Low weight carpet and carpet tile and methods of manufacture, sizing and installation
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Solution Overview
Problem
Current carpet tiles for mass transit vehicles, particularly passenger aircraft, are heavy, require multiple sizes to cover varying widths, and necessitate the removal of seats and equipment for installation and replacement, while lacking the necessary weight reduction and meeting flame, smoke, and toxicity standards.
Innovation Solution
The development of low-weight carpet tiles with orthogonally ambiguous designs and hollow glass microspheres in the backing layer, allowing for minimal tile sizes and easy installation without seat removal, using adhesives like APAC acrylic or TacTiles connectors, and meeting industry standards for flame, smoke, and toxicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional carpet tiles with heavy backing layers are used, then dimensional stability and strength are improved, but weight increases making them unsuitable for aircraft applications
Solution Approach 1:
The patent uses a composite backing structure combining a woven fabric layer (providing tensile strength and dimensional stability) with a foam layer (providing cushioning and weight reduction). This composite structure achieves the required strength properties while significantly reducing weight compared to conventional solid backing layers.
Solution Approach 2:
The foam layer in the backing structure provides a porous, cellular structure that reduces material density and overall weight while maintaining structural integrity. The porous foam compensates for the reduced mass by providing structural support through its cellular architecture rather than sheer material weight.
2Area of stationary object
If multiple sizes of square carpet tiles are used to cover varying widths between tracks, then complete coverage is achieved, but the number of different tile products increases and installation complexity increases
Solution Approach 1:
The carpet tile is segmented into a modular rectangular format with standardized dimensions that can be systematically arranged to cover various widths. The rectangular shape allows for efficient tiling patterns that adapt to different space requirements without requiring multiple tile size variants.
Solution Approach 2:
A single rectangular carpet tile design serves multiple functions and configurations, replacing the need for multiple specialized tile sizes. The universal rectangular format can be arranged in different patterns and configurations to accommodate varying widths between aircraft tracks, making one tile type versatile for all applications.
3Strength
If broadloom carpet strips are used, then good strength and wear properties are achieved, but removal and replacement requires removing seats and equipment
Solution Approach 1:
The carpet flooring system is segmented into individual removable tile modules rather than continuous broadloom strips. This segmentation allows tiles to be independently removed and replaced without affecting adjacent areas, eliminating the need to remove seats and equipment that would be required to access and replace continuous carpet strips.
Solution Approach 2:
Individual carpet tiles can be extracted and removed from the flooring system independently, allowing for localized replacement of damaged tiles without disturbing the surrounding carpet or requiring removal of overhead equipment and seats. This extraction capability provides easy maintenance access.
4Area of stationary object
If carpet tiles are cut to fit varying widths, then precise coverage is achieved, but time consumption increases and waste is generated
Solution Approach 1:
Carpet tiles are manufactured in advance with precise standardized rectangular dimensions that are pre-configured for optimal coverage. This preliminary sizing eliminates the need for on-site cutting and fitting, allowing installers to simply lay the pre-sized tiles directly onto the floor, significantly reducing installation time and eliminating cutting waste.
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
This solution reduces the number of tile sizes needed, simplifies installation and replacement, achieves weight reduction, and complies with industry standards for mass transit vehicles, enhancing durability and aesthetic appeal while maintaining dimensional stability.
Implementation Method 1
The backing layer may use low weight filler such glass spheres, and preferably hollow glass microspheres.
Data Source
AI summary
Low weight and non-square carpet tile suitable for use in mass transit vehicles, particularly passenger aircraft. The carpet tile preferably weighs less than about 82 ounces per square yard. The carpet tile of this invention may have a carpet pile and at least one backing layer. The backing layer may use low weight filler material. Secondary backing plastic material may be compressed into the tile structure with pressure rollers or other pressure applying process on an improved tile production line. The carpet tiles satisfy transportation industry standards for flame, smoke and toxicity. Tiles may be sized during manufacture and installed in configurations that minimize the number of tile sizes needed and minimize the need for cutting tiles during installation. The patterns used for such tiles may be orthogonally ambiguous or otherwise suitable for "random" installation. In other embodiments, a passenger aircraft cabin includes a floor having rectangular carpet tiles installed thereon, and the carpeting can be installed in the aircraft without removing seats from the aircraft.