Recyclable Laminated Surface Covering With Heat-Activated Bonding
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Solution Overview
Problem
Conventional recyclable floor coverings, such as carpets and matting, require substantial amounts of solvents and adhesives during production, leading to environmental pollution and are difficult to recycle due to dissimilar materials and complex manufacturing processes, including the use of non-recyclable PVC and glass fibers.
Innovation Solution
A laminated surface covering composed of a facing material bonded to a backing material via a heat-activated bonding material, which is mostly solvent-free, allowing for uniform bonding and recycling of materials like recycled rubber and PVC, reducing environmental impact and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
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 and chemical parameters of the bonding material from conventional solvent-based adhesives to a water-based polymer emulsion system. This parameter change maintains bonding capability while eliminating harmful organic solvent emissions, directly resolving the contradiction between manufacturing ease and environmental harm.
Solution Approach 2:
The patent converts the typically problematic water-based polymer emulsion (which can be difficult to bond with) into an effective bonding agent by optimizing its composition and curing characteristics. This transforms a potentially harmful or ineffective material into a beneficial environmentally-friendly alternative that achieves reliable layer bonding without pollution.
2Adaptability or versatility
If dissimilar materials are used in conventional carpets and matting, then design flexibility and functionality are improved, but recyclability deteriorates due to difficulty in separating and recycling materials
Solution Approach 1:
The patent segments the floor covering into distinct functional layers (wear layer, cushion layer, backing layer) that can be independently designed for performance while maintaining compatibility for recycling. Each layer uses materials selected for both their functional properties and their recyclability, allowing the segmented structure to satisfy both design flexibility and ease of recycling.
Solution Approach 2:
The patent employs homogeneous material composition within each layer and ensures material compatibility across layers, using primarily rubber-based materials throughout. This homogeneity approach maintains design flexibility through material formulation variations while enabling efficient recycling by eliminating incompatible material combinations that would complicate recycling processes.
3Stability of the object's composition
If glass fiber layer is added to PVC backing for dimensional stability, then structural stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the glass fiber layer from the conventional construction, achieving dimensional stability through alternative means. By removing this complex component, the patent simplifies manufacturing while maintaining the required structural properties through improved rubber compound formulation and layer construction.
Solution Approach 2:
The patent uses composite rubber material formulations within the backing layer to provide dimensional stability without requiring additional reinforcement layers. The composite rubber composition incorporates fillers and additives that enhance structural properties, replacing the need for glass fiber reinforcement and simplifying the overall construction.
4Ease of manufacture
If liquid adhesive is applied during production, then bonding between layers is achieved, but uniformity of adhesive layer is poor creating difficulties in adding flocking layer
Solution Approach 1:
The patent changes the rheological parameters of the bonding material by using a polymer emulsion with optimized viscosity and spreadability characteristics. This parameter change enables uniform application and distribution of the bonding layer, eliminating the non-uniformity problems associated with conventional liquid adhesives and facilitating subsequent flocking layer application.
Solution Approach 2:
The patent replaces the mechanical spreading and leveling process required for liquid adhesives with a system based on the self-leveling properties of the polymer emulsion. The emulsion formulation provides inherent uniformity through its flow and curing characteristics, reducing reliance on mechanical application precision and improving overall bonding layer uniformity.
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 provides a recyclable floor covering with reduced solvent use, uniform bonding, and improved recyclability, minimizing environmental harm and manufacturing costs while maintaining aesthetic appeal.
Implementation Method 1
a layer of bonding material which is heat-activated bonding material
Data Source
Figure 1~4
Figure 5~6
Figure 7A
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.