Thermoplastic Polymer Coating for Recyclable Carpet Backing
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Solution Overview
Problem
The existing methods for attaching a secondary backing to a primary backing in carpets and synthetic turf require large amounts of adhesive, which increases the cost and is not recyclable, and there is a need for a method that uses smaller amounts of adhesive without compromising the physical properties of the finished product.
Innovation Solution
A method involving the application of an aqueous dispersion of thermoplastic polymer particles to a primary backing, heating to remove water, and then cooling to adhere the secondary backing, using a process that involves infrared heaters and a chilled press roller to secure the backings together with reduced adhesive usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If hot melt thermoplastic adhesive is used to attach secondary backing to primary backing, then recyclability is improved, but adhesive quantity required increases
Solution Approach 1:
The patent changes the physical state parameters of the thermoplastic adhesive by using aqueous dispersion form instead of hot melt, and controls particle size (1-1000 microns) to achieve proper adhesion with reduced quantity. The dispersion allows the adhesive to remain in a usable state at lower temperatures and quantities while maintaining bonding effectiveness.
Solution Approach 2:
The patent introduces water as an intermediary medium to carry the thermoplastic polymer particles to the bonding interface. The aqueous dispersion acts as a carrier that delivers the adhesive particles uniformly, allowing for reduced overall adhesive quantity while ensuring adequate coverage and bonding performance.
2Quantity of substance
If reduced amount of adhesive is used, then cost is reduced, but physical properties of finished product may be compromised
Solution Approach 1:
The patent segments the adhesive into discrete polymer particles (1-1000 microns) rather than using continuous adhesive layers. This particle segmentation allows for reduced total adhesive quantity while maintaining effective bonding at particle-level contact points, and the segmented structure enables better distribution and penetration into substrate surfaces.
Solution Approach 2:
The patent creates a composite adhesive system combining thermoplastic polymer particles with aqueous dispersion medium. This composite formulation provides both the bonding functionality of thermoplastic polymers and the delivery benefits of water-based systems, achieving reliable physical properties with reduced adhesive quantity.
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
This method allows for the secure attachment of a secondary backing to a primary backing using significantly less adhesive, maintaining the desired physical properties and enabling the production of fully recyclable carpet and synthetic turf products.
Implementation Method 1
heating the aqueous dispersion to a temperature sufficient to remove water therefrom
Implementation Method 2
heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles
Implementation Method 3
allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the loop backs are adhered to the primary backing
Data Source
AI summary
The invention comprises a method. The method comprises applying a quantity of an aqueous dispersion of thermoplastic polymer particles to a primary backing and loop backs of a tufted carpet or a tufted synthetic turf, wherein the thermoplastic particles have an average particle size less than 1,000 microns. The method also comprises heating the aqueous dispersion to a temperature sufficient to remove water therefrom, and heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles. The method further comprises allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the loop backs are adhered to the primary backing.