Primary base fabric for tufted carpet, and method of manufacturing same
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Solution Overview
Problem
Laminating non-woven fabrics with different colored fibers often results in inconsistent adhesion, leading to delamination and separation during the tufting process, which compromises their ability to support pile yarns effectively.
Innovation Solution
A primary base fabric for tufted carpets is created by laminating a first non-woven web with carbon-containing thermoplastic resin fibers and a second non-woven web with a lower or no carbon content thermoplastic resin fibers, using emboss processing to unify them, ensuring strong bonding and distinct color differentiation between the front and back sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two non-woven fabrics with different colored fibers are laminated using adhesive, then color differentiation between front and back sides is achieved, but adhesion consistency deteriorates leading to delamination
Solution Approach 1:
A hot-melt adhesive layer is introduced as an intermediary between the first and second non-woven fabrics. This adhesive mediator provides consistent bonding across the entire lamination interface, ensuring uniform adhesion regardless of the different fiber compositions and colors of the two fabrics, thereby preventing delamination during tufting operations.
Solution Approach 2:
The bonding mechanism is changed from chemical adhesive bonding to thermal bonding through embossing. By controlling temperature, pressure, and embossing pattern parameters, the thermoplastic resin fibers are melted and fused at the interface, creating a reliable bond that maintains adhesion consistency while allowing color differentiation between front and back sides.
2Ease of manufacture
If adhesive is used to laminate non-woven fabrics, then lamination is achieved, but adhesion property uniformity deteriorates
Solution Approach 1:
The hot-melt adhesive serves as a uniform intermediary layer that distributes bonding forces evenly across the entire contact surface between the two non-woven fabrics. This intermediary layer compensates for variations in fiber composition and surface properties, ensuring uniform adhesion properties throughout the laminate structure.
Solution Approach 2:
The adhesive bonding system is replaced with a thermal-mechanical bonding system using embossing. The embossing process applies controlled heat and pressure to melt thermoplastic resin fibers at the interface, creating a mechanically interlocked bond that ensures uniform adhesion properties across the entire lamination area.
3Ease of manufacture
If non-woven fabrics are laminated with adhesive, then lamination is achieved, but structural unity deteriorates during tufting
Solution Approach 1:
The hot-melt adhesive layer acts as a structural intermediary that integrates the first and second non-woven fabrics into a unified composite structure. This adhesive intermediary distributes mechanical stresses uniformly during tufting operations, preventing delamination and maintaining the structural integrity and unity of the entire base fabric assembly.
Solution Approach 2:
The invention creates a multi-layer composite material structure consisting of the first non-woven fabric, hot-melt adhesive layer, and second non-woven fabric. This composite structure combines the advantages of different fiber compositions and colors while ensuring structural unity through the bonding action of the adhesive intermediary, enabling the composite to function as a unified support during tufting.
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 method achieves satisfactory lamination and unification of non-woven webs with different carbon contents, preventing delamination and ensuring the primary base fabric provides effective support for pile yarns with enhanced peel strength, maintaining color differentiation and flexibility.
Implementation Method 1
the constituent fibers are mutually bonded through the melting and the solidification of the low-melting point resin in emboss portions in emboss processing
Implementation Method 2
the primary base fabric is a product prepared by unifying the first non-woven web and the second non-woven web through an emboss processing
Data Source
Figure 1~2
AI summary
A primary base fabric 10 for a tufted carpet includes a first non-woven web 11 and a second non-woven web 12 laminated on each other. The first non-woven web 11 is constituted with a first constituent fiber 13 formed with a first thermoplastic resin and containing carbon. The second non-woven web 12 is constituted with a second constituent fiber 15 formed with a second thermoplastic resin and having a carbon content lower than the carbon content of the first constituent fiber 13 or containing no carbon. The primary base fabric 10 is a product prepared by combining the first non-woven web 11 and the second non-woven web 12 through an emboss processing.