Tufted Backing Material Color Change by Reversing a Dual-Sided Roll

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Solution Overview

Problem

The existing processes for manufacturing tufted backing materials are labor-intensive and time-consuming, requiring frequent changes of rolls with different colored backing materials, leading to increased labor costs and raw material stock requirements, especially in the carpet industry where a wide color range is common.

Innovation Solution

A process involving a roll with one side colored differently from the other, where the roll is rotated 180° and unwound in alternating directions to tuft both sides efficiently, reducing the need for multiple rolls and minimizing labor and time in color changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple rolls of backing material with different colors are stored and used, then the desired color range for carpet styles can be provided, but the total stock items and raw material stock levels increase

Engineering Contradiction:
Improvecolor rangeVSAvoidraw material stock
Core Design Contradiction:
Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The backing material is divided into two distinct sides with different colors. Each roll provides both colors through its two sides, effectively segmenting the color provision function within a single roll structure rather than requiring separate rolls for each color

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

A single roll of backing material serves multiple functions by providing both the first color and the second color on its two respective sides. This multi-functional roll can be used to produce tufted backing materials with tufts extending from either side, replacing the need for multiple single-color rolls

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If rolls of backing material are frequently changed to different colors, then the desired color can be provided, but the process becomes labor-intensive and time-consuming

Engineering Contradiction:
Improvecolor change capabilityVSAvoidcolor change time
Core Design Contradiction:
Adaptability or versatilityVSLoss of time

Solution Approach 1:

The roll is designed to be dynamically reconfigurable by rotating it 180 degrees. This dynamic adjustment allows the tufting device to access either side of the backing material without requiring physical replacement of the roll, making the color change process quick and operationally flexible

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

Both colors are pre-prepared on the same roll before the tufting process begins. The backing material is manufactured with the first side exhibiting the first color and the second side exhibiting the second color, so that both color options are ready in advance and no time is lost during production for color changes

Inventive Principle:
Principle #10Preliminary action

3Adaptability or versatility

If rolls of backing material are frequently changed to different colors, then the desired color can be provided, but labor costs increase

Engineering Contradiction:
Improvecolor change capabilityVSAvoidlabor intensity
Core Design Contradiction:
Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The roll is designed to be dynamically reconfigurable by rotating it 180 degrees. This dynamic adjustment allows the tufting device to access either side of the backing material without requiring physical replacement of the roll, making the color change process quick and operationally flexible

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The backing material roll itself provides both color options through its two sides, making the system self-sufficient for color variations. The operator simply rotates the roll rather than manually replacing it, allowing the equipment to serve its own color change needs without external intervention

Inventive Principle:
Principle #25Self-service

Data Source

PatentUS8448589B2Process to manufacture tufted backing materials
Publication Date: 2013.05.28 LOW & BONAR BV

AI summary

A process to manufacture tufted backing materials comprises the steps of a) providing a roll bearing a backing material which backing material comprises a first side exhibiting a first colour and a second side exhibiting a second colour, wherein the first colour is different from the second colour, the first side is the front side and the second side is the rear side, b) unwinding the backing material from the roll, c) tufting the backing material, d) cutting the backing material at a position between the roll bearing the backing material and the tufting device, e) rotating the roll bearing the backing material by an angle of 180°, f) unwinding the backing material from the roll in a second unwinding direction which is opposite to the first unwinding direction and guiding the backing material into the tufting device, and g) tufting the backing material. A backing material for tufted carpets or filters comprising a first woven or non-woven layer having a second colour different from the first one is also described.