Polyester Tufted Carpet Tile Structure for Full Recyclability
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Solution Overview
Problem
The majority of tufted floorcoverings, such as carpets, end up in landfills due to their complex composition, making recycling difficult and contributing to landfill space and cost issues, while existing single polymer carpet constructions face performance and cost challenges.
Innovation Solution
A 100% polyester tufted carpet construction with a specific layer configuration, including solution-dyed face yarn, polyester primary and secondary backing layers, and a hot melt adhesive with high recycled content, designed to be fully recyclable without separation, using processes like depolymerization and melt processing to regenerate polyester materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-layer carpet construction with various materials is used, then performance requirements (delamination resistance, tuft bind, dimensional stability) are met, but recyclability deteriorates due to incompatible materials
Solution Approach 1:
The patent applies homogeneity by using polyester as the common polymer base for all carpet layers including face yarn, primary backing, adhesive, and secondary backing. This uniform material composition enables the entire carpet construction to be recyclable through depolymerization processes while maintaining the diverse functional requirements of each layer.
2Ease of manufacture
If single polymer construction is used, then recyclability is improved, but performance and cost challenges arise
Solution Approach 1:
The patent applies segmentation by dividing the carpet into distinct functional layers (face yarn, primary backing, adhesive layer, secondary backing) all made from polyester. This allows each layer to be optimized for its specific function while maintaining compatibility for recycling, as each layer can be processed separately or together through depolymerization.
Solution Approach 2:
The patent uses composite materials by combining different polyester forms (staple fiber, continuous filament, nonwoven, woven) within a single polymer family. This creates a multi-functional carpet construction that meets performance requirements for delamination resistance, tuft bind, and dimensional stability while remaining compatible for recycling through polyester depolymerization processes.
3Ease of manufacture
If landfill disposal is used, then disposal cost is reduced for manufacturers, but environmental impact and landfill space costs increase
Solution Approach 1:
The patent applies discarding and recovering by designing the carpet for complete recovery through depolymerization. The polyester-based construction allows all layers to be broken down into monomers or oligomers that can be repolymerized into new polyester products, eliminating landfill disposal and creating a circular economy model for carpet materials.
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 solution achieves commercial performance standards with enhanced recyclability, reducing landfill disposal and environmental impact, while maintaining performance metrics like delamination resistance, tuft bind, and dimensional stability, and allows for the production of high-quality recycled polyester products.
Implementation Method 1
a polyester hot melt adhesive
Implementation Method 2
using processes like depolymerization and melt processing to regenerate polyester materials
Implementation Method 3
using processes like depolymerization and melt processing to regenerate polyester materials
Data Source
AI summary
This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.