Polyolefin Carpet Coating for Fray-Resistant Woven Backing
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Solution Overview
Problem
Conventional latex coating compounds, such as carboxylated SB and acrylate-based systems, exhibit incompatibility with polyolefin fibers, leading to weak associations and increased fraying issues in woven carpets, particularly with apolar polyolefin substrates, resulting in carpet fraying and the need for additional edge protection methods like serging.
Innovation Solution
Aqueous polyolefin dispersion-based coating compounds are developed, comprising a polyolefin-based polymer, a stabilizing agent, and a wetting agent, without fillers, to enhance yarn coverage and adhesion, thereby improving fray resistance and eliminating the need for serging by forming a transparent, non-hazy film that allows strike-through and enhances carpet brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carboxylated SB and acrylate-based latex coating compounds are used, then adhesive bonding is provided, but incompatibility with polyolefin fibers occurs leading to weak associations and increased fraying
Solution Approach 1:
The patent changes the chemical composition parameters of the coating compound by using polyolefin-based dispersible master batches instead of conventional latex, and by controlling filler content within specific ranges (0-600 phr) to achieve compatibility with polyolefin fibers while maintaining adhesive bonding strength and fray resistance
Solution Approach 2:
The patent creates a composite coating system combining polyolefin-based polymer with fillers (such as calcium carbonate, talc, or silica) in specific proportions to achieve both adhesion to polyolefin fibers and structural integrity for fray resistance, resolving the contradiction between bonding strength and fray resistance
2Reliability
If yarn coverage is increased to protect against fraying, then fray resistance improves, but manufacturing complexity and additional processes (serging) are required
Solution Approach 1:
The patent extracts the need for additional serging processes by incorporating sufficient filler content (0-600 phr) directly into the coating compound formulation, allowing the coating alone to provide both adhesion and fray protection, thereby simplifying the manufacturing process
Solution Approach 2:
The coating compound is designed to perform multiple functions simultaneously: providing adhesive bonding, achieving yarn coverage for fray resistance, and enabling transparent non-hazy film formation, eliminating the need for separate serging operations
3Strength
If conventional latex coating compounds are applied, then adhesive bonding is achieved, but transparent non-hazy film formation is compromised due to the Tyndall effect
Solution Approach 1:
The patent changes the base polymer from conventional latex to polyolefin-based dispersible master batches and carefully controls filler particle size and distribution (0-600 phr) to minimize light scattering and eliminate the Tyndall effect, achieving both adhesion and optical clarity
Solution Approach 2:
The patent optimizes the local properties of the coating by selecting specific filler types and sizes that provide adhesion while minimizing light scattering in the visible spectrum, creating regions of the coating that simultaneously bond to fibers and maintain optical transparency
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 non-fraying woven carpets with improved adhesive and cohesive bonding, resistance to water and stains, and allows for easier recycling, while eliminating the need for serging and reducing the Tyndall effect, resulting in a more durable and aesthetically enhanced product.
Implementation Method 1
The coating compound may be applied as a single coating or layer or as a multiple layered system... The carpet typically passes through an oven that dries the latex on the carpet
Implementation Method 2
an aqueous dispersion including (A) at least one base polymer selected from the group consisting of an ethylene-based co-polymer and a propylene based co-polymer; (B) at least one polymeric stabilizing agent
Implementation Method 3
a wetting agent, wherein the base polymer comprises a polyolefin-based polymer
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A method of preparing a woven carpet comprising applying a coating compound as an adhesive layer to the woven carpet to form a coated woven carpet, wherein the coating compound comprises an aqueous dispersion comprising a base polymer, a stabilizing agent, and a liquid medium, wherein the base polymer comprises a polyolefin-based polymer; and a wetting agent. A woven carpet comprising a woven substrate; and an adhesive layer comprising a dehydration product of a coating compound comprising an aqueous dispersion comprising a base polymer, a stabilizing agent, and a liquid medium, wherein the base polymer comprises a polyolefin-based polymer; and a wetting agent.