Polyester tufted carpet with polyester extrusion coating
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Solution Overview
Problem
Polyester tufted carpets used in the automotive industry rely on latex coatings, which complicate recycling and increase costs, as they are difficult to recycle and generate volatile organic compounds.
Innovation Solution
A method of manufacturing polyester tufted carpets where polyester yarn is tufted into a primary backing, and a polyester extrusion coating is applied to the backside to form a secondary backing layer, eliminating the need for latex adhesives and allowing for a fully recyclable polyester composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If latex coating is used to adhere yarn to backing, then adhesion strength is improved, but recyclability deteriorates and volatile organic compounds are generated
Solution Approach 1:
The patent removes the latex coating component from the carpet construction by using a tufting method where yarn is mechanically interlocked with the backing through barbed wires or similar anchoring structures, eliminating the source of volatile organic compounds while maintaining adhesion through mechanical rather than chemical bonding
Solution Approach 2:
The patent replaces the chemical adhesion mechanism (latex coating) with a mechanical anchoring system (barbed wires, interlocking structures) that physically secures the yarn to the backing, thereby eliminating harmful chemical emissions while maintaining strong attachment
2Strength
If latex coating is used to adhere yarn to backing, then adhesion strength is improved, but recyclability deteriorates
Solution Approach 1:
The patent extracts the latex coating from the carpet system and replaces it with a mechanical anchoring mechanism using barbed wires or interlocking structures, allowing the carpet to be disassembled and recycled into its component materials without the contamination of synthetic latex adhesives
Solution Approach 2:
The patent enables the recovery and recycling of carpet components by eliminating the latex coating that would otherwise contaminate and complicate the recycling process, allowing yarn and backing materials to be separated and reused more efficiently
3Strength
If latex coating is used, then adhesion is achieved, but manufacturing cost increases
Solution Approach 1:
The patent employs simple, inexpensive mechanical anchoring elements such as barbed wires or basic interlocking structures that can be manufactured at low cost and integrated directly into the tufting process, replacing expensive latex coating materials and application processes
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 enables cost reduction and improved recyclability of polyester tufted carpets, meeting OEM requirements while avoiding the use of latex coatings and associated volatile organic compounds, resulting in a more efficient recycling process.
Implementation Method 1
extruding polyester and forming a polyester extrudate and applying the polyester extrudate to the second side of said primary backing wherein the polyester extrudate provides a secondary backing layer that engages the polyester yarn
Data Source
AI summary
The present invention relates polyester tufted carpet where the tufts are engaged with a primary polyester backing and where a polyester extrusion coating is applied to the backside of the primary backing to lock the tufts which therefore avoids the use of a latex adhesive.