Polyester carpet tile or carpet strip and method for manufacturing a polyester carpet tile or carpet strip

The patent removes the foam base layer and thermoplastic stabilising material from the carpet tile structure, retaining only the primary carpet base with pile yarns. This extraction eliminates the heavy components while preserving the essential carpet functionality, thereby reducing weight without compromising fire resistance since the pile yarns themselves provide adequate fire performance for the application.

The invention applies local quality by concentrating the structural integrity and fire resistance properties in the primary carpet base and pile yarns themselves, rather than relying on additional heavy layers. The primary carpet base is designed with sufficient density and material properties to provide both mechanical stability and fire resistance locally, eliminating the need for separate heavy reinforcement layers.

The patent changes the bonding parameter from chemical (PVC adhesive) or partial fusion to complete thermal fusion at elevated temperatures. This parameter change transforms the bonding mechanism, creating a homogeneous molten structure that solidifies into a fray-resistant edge, eliminating the problems associated with adhesive residues or incomplete bonding while maintaining ease of manufacture through a single-step thermal process.

The invention creates a composite structure where the pile yarns, primary carpet base, and molten material fuse into a unified composite mass at the cutting edge. This composite formation integrates all components into a single homogeneous structure that resists fraying, combining the structural benefits of the primary carpet base with the binding properties of the thermoplastic pile yarns and molten material.

The patent extracts and eliminates the foam base layer and thermoplastic stabilising material layers that complicate recycling. By removing these heterogeneous layers, the carpet tile becomes composed primarily of recyclable textile materials (primary carpet base and pile yarns) that can be more easily processed and reused, thereby improving recyclability while maintaining sufficient structural stability through the strengthened primary carpet base.

The invention applies homogeneity by using primarily textile materials (primary carpet base and pile yarns) with similar thermal and chemical properties throughout the carpet tile structure. This material homogeneity facilitates uniform processing during recycling, allowing the entire carpet tile to be treated as a single recyclable commodity rather than requiring separation of dissimilar layers, thereby improving ease of recycling.

The patent extracts and removes the heavy foam base layer and thermoplastic stabilising material that contribute to excessive weight. The resulting lightweight carpet tile, composed mainly of the primary carpet base and pile yarns, significantly reduces the load on raised floors while maintaining adequate fire resistance through the inherent fire performance of the textile materials and optimized structure.

The invention applies local quality by concentrating fire resistance properties in the primary carpet base and pile yarns where they are most needed for safety, rather than distributing weight through heavy foam and thermoplastic layers throughout the entire carpet tile structure. This localized approach to fire safety eliminates unnecessary weight while maintaining fire protection at the critical user interface level.

The patent extracts and removes the heavy foam base layer and thermoplastic stabilising material that make carpet tiles difficult to handle. The resulting lightweight carpet tile, consisting primarily of the primary carpet base and pile yarns, significantly improves ergonomics for installers during carrying and installation while maintaining sufficient structural integrity through the strengthened primary carpet base design.

The invention applies local quality by concentrating structural integrity in the primary carpet base where it is most needed for maintaining carpet tile shape and stability during handling, rather than distributing weight through heavy layers throughout the entire structure. This localized reinforcement provides adequate strength for structural integrity while minimizing overall weight for installer comfort.