Polyurethane Floor Covering with Controlled Cure Index
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for installing wall-to-wall carpet, such as tack strips and adhesives, are labor-intensive, expensive, and difficult to remove, and do not accommodate easy replacement or cleaning, while alternative methods like carpet tiles face issues with cupping and doming, leading to costly and damaging removal processes.
Innovation Solution
A floor covering system featuring a layer of polyurethane with a cure index between 70 and 90, applied to the back surface of various materials like carpet, wood, or ceramic tiles, allowing for easy application and removal without adhesives or tack strips, using a method that involves applying an uncured polyurethane layer to the subfloor and allowing it to cure before attaching the floor covering material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional adhesive methods are used to install carpet, then the carpet is securely retained on the floor, but the removal process leaves significant residue requiring large amounts of labor and the floor must be prepared for subsequent installations
Solution Approach 1:
The patent applies parameter changes by using polyurethane with a specific cure index range (70-90) that creates an optimal balance between adhesion strength for carpet retention and ease of removal without residue. This specific parameter range allows the adhesive to be strong enough to secure the carpet during use but weak enough to remove cleanly, resolving the contradiction between reliable retention and easy removal.
2Reliability
If tack strips are used to install wall-to-wall carpet, then the carpet is secured to the floor, but the installation process is labor-intensive and time-consuming
Solution Approach 1:
The patent extracts the problematic tack strip component from the installation system and replaces it with a continuous polyurethane adhesive layer. This eliminates the need for mechanical tack strips and their associated labor-intensive installation processes, while maintaining reliable carpet retention through the chemical adhesion properties of the polyurethane.
Solution Approach 2:
The patent replaces the mechanical tack strip system with a chemical adhesive system based on polyurethane. This substitution transforms the installation process from mechanical fastening requiring specialized tools and multiple workers to a simpler application process that improves productivity while achieving the same retention reliability.
3Stability of the object's composition
If carpet is stretched during installation to prevent wrinkling and buckling, then dimensional stability is improved, but the carpet elongation under tension causes it to require re-stretching over time
Solution Approach 1:
The patent applies preliminary action by allowing the polyurethane adhesive to cure and establish a stable bond between the carpet and floor before the carpet is subjected to use conditions. This pre-established chemical bond prevents the carpet from shifting or wrinkling over time, eliminating the need for re-stretching while maintaining dimensional stability throughout the carpet's service life.
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
Enables easy application and removal of floor coverings without damaging the material or the floor, reduces labor and costs associated with installation and replacement, and allows for versatile use with different types and materials.
Implementation Method 1
a layer of polyurethane on the back surface of the floor covering material, the polyurethane having a cure index of between approximately 70 and 90
Data Source
AI summary
The invention comprises an improved floor covering product. The floor covering product comprises a floor covering material having a face surface and a back surface. On the back surface of the floor covering material is a layer of polyurethane having a cure index of between approximately 70 and 90. A method of using the floor covering product is also disclosed.