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 and require adhesive layers, necessitating a need for a composite without delamination and without an adhesive layer.
Innovation Solution
A composite comprising a woven, non-woven, or knitted face fabric with protruding fibers interlocked with a non-woven backing material, bonded through heat-induced melting of specific polymers with different melting points to eliminate the need for adhesive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive layers are used to bond face fabric to backing material, then bonding strength is improved, but product complexity and potential delamination increase
Solution Approach 1:
The patent removes the adhesive layer from the composite structure entirely. Instead of using adhesive to bond the face fabric to the backing material, it employs a mechanical interlocking system where protruding fibers from the face fabric engage with loops formed in the backing material, creating an adhesive-free bonded composite.
Solution Approach 2:
The patent introduces protruding fibers as an intermediary mechanical element between the face fabric and backing material. These fibers act as a mediator that physically interlocks with the backing material structure, providing bonding strength without requiring chemical adhesives.
2Ease of manufacture
If adhesive layers are used to bond fabrics, then initial bonding is achieved, but long-term reliability decreases due to delamination
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical bonding mechanism (fiber interlocking). The protruding fibers physically engage with loops in the backing material through mechanical interlocking, providing both ease of manufacture and long-term reliability without delamination.
Solution Approach 2:
The patent creates a composite structure where the bonding mechanism is distributed throughout the material interface rather than concentrated in a separate adhesive layer. The protruding fibers and backing material loops form an integrated composite system that resists delamination through mechanical interlocking.
3Ease of manufacture
If adhesive layers are applied to bond fabrics, then bonding process is simplified, but manufacturing precision decreases due to adhesive uniformity issues
Solution Approach 1:
By removing the adhesive layer entirely, the patent eliminates all issues related to adhesive application uniformity, distribution, and consistency. The bonding process relies on the inherent mechanical interlocking capability of the fiber structures, which are controlled during fabric formation rather than requiring precise adhesive application.
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 achieves enhanced physical properties like wear resistance and edge fraying, suitable for secondary processes such as molding and texturing, while eliminating delamination.
Implementation Method 1
applying heat to at least partially melt or soften 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.