Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
  • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
  • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
  • D06N7/0073—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
  • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
  • D06N7/0078—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as a hot melt
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
  • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
  • D06N7/0086—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing characterised by the cushion backing, e.g. foamed polyurethane
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2201/00—Chemical constitution of the fibres, threads or yarns
  • D06N2201/08—Inorganic fibres
  • D06N2201/082—Glass fibres
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2203/00—Macromolecular materials of the coating layers
  • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D06N2203/042—Polyolefin (co)polymers
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2203/00—Macromolecular materials of the coating layers
  • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06N2203/061—Polyesters
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2203/00—Macromolecular materials of the coating layers
  • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06N2203/068—Polyurethanes

Definitions

• the present invention relates to cushioned, foam backed, or cushion backed surface covering, wall covering, floor covering, flooring material, carpet, carpet tile, or the like, and more particularly, to a low weight, cushioned carpet, carpet tile and method.
• a process and apparatus for forming the cushion backed floor covering, carpet or carpet tile of the present invention are also provided.
• a primary carpet fabric 12 is embedded in an adhesive layer 16 in which is embedded a layer of glass scrim or non- woven material.
• a foam base composite 19 is likewise adhesively bonded to the adhesive layer 16.
• the primary carpet fabric 12 includes a loop pile layer 20 tufted through a primary backing 22 by a conventional tufting process and held in place by a pre-coat backing layer of latex 24 or other appropriate adhesives including a hot melt adhesive or the like.
• the foam base composite 19 of the tufted carpet product includes an intermediate layer 26 molded to a layer of urethane foam 28 as illustrated.
• the bonded carpet product (FIG.
• the primary bonded carpet fabric 12 has somewhat different components from that of the tufted product in that it has cut pile yarns 34 implanted in a PNC, latex, or hot melt adhesive 36 having a woven or non- woven reinforcement or substrate layer 38 of fiberglass, nylon, polypropylene, or polyester.
• the cost associated with such modular formation and assembly practices may be reduced by a simplified operation in which a primary carpet fabric, either with or without a stabilizing layer of scrim or the like, is laid directly into a polyurethane-forming composition and thereafter curing the polyurethane.
• the process can be made even more efficient if the polyurethane-forming composition requires no pre-curing prior to joining the carpet base.
• the invention described in the 5,948,500 patent also provides a particularly simple composite structure amendable to in-situ formation of a stable cushion carpet composite which is not believed to have been previously utilized. Specifically, it had not been previously recognized that a single process could be used to bring all the layers of the cushioned carpet composite together by laying a primary carpet fabric, either with or without some degree of preheat, directly into a mechanically frothed polyurethane- forming composition prior to curing the polyurethane and without an intermediate layer of material.
• the prior art carpet forming processes typically required the separate formation of a foam base composite having a backing layer and a layer of urethane foam.
• the backing layer is then used as an intermediate layer to which a primary carpet fabric and reinforcing layer can be adhesively bonded.
• the base of the primary carpet fabric is adhesively bonded to a layer of non-woven glass reinforcement material to form a preliminary composite.
• a puddle of polyurethane-forming composition is simultaneously deposited across a woven or non-woven backing material.
• the preliminary composite and the polyurethane-forming composition are thereafter almost immediately brought together with the preliminary composite being laid into, and supported by, the polyurethane- fo ⁇ ning puddle.
• the entire s ⁇ ucture is then heated to cure the ol uiei aiic f ⁇ miin composition.
• the preliminary composite may be slightly heated to about 120 degree F to improve heating efficiency although the process may likewise be carried out without such preheating.
• a superior cushion backed carpet tile or modular cushion back carpet tile on the market today for example, sold under the trademark Comfort Plus ® by Milliken & Company of LaGrange, Georgia has a primary carpet fabric with a face weight of about 20 to 40 oz/yd 2 , a hot melt layer of about 38 to 54 oz/yd 2 , a cushion of about 0.10 to 0.2 inches thick, a weight of about 28-34 oz/yd 2 , and having a density of about 18 lbs. per cubic foot, and an overall product height of about 0.4 - 0.8 inches.
• This superior cushion back carpet tile provides excellent resilience and under foot comfort, exhibits performance characteristics that rate it for very heavy commercial use, and has achieved a notable status throughout the industry as having excellent look, feel wear, comfort, and cushion characteristics, performance, properties, and the like.
• Such a superior cushion backed carpet tile is relatively expensive to produce due to the high quality and quantity of materials utilized.
• the low weight carpet composite and low weight carpet tile of the r heat invention may be printed with orientation independent designs or designs having the ability to seam properly without cutting the tiles in register with the design and to allow the carpet to be installed monolithically as well as by conventional quarter turn "Parquet", or by ashler (brick).
• the prefened installation techniques are monolithic or ashler with or without floor adhesives.
• the cushion may have a density of about 13 - 16 lbs. per cubic foot or less.
• Such a low weight modular carpet composite or low weight modular carpet tile has unexpectedly been found to have excellent look, wear cushion, resilience, under foot comfort, and exhibits performance characteristics that rate it for heavy commercial use.
• a low weight carpet composite or low weight carpet tile may be used in place of standard weight cushion backed or hard backed carpet tile, or broadloom thus reducing cost, reducing material requirements, reducing weight, reducing energy requirements, reducing environmental impact, and the like.
• a low weight modular carpet composite is cut into modular carpet tiles or carpet squares, for example, 18 inches X 18 inches, 36 inches X 36 inches, 50 cm X 50 cm, 1 meter X 1 meter, 48 inches X 48 inches, or the like.
• the low weight carpet composite or low weight carpet tile of the present invention may be installed on site or on flooring by all of the conventional installation techniques as well as can be constructed for adhesive-free installation, self-stick, or the like.
• the low weight carpet composite and low weight carpet tile of the present invention may be printed with orientation independent designs oi designs having ie ability tor seam properly without cutting the tiles in register with the design and to allow the carpet to be installed monolithically as well as by conventional quarter turn "Parquet", or by ashler (brick).
• the preferred installation techniques are monolithic or ashler with or without floor adhesives.
• a carpet composite or carpet tile having excellent look, feel, wear, resilience, and under foot comfort and exhibiting performance characteristics that rate it for heavy commercial use can be formed by combining a low weight primary carpet with a hot melt or resilient layer and a lightweight cushion.
• a low weight modular carpet tile having an overall height of about 0.20 to 0.5 inches thick depending on the construction of the carpet tile (the number of layers or components) and which can be cut in any conventional shape or size.
• the low weight carpet composite of the present invention is especially adapted to be cut for use as low weight modular ca ⁇ et tiles, but also finds applicability as other carpet or flooring, such as, carpet, broadloom area rugs, runners, floor mats, or the like.
• the reinforcement layer may be bonded to the base of the primary carpet fabric by the polyurethane foam or by a separate adhesive.
• the reinforcement layer may be bonded to the base of the primary carpet fabric by the polyurethane foam or by a separate adhesive.
• It is a further feature of the present invention to provide a process for forming a cushioned carpet composite including the simultaneous continuous steps of adhering a woven or non- woven reinforcement material to the base of a primary carpet fabric; depositing a puddle of a polyurethane-forming composition across a backing layer or support structure and laying the primary carpet fabric and adhered reinforcement material into the puddle of polyurethane-forming composition deposited on the backing layer.
• It is a further feature of the present invention to provide a process for forming a cushioned carpet composite including the steps of adhering a woven or non- woven reinforcement material to the base of a primary carpet fabric and adhering a polyurethane foam and backing layer to the reinforcement material.
• It is a further feature of the present invention to provide a process for forming a cushioned carpet composite including the simultaneous continuous steps of forming a primary ca ⁇ et fabric; forming a polyurethane foam layer, and adhering the primary carpet fabric to the polyurethane foam layer.
• the polymer application unit and the adhesive application unit being simultaneously operable in controlled relation to one another such that the primary carpet with the adhered reinforcement layer may be laid directly into the polymer.
• a cushioned ca ⁇ et, composite, or tile is provided.
• the cushioned ca ⁇ et includes a primary ca ⁇ et having a primary base and a plurality of pile-forming yams projecting outwardly S oul one side.
• a layer of reinforcement material is bonded to the primary base on the side away from the pile- forming yarns.
• the reinforcement material is adjacent to, and embedded at least partially in, a cushion layer of polymer such as polyurethane.
• An optional backing material is preferably disposed on the underside of the cushion layer.
• the backing material may include an adhesive backing on the side away from the cushion layer.
• a cushioned ca ⁇ et, composite, or tile is provided.
• the cushioned ca ⁇ et includes a primary ca ⁇ et having a primary base and a plurality of pile-forming yarns projecting outwardly from one side.
• a layer of reinforcement material is bonded to the primary base on the side away from the pile- forming yarns.
• the reinforcement material is adjacent to a cushion layer of polymer such as polyurethane.
• An optional backing material is preferably disposed on the underside of the cushion layer.
• the backing material may include an adhesive backing on the side away from the cushion layer.
• a cushioned ca ⁇ et, composite, or tile is provided.
• the cushioned ca ⁇ et includes a primary ca ⁇ et having a primary base and a plurality of pile-forming yarns projecting outwardly from one side.
• a cushion layer is bonded to the primary base on the side away from the pile-forming yarns.
• a reinforcement material may be embedded in the cushion layer of polymer such as polyurethane.
• the cushion layer may be bonded to the primary ca ⁇ et by a layer of hot melt.
• An optional backing material is preferably disposed on the underside of the cushion layer.
• the backing material may include an adhesive backing on the side away from the cushion layer.
• a process for making a cushioned ca ⁇ et involves obtaining a primary ca ⁇ et fabric comprising a plurality of pile-fonning yams extending outwardly from one side of a primary base.
• a layer of reinforcement material is adhered to the primary ca ⁇ et fabric on the side, from which the pile-forming yams do not extend, thereby forming a preliminary composite.
• a puddle of polymer such as a polyurethane-forming composition is applied to one side of a backing material and preferably doctored to desired thickness to form a cushion layer.
• the preliminary composite is then adhered to the cushion layer. Following this mating operation, the ca ⁇ et is cut to size or into tiles.
• a process for making a cushioned ca ⁇ et involves obtaining a primary ca ⁇ et fabric comprising a plurality of pile-forming yarns extending outwardly from one side of a primary base. A puddle of polymer such as a polyurethane-forming composition is applied to one side of a backing material and preferably doctored to desired thickness. The primary ca ⁇ et fabric is then laid into the puddle of polymer without curing. Following this mating operation, the polymer is preferably heat cured and the ca ⁇ et is cut into tiles.
• a primary ca ⁇ et fabric comprising a plurality of pile-forming yarns extending outwardly from one side of a primary base.
• a puddle of polymer such as a polyurethane-forming composition
• the primary ca ⁇ et fabric is then laid into the puddle of polymer without curing. Following this mating operation, the polymer is preferably heat cured and the ca ⁇ et is cut into tiles.
• a process for making a cushioned ca ⁇ et involves obtaining a primary ca ⁇ et fabric comprising a plurality of pile-forming yarns extending outwardly from one side of a primary base. A layer of reinforcement material is adhered to the primary ca ⁇ et fabric on the side, from which the pile-forming yarns do not extend, thereby forming a preliminary composite. A puddle of polymer such as a polyurethane-forming composition is applied to one side of a backing material and preferably doctored to desired thickness. The preliminary composite is then laid into the puddle of polymer without curing. Following this mating operation the polymer is preferably heat cured and the ca ⁇ et is cut into tiles.
• a primary ca ⁇ et fabric comprising a plurality of pile-forming yarns extending outwardly from one side of a primary base.
• a layer of reinforcement material is adhered to the primary ca ⁇ et fabric on the side, from which the pile-forming yarns do not extend, thereby forming a preliminary composite.
• an apparatus for use in forming a cushioned ca ⁇ et composite comprising: a reinforcement bonding unit for bonding a layer of reinforcement material to the underside of a primary ca ⁇ et fabric to form a preliminary caipet composite; olyiue a lication unit for dis ensing polyurethane-forming composition across the surface of a carrier fabric; a mating unit for laying said preliminary ca ⁇ et composite into said polyurethane-forming composition; and means for heat curing the polyurethane-forming composition subsequent to said preliminary composite being laid into said polyurethane-forming composition; wherein said reinforcement bonding unit, said polymer application and said mating unit are operable in a continuous, simultaneous manner.
• an apparatus for use in forming a cushioned ca ⁇ et composite comprising: a reinforcement bonding unit for bonding a layer of reinforcement material to the underside of a primary ca ⁇ et fabric to form a preliminary ca ⁇ et composite; a polymer application unit for dispersing a polyurethane-forming composition across the surface of a carrier fabric; means for heat curing the polyurethane-forming composition to form a cushion layer, and a mating unit for joining the ca ⁇ et composite and cushion layer.
• an apparatus for use in forming a cushioned ca ⁇ et composite comprising: a reinforcement bonding unit for bonding a layer of reinforcement material to the underside of a primary ca ⁇ et fabric and to the top side of a cushion layer to form a ca ⁇ et composite.
• a modular ca ⁇ et tile is manufactured by: tufting broadloom at a weight of 15 oz/yd 2 or less, printing a design in broadloom form, applying a cushion backing system, and cutting into square tiles.
• the low weight modular ca ⁇ et tile of the present invention is aesthetically pleasing and exhibits performance characteristics that rate it for a heavy commercial application.
• the combination of a low weight ( ⁇ 15 oz/yd 2 ) tufted ca ⁇ et, hot melt layer, and cushion backing alec provides resilience and under-foot comfort.
• the low weight ca ⁇ et, composite, and tile of the present invention is especially suited for broadloom because of: a. Tufted construction b. Applied design c. Attached cushion backing
• the low weight carpet, composite, and tile of the present invention is well adapted for modular applications because of: a. Post applied design b. Tufted construction c. Cushion backing
• FIG. 1A is a cut-away view of a tufted ca ⁇ et with a cushioned composite structure.
• FIG. IB is a cut-away side view of a bonded ca ⁇ et inco ⁇ orating a cushioned composite structure.
• FIG. 2 is a schematic view illustrating an exemplary embodiment of the apparatus and process of the present invention.
• FIG. 3 A is a cut-away side view of a tufted ca ⁇ et inco ⁇ orating a structure formed by the apparatus and process of the present invention as illustrated in FIG. 2.
• FIG. 3B is a cut-away side view of a bonded ca ⁇ et inco ⁇ orating a stracture formed by the apparatus and process of the present invention as illustrated in FIG. 2.
• FIG. 4A is a cut-away side view of an alternative embodiment of a tufted ca ⁇ et having no reinforcement layer.
• FIG. 4B is a cut-away side view of an alternative embodiment of a bonded ca ⁇ et having no reinforcement layer.
• FIG. 5 is a schematic view illustrating an alternative apparatus and process according to the present invention for forming a cushioned ca ⁇ et composite without separate adhesive bonding between the primary ca ⁇ et and the reinforcement layer.
• FIG. 6A is a cut-away side view of an alternative stracture for a tufted ca ⁇ et formed by the apparatus and process illustrated in FIG. 5.
• FIG. 6B is a cut-away side view of an alternative structure for a bonded ca ⁇ et formed by the apparatus and process illustrated in FIG. 5.
• FIG. 7 is a schematic view illustrating yet another alternative apparatus and process according to the present invention for forming a cushioned ca ⁇ et composite without separate adhesive bonding between the primary ca ⁇ et and the reinforcement layer as illustrated in FIGS. 6A and 6B.
• Figure 8 is a schematic flow diagram of the production of low weight modular ca ⁇ et tiles in accordance with one embodiment of the present invention.
• Figure 9 is a tabular representation of the materials, dimensions, temperatures, and the like used in the process of Figure 8.
• Figures 10 — 18 are cut-away side views of respective tufted and bonded low weight ca ⁇ et, composite, or tiles in accordance with different embodiments or aspects of the present invention.
• Figures 10A and 11 - 18 show a looped pile in the primary ca ⁇ et and Figure 10B shows a bonded primary ca ⁇ et, it is to be understood that a bonded or tufted loop and/or cut pile may be used and that the pile may be sculptured, printed, dyed, and or the like as desired.
• Figures 19 and 19A are respective schematic illustrations of alternative apparatus and process in accordance with selected embodiments of the present invention.
• a low weight surface covering, wall covering, flooring, ca ⁇ et, floor covering, ca ⁇ et composite, or modular ca ⁇ et tile and method is provided which is aesthetically pleasing, exhibits performance characteristics that rate it for heavy commercial use, has resilience and underfoot comfort, and which may be dyed, printed, and installed as can be done with conventional foam backed or cushion backed ca ⁇ et, composite, or tiles.
• FIG. 2 A schematic view illustrating an exemplary apparatus and process used in forming the low weight, cushioned surface covering, wall covering, flooring, floor covering, ca ⁇ et or tile of the present invention is illustrated in FIG. 2.
• the apparatus is designated generally by reference numeral 100.
• a primary ca ⁇ et fabric 112 which may inco ⁇ orate either a tufted or a bonded configuration (with loop and/or cut pile) as described above is drawn from a mounted ca ⁇ et roll 114.
• the primary ca ⁇ et fabric 112 preferably includes a plurality of pile-forming yarns projecting outwardly from one side of a primary backing or base.
• the primary ca ⁇ et 112 used in the present invention is a tufted ca ⁇ et
• its configuration will preferably conform to that of the primary ca ⁇ et 12 illustrated in regard to that in FIG. 1 A, while if the primary ca ⁇ et 112 used in the present invention is a bonded product, its configuration will be that of the primary ca ⁇ et 12 illustrated in FIG. IB.
• the primary ca ⁇ et 112 may include one or more backing cr base layers.
• the component stracture of the primary ca ⁇ et fabric is not critical to the present invention. Rather it is intended that any low weight (low face weight) primary ca ⁇ et fabric having a pile forming portion and a primary base may be utilized as the primary ca ⁇ et fabric.
• primary base is meant any single layer or composite stracture including, inter alia, the commonly used layered composite of primary backing 22 and latex pre-coat 24 previously described in relation to the tufted product (FIG. 1A) and the adhesive layer 36 with reinforcement substrate 38 previously described in relation to the bonded product (FIG. IB).
• polyester in the primary base structure may be desirable due to the eventual heat curing such structure may undergo.
• Other embodiments as may occur to those of skill in the art may, of course, also be utilized.
• the pile forming yarns could be heat tacked to the substrate 38 as described in U. S. Patent No. 5,443,881 (hereby inco ⁇ orated by reference herein) to permit simplified construction of a primary ca ⁇ et.
• the primary ca ⁇ et fabric 112 preferably comprises a loop pile layer 120 of pile-forming yams tufted into a primary backing 122 as is well known and held in place by a pre-coat of adhesive 124 such as latex or a hot melt adhesive. It is contemplated that the latex or hot melt adhesive may be added in-line after removal from the ca ⁇ et roil prior to the application of any other adhesive as described below.
• the ca ⁇ et may be steamed after addition of the pre-coat to facilitate subsequent printing operations if desired to reduce stresses.
• the two basic primary backing constractions are woven polypropylene and non- woven polyester. Each material may have a variety of construction characteristics engineered for a specific end use.
• the preferred primary backing material is 20 pick per inch, woven polypropylene, with needle punched nylon fleece.
• the primary ca ⁇ et 112 is a loop pile tufted ca ⁇ et formed by tufting a non-heatset yam through the primary backing, then washing, steaming, drying, and injection dyeing to form, preferably, a monolithic or orientation independent design, color, or pattern thereon to form, for example, a 12 foot wide primary ca ⁇ et precursor of loop pile 120 and primary backing 122.
• a non-heatset yam By using non- heatset yarn, and originally tufting the yam at a rather long loop length, the washing, steaming, drying and dying steps shrink the yam to form smaller, tighter loops and provide a denser surface to the primary ca ⁇ et precursor.
• this primary ca ⁇ et precursor is split in half and rolled to form, two separate six foot wide rolls of split primary ca ⁇ et precursor.
• one roll of the split primary ca ⁇ et precursor is used as ca ⁇ et 114 in the apparatus of Figures 2 or ca ⁇ et 314 in Fig. 5 or 7.
• the latex pre-coat or hot melt adhesive coat 124 is added to the back of the primary ca ⁇ et precursor to form a primary ca ⁇ et fabric 112 in the upper run of the apparatus of Fig. 2 downstream of the accumulator 150 and upstream of the reinforcement bonding unit 155.
• a thin layer of latex pre-coat is applied to the back of the primary ca ⁇ et precursor using a coating roller.
• the primary ca ⁇ et precursor (not having a latex pre-coat) is rolled or wound with the primary backing 122 exposed.
• the apparatus and process of the present invention may include the entire assembly process from tufting the yarn in the primary backing, dying iui tufted yaui, latex pre-coating the back of the primary backing, hot-melt coating the fiberglass reinforcing material, foam coating the felt secondary backing, laminating the primary ca ⁇ et, reinforcing fiberglass, and foam cushioning layer, heating or curing the laminate, and cutting the ca ⁇ et composite into ca ⁇ et tiles, runners, area rags, or the like.
• the process may be broken down into its respective steps and done in a batch rather than a continuous mode, although the continuous mode of operation is preferred.
• the primary ca ⁇ et may be formed in one operation and placed on rolls.
• the cushion backing or foam layer may be formed in a separate operation and be placed on a roll.
• the two may be joined by a mating unit using an adhesive, hot melt, hot melt with reinforcing layer, or the like.
• the primary ca ⁇ et fabric 112 preferably comprises aplurality of cut pile yams 134 implanted in an adhesive 136 such as a latex or hot melt adhesive which is laminated to a reinforcement or substrate layer 138 of a woven or non-woven material including fiberglass, nylon, polyester, or polypropylene.
• this substrate layer 138 may be pre-coated with latex or other thermoplastic polymers to permit melting adhesion with the cut pile yams 134 upon the application of heat, thereby potentially reducing or eliminating the need for the latex or hot melt adhesive 136.
• the yams 120, 134 may be either spun or filament yams and are preferably formed from a polyamide polymer such as nylon 6 staple, nylon 6 filament, or nylon 6,6 staple, nylon 6,6 filament, available from DuPont Fibers in Wilmington, Del., although other suitable natural or synthetic yams may likewise be employed as will be recognized by those of skill in the art.
• a polyamide polymer such as nylon 6 staple, nylon 6 filament, or nylon 6,6 staple, nylon 6,6 filament, available from DuPont Fibers in Wilmington, Del., although other suitable natural or synthetic yams may likewise be employed as will be recognized by those of skill in the art.
• polyester staple or filament such as polyethylene terephthalate (PET), and polybutylene terephthalate (PBT); polyolefins, such as polyethylene and polypropylene staple or filament; rayon; and polyvinyl polymers such as polyacrylonitrile, wool, nylon/wood blends, Lyocell, rayon, saran, acetate, glass, aramid, fluorocarbon, Sulfar, acrylic, Pelco, olefin, melamine, polybenzimidazole, and combinations thereof.
• a variety of deniers, plies, twist levels, air entanglement, and heatset characteri ⁇ ties can be used to construct the y m.
• the preferred yam is nylon , , filament, 1360 denier, 1 ply, no twist, no entanglement, and no heatset.
• Another yarn is nylon 6,6, filament, 1350 denier, no ply, nominal twist (0-1 twist), non-heat set.
• the adhesive pre-coat 124 is preferably styrene butadiene rubber (SBR) latex but other suitable materials such as polyvinyl chloride (PNC), ethylene vinyl acetate (EN A), polyurethane, acrylic, and hot melt adhesives as are well known to those of skill in the art may likewise be utilized.
• SBR styrene butadiene rubber
• PNC polyvinyl chloride
• EN A ethylene vinyl acetate
• polyurethane acrylic
• hot melt adhesives as are well known to those of skill in the art may likewise be utilized.
• a hot melt adhesive it is contemplated that a reinforcement material such as a glass scrim could be directly attached to form a composite laminate without the use of adhesives.
• the adhesive pre-coat 124 may be entirely eliminated in the tufted product if the loop pile 120 is tufted in suitably stable relation to the primary backing 122.
• the commonly used hot melts are bitumen, polyolefin-based thermoplastic, and polyurethan
• the primary ca ⁇ et fabric 112 is conveyed by means of a plurality of rolls through an accumulator 150 as is well known in the art to a reinforcement bonding unit 155.
• a sheet of reinforcement material 158 is likewise conveyed to the reinforcement bonding unit 155.
• the reinforcement material 158 is preferably fiberglass non-woven material such as a 2.0 oz/yd 2 fiberglass mat or tissue containing a urea formaldehyde binder although alternative materials may include woven glass, woven polyester, and non- woven polyester.
• an adhesive 160 such as a hot melt adhesive is preferably applied to the reinforcement material 158 by means of a film coater or other such unit as are well known.
• the reinforcement material 158 and the primary ca ⁇ et fabric 112 are thereafter preferably passed in mating relation between joining members such as rolls 163, 165, thereby bonding the reinforcement material 158 to the underside of the primary carpel fabric 112. That is, the reinforcement material 15G is bonded on the side of the primary ca ⁇ et fabric 112 from which the pile forming yams do not project.
• the bonding of the reinforcement material 158 to the underside of the primary ca ⁇ et fabric 112 produces a preliminary composite 166 which is thereafter laid into a puddle of polymer or foam forming composition such as a polyuremane-forrning composition as described below.
• reinforcement bonding unit 155 is illustrated in its preferred embodiment as inco ⁇ orating a film coater, it is to be understood that alternative equivalent means such as application rolls, spray headers and the like may also be utilized.
• alternative means for the application of adhesive 160 are disclosed in U.S. Pat. No. 4,576,665 to Machell.
• a backing material 170 such as a non-woven backing is passed through a scray 172 to a polymer application unit 175 which preferably includes a polymer discharge unit 176 and a doctor blade 177.
• the backing material 170 is coated with a polymer 178 such as a polyurethane-forming composition as disclosed more fully below.
• the backing material 170 is woven or non-woven synthetic fiber material such as 10% to 100% polyester/polypropylene, preferably 50% polyester, 50% polypropylene non- woven fibrous material which is available from Spartan Mills Company in Spartanburg, S.C. While this represents the backing material of preference, it is to be understood that any number of alternative compositions may likewise be utilized as dictated by requirements regarding shrinkage and installation.
• the commonly used secondary backing materials include non-woven polyester, non- woven polyester and polypropylene blends, or woven polypropylene. By way of example only, in instances where very little or no shrinkage may be tolerated, the backing material may be up to 100% polyester.
• non- woven backing material may be preferred, it is contemplated that either woven or non-woven constractions may be utilized as can materials other than polyester, polypropylene, and polyester/polypropylene such as nylon, fiberglass and the like.
• the thickness of the backing material 170 preferably varies in the range of from about 0.01 inches to about 0.19 inches, although a range of between about 0.05 inches and 0.12 inches may be most preferred.
• the polymer application unit 175 applies a deposit of a polymer 178 (FIGS. 3 A, 3B) to the backing material 170 after which the height of the polymer is doctored to a desired level.
• the polymer applied is a polyurethane-forming composition based on a so-called soft segment pre-polymer of MDI (diphenylmethane diisocyanate) or an MDI derivative.
• the polyurethane-forming composition also preferably inco ⁇ orates a silicone surfactant to improve both the frothability and stability of the polyurethane layer or "puddle" which is spread across the surface of the backing material 170.
• the commonly used foam density is 18 lbs. per cubic foot with a thickness of greater than 0.10 inches.
• the preferred density is 16 lbs. per cubic foot with a thickness of 0.06 inches.
• the preferred polyurethane-forming composition for use in the present invention is disclosed in U.S. Pat. No. 5,104,693 to Jenkines the teachings of which are inco ⁇ orated herein by reference.
• the preferred polyurethane-forming composition which is applied across the surface of the carrier backing 170 includes:
• At least one isocyanate-reactive material having an average equivalent weight of about 1000 to about 5000;
• MDI diphenylmethane diisocyanate
• the polyurethane-forming composition also preferably contains a silicone surfactant to improve frothability and stability in the form of an Organo-silicone polymer such as are disclosed generally in U.S. Pat. No. 4,022,941 to Prokai et al. the teachings of which are inco ⁇ orated herein by reference.
• the preferred surfactant is preferably a linear siloxane-polyoxyalkylene (AB) block copolymer and specifically a polyalkyleneoxidemethylsiloxane copolymer.
• AB linear siloxane-polyoxyalkylene
• One such silicone surfactant which is particularly useful is available under the trade designation L-5614 from OSI Specialties, Inc. whose business address is believed to be 6525 Comers Parkway, Suite 311, Norcross, Ga. 30092.
• the silicone surfactants are preferably used in amounts ranging from about 0.01 to about 2 parts per hundred parts by weight of component (A) and more preferably from about 0.35 parts to about 1.0 parts by weight of component (A) and most preferably from about 0.4 to 0.75 parts per hundred parts by weight of component (A).
• the layer or "puddle" of polymer deposited is preferably doctored to a pre-determined height by means of a doctor blade located at the polymer application unit 175. While a simple mechanical doctor blade is preferred, alternative equivalent means such as an air knife or the like may also be used. Such an air knife is disclosed, for example, in U.S. Pat. No. 4,512,831 to Tillotson (hereby inco ⁇ orated by reference herein).
• the primary ca ⁇ et fabric 112 which is preferably joined to reinforcement material 158 to form the j ⁇ i , / o pusile I ⁇ C is laid directly into the polyurethane-forming composition immediately after it is doctored to the appropriate level without any need to significantly heat either the preliminary composite 166 or the polyurethane-forming composition. Accordingly, the preliminary composite 166 and the backing material 170 with the applied polyurethane-forming composition may be simultaneously delivered at room temperature to a mating roll 180 immediately following the application and doctoring of the polyuremane-forming composition.
• the preliminary composite 166 may be slightly preheated to improve operating control during lamination and curing but such preheat is not essential to formation of the desired product.
• the process described above results in the layer of reinforcement material 158 being laid adjacent to and at least partially embedded in the layer of polyurethane 178. That is, the reinforcement material 158 is preferably in intimate contact with the polyurethane 178 such that the polymer material is bonded to the reinforcement material and will hold the reinforcement in place.
• the resulting composite may be heated in a heating unit 182 by means of conduction, radiant, or convection heaters as are well known in the art. Contact conduction heaters may be preferred. Such heating may be carried out at a temperature of between about 250°F and about 325°F for between about 2 minutes and 8 minutes.
• the resulting cured foam or foam cushion layer (FIGS. 3 A, 3B) which is produced thereby has a density of between about 12 pounds per cubic foot and about 20 pounds per cubit foot preferably between about 14 pounds per cubic foot and about 16 pounds per cubic foot, and more preferably about 16 pounds per cubic foot.
• the cushioned ca ⁇ et composite which is formed may be passed over a unidirectional heat sG .ce 135 such a ⁇ plate heater or roll heater at about 400° F to fuse any outstanding fibers on the backing material 170 into a sooth surface.
• the carpet composite, which is formed will thereafter be rolled, cut, sliced, or the like.
• it is prefened that it be cut into ca ⁇ et tiles almost immediately (rather than rolled) to avoid any undesired cupping or curl. After the carpet tiles are cut from the composite, they are stacked, packaged and stored or shipped to the customer or store.
• the reinforcement material 158 may be left completely out of the process thereby making the use of the adhesive application apparatus 155 and adhesive 160 completely unnecessary.
• the primary ca ⁇ et fabric may be laid directly into the polyurethane- forming composition thereby yielding a composite structure as illustrated in FIGS. 4A and 4B with the polyurethane 278 immediately adjacent to the primary ca ⁇ et fabric 212 and as described in U.S. Patent No. 6,203,881 hereby inco ⁇ orated by reference.
• a hot melt layer may be used to mate the primary carpet to the cushion layer with or without the reinforcement material (Fig. 12).
• a hot melt layer may be used to mate the primary carpet to the cushion layer with or without the reinforcement material (Fig. 12).
• the backing 170, 270 may have an adhesive quick release backing attached to the face to which the polyurethane-forming composition is not applied.
• a quick release backing will permit the ca ⁇ et to be readily installed and removed without damaging the polyurethane cushion 178, 278.
• the backing 170, 270 might be completely eliminated such that the polyurethane cushion 178, 278 would directly contact the flooring as disclosed in relation to U.S. Pat. No. 4,286,003 which is inco ⁇ orated herein by reference.
• an adhesive-free ca ⁇ et and method is described for example in co-pending U. S. Patent Application Serial No.
• caipet tiles for adhesive- free installations have a cup of about 3/16 inch or less and a curl of 1/16 inch or less.
• the tufted surface covering, tufted low weight modular ca ⁇ et or low weight modular ca ⁇ et tile of the present invention may have the following layers: yarn, primary backing, latex pre-coat adhesive, hot melt adhesive, fiberglass, polyurethane foam, and felt (Fig. 10A), it is contemplated that one or more of these layers may be eliminated or substituted for and still provide a low weight carpet or tile having the desired properties or characteristics.
• the latex pre-coat adhesive layer may be replaced by a bitumen hot melt layer (Fig. 11)
• the felt layer may be eliminated on a free lay (no floor adhesive) installation product (Fig. 16)
• the glass layer may be el iinated (Fig. 12), or the like.
• FIG. 5 An alternative process and apparatus for producing a cushioned ca ⁇ et composite according to the present invention is shown schematically in FIG. 5.
• a primary ca ⁇ et fabric 312 having either a tufted or a bonded configuration is drawn from a mounted ca ⁇ et roll 314, through an accumulator 350, in the same manner described above.
• a reinforcement material 358 such as a non-woven glass is delivered to a polymer contact roll 360 or similar device such as an extrusion coater.
• the polymer contact roll 360 preferably is in rolling contact with both the surface of the reinforcement material 358 as well as with an accumulation of a polymer 378 such as the polyurethane- forming composition previously described.
• the polymer contact roll 360 serves to pick up a portion of the polymer 378 and to pass the polymer over and through the reinforcement material 358.
• a backing material 370 such as the non-woven polyester/polypropylene described above is preferably passed in adjacent mating relation to the polymer-coated reinforcement material 358 between the polymer contact roll 360 and a backing material mating roll 379.
• a doctor blade 377 serves to control the depth of the polymer which does not pass through the reinforcement material 358 into contact with the backing material 370.
• a polymer sandwich structure is formed preferably comprising a layer of backing material 370, a relatively thin layer of polymer 378 such as polyurethane which has been passed through a layer of reinforcement material 358, and a doctored layer of polyurethane 378 which was not passed through the reinforcement material 358.
• This polymer sandwich structure can thereafter be passed to the mating roll 380 for joinder with the primary ca ⁇ et fabric 312 by laying the primary ca ⁇ et fabric 312 directly into the doctored layer of polyurethane 378 without any pre-curing operation. Thereafter, the composite is heated, cured, and rolled or cut.
• a potentially preferred configuration for a resulting tufted ca ⁇ et composite is illusfrated in FIG. 6A.
• the reinforcement material 358 will be at least partially surrounded by, and embedded in, the polyurethane 378. As illusfrated, it is contemplated that the layer of pre-coat may be eliminated in the tufted stracture since the tufts may be held in place by the polyurethane 378. A potentially preferred configuration for a resulting bonded ca ⁇ et composite is shown in FIG. 6B.
• the reinforcement material and hot melt layers can be eliminated simply by not feeding the reinforcement 358 along with the felt 370 and primary ca ⁇ et 312.
• a further alternative process and apparatus for joining all layers of the cushioned ca ⁇ et composite is illusfrated in FIG. 7.
• a layer of reinforcement material 358 is preferably passed adjacent to a polymer contact roll 360 which is in simultaneous rolling contact with both the reinforcement material 358 and a deposit of polymer 378.
• the polymer contact roll 360 serves to spread a portion of the polymer 378 through the reinforcement material 358 to create a coating on both sides thereof.
• the reinforcement material 358 with its coating of polymer 378 is then joined in a laminate stracture to the primary ca ⁇ et fabric 312 and a layer of backing material 370 by passage through the nip between the doctor blade 377 and backing material mating roll 379. Thereafter, the composite is heated, cured, and rolled or cut. This practice will yield a bonded ca ⁇ et composite structure substantially similar to those which are illusfrated in FIGS. 6A and 6B.
• the designs that are printed on the low weight modular ca ⁇ et or ca ⁇ et tile are preferably characterized as orientation independent or as having the ability to seam properly without cutting the tiles in register with the design.
• the techniques used to create these designs make it possible to install modular ca ⁇ et monolithically rather than quarter turn or ashler.
• the commonly used techniques of modular ca ⁇ et installation such as quarter turn (parquet), monolithic, and ashler (brick) may be used to install low weight ca ⁇ et or ca ⁇ et tiles of the present invention.
• the prefened technique is monolithic or ashler.
• a floor adhesive may or may not be used depending on whether the ca ⁇ et or tile is designed for adhesive-free installation or conventional adhesive installation.
• the ca ⁇ et tile may be self-stick and contain an adhesive quick release backing attached to the face of the backing 170, 270 opposite the polyurethane foam.
• the felt and hot melt layers can be eliminated by, for example, feeding the primary ca ⁇ et 314 through an apparatus similar to that shown in Fig. 5 of the drawings, except that the ca ⁇ et is inverted and the polymer layer or layers are applied directly to the reinforcement material and/or lower surface of the primary ca ⁇ et.
• the reinforcement material such as glass is eliminated by not feeding the reinforcement material along with the ca ⁇ et and polymer.
• the low weight modular ca ⁇ et tile of Example I below was tested using a hexapod test as described below.
• test specimen was subjected to the reported cycles of "Hexapod" tumbling, removing the specimen every 2,000 cycles for restoration by vacuuming.
• Electrolux upright vacuum cleaner (Discovery II) was used, making four (4) forward and backward passes along the length of the specimen.
• the samples were assessed using daylight equivalent vertical lighting (1500 lux). Samples were viewed at an angle of 45 degrees from 1 l A meter distance, judging from all directions.
• the samples were also measured for pile height before and after testing to obtain a pile height retention value.
• a tufted ca ⁇ et was produced by the apparatus and process as illustrated and described in relation to FIG. 2.
• the ca ⁇ et produced has the configuration illustrated and described in relation to FIG. 3A.
• the production parameters were as follows: Yam 15 ounces per sq. yd. nylon 6,6 loop pile continuous filament
• Non-woven 50% polypropylene, 50% polyester
• a tufted ca ⁇ et is produced by the apparatus and process as illustrated and described in relation to FIG. 2.
• the ca ⁇ et has the configuration illustrated and described in relation to
• FIG. 3 A The production parameters are as follows:
• Non-woven 50% polypropylene, 50% polyester
• a tufted ca ⁇ et is produced by the apparatus and process as illustrated and described in relation to FIG. 2.
• the ca ⁇ et has the configuration illusfrated and described in relation to FIG. 3 A.
• the production parameters are as follows:
• Non- woven 50% polypropylene, 50% polyester
• a tufted ca ⁇ et is produced by the apparatus and process as illustrated and described in relation to FIG. 5.
• the ca ⁇ et has the configuration illustrated and described in relation to FIG. 6 A.
• the production parameters are as follows: Yarn 15 ounces per sq. yd. nylon 6,6 loop pile continuous filament, white, 1350 denier, not plied, not twisted, not heat set
• Non-woven 50% polypropylene, 50% polyester
• a tufted ca ⁇ et is produced by the apparatus and process as illustrated and described in relation to FIG. 19.
• the ca ⁇ et has the configuration illusfrated and described in relation to FIG. 18.
• the production parameters are as follows: Yarn 15 ounces per sq. yd. nylon 6,6 loop pile continuous filament, white, 1350 denier, not plied, not twisted, not heat set
• Gmax - Gmax simulates footfall onto a surface. The measure is reported as multiples of "g" (gravities), or Gmax. The lower the value, the lower the force upon impact, and the more comfortable underfoot the product feels. The higher the value, the higher the force upon impact, and the less comfortable the ca ⁇ et feels.
• Cushion Resilience - Cushion resiliency measures the rebound percent of a metal ball when dropped from a standard height. It shows the shock absorbing character of the cushion, which helps reduce visible wear of the ca ⁇ et face. The higher the value, the higher the rebound percent, and the more resilient the cushion.
• Appearance Retention Rating (ARR) - the ARR value is determined by grading the appearance change of ca ⁇ et subjected to exposure conditions in accordance with either the ASTM D-5252 (Hexapod) or ASTM D-5417 (Nettermann) test method using the number of cycles for short and long-term tests specified.
• the low weight modular ca ⁇ et tile of the present invention had an APR of about 4.0 short term and 3.5 long term.
• the low weight polyurethane cushion back ca ⁇ et tile of the present invention is very durable and can withstand 25,000 cycles or more of the caster chair test without failure.
• the low face weight primary ca ⁇ et preferably has a face weight of less than 15 oz/yd , more preferably 12 oz/yd 2 or less.
• the low weight ca ⁇ et tile of the present invention is unexpectedly very merchantable and commercially viable due in part to its reduced cost; look, wear, and cushion characteristics; seamability; patterned monolithic design; uniformity of appearance between tiles; constant shade; durability; less crush; short pile; dense surface; and combinations thereof.
• One method used to achieve sufficient yarn coverage, suitable for patterning and resilience in commercial use, on the low face weight ca ⁇ et tile of the present invention is to utilize a singles yam of sufficient denier, in the range of lOOOd and 1400d, in a non- heatset form. By using non-heatset yarn, the shrinkage which normally takes place in heatsetting (typically about 11%), now takes place in the wet processing of dyeing the tufted ca ⁇ et.
• the ca ⁇ et enters the continuous dye steamer, where the yarn bulks (shrinks -11%) in the formed fabric of the ca ⁇ et, thus dramatically increasing the coverage of the ca ⁇ et face, lowering the pile height, and making a much denser face fabric.
• the positive result of this post fabric formation shrinkage is better ca ⁇ et performance with low density face weight, and improved aesthetic appearance due to the improved coverage.
• an open cell foam such as a polyurethane foam in the foam or cushion backing.
• each file is easier to handle during installation, easier to cut, and easier to bend.
• foam cushion there are at least four options or examples of the foam cushion to obtain low weight, commercially acceptable foam products using polyurethane.
• a third option would be to use an unfilled polyurethane (Prime urethane) system. High densities such as above are not possible with prime however, they perform because of the wall structure and the fact that no filler is present If we consider a prime to be at 6 #/cu. ft. applied at the thickness limits above the polymer weight would be 2.88 - 8.64 oz/sq. yd. 4) A fourth option is also possible. Textile Rubber has a polyurethane system available called "Kangahide" which has only 15 parts of a filler material and is applied at 6 - 9 lb/cu. ft. density, if a polymer calculation is again made at the describe thickness limits it would be 4.3 - 13.02 oz/sq. yd. Although the above examples have to do with Polyurethane, a water based foam system can also be used.
• the ca ⁇ et composite may be cut into tiles and then each cut tile may be printed.
• the cut tiles or blanks may be jet dyed or dye injection printed. This provides for improved design or pattern registration on the tiles and allows for monolithic installation of complex designs.
• the invention relates to a single 1350d, white ca ⁇ et yam that is tufted into a backing.
• the face weight is usually about 12 ounces/yd 2 .
• the resulting face fabric is weak, and has many "holes" where the backing is visible through the face.
• the face is applied to a cushion backing by a hot-melt resilient layer.
• the ca ⁇ et is passed through the broadloom Millifron jet dye process, whereby the steam and dry heat involved in the dye fixation process shrink the tuft yams. The shrinkage results in short, dense tufts that are durable and have good appearance.
• the roll is then cut into tiles and shipped.
• the low weight cushion backed ca ⁇ et of the present invention provides for one or more of the following:
• Backing a. Different backing - polypropylene (woven) b. Nylon cap (for functionality)

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• Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)

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  • 2001-05-31 CA CA002410155A patent/CA2410155A1/en not_active Abandoned
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