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 a fully recyclable tufted carpet made entirely from polyester materials, including 100% polyester solution-dyed face yarn, polyester primary and secondary backing layers, and a polyester adhesive layer, allowing for easy recycling without separation steps through processes like depolymerization or melt processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional multi-material carpet construction is used, then performance requirements are met, but recyclability is severely limited

Engineering Contradiction:

Improveperformance requirementsVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies homogeneity by constructing the entire carpet from polyester materials only - face yarn, primary backing, adhesive, and secondary backing are all polyester. This single-material composition enables complete recyclability while meeting all performance requirements through proper material selection and construction methods.

Inventive Principle:

Principle #33Homogeneity

2Strength

If inorganic fillers are added to precoat adhesive, then cost is reduced and tuft bind strength is improved, but downstream recycling becomes difficult

Engineering Contradiction:

Improvetuft bind strengthVSAvoidrecycling difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates inorganic fillers from the precoat adhesive composition. By using a clear polyester adhesive without fillers like calcium carbonate or barium sulfate, the adhesive maintains sufficient tuft bind strength while enabling complete recyclability of the carpet through melt processing or depolymerization.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical composition parameters of the precoat adhesive by specifying it must be polyester-based and filler-free. This parameter change transforms the adhesive from a traditional filled latex or EVA composition into a recyclable polyester adhesive that maintains bonding performance without compromising end-of-life recyclability.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If multiple adhesive layers with different viscosities are used, then delamination resistance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedelamination resistanceVSAvoidadhesive layer complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the adhesive system into multiple layers with different viscosity characteristics. A first adhesive layer with lower viscosity provides initial bonding, while a second adhesive layer with higher viscosity provides structural support and delamination resistance. This segmentation achieves superior performance while maintaining manufacturability through standardized application processes.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If polyester materials are used throughout, then recyclability is achieved, but manufacturing precision requirements increase

Engineering Contradiction:

ImproverecyclabilityVSAvoidmaterial consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent specifies precise parameter ranges for polyester materials including intrinsic viscosity (IV ≥ 0.50 dl/g), molecular weight, and composition percentages. These parameter controls ensure material consistency and performance reliability while maintaining complete recyclability. The adhesive layers have specified viscosity ranges and polyester content requirements that guarantee both performance and recyclability.

Inventive Principle:

Principle #35Parameter changes

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 converting old carpets into new polyester products, thus minimizing environmental impact.

Implementation Method 1

The adhesive layer secures the face yarn to the primary backing layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

placing the polyester carpet in a heat processing device to heat and melt the polyester carpet

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

placing the extrusion device over a screen and forcing the molten polyester through the screen and extrusion device die to form polyester chips

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS11673291B2Recyclable single polymer floorcovering article

Publication Date: 2023.06.13 MILLIKEN & CO

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.