Renewable Calcium Carbonate Filler for Stronger, Flexible Carpet Backing

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Solution Overview

Problem

Conventional mineral fillers used in carpet manufacturing, such as calcium carbonate, are mined, leading to environmental and economic concerns, and it is challenging to achieve a balance between tensile strength and elongation at the breaking point without compromising the carpet's performance.

Innovation Solution

A mineral filler composition is developed using a renewable source of calcium carbonate, characterized by a weight ratio of calcium to magnesium of at least 10:1 and substantially free of calcium oxide, which is heat-treated and size-reduced to create a particulate filler suitable for use in carpet backings, providing improved tensile strength and elongation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional mined calcium carbonate is used as mineral filler, then the carpet achieves adequate tensile strength, but the environmental impact increases and economic benefits decrease

Engineering Contradiction:

Improvetensile strengthVSAvoidenvironmental impact

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the source parameter of calcium carbonate from mined to renewable biological sources (eggshells, seashells, bone meal), fundamentally altering the environmental impact parameter while maintaining the strength-providing function of the mineral filler

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes waste biological materials (eggshells, seashells, bone meal) that would otherwise be discarded, converting them into valuable mineral filler. This approach reduces both environmental impact and production costs while maintaining functional performance

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Strength

If the calcium to magnesium ratio is increased to improve tensile strength, then the carpet's strength increases, but the flexibility and elongation at breaking point decrease

Engineering Contradiction:

Improvetensile strengthVSAvoidflexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent optimizes the calcium to magnesium ratio parameter within a specific range (10:1 to 100:1) to achieve the optimal balance between tensile strength and flexibility, rather than using extreme ratios. This controlled parameter adjustment allows simultaneous improvement of both contradictory properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite mineral filler composition that combines calcium carbonate with controlled magnesium carbonate content, along with specific particle size distributions and surface treatments, to achieve synergistic effects that balance strength and flexibility

Inventive Principle:

Principle #40Composite materials

3Reliability

If the calcium oxide content is reduced to improve carpet durability, then the tensile strength increases, but the manufacturing complexity increases

Engineering Contradiction:

Improvecarpet durabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent performs preliminary heat treatment of the biological calcium carbonate source to pre-control the calcium oxide content before the filler is incorporated into the carpet backing. This advance treatment simplifies subsequent manufacturing steps while ensuring durability requirements are met

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent selects biological sources (eggshells, seashells, bone meal) that naturally have low calcium oxide content, allowing the material to essentially self-regulate the calcium oxide level without requiring complex manufacturing interventions to reduce it

Inventive Principle:

Principle #25Self-service

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 renewable mineral filler composition enhances the carpet's tensile strength and elongation at the breaking point, offering improved flexibility and durability while reducing environmental impact and production costs.

Implementation Method 1

heat treating the renewable biological calcium carbonate source under conditions effective to remove residual organic material

Methodology Applied

Scientific EffectHeat treatment: Heating

Implementation Method 2

size reducing the heat treated renewable biological calcium carbonate source to provide a particulate mineral filler composition having a predetermined particle size distribution

Methodology Applied

Scientific EffectMechanical size reduction: Fracture Mechanics

Data Source

PatentUS9943856B2Mineral filler compositions, methods for making mineral filler compositions and carpets manufactured from same

Publication Date: 2018.04.17 COLUMBIA INSURANCE CO

AI summary

Disclosed are calcium carbonate mineral filler compositions, wherein the composition has a mineral content characterized by a weight ratio of calcium to magnesium of at least 10:1, and wherein the composition is at least substantially free of calcium oxide. Also disclosed are methods for making a mineral filler composition from a renewable biological source of calcium carbonate. Also disclosed are carpets comprising the mineral filler from renewable biological source produced by the methods disclosed herein.