Functionalized carpet and method for making the carpet
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Solution Overview
Problem
Standard needle punched carpets fail to meet specific needs in temporary event settings due to limitations in customization and environmental conditioning, particularly in large areas where they cannot effectively characterize the environment or address specific requirements such as odor control and insect repellence.
Innovation Solution
A functionalized carpet with a polymer-based upper layer of needle punched fibers and a resin-based lower reinforcing layer, incorporating microcapsules that release fragranced, antibacterial, or heat-adjusting substances upon use, and optionally a rubbery base for improved adhesion and liquid barrier, allowing for customization and environmental modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard needle punched carpets are used for temporary events, then production cost is reduced and manufacturing is simplified, but the ability to customize and condition the environment is insufficient
Solution Approach 1:
The microcapsules containing functional substances (fragrances, antibacterial agents, heat-adjusting compounds) are incorporated into the carpet during the manufacturing process, specifically within the gaps formed by the needle punching of carded fibres. This preliminary incorporation allows the carpet to be produced in advance with embedded functionality, ready to release substances when deployed at events without requiring additional customization steps.
Solution Approach 2:
The invention changes the chemical and functional parameters of the carpet by incorporating microencapsulated substances that can modify ambient conditions. The microcapsules contain substances that can change fragrance levels, antibacterial properties, and heat adjustment capabilities, transforming a standard carpet into a multi-functional environmental conditioning system.
2Adaptability or versatility
If microcapsules are incorporated into the needle punched fibres, then environmental conditioning capability is improved, but the structural complexity increases
Solution Approach 1:
The needle punching process creates a mat of carded fibres with inherent gaps and porosity between the fibres. The invention utilizes this existing porous structure to house the microcapsules, eliminating the need for separate compartments or complex structural modifications. The microcapsules are simply positioned within the naturally occurring gaps in the fibre mat.
Solution Approach 2:
The microcapsules are nested within the structure of the needle punched carpet, specifically positioned in the gaps between fibres. This nesting approach integrates the functional elements within the existing carpet structure rather than adding external components, thereby minimizing increases in overall structural complexity.
3Area of stationary object
If the carpet is designed for large surface areas, then coverage for events is improved, but the ability to characterize the environment specifically is reduced
Solution Approach 1:
The carpet is designed with multi-functional microcapsules that can provide various environmental conditioning effects (fragrance, antibacterial protection, heat adjustment) across large surface areas. This universal design allows a single carpet product to serve multiple event types and environmental needs, maintaining adaptability even at large scales.
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 carpet effectively conditions the environment by releasing substances as needed, enhancing appearance and functionality in temporary event settings while maintaining substance efficacy until use, allowing for pre-production and efficient deployment.
Implementation Method 1
The predetermined substance contained in the microcapsules is chosen from fragranced volatile substances, antibacterial volatile substances, heat adjusting substances and odour-absorbing volatile substances
Implementation Method 2
a process for mutual penetration by the vertical movement of a plurality of needles. The penetration action gives the mat of non-woven fibres a certain consistency
Implementation Method 3
the lower reinforcement layer is designed to guarantee a gripping surface for the adhesive means for anchoring the carpet to the flooring to be covered
Implementation Method 4
the base of rubbery material guarantees an excellent adhesion to the flooring
Implementation Method 5
the above-mentioned base made of rubbery material constitutes an impermeable barrier to the penetration of liquids
Data Source
AI summary
Described is a functionalized carpet for covering floorings, comprising an upper layer of needle punched fibres of the polymeric type in which there are gaps between the fibres and a lower reinforcing layer configured for retaining the fibres of the upper layer.