Microwave curing of uncured latex carpet

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for curing precoated carpet tiles using natural gas direct fired ovens are inefficient and non-renewable, with heating processes that are not always uniform, leading to increased production time and energy costs.

Innovation Solution

The use of microwave curing technology to replace traditional ovens, allowing for rapid and uniform curing of the precoating composition applied to the primary backing layer, which is then integrated with a thermoplastic backing layer to form a bonded floor covering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If natural gas direct fired ovens are used for curing precoated carpet, then the curing process can be performed continuously, but the energy consumption is high and the heating uniformity is poor

Engineering Contradiction:

Improveenergy consumptionVSAvoidheating uniformity

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The patent replaces the conventional thermal convection heating system (mechanical/thermal system) with microwave heating technology. The microwave curing apparatus uses electromagnetic radiation to directly heat the precoating material, eliminating the need for hot air circulation and significantly improving both energy efficiency and heating uniformity. The microwave energy penetrates the material and causes molecular vibration, generating heat uniformly throughout the precoating layer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental heating parameter from thermal convection (hot air temperature) to electromagnetic radiation (microwave frequency and power). By controlling microwave power levels and exposure time, the system achieves precise and uniform curing of the precoating material, resolving the heating uniformity issue while reducing overall energy consumption.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If natural gas direct fired ovens are used for curing precoated carpet, then the curing process can be completed, but the production time is increased

Engineering Contradiction:

Improveproduction timeVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The microwave heating system replaces the slow thermal convection process with rapid electromagnetic heating. Microwaves directly energize the water molecules and other polar substances in the precoating material, causing rapid heating and curing in a fraction of the time required by conventional ovens, thereby increasing production speed while reducing energy consumption.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The microwave curing process uses periodic electromagnetic waves at specific frequencies (typically 2.45 GHz) to efficiently transfer energy to the precoating material. This periodic electromagnetic action creates rapid molecular vibration and heating, achieving cure in much shorter time compared to continuous thermal exposure in conventional ovens.

Inventive Principle:

Principle #19Periodic action

3Use of energy by moving object

If natural gas is used for heating in the curing process, then the curing can be achieved, but the energy source is non-renewable and costs increase

Engineering Contradiction:

Improveenergy source sustainabilityVSAvoidproduction cost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent substitutes the combustion-based thermal system (natural gas) with an electromagnetic field-based system (microwaves). This replacement eliminates dependence on non-renewable fossil fuels and transitions to an electricity-based energy source, which can be generated from renewable sources. The microwave system also operates at higher efficiency, converting electrical energy directly into localized heat within the material, reducing overall energy costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method significantly reduces production time, minimizes energy consumption, and achieves high energy efficiency by using electricity instead of natural gas, while ensuring uniform heating and faster curing times, resulting in a more sustainable and cost-effective carpet tile production process.

Implementation Method 1

microwave curing technology to replace traditional ovens, allowing for rapid and uniform curing of the precoating composition

Methodology Applied

Scientific EffectMicrowave heating: Microwave Radiation

Implementation Method 2

microwave curing the precoating

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Data Source

PatentEP2693918B1Microwave curing of uncured latex carpet

Publication Date: 2019.08.21 INTERFACE AUST

Figure 1
Figure 2
Figure 3

AI summary

There is disclosed a floor covering comprising a primary backing having a fibrous face and an underside; and a microwave cured precoat layer on the underside of the primary backing. There is also disclosed herein a method of making a floor covering comprising: tufting or implanting a fibrous material or yarn into a primary backing; precoating the underside of the primary backing layer by applying a precoating composition followed by microwave curing the precoating. An apparatus for curing a precoated primary backing layer.also described.