Textile floor-covering with liquid blocking surface
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Solution Overview
Problem
Conventional textile floor-coverings lack the ability to effectively contain liquid spills, especially from higher heights, and often require additional liquid-blocking sub-layers, which can compromise surface softness and durability, while solid floor-coverings provide better spill containment but lack cushioning and aesthetics.
Innovation Solution
A fibrous-faced floor-covering composite with a thin, extensible barrier layer and a deep low-density cushion backing, laminated in a flat configuration to prevent fluid penetration for at least 24 hours, featuring a face layer that stretches initially and tightens to maintain barrier integrity under load, and a porous cushion layer for moisture escape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a deep, open, and soft textile face layer is used to provide cushion, then surface softness is improved, but liquid spill containment capability deteriorates
Solution Approach 1:
The invention divides the floor covering into distinct functional layers: a soft textile face layer for cushioning and an independent liquid barrier layer for spill containment. This segmentation allows each layer to perform its specific function without compromising the other, resolving the contradiction between softness and liquid containment.
Solution Approach 2:
The liquid barrier layer acts as an intermediary between the soft textile face layer and the underlying floor. It mediates the conflict by providing liquid containment while allowing the face layer to maintain its soft, open structure for comfort.
2Reliability
If liquid-blocking sub-layers are added to the underside of carpets, then liquid containment is improved, but surface softness and durability deteriorate
Solution Approach 1:
The invention extracts the liquid barrier function from the traditional underside location and places it directly beneath the face layer. This repositioning allows the barrier to protect against spills while the face layer maintains direct contact with users, preserving surface softness and durability.
Solution Approach 2:
Instead of placing the barrier layer in the vertical dimension at the bottom of the carpet, the invention positions it in the horizontal dimension directly under the face layer. This dimensional change optimizes both liquid containment and surface properties.
3Reliability
If repellent treatments are applied to pile structures, then liquid resistance is improved, but durability deteriorates due to wear from traffic and cleanings
Solution Approach 1:
The invention replaces the wear-prone repellent treatment on the face layer with a dedicated liquid barrier layer designed to contain spills. The barrier layer can be simpler and more durable since it doesn't need to maintain repellent properties under traffic, only provide physical containment.
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 provides a durable, soft surface that effectively contains liquids dropped from up to 1 meter for 24 hours, maintains delamination resistance, and allows for easy cleaning, preventing bacterial growth and maintaining surface softness.
Implementation Method 1
a fibrous-faced floor-covering composite with a thin, extensible barrier layer... featuring a face layer that stretches initially and tightens to maintain barrier integrity under load
Implementation Method 2
a porous cushion layer for moisture escape
Data Source
AI summary
A composite floor-covering comprising a fabric face layer, a barrier layer and a cushion backing layer is disclosed. The fabric face layer is attached to the barrier layer by a first adhesive layer and the barrier layer is attached to the cushion backing layer by a second adhesive layer. The fabric face layer on the composite floor covering can stretch up to an initial amount under a first pressure and can stretch beyond under a second pressure wherein the second pressure is higher than the first pressure. The composite floor-covering has a water vapor transmission rate of less than about 5.0 cm3/m2/24 hour at 100° F. and 90% RH.