Polyurethane Foam Fiber Web for Recycled Carpet Underlayment
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Solution Overview
Problem
Existing methods for recycling post-consumer carpet fibers into new products are inefficient due to fiber damage, contamination, and the inability to produce large surface area carpet underlayment products with satisfactory tear strength, compression sets, and load-bearing capabilities.
Innovation Solution
A process involving the formation of a web layer with post-consumer fibers, integrated with a polyurethane foam formulation that cures rapidly, allowing for the production of a foamed polyurethane floor covering product with uniform properties, suitable for various cushioning applications, including underlayment and attached carpet products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-consumer carpet fibers are recovered and reused in underlayment products, then environmental sustainability is improved, but the fibers are heavily damaged and contaminated making them unsuitable for new carpet facings
Solution Approach 1:
The patent changes the application parameters by shifting the use of recovered fibers from carpet facing (high performance requirement) to underlayment cushion (lower performance requirement), where the fibers' cushioning properties are utilized rather than their aesthetic or structural properties. This parameter change allows the use of damaged and contaminated fibers that would be unsuitable for carpet facings.
Solution Approach 2:
The patent creates a composite material by combining recovered carpet fibers with polyurethane foam and binder materials to form an integrated underlayment cushion product. The composite structure allows the recovered fibers to contribute to cushioning properties while the foam and binder provide structural integrity, compensating for the fibers' damaged state.
2Strength
If traditional molding processes are used to produce polyurethane foam products with fibers, then fiber reinforcement is achieved, but the process cannot produce large surface area carpet underlayment products with satisfactory tear strength and compression sets
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: (1) forming a web of recovered fibers, (2) applying polyurethane foam formulation to the fiber web, and (3) curing to create the final product. This segmentation allows for continuous production of large surface area underlayment products while maintaining fiber reinforcement and mechanical properties through the integrated foam-fiber structure.
Solution Approach 2:
The patent merges the fiber web formation process with the polyurethane foam application and curing process to create an integrated manufacturing system. The foam and fibers are combined in a single continuous process, allowing the foam to impregnate and bind the fibers throughout the product thickness, achieving both large surface area production and satisfactory tear strength.
3Productivity
If rapid curing polyurethane foam formulation is used, then production efficiency is improved, but process control becomes more challenging
Solution Approach 1:
The patent applies preliminary action by pre-cooling the polyol component before mixing with the polyisocyanate. This pre-cooling delays the onset of the exothermic curing reaction, providing a longer working time for foam application and gauge adjustment. The controlled temperature management allows rapid curing to occur after application, maintaining production efficiency while improving process control.
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 process enables the production of cost-effective, high-quality polyurethane foam products with minimal roll set, suitable for large-scale industrial use, achieving desired performance criteria such as tear strength, low compression sets, and retention of cushioning performance under foot traffic.
Implementation Method 1
reacting together to form a foamed polyurethane floor covering product
Implementation Method 2
The polyurethane foam formulation includes water, which reacts with the polyisocyanate to simultaneously generate a blowing gas (carbon dioxide)
Implementation Method 3
The wetted web layer is then heated to a temperature of from 80 to 160°C to cure the polyurethane foam formulation
Data Source
AI summary
Polyurethane floor covering products are formed from a web layer containing at least 30% by weight fibers. A cooled polyurethane foam formulation which includes at least one polyisocyanate, water and at least one polyol having an equivalent weight of at least 500 is applied to the web layer. The wetted web layer is then compressed to mechanically wet out the fibers, gauged and heated to cure the foam formulation.