Recyclable single polymer floorcovering article
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Solution Overview
Problem
The majority of tufted floorcoverings, such as carpets, end up in landfills due to their complex composition, making recycling difficult and contributing to landfill space issues and environmental concerns.
Innovation Solution
Development of 100% recyclable tufted carpet tiles made entirely from polyester, comprising solution-dyed face yarn, polyester primary and secondary backing layers, and a polyester adhesive layer, allowing for easy recycling through processes like depolymerization or melt processing without the need for separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-material carpet construction is used, then performance requirements are met, but recyclability deteriorates
Solution Approach 1:
The patent applies homogeneity by constructing the entire carpet from polyester materials only - the face yarn, primary backing, secondary backing, and adhesive layer are all made from polyester. This single-material composition maintains commercial performance while enabling complete recyclability, as the homogeneous polyester structure can be processed together without separation.
2Strength
If inorganic fillers are added to precoat adhesive, then cost is reduced and tuft bind strength is improved, but recyclability deteriorates
Solution Approach 1:
The patent extracts and removes inorganic fillers from the precoat adhesive composition. The adhesive layer is formulated without CaCO3, BaSO4, coal fly ash, or recycled glass cullet, eliminating the contamination that would prevent recycling. This extraction maintains adhesive functionality while enabling complete polyester recyclability.
3Ease of manufacture
If landfill disposal is used, then disposal cost is avoided, but environmental harm increases and landfill space is consumed
Solution Approach 1:
The patent enables discarding and recovering by making the carpet fully recyclable through its single-polyester construction. At end-of-life, the polyester carpet can be collected, processed, and recovered to create new polyester products, eliminating landfill disposal and associated environmental harm while creating economic value from the discarded material.
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 enables carpets to meet commercial performance standards while being fully recyclable, reducing landfill disposal and promoting sustainable waste management by facilitating the reuse of polyester materials.
Implementation Method 1
The adhesive layer is interposed between the primary backing layer and the secondary backing layer
Implementation Method 2
allowing for easy recycling through processes like depolymerization or melt processing
Implementation Method 3
allowing for easy recycling through processes like depolymerization or melt processing
Data Source
AI summary
This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.