Needle-Punched Polymer Composite Bonding Without Adhesives
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Solution Overview
Problem
Commercially available composites for floor and wall coverings suffer from delamination issues due to the use of adhesive layers, necessitating a need for a composite without delamination and a method to manufacture such a composite.
Innovation Solution
A composite is formed by needle-punching a woven, non-woven, or knitted face fabric with protruding fibers into a non-woven backing material, using polymers with specific melting points, and bonding them together through heat to create a durable interlock without an adhesive layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an adhesive layer is used to laminate the face fabric to the backing material, then the composite can be manufactured, but delamination occurs and reliability deteriorates
Solution Approach 1:
The patent removes the adhesive layer entirely from the composite structure. Instead of using chemical adhesives to bond the face fabric to the backing material, the invention relies on mechanical interlocking through needle punching, where fibers from the face fabric are physically entangled with the backing material, eliminating the source of delamination problems
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical bonding mechanism (needle punching). The needle punch process physically interlocks fibers from the face fabric with the backing material through mechanical entanglement and friction, providing a more reliable bond that resists delamination
2Reliability
If the face fabric is needle punched to interlock fibers with the backing material, then delamination is eliminated, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines multiple functions into the needle punching process itself. The needle punch machine simultaneously performs fiber entanglement, mechanical interlocking, and bonding operations in a single integrated process, eliminating the need for separate adhesive application and drying steps, thereby reducing overall process complexity despite the sophisticated needle punching mechanism
3Strength
If heat is applied to melt polymers for bonding, then strong bonding is achieved, but energy consumption increases
Solution Approach 1:
The patent utilizes the phase transition of polymers from solid to molten state through controlled heating. By applying heat to melt the polymer components in the face fabric and backing material, the materials become viscous and can flow into each other, creating strong intermolecular bonds upon cooling. This phase transition approach provides superior bonding strength compared to mechanical interlocking alone
Solution Approach 2:
The patent changes the thermal parameters of the polymer materials to achieve bonding. By controlling the temperature, pressure, and dwell time during the heating process, the polymer melts at specific temperatures and solidifies upon cooling, creating a strong bond. This parameter-based control allows for energy-efficient processing by heating only to the necessary melting point without excessive energy input
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 composite exhibits enhanced wear resistance and edge fraying properties, suitable for secondary processes like molding and texturing, and eliminates delamination, providing a strong and durable material for flooring and wall applications.
Implementation Method 1
applying heat thereby at least partially melting or softening the first polymer and the third polymer such that they bond together
Implementation Method 2
applying heat thereby at least partially melting or softening the first polymer and the third polymer such that they bond together
Data Source
AI summary
Described is a composite made from a woven fabric, a non-woven fabric, or a knitted face fabric and a non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude into the non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric has a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point. The nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point. The woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.