Recyclable Laminated Floor Covering With Heat-Activated Bonding
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Solution Overview
Problem
Conventional recyclable floor coverings face challenges due to the use of solvents and adhesives in production, leading to environmental pollution and difficulties in recycling, particularly with materials like PVC and glass fibers, which are not easily recyclable and produce hazardous fumes when heated.
Innovation Solution
A process involving a laminated surface covering with a heat-activated bonding layer between a rubber material and a flocked material, using a conveyor system to apply and bond materials with minimal solvent use, allowing for a uniform and recyclable flooring material produced on a continuous laminator line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional solvents and adhesives are used during production, then bonding between layers is achieved, but environmental pollution increases and harmful emissions are produced
Solution Approach 1:
The patent changes the physical state of the bonding material from liquid (solvent-based adhesive) to solid (granulated thermoplastic material). This parameter change eliminates the need for solvents and harmful emissions while maintaining effective bonding through heat activation and melting of the granulated material between layers.
2Strength
If liquid adhesive is applied during production, then layer bonding is achieved, but uniformity of the bonding layer is poor
Solution Approach 1:
The patent replaces the mechanical application method of liquid adhesive (brushing, rolling, or spraying) with a thermal-mechanical process. Solid granulated bonding material is applied uniformly and then activated by heat and pressure, which melts the material and creates a uniform bonding layer without the variability inherent in liquid application methods.
3Stability of the object's composition
If PVC and glass fiber are used in floor covering production, then structural stability is achieved, but recyclability decreases and hazardous fumes are produced when heated
Solution Approach 1:
The patent changes the material composition from non-recyclable PVC and glass fiber to recyclable thermoplastic materials. The granulated bonding material consists of thermoplastic polymers that can be melted and reformed, enabling the entire floor covering to be recyclable while maintaining dimensional stability through the thermoplastic properties.
4Stability of the object's composition
If glass fiber layer is added between PVC backing and flocking, then dimensional stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts and removes the glass fiber layer from the floor covering structure, replacing it with a granulated thermoplastic bonding material layer. This simplifies the manufacturing process by eliminating the need for separate glass fiber application steps while maintaining dimensional stability through the thermoplastic material's inherent properties.
5Ease of manufacture
If conventional recycling techniques including liquidation are used, then material disposal is achieved, but effectiveness is poor and hazardous fumes are produced
Solution Approach 1:
The patent enables true recycling by using thermoplastic materials throughout the floor covering construction. The granulated bonding material and thermoplastic backing can be melted down and reformed into new products, transforming the disposal process from hazardous liquidation to beneficial material recovery while eliminating harmful emissions.
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 reduces environmental impact by minimizing solvent use, enhances uniformity and appearance of the flooring, and facilitates recycling by using recycled rubber granules inter-bonded with a chemical bonding agent, creating a durable and eco-friendly flooring material.
Implementation Method 1
heating at least one of the first material and the second material
Implementation Method 2
heat-activated bonding layer between a rubber material and a flocked material
Implementation Method 3
applying pressure to bond the first material and second material together via the bonding material
Implementation Method 4
recycled rubber granules inter-bonded with a chemical bonding agent
Data Source
AI summary
A process and system for making a laminated surface covering and the surface covering itself are described. The covering includes several layers bonded to each other. The system performs the process. One example of the process includes passing a first material across a first conveyor, passing a second material across a second conveyor, passing a bonding material across a third conveyor, contacting the first material and the second material to the bonding material, and heating at least one of the first material and the second material. The process also includes introducing the first material, the second material, and the bonding material into a pressure zone such that the bonding material is introduced between a bottom surface of the first material and a top surface of the second material. The process applies pressure to bond the first material and second material together via the bonding material to produce a laminated material.