties are lacking
Solution Approach 1:
The patent combines hot melt adhesive with a laminated film to create a composite backing structure. The hot melt adhesive layer provides cost-effectiveness and ease of manufacture, while the laminated film layer contributes fluid barrier properties and enhanced tuft bind strength. This composite approach allows the system to achieve multiple performance targets simultaneously without sacrificing manufacturing efficiency.
2Strength
If conventional wet coating process is used, then tuft bind strength is achieved, but significant natural gas is consumed for oven heating
Solution Approach 1:
The patent extracts and eliminates the oven heating step from the conventional wet coating process. By using hot melt adhesive that is applied in a molten state and then cooled to set, the process removes the need for energy-intensive oven drying while maintaining adequate tuft bind strength through the adhesive's inherent bonding properties.
Solution Approach 2:
The patent changes the temperature parameter profile of the coating process. Instead of applying adhesive at room temperature and then heating in an oven, the process applies adhesive at elevated temperature (molten state) and allows it to cool and set naturally. This parameter inversion eliminates the need for continuous heating while achieving proper adhesive bonding.
3Ease of operation
If conventional carpet construction is used, then basic carpet functionality is achieved, but recyclability is limited
Solution Approach 1:
The patent segments the carpet backing into distinct functional layers: a hot melt adhesive layer and a laminated film layer. This segmentation allows each layer to be optimized for its specific function while also enabling easier separation and recycling. The laminated film can be designed as a recyclable barrier layer that can be detached or processed separately from the adhesive and primary backing 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 solution achieves improved tuft bind strength, enhanced fluid barrier properties, and increased recyclability of carpets, while reducing production costs and environmental impact through the use of a hot melt adhesive and laminated film combination.
Implementation Method 1
an adhesive layer comprising a hot melt adhesive composition applied to the back surface of the primary backing material, wherein the adhesive composition is configured to substantially encapsulate at least a portion of the back stitches
Implementation Method 2
a laminated film having fluid barrier properties
Data Source
AI summary
This disclosure relates to a carpet having fluid barrier properties. The disclosed carpet comprises: (a) a greige good comprising: i) a primary backing material having a face surface and a back surface; ii) a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of back stitches; b) an adhesive layer comprising a hot melt adhesive composition applied to the back surface of the primary backing material, wherein the adhesive composition is configured to substantially encapsulate at least a portion of the back stitches; and c) a laminated film having fluid barrier properties. Also disclosed are methods for making the carpet described herein.