Textile backing formed from recycled materials
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Solution Overview
Problem
There is a need to increase the recycled content in flooring products, particularly carpet and carpet tiles, to reduce the amount sent to landfills and to utilize post-consumer materials effectively.
Innovation Solution
The development of textile backings for carpet and carpet tiles using high percentages of post-consumer recycled materials, such as post-consumer PVC backing and post-industrial PVC pellets, which are processed into foamed or non-foamed structures with enhanced cushioning and moisture resistance properties, reducing the reliance on virgin materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-consumer recycled materials are used to increase recycled content, then environmental sustainability is improved, but material quality and performance may deteriorate
Solution Approach 1:
The patent applies composite materials by combining post-consumer recycled PVC with post-industrial recycled PVC and virgin PVC resins in specific ratios. This creates a multi-component composite that leverages the advantages of each material type while compensating for their individual weaknesses, achieving both high recycled content (50-100%) and acceptable performance characteristics for flooring applications
Solution Approach 2:
The patent employs parameter changes by systematically varying the compositional ratios of different PVC sources (post-consumer, post-industrial, virgin) and processing parameters to optimize both environmental sustainability and material quality. By adjusting these parameters, the formulation achieves desired mechanical properties, cushioning characteristics, and moisture resistance while maintaining high post-consumer content
2Loss of substance
If high percentages of post-consumer recycled materials are used, then waste reduction is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by separating and processing different types of recycled materials (post-consumer carpet, post-industrial PVC) through distinct collection and preprocessing channels before combining them. This segmented approach allows each material stream to be optimized independently, simplifying the overall manufacturing process while achieving high waste reduction goals
Solution Approach 2:
The patent implements discarding and recovering by systematically collecting post-consumer carpet and other PVC-containing materials that would otherwise be discarded in landfills, processing them through recycling streams, and recovering valuable PVC content for reuse in new flooring products, thereby reducing waste while managing manufacturing complexity through established recycling infrastructure
3Quantity of substance
If post-industrial materials are reduced, then cost is improved, but material consistency may worsen
Solution Approach 1:
The patent uses parameter changes by precisely controlling the ratio of post-consumer recycled PVC to post-industrial and virgin PVC components within optimized ranges. This parameter optimization ensures that cost is reduced through minimized post-industrial content while material consistency is maintained through sufficient virgin resin content that acts as a stabilizing matrix
Solution Approach 2:
The patent applies composite materials by creating a tri-component system where post-consumer recycled PVC provides cost benefits and environmental advantages, post-industrial PVC contributes to material consistency, and virgin PVC ensures baseline performance and uniformity. This composite structure allows cost optimization while maintaining composition stability
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 approach significantly increases the post-consumer recycled content in flooring products, reduces waste sent to landfills, and offers improved cushioning and moisture resistance while minimizing the use of costly post-industrial materials.
Implementation Method 1
processed into foamed or non-foamed structures with enhanced cushioning and moisture resistance properties
Data Source
AI summary
Backings for carpet and carpet tiles are formed from various post-consumer and/or post-industrial polymeric waste materials, for example, post-consumer textile waste material (e.g., carpet and carpet tiles), post-industrial textile waste material (e.g., carpet and/or carpet tiles), and/or other post-consumer and/or post-industrial polymeric materials.