Recyclable single polymer floorcovering article
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Solution Overview
Problem
Existing tufted floorcovering articles, such as carpets, are difficult to recycle due to their complex composition of multiple incompatible materials, leading to high landfill disposal rates and environmental impact.
Innovation Solution
Development of tufted carpet tiles made entirely from polyester, with a specific construction that includes 100% polyester face yarn, primary and secondary backing layers, and adhesive layers, allowing for easy recycling without separation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-material construction is used, then performance requirements are met, but recyclability deteriorates
Solution Approach 1:
The patent applies homogeneity by constructing the entire carpet tile from polyester materials only - the face yarn, primary backing, adhesive layers, and secondary backing are all made from polyester. This eliminates material incompatibility and enables complete recyclability while maintaining commercial performance specifications through optimized polyester formulations and construction methods.
2Adaptability or versatility
If multiple incompatible materials are used, then functional performance is improved, but separation complexity increases
Solution Approach 1:
The patent eliminates separation complexity by using polyester throughout all carpet tile components - face yarn, primary backing, adhesive layers, and secondary backing. This homogeneous single-polymer construction removes the need for complex material separation processes required by traditional multi-material carpets.
3Ease of manufacture
If polyester adhesive layers are used, then recyclability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent manages manufacturing complexity through parameter optimization - using polyester adhesives with specific viscosity ranges (3,000-10,000 cps at 350°F) and applying them in controlled layers. These parameter specifications ensure proper adhesive performance and bonding while maintaining compatibility with recycling processes, balancing manufacturability with recyclability.
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.