Polyester transport carpet and method for manufacturing a polyester transport carpet
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Solution Overview
Problem
Current flame-retardant carpets for aircraft interiors face challenges with insufficient load resistance, dimensional stability, and weight, as well as complex recycling due to the use of intermediate layers that bond with fabric threads, leading to increased weight and hindered recyclability.
Innovation Solution
A flame-retardant carpet design featuring mechanically or mechanically woven fabric with partially fused warp threads on the backside, laminated with a lightweight needle felt using 100% flame-retardant thermoplastic polyester, eliminating the need for heavy intermediate layers and allowing for easier recycling, and utilizing a PES adhesive for further improved recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a lightweight smooth fabric is used as the top layer, then the weight per unit area is reduced, but the load resistance and dimensional stability become insufficient
Solution Approach 1:
The fabric is pre-reinforced by fusing warp threads together before the carpet assembly process. This preliminary strengthening action allows the lightweight smooth fabric to achieve sufficient load resistance without adding weight through a heavier fabric construction.
Solution Approach 2:
The invention creates a composite structure where the smooth fabric is combined with a fused thread reinforcement layer. The fabric provides lightweight properties while the fused threads provide structural strength, achieving both low weight and high load resistance through material composition.
2Stability of the object's composition
If a polyacrylate-based adhesive intermediate layer is applied to laminate the fabric to needle-punched felt, then the dimensional stability improves, but the weight per unit area increases and recyclability deteriorates
Solution Approach 1:
The invention removes the polyacrylate-based adhesive intermediate layer entirely, replacing it with a direct thermal bond between the fabric and needle-punched felt. This extraction eliminates the harmful adhesive while maintaining the laminated structure through alternative bonding mechanisms.
Solution Approach 2:
The mechanical/chemical bonding system using polyacrylate adhesive is replaced with a thermal bonding system where heat melts the polyester threads to create bonds. This substitution eliminates the adhesive layer while achieving the same dimensional stability function.
3Strength
If a polyacrylate-based adhesive intermediate layer is used to bond fabric and needle-punched felt, then the layers are laminated together, but the separation and recycling of threads become difficult
Solution Approach 1:
The polyacrylate adhesive intermediate layer is completely removed from the carpet structure. This extraction eliminates the substance that prevents separation, allowing the fabric and needle-punched felt to be easily separated for recycling while maintaining bonding strength through thermal fusion.
Solution Approach 2:
The invention enables the discarding of the adhesive intermediate layer to facilitate recovery and recycling of the fabric and needle-punched felt threads. By eliminating the bonding adhesive, the components can be separated and recovered independently for reuse.
4Stability of the object's composition
If the adhesive partially mixes with warp and weft threads to hold them together, then the fabric structure is stabilized, but the intermediate layer weight increases and recycling complexity increases
Solution Approach 1:
The chemical mixing of adhesive with threads is replaced by thermal fusion of the threads themselves. The polyester threads are heated to melt and fuse together, providing structural stability without requiring adhesive penetration and mixing, thereby simplifying the structure for recycling.
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 provides enhanced load resistance, dimensional stability, reduced weight per unit area, and simplified recycling, while meeting stringent standards for flame retardancy and toxicity, thus offering a lightweight, durable, and easily recyclable carpet solution for aircraft interiors.
Implementation Method 1
leading the back face of the fabric along a heated surface to at least partially melt a portion of the warp yarns
Implementation Method 2
the back face of the fabric along a heated surface to at least partially melt a portion of the warp yarns
Implementation Method 3
utilizing a PES adhesive for further improved recyclability
Data Source
Figure 1~3
AI summary
The present invention relates to a flame-retardant carpet which is suitable for the interior of transport means, preferably aircraft, comprising a carpet woven by machine or mechanically, comprising warp and weft threads, a needled felt, an intermediate layer between the needled felt and the fabric woven by machine or mechanically, wherein some of the warp threads on the rear face of the fabric woven by machine or mechanically are at least partially fused together. The invention also relates to a method for manufacturing a flame-retardant carpet which is suitable for the interior of transport means, in particular aircraft.