Method to Manufacture a Recyclable Textile Product and the Said Product
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Solution Overview
Problem
Current methods for manufacturing textile products, such as floor coverings, face challenges in achieving high tuft bind durability and recyclability, particularly when using latex or synthetic polymer adhesives, which often result in products that are not fully recyclable and have issues with moisture resistance and mechanical strength.
Innovation Solution
A method involving a polyester-based system where polyester yarns are stitched through a polyester sheet, with a polyester adhesive having a hydrophilic-lipophilic balance (HLB) value between 7.6 and 10.5, applied as an aqueous dispersion, heated, and then cooled to solidify, ensuring strong bonding without the need for additional fillers or adhesives, and allowing for easy recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If latex or synthetic polymer adhesives are used to bond yarns to the backing, then strong bonding and high tuft bind durability are achieved, but the product becomes non-recyclable and moisture-resistant properties deteriorate
Solution Approach 1:
The patent uses polyester adhesive that is chemically identical to the polyester yarns and backing material, creating a homogeneous composition throughout the carpet. This allows the entire product to be recycled together as a single material type, eliminating the contamination problem caused by dissimilar materials in conventional carpets using latex or synthetic polymer adhesives.
Solution Approach 2:
The patent changes the chemical composition parameter of the adhesive from dissimilar materials (latex, synthetic polymers) to polyester, which matches the yarn and backing material. This parameter change enables both strong bonding performance and full recyclability of the carpet product.
2Strength
If latex adhesive is used to bond yarns to the backing, then strong bonding is achieved, but moisture resistance deteriorates allowing moisture penetration and mildew formation
Solution Approach 1:
By using polyester adhesive that matches the polyester yarns and backing, the patent creates a homogeneous hydrophobic material system that naturally resists moisture penetration, eliminating the moisture absorption problem associated with latex-based adhesives.
3Ease of manufacture
If hot melt adhesives are used for bonding, then ease of manufacture and recyclability are improved, but tuft bind strength deteriorates to levels suitable only for low-end applications
Solution Approach 1:
The patent changes the adhesive material parameter to polyester, which provides superior bonding strength compared to conventional hot melt adhesives, while maintaining the recyclability advantage because the polyester adhesive is chemically identical to the other carpet components.
4Strength
If dissimilar materials are used for yarns, backing, and adhesive, then bonding performance is improved, but recyclability deteriorates due to material contamination
Solution Approach 1:
The patent applies homogeneity by making the adhesive chemically identical to the yarns and backing (all polyester), which enables the entire carpet to be recycled together without material separation or contamination, while still achieving strong bonding performance.
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 method produces a textile product with high tuft bind strength and durability suitable for high-end applications while being easily recyclable, using commonly available equipment and avoiding the use of additional chemicals, thus addressing the limitations of existing technologies.
Implementation Method 1
heating the polyester particles to above a temperature at which the polyester of these particles softens
Implementation Method 2
cooling the polyester of the particles to below a temperature at which this polyester solidifies
Implementation Method 3
removing the aqueous dispersion medium from the said quantity of the aqueous dispersion
Data Source
AI summary
A method to manufacture a (recyclable) polyester textile product is disclosed which includes providing a first polyester sheet, stitching polyester yarns through the first sheet to form a pile on a first surface of the first sheet, the pile extending from this first surface, and to form loops of the yarns at an opposing second surface of the first sheet, applying a first quantity of a dispersion including an aqueous dispersion medium and polyester particles dispersed in the medium, to the second surface of the first sheet, thereafter removing the aqueous dispersion medium from the said quantity of the aqueous dispersion, heating the polyester particles to above a temperature at which the polyester of these particles softens, and subsequently cooling the polyester of the particles to below a temperature at which this polyester solidifies to therewith interconnect the loops and the first sheet with the solidified polyester.