JP2020521591A - Floor covering having general-purpose backing, and method of manufacturing and recycling the same - Google Patents

Abstract

Dimensionally stable universal floor coverings include tufted fibers with stitches, reinforcement layers operably bonded to the stitches to provide dimensional stability throughout the floor covering. The reinforcement layer operably associated with the stitch is made of fibers and an adhesive that are molded into a reinforcement layer of laminated fibers, and/or the fibers and the adhesive adhere to the fibers contained within the stitch. Molded into layers of agent. The fibers and adhesive are mixed and then moved by an applicator towards the stitch. A curved sliding path is formed in the curved portion of the applicator to improve the transfer of fiber and adhesive to the stitch. A removable tip on the end of the curved portion of the applicator improves the penetration of the adhesive and presses the fiber against the end of the stitch. A peelable adhesive cover system is provided over the fibrous layer to provide additional strength and stability, and to allow the universal floor covering to be removably attached to a support surface.

Description

CROSS REFERENCE TO RELATED APPLICATIONS The present invention claims priority to US Provisional Application No. 61/797,496, filed December 10, 2012, and is now US Patent No. 9339136. Filed on April 14, 2016, which is a continuation-in-part of US patent application Ser. No. 14/090,190, filed November 26, 2013, and is now US Pat. No. 9506175. U.S. Patent Application No. 15/155,348 filed May 16, 2016, which is a continuation-in-part of U.S. Patent Application No. 15/098,509 and is now U.S. Patent No. 9681768. , Which is a continuation-in-part application of US patent application No. 15/372,465 filed on Dec. 8, 2016, which is now a US patent No. 9775457. Co-pending US patent application Ser. No. 15/607,789 filed May 30, 2013, the entire disclosures of which are hereby incorporated by reference. ..

The present disclosure is directed to the field of textile floor coverings such as wide carpets and modular carpet tiles, and in particular to general purpose textile floor coverings having a fiber reinforced polymer backing. More particularly, according to one or more aspects provided herein, the present disclosure is directed to floor coverings including tufted backing and a general backing system, and manufacturing such floor coverings. It also covers how to install, recycle and recycle.

With the advent of tufting equipment, floor coverings have evolved over time from woven carpets to the tufted carpets used today. Mechanical tufting started with a single needle, similar to a sewing machine. A needle carries a thread through the primary backing substrate, which creates a stitch on the backside adjacent the primary backing substrate. On the surface, a looper holds the yarn at a specific height above the primary backing substrate, forming a pile of carpet. The tufted yarn and primary backing substrate are collectively referred to as the tufted backing.

Single needle configurations have evolved into multiple needles working side by side, and tufted carpets are now made this way. A tufting width of up to 16 feet is possible with this facility, and if such a carpet is sold in this width it is referred to in the industry as a "broad" carpet. Carpets of this type are the preferred floor coverings in today's residential and commercial buildings.

Modular carpet products (carpet tiles) have been introduced to address some of the problems faced by wide carpet products. Modular carpets are not practical for wide carpets because individual tiles in the equipment can be removed and replaced when they become dirty or worn, such as in offices, airports, and other busy areas. It was useful in the application.

Both wide carpet and tile carpet designs have faced stability challenges and problems. Without another reinforced bedding and/or one or more secondary backing layers, wide carpet designs tend to "grow", which leads to undesired stretch. Modular tiles with a heavy backing layer are stiff. As a result, modular tiles tend to be bowl-shaped or curled. Another problem with modular tiles and wide carpets arises due to problems with variations in thickness and weight. In today's carpet designs, separating and recycling different chemical compositions and components of multiple backing layers and preformed reinforcing layers from the yarns allows multiple layers made of different materials to be joined and used. It is virtually impossible because it has been done. In addition, floor covering manufacturers have multiple backing layers, preformed reinforcement layers, and significant material costs associated with different materials, and expensive manufacturing or processing procedures.

With regard to stability, it is known in the carpet industry that the machine direction of the carpet contributes the most to dimensional stability issues. The "machine direction" is considered to be the direction in which the yarn is tufted. Yarns that form a series of continuous loops in the machine direction are inherently unstable, especially when exposed to heat and/or moisture. Furthermore, the primary backing substrate tends to shrink more in the machine direction of the floor covering. Therefore, the machine direction is almost always the direction in which the bedding will become more unstable.

There has been a need for lower cost, dimensionally stable floor coverings that can be used as wide products or any of a variety of modular products. Although the referenced related patent application discloses a new and unique universal carpet having a backing layer for reinforcement in the past, different beneficial innovations and discoveries herein enhance and improve the universal carpet invention. Disclosed and claimed.

Related patent applications are primarily directed to dimensionally stable floor coverings with general purpose fiber reinforced backings. Floor coverings may be used in wide products or any of a variety of modular products. The method of manufacture and the resulting product include a tufted backing having a primary backing substrate and a plurality of yarns tufted through the primary backing substrate. The primary backing substrate comprises a front surface and a back surface opposite the front surface, and a portion of each thread forming a stitch disposed on the back surface of the primary backing substrate.

A preferred method of manufacture and the resulting product includes forming wet-laid, laminated, fiber-reinforced layers that are substantially parallel to the machine direction, thereby imparting dimensional stability to the floor covering. This preferred method of manufacture and product also provides other benefits, including the same primary backing substrate can be used in all types of floor covering products, thereby providing current advantages over preformed reinforcement layers. Removing requirements simplifies the manufacturing process and reduces costs. In addition, the production method of the present invention includes, for example, forming a layer of the fiber and the adhesive between the fiber-reinforced layer and the primary backing substrate, or a single layer of the fiber and the adhesive arranged in and between stitches. It also includes forming.

In a preferred method of manufacture, pressure is applied in a controlled manner between the applicator and the tufted backing to move the composite of adhesive and reinforcing fibers in a direction toward the backside of the primary backing substrate. The fibers are predominantly aligned to extend predominantly in the machine direction while the tufted backing is moved in the machine direction under controlled pressure applied to the composite of fibers and adhesive. This manufacturing method also filters the adhesive and the reinforcing fibers in situ so that the adhesive is separated from the reinforcing fibers. The adhesive is forced into the void space of the thread and the fibers are strained from the adhesive. Wet-laid, laminated, fiber-reinforced layers are formed that are substantially parallel to the direction of movement of the tufted backing, which provides dimensional stability to the entire floor covering. In an alternative related method of the preferred method of manufacture, a fiber and adhesive reinforcing layer is formed between the fiber reinforcing layer and the primary backing substrate, or a single fiber and adhesive reinforcing layer is stitched. Formed on and in contact with the primary backing substrate.
Inventions previously disclosed and inventions disclosed herein also include, but are not limited to:
a. A method of selecting tufted yarns, primary backing substrates, reinforcing fibers, and adhesives to provide the desired performance characteristics to be exhibited in universal wide carpets and modular carpets,
b. A method of selecting an equipment arrangement for applying adhesive and reinforcing fibers to a tufted backing,
c. Adhesives and fibers are conditioned by selectively mixing the reinforcing fibers into the adhesive and/or injecting compressed air into the adhesive and reinforcing fibers to provide a desirable composite of adhesive and reinforcing fibers. To help you to be in condition and place,
d. Selective use of vacuum, pressure control devices, and/or peel applicators, for example, to move the adhesive into multiple stitched portions of the thread or into the backside of the primary backing substrate, such as in the applicator. The fibers and the adhesive move into the space between the stitched parts before or during the application of pressure to the tufted backing, or the adhesive and the fibers are separated from the applicator and Providing a lubricated sliding path between the adhesive/fiber mixture and the applicator to move the fiber/mixture to the end of the stitch to ensure that the adhesive and/or fiber is To be able to move,
e. To achieve desired properties and designs for general purpose carpet by selectively using, moving and setting applicator placement,
f. Producing the desired general purpose carpet in either a broad product or a modular product by controlling the pressure applied by the applicator and the speed of movement of the tufted backing,
g. Controlled cutting of roll-shaped wide and modular carpets for transportation and installation,
h. Recycling the general purpose carpet so that the tufted carpet components and reinforcing fibers remain when necessary, and i. In a preferred embodiment, a peelable adhesive cover system with gecko-like, non-adhesive properties is used to provide additional stability in the machine direction so that the carpet can be removably attached to a support surface. To do.

These and other features and benefits of the present invention will be better understood with reference to the following description and appended claims. The accompanying drawings, which form a part of this specification, illustrate various embodiments of the invention and, together with the description, serve to explain the principles of the products and methods of the invention.

The complete and practicable disclosure, including the best mode, for the present products and methods is described herein for the person of ordinary skill in the art, and the specification refers to the accompanying drawings.
FIG. 4 is a schematic diagram of an equipment arrangement for applying adhesive layers and reinforcing fibers to a tufted backing fabric that may be used in the production of floor covering products of the invention described herein. FIG. 6 is a partial perspective view of an applicator and a movable tufted backing fabric that operates to produce the inventive floor covering product described herein. FIG. 3 is a cross-sectional view of FIG. 2, showing the use of one or more vacuums and mixing of the adhesive and the composite of reinforcing fibers. FIG. 4 is a detailed schematic diagram of the primary backing substrate, stitches, and small cross-sections of fibers after using the first vacuum in FIG. 3, the vacuum being applied before the applicator applies pressure to the tufted backing; Meanwhile, it is operating at a high level of controlled vacuum to move the fibers and adhesive into the space between the stitched portions. Primary backing substrate, stitches, fibers, and fiber reinforcement after using a first vacuum, a high level of controlled vacuum, and applying pressure in a controlled manner between the applicator and the tufted backing FIG. 3 is a detailed schematic diagram of a small cross-sectional portion of a layer. A small cross-section of the primary backing substrate, stitches, and fiber reinforcement layers after using a first vacuum in FIG. 3 and applying pressure in a controlled manner between the applicator and the tufted backing fabric in FIG. It is a detailed schematic diagram of. A small cross-sectional portion of the primary backing substrate, stitches, and fiber reinforcement layers in FIG. 3 after using a second vacuum and after applying pressure in a controlled manner between the applicator and the tufted backing fabric in FIG. It is a detailed schematic diagram of. FIG. 3 is a cross-sectional view of FIG. 2 showing the use of one or more vacuums and injection of compressed air when mixing the adhesive and reinforcing fiber composite. Application of adhesive layers and reinforcing fibers to tufted backing, use of vacuum, and mixing of adhesive and reinforcing fiber composites that can be used in the production of floor covering products of the invention described herein. It is a schematic diagram of equipment arrangement for injecting compressed air at the time of performing. Details of small cross-sections of the primary backing substrate, stitches, and fiber reinforcement layers after using a vacuum in FIG. 6 and after applying pressure in a controlled manner between the applicator and the tufted backing fabric in FIG. It is a schematic diagram. FIG. 3 is a schematic diagram of an embodiment of an equipment arrangement for cutting and winding the general purpose floor covering described herein. FIG. 8 is a schematic diagram of another embodiment of an equipment arrangement for cutting and winding the general purpose floor covering described herein. FIG. 8B is a partial cross-sectional view of an embodiment of an equipment arrangement for cutting and winding the universal floor covering shown in FIG. 8A. FIG. 6 is a schematic diagram showing another embodiment of using a pressure control device and an applicator to form a fiber and adhesive mixture in the space between the fiber reinforcement layer and the stitched portion. FIG. 6 is a schematic diagram showing yet another embodiment of using a pressure control device and an applicator to form a mixture of fibers and adhesive in the void spaces of the fiber reinforcement layer and the stitched portion. FIG. 11 is a schematic top view of an embodiment of the pressure control device disclosed in FIGS. 9 and 10. Embodiments of the present invention that include a peel applicator and methods of forming a peelable tacky cover having gecko-like, non-tacky properties that allow a carpet to be removably attached to a support surface. It is a schematic diagram which shows an illustration. FIG. 6 is a schematic cross-sectional view of an embodiment of a primary conditioning/smoothing member that may be used in a method of forming a peelable adhesive cover having gecko-like, non-adhesive properties. FIG. 5 is a cross-sectional schematic view of an embodiment of a secondary adjustment member that may be used to form a peelable adhesive cover. FIG. 3 is a partial cross-sectional view of an exemplary universal carpet having one embodiment of a peelable adhesive cover and an embodiment of an arrangement for cutting a universal carpet having a peelable adhesive cover. It is a schematic diagram of another embodiment of a peelable adhesive cover. The cross-sections shown are those along the machine direction of the product (ie, the direction in which the carpet product is tufted and coated).

With reference to details of embodiments of the products and methods of the present invention, one or more examples of embodiments are illustrated in the drawings. Each example is provided by way of explanation of the invention, not as a limitation of the invention. It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. Accordingly, the present invention is intended to cover such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 is a schematic diagram of an arrangement according to the present invention for applying an adhesive and reinforcing fibers to a tufted backing fabric to form a general reinforcing backing layer 10. The reinforcing backing layer 10 is used in both wide and modular floor coverings. The floor covering shown in FIG. 1 comprises a tufted backing 12 made by tufting threads 14 in a first direction through a primary backing substrate 16. As is known, the primary backing substrate 16 and tufted backing 12 have a front surface and a back surface opposite the front surface. The threads 14 form stitches 18 on the back surface of the primary backing substrate 16 and there is a void space between each thread 14. The reinforcing backing layer 10 includes an adhesive 20 and a plurality of fibers 22 wrapped with the adhesive 20 to create a continuous fiber layer 24 on the back surface of the tufted backing 12.

The tufted backing 12 is moved relative to the applicator 26, as shown schematically in FIG. A composite containing a mixture of adhesive 20 and reinforcing fibers 22 is moved into the space between stitch 18 and applicator 26. Pressure is applied between the applicator 26 and the tufted backing in a controlled manner to move the adhesive and fiber composite in a second direction toward the backside of the primary backing substrate 16.

The fibers 22 are aligned with each other in a first direction, while the tufted backing fabric 12 is controlledly moved in a first direction, i. That is, the fiber reinforcing layer 24 is formed substantially parallel to the machine direction. Simultaneously with the controlled movement of the substrate 12 and the application of pressure by the applicator 26, the adhesive and fiber composite is strained in situ, causing the adhesive 20 to move into the interstitial space between the threads 14. The adhesive is separated from the fibers 22 as is done. The fibers 22 are prevented from entering the space of the gap, and the fibers 22 are laminated to each other by an adhesive to form a continuous wet-laid fiber reinforcement layer 24 that is substantially parallel to the first direction. After curing, the fiber reinforcement layer and the separated adhesive provide dimensional stability to the entire floor covering.

FIG. 2 is a partial view of an arrangement for applying adhesive and reinforcing fibers to a tufted backing to form a universal reinforced backing that can be used in wide flooring and modular flooring. The tufted backing 12 has a belt 28 in a first or machine direction such that the tufted backing 12 contacts a composition or mixture of adhesive 20 and reinforcing fibers 22 disposed within a housing 30. Is moved by (Fig. 3).

In accordance with one aspect of the present invention, as shown in FIG. 3, the surface and primary surface of tufted backing 12 prior to applying pressure between applicator 26 and tufted backing 12 in a controlled manner. A vacuum tube 32 is placed to apply a vacuum to the backing substrate 16. The use of vacuum 32 helps move the adhesive and fiber composite in a direction toward the backside of the primary backing substrate 16. Also, applying a vacuum during movement of the backing and prior to applying pressure at applicator 26 also helps align and align the reinforcing fibers 22 before squeezing the reinforcing fibers 22 from the adhesive 20. Also, applying a vacuum prior to applying pressure also helps hold the fibers tightly to each other and to the stitch 18 to prevent the fibers from slipping and to aid in forming the non-woven fiber reinforcement layer 24. ..

FIG. 3A illustrates a high level of controlled vacuum via vacuum tube 32 to move fibers 22 into the space between stitched portions 18 before applicator 26 applies pressure to primary backing substrate 16. FIG. 4 is a detailed view of a small cross-section of the primary backing substrate 16, stitches 18, and fibers 22 when pulled. In certain carpet specifications, the machine-direction fiber-reinforced layer 24 is reinforced or independent with respect to the machine-direction fiber-reinforced layer 24, which alone as described above, provides dimensional stability to the entire floor covering, It may be desirable to have strength from the fibers in the spaces between the stitched portions.

Depending on the amount of vacuum and the operational alignment between the vacuum tube 32 and the applicator 26, the amount of fibers 22 in the space between the stitched portions 18 and the final location of movement of the fibers 22 can be, for example, It can be controlled to form a fibrous layer to engage the primary backing substrate 16 when greater strength is desired. Thus, FIG. 3B is only one configuration of fibers 22 that occurs in response to the amount and time of vacuum and the operational alignment of both vacuum tube 32 and applicator 26.

FIG. 3B illustrates applying pressure in a controlled manner between applicator 26 and backing substrate 16 after using a high level of controlled vacuum to move fibers 22 into the space between stitched portions 18. FIG. 4 is a detailed view of the primary backing substrate 16, stitches 18, fibers 22, and fiber reinforcement layer 24 after being crushed. As shown in the embodiment of FIG. 3B, a fiber reinforcement layer 24 confines the fibers 22 and adhesive 20 in the space between the stitched portions 18. The amount of pressure and movement applied by the applicator 26 to the primary backing substrate 16 controls the position and orientation of the fibers 22 in the space between the stitched portions 18.

Due to the equipment and operational structures illustrated and described in connection with FIGS. 3A and 3B, the individual movements and locations of the fibers 22 and adhesive 20 into the spaces between the stitched portions and/or the fibers 22. And the adhesive 20 results in integral movement and location and/or formation of a fibrous layer that engages the stitched portions.

The primary backing substrate 16 is porous and the threads penetrate into the backing substrate 16 to increase the porosity of the backing substrate. Due to this porosity, the vacuum at the surface of the backing substrate 16 causes the adhesive 20 to penetrate completely into the space between the substrate 16 and the fibrous layer 24, including penetrating into the stitches 18. To do. FIG. 4A shows that the adhesive 20 has penetrated into the space between the substrate 16 and the fiber layer 24. It is also advantageous for selectively controlling the vacuum so that the primary backing substrate 16 receives a controlled amount of adhesive. For example, a polypropylene woven primary backing substrate may have a layer of adhesive within it of about 5% of the thickness of the backing substrate as a result of the vacuum, whereas a polyester non-woven primary backing substrate. The vacuum can be controlled so that the substrate can have a layer of adhesive within it about 25% of the thickness of the backing substrate as a result of the vacuum. The adhesive layer formed in the primary backing substrate 16 by the vacuum increases the strength of the primary backing substrate 16 and bonds the threads 14 together for quality improvement.

FIG. 3 shows another vacuum tube 34 for applying a vacuum to the tufted backing 12 surface and the primary backing substrate 16. A vacuum through tube 34 occurs after applying pressure in a controlled manner between applicator 26 and tufted substrate 12. After applying a vacuum through the vacuum tube 32 and after applying a pressure controlled by the applicator 26, the fibers wrapped in the adhesive for laminating the fiber reinforcement layers on each other are removed and the fiber layer 24 is removed. Is substantially free of adhesive. As shown in FIG. 3, FIG. 4B, and FIG. 5, a vacuum is further applied through the tube 34 to form the bonding portion 36. The bond site 36 allows mechanical attachment and/or bonding with other layers of materials such as thermoplastics.

As shown in FIG. 3, a mixer 38 is placed in the composite of adhesive 20 and reinforcing fibers 22, either before and/or while applying a vacuum through tube 32. Then, mix the adhesive and the fiber. The mixing of the adhesive and the fibers hinders the soft assemblage of the reinforcing fibers 22, which allows the fibers 22 to be placed in a better location due to the vacuum as described above.

FIG. 5 illustrates another aspect of the invention in which a mixing chamber 40 is provided that includes a mixer 42 that mixes the fibers 22 and the adhesive 20 with the injected compressed air. Injecting compressed air into the adhesive/fiber mixture allows them to pass individually from the mixing chamber 40 to the housing 30 and then further into the space between the applicator 26 and the stitching portion 18. Space is provided between the fibers of the. Injecting air also helps prevent soft ensemble and helps disperse the fibers to form a more uniform fiber reinforcement layer 24. Another benefit of injecting air is an increase in the viscosity of the adhesive, which helps the fibers to form as layers during the filtration process described above.

6 and 6A illustrate another embodiment of the invention in which applicator 26 contacts tufted backing 12 and applies pressure to provide a vacuum in a direction past primary backing substrate 16. The vacuum from the applicator 26 occurs at the same time as the applicator 26 applies a controlled pressure to the primary backing substrate 16. In this embodiment of the invention, the composite of adhesive 20 and fibers 22 as previously disclosed is urged or pressed to move toward the backside of the primary backing substrate 16. Further, the fibers 22 are aligned and extend predominantly in the machine direction while the tufted substrate 12 is moving under pressure with an applicator 26 to form a fiber layer 24 that is substantially parallel to the machine direction. .. The adhesive/fiber composition is then filtered in-situ so that the adhesive is pulled by the vacuum into the space between the primary backing substrate 16 and the stitched portion 18.

While the carpet is moving relative to applicator 26 in FIG. 6, a thin layer 44 of adhesive is formed on fiber reinforcement layer 24 (FIG. 6A). Depending on the applicator 26 and vacuum configuration as shown in FIG. 6 and the location of engagement of applicator 26 with thread 14, it engages stitch portion 18 on one side, as previously disclosed. The fiber reinforcement layer 24 is formed. In addition, a thin layer 44 of adhesive only is formed on the opposite side of the fiber reinforcement layer 24, as shown in FIG. 6A. The thin layer of adhesive 44 obviates the need to cover the otherwise exposed surface of the reinforcement layer 24 with any other type of adhesive such as polyethylene, PVC, or foam.

In the embodiment of the invention of FIG. 1, applicator 26 engages a puddle of adhesive 20 and fibers 22, while in the embodiment of the invention of FIGS. 6-6A applicator 26 engages only thread 14. To do. The tufted backing 12 in both embodiments is moved relative to the applicator 26 to provide a space between the stitched portion 18 and the applicator 26, and in both embodiments adhesive 20 and fiber 22 puddle. And in both embodiments pressure is applied in a controlled manner between applicator 26 and tufted backing 12 to push adhesive 20 and fibers 22 toward the backside of primary backing substrate 16. In both embodiments, the fibers 22 are aligned during the movement of the tufted backing 12 under pressure such that the fibers 22 are aligned and substantially parallel to the machine direction. And in both embodiments, the adhesive/fiber composition is used to push the adhesive out of the reinforcing fibers and to push the adhesive into the interstitial spaces between the threads 14. Filtered in place. Also, both embodiments of the invention provide a vacuum to move the adhesive to the stitched portion of the thread and to the back of the primary backing substrate to provide dimensional stability. Further, in both embodiments, the adhesive/fiber composition is mixed and/or compressed air is injected into the adhesive/fiber composition to condition the adhesive/fiber composition to exert pressure. Helps to get the preferred state before adding. Although there is no difference in functionality between the embodiment shown in FIG. 1 and the embodiment shown in FIGS. 6 and 6A, the physical arrangement of applicator 26 and vacuum in FIG. 1 as compared to FIGS. The difference results in the formation of a thin adhesive layer 44 of additional benefit, which eliminates the potential need to cover the otherwise exposed surface of the reinforcement layer 24 after curing.

The vacuum applicator disclosed in FIG. 6 can also be used with a pool of only the adhesive 20 that does not include the fibers 22. When used in this manner, a vacuum is directed through the porous primary backing substrate 16 to penetrate the adhesive 20 into the interstitial spaces between the threads 14 and into the stitches 18. The vacuum can be selectively controlled so that the primary backing substrate 16 also receives a controlled amount of adhesive as described above. Therefore, the applicator 26 in FIG. 6 is flexible so that it can be used with the adhesive 20 alone, or the adhesive 20 can be used with the fibers 22.

As mentioned above, in each of the embodiments of the present invention, applicator 26 applies sufficient pressure in a controlled manner to direct the composite of adhesive 20 and fibers 22 toward the backside of primary backing substrate 16. Move to. The pressure or compression force applied by the applicator 26 depends on the configuration of the applicator 26, the linear velocity of the reinforcing backing layer 10, the viscosity of the adhesive 20, and the diameter/weight of the fibers 22. The pressure of the applicator is sufficient to move the adhesive 20 into the interstitial space between the threads 14, and if desired, the adhesive 20 may be removed as shown in FIGS. 4A, 4B, 6A. Sufficient to move into the stitch 18 on the back of the backing substrate 16. The pressing force or compressive force applied by the applicator 26 is also sufficient to remove the adhesive 20 from the fiber layer 24 other than that required for laminating the fiber layer 24. 3, 5 and 6 control the applicator pressure so that the applicator pressure is sufficient to move the adhesive 20 into the interstitial spaces between the threads 14 and into the stitches 18. The structure of the applicator 26 for doing so is shown. In FIGS. 3 and 5, the rotatable applicator 26 has a crescent or partially circular shape at one end and a counterweight (not shown) at the other end. The counterweight can be removed or added in response to the pressure applied by the applicator 26 to control the migration of the adhesive 20 and fiber 22 composition in the direction toward the backside of the backing substrate 16. You can FIG. 6 shows the applicator 26 also including a vacuum so that the applicator exerts controlled pressure as described above so that the vacuum helps to form the layer 44 (FIG. 6A).

The floor covering embodiments disclosed in Figures 1-6A can be recycled so that only washed tufted carpet and open reinforcing fibers remain. Floor coverings made in accordance with the present invention can be transported through a steam chamber where the floor covering is exposed to steam to dissolve the adhesive composition. This allows the tufted carpet, reinforcing fibers, and adhesive to be separated from each other and recycled.

FIGS. 7, 8A and 8B show two embodiments of the equipment arrangement for cutting and winding the general-purpose floor covering 50 described above. Referring to the first embodiment of FIG. 7, a universal floor covering 50 including a tufted backing 12 and a backing layer 10 has a plurality of fastenings at designed intervals along the length of a roll 56 of the universal floor covering. It is periodically and selectively cut by the fixing pattern cutting roller 52 for forming the pattern 54. For modular carpets, the locking pattern 54 allows the modular carpet to be placed on the roll as a continuous, but segmented, modular carpet for shipping and installation. Today, modular carpets are cut with the act of moving a little further and stopping, treating each square module as an individual unit. These modular units must be packaged separately and then palletized for shipping and installation. The ability to wind a modular carpet as a continuous, yet segmented, modular carpet is of great benefit to the known modular carpet process, which cuts separate square modules that are boxed for shipping and installation. is there.

8A and 8B show another embodiment of an equipment arrangement for cutting and winding a universal floor covering 50. In this embodiment, the universal floor covering 50 is periodically cut by a cutting roller 58 having a cutting edge 60 to make a plurality of cuts 62 along the length of the roll 56 of the universal floor covering. As shown in FIG. 8B, the cutting edge 60 does not penetrate the backing layer 10. This embodiment allows the carpet to be placed on the roll as a continuous but segmented carpet for shipping and installation, such as that shown in FIG.

The equipment and operating techniques provided by the exemplary embodiments of FIGS. 7, 8A, and 8B are applicable to both wide carpet and modular general purpose carpets of the present invention. Both wide carpet and modular carpet can be shipped on the same roll by the designed chopping and wrapping of each roll of the universal floor covering 50 as described herein. For modular carpet, the cut-and-roll technique shown insures that the modules to be combined will be placed next to the mating module at the time of manufacture, as the modules are not separated. Also, the programming used to cut and wrap a section of a universal floor covering can also be used to cut and wrap any other layer below the general floor covering, This ensures a size match between the universal section and the underlying layer.

The dimensionally stable floor coverings disclosed herein are installed without the need for conventional stretching or the use of conventional permanent flooring fixtures such as tax trips or adhesives. It has sufficient stability and flexibility. This simplifies the installation and reduces the time and cost required for installation. The universal floor coverings disclosed herein may comprise layers such as high coefficient of friction backing layers. Examples of high friction coefficient backing include acrylic latex and natural latex. According to the present invention, it is only necessary to measure the size of the floor covering, match the size of the room in which the floor covering is installed, and then spread the floor covering in the room.

As described above with respect to FIGS. 7, 8A, and 8B, another layer, such as a cushion layer, is programmably chopped and wrapped to suit the designed chopping and wrapping of a section of a universal floor covering. , It is possible to guarantee that the section of the general-purpose carpet and the layer below it are matched in size. Alternatively, additional layers, such as layer 44 of FIG. 6A, can be added during the manufacturing process such that the general floor covering already includes a cushioning or friction layer before the general floor covering is rolled. Thus, the dimensionally stable floor covering of the present invention significantly reduces the manufacturing, shipping, and installation costs associated with conventional floor coverings.

Based on the foregoing description of the invention, specific manufacturing procedures are required to produce the desired dimensionally stable floor coverings for a particular application. Since the bedding material disclosed herein can be used for all wide or modular products, the materials used for tuft yarn 14, primary backing substrate 16, reinforcing fibers 22, and adhesive 20 are: , Designed and selected taking into account the desired properties of either the wide carpet or the modular carpet to be manufactured and installed. For example, the viscosity of the adhesive 20 is selected to ensure the desired strength and amount of penetration into the primary backing substrate 16, as described above. Furthermore, the length and diameter of the fibers 22 are selected according to the desired strength of the floor covering. The tuft yarn 14 is selected mainly based on the aesthetic properties and durability of the tuft stitch 18, and the porosity and strength. Further, the primary backing base material 16 is selected in terms of strength and porosity according to the amount of the adhesive 20 that is desired to be penetrated in the primary backing base material 16.

As mentioned above, there is no functional or component difference in the universal backing layer 10 formed from the embodiments shown in FIGS. 3, 4A, 4B, 6 and 6A. Due to differences in the physical arrangement of the applicator 26 and vacuum of FIG. 3 when compared to FIGS. 6-6A, for example, formation of a pre-cure adhesive layer 44 that eliminates the need to cover the reinforcement layer 24 after cure (FIG. 6A). , Or the flexibility of using the applicator 26 of FIG. 6 using only the adhesive 20 or using the adhesive 20 in combination with the fibers 22. Thus, one procedure in making a universal floor covering with the desired dimensional stability for a particular application is to use the manufacturing arrangement shown in FIGS. 3, 4A, 4B or the manufacturing arrangement shown in FIGS. 6, 6A. Related to choosing one of the placements.

Using vacuum, mixing, and compressed air to help condition the composite of adhesive 20 and fibers 22 to the desired state and position prior to applying pressure to form the reinforcing layer 24. Injection was described in Figures 3-6A. The vacuum is used to help move more adhesive 20 into the stitches 18 and into the spaces between the stitches 18. A vacuum can also be used to move the adhesive 20 to a selected depth on the backside of the primary backing substrate 16. The mixing of the fibers 22 and the adhesive 20 occurs before the adhesive 20 and the fibers 22 are filtered in situ. In addition, compressed air may be injected into the adhesive/fiber composition to provide space between the fibers 22 prior to applying pressure to the composition. The selection of the conditioning step is made after the desired properties of the floor covering are known and the manufacturing arrangement is selected.

After preconditioning the composition of adhesive 20 and fibers 22 into the desired state and position, applicator 26 is controlled to apply pressure toward the backside of primary backing substrate 16. Due to the difference in friction between the smooth surface of the applicator 26 and the fibrous texture of the stitch 18, the fibers 22 are more strongly attracted to the stitch 18 rather than the applicator 26. The increased pressure from the applicator 26 reduces the gap between the applicator 26 and the stitch 18 so that the fibers 22 extend predominantly in the machine direction to form the fiber-reinforced layer and the adhesive 20 causes the primary backing substrate. Pressed towards the back of the material 16 to form a layer of adhesive. The application of pressure by the applicator 26 provides the desired thickness to the fiber reinforcement layer and the adhesive into the stitches 18, into the spaces between the stitches 18, and, if desired, the primary backing substrate. Controlled to move into the back side of 16.

Another embodiment of the present invention is disclosed in Figures 9-11. In this embodiment, as shown in FIGS. 9 and 10, a rotatable, linearly moveable and selectively angle adjustable pressure control device 80 provides for separating and dispersing the fibers 22 in the adhesive 20. Has been. The controller 80 also uniformly and continuously directs the conditioned composite of the adhesive 20 and the dispersed fibers 22 toward the gap between the applicator 26 and the stitch 18, toward the primary backing substrate 16, and Move towards the space between the stitches 18. The migration of the adhesive 20 and dispersed fibers 22 is generally at an acute angle to the gap between the applicator 26 and the stitch 18, and the adhesive/fiber composition is between the applicator 26 and the backing substrate 16. It is possible to arrive at the same time or at the same time in the entire area or space. In addition, as shown in FIG. 9, the applicator 26 engages the dispersed fibers 22 and adhesive 20 to act as a vortex that acts on the adhesive and fiber mixture while the backing substrate 16 moves in the machine direction. It has a relatively long curved and angled surface portion 82 that provides force. The vortex force is provided in addition to the regulating force provided by controller 80 to move adhesive 20 and dispersed fibers 22 toward primary backing substrate 16. The vortex force then helps align the fibers 22 before they enter the gap separating the applicator 26 and the stitch 18.

The controller 80 also mixes or conditions the adhesive 20 and the fibers 22 to help prevent soft quasi-assembly of the fibers as they move, as described above. In addition, compressed air can be injected into the adhesive/fiber mixture to help maintain the spaces between the individual fibers 22, as shown in FIG. The injection of air also causes the adhesive 20 to bubble to further aid in the desired distribution of the fibers 22 before they reach the gap between the applicator 26 and the stitch 18.

FIG. 10 shows an alternative to the embodiment shown in FIG. As shown in FIG. 10, a movable pressure device 84 applies pressure to the fibers 22 and adhesive 20 after the fibers 22 have been dispersed and separated by a rotatable controller 80. The pressure provided by the movable pressure device 84 is functionally equivalent to the vortex pressure described with respect to FIG. Movable pressure device 84 serves as a functional alternative to the vortex forces created by surface portion 82. Also, the pressure applied by the device 84 can be adjusted to allow a controlled amount of adhesive 20 to penetrate the primary backing substrate 16 to improve the strength of the primary backing substrate 16. Further, the force applied by the device 84 can be controlled to engage the fibers 22 with the primary backing substrate 16 for additional strength.

An embodiment of a rotatable and movable pressure control device 80 is shown in FIG. The illustrated controller 80 includes one or more blades 86, each blade having a ridge 88 with a tip at the end to prevent damage to the fibers 22. The thickness of each blade 86 is preferably less than the length of fiber 22. The pressure control device 80 is sized to exert pressure on the entire pool of adhesive 20 and fibers 22 so that the fibers 22 separate and disperse in the adhesive 20 as shown in FIGS. And position. Depending on the size of the pool of adhesive 20 and fibers 22, it may be necessary to provide one or more pressure control devices 80 so that the fibers 22 separate and disperse within the adhesive 20.

As shown in FIGS. 9 and 10, the pressure control device 80 applies pressure in a controlled manner such that the applicator 26 presses the adhesive 20 and fibers 22 toward the backside of the primary backing substrate 16. At the same time, the adhesive 20 and dispersed fibers 22 are placed and actuated to move them into the space between the stitched portions 18. This allows the formation of the fiber reinforcement layer 24 and the formation of the mixture of fibers 22 and adhesive 20 in the space between the stitched portions 18 to occur simultaneously or simultaneously. The final result of the simultaneous or simultaneous formation just described is the same as the final result using the vacuum tube 32 shown in FIG. 3B. Another aspect and feature of the embodiment shown in FIGS. 9-11 is that the applicator 26 is selectively moved to stitch so that the adhesive 20 and fibers 22 are moved only into the space between the stitches 18. It is possible to make contact with 18. Accordingly, the embodiments disclosed in FIGS. 9-11 move the fibers 22 and the adhesive 20 into the space between the stitch portions 18 for alignment, or in the space between the stitch portions 18. To form a fiber reinforcement layer 24 that captures the fibers 22 and the adhesive 20.

9 and 10 also show the use of apparatus 90 to form a cushioning or friction layer 92 made of a suitable material 94, such as a latex material or a thermoplastic material. As described above, after formation of the fiber reinforcement layer 24, the desired cushion or friction layer 92 of material 94 is formed before or after curing. During formation of the layer 92 prior to curing, the material 94 is forced into the reinforcing layer 24 by the device 90 to improve the tensile strength of the fiber 22 and to better laminate the fiber 22. At the same time as the material 94 is pressed into the reinforcement layer 24, the layer 92 is formed with the desired thickness to provide a cushioning or friction layer to the carpet. Alternatively, as described above, if applicator 26 is moved to contact stitch 18 without forming reinforcement layer 24, or if it is too thin to provide significant reinforcement properties, device 90 may be moved toward stitch portion 18. The material 94 can then be applied to form a cushioning or friction layer 92 that traps the fibers 22 and adhesive 20 present in the spaces between the stitched portions 18.

12-16 disclose and disclose another embodiment of the invention described with respect to FIGS. 9-11. Referring to FIG. 12, the crescent-shaped release applicator 26 includes a curved or angled engagement surface with a removable tip portion 100 at one end of the engagement surface. The fluid chamber portion 102 provides a sliding path along the engagement surface, the sliding path being located between the release applicator 26 and the adhesive 20 and fiber 22 mixture. A separating or lubricating layer 104 is formed between the release applicator 26 and the moving mixture of adhesive 20 and fibers 22. Layer 104 separates the moving adhesive 20 and fiber 22 mixture from frictional contact with the mating surface of crescent applicator 26.

In the preferred embodiment of the peel applicator 26, the engagement surface portion of the peel applicator 26 is curved to impart a vortex or tunnel force to the mixture of adhesive 20 and fibers 22. The vortex or tunnel force provides a directional force or pressure to move the mixture of adhesive 20 and fibers 22.

A selectively rotatable applicator 26 and a counterweight (not shown) provide a variable and selective control of the pressure provided by the applicator 26 which causes the adhesive 20 and/or fibers 22 to be primary. It is selectively moved toward the backing substrate 16. Further, as described above in connection with FIGS. 9 and 11, the controller 80 mixes the conditioned adhesive 20 and fiber 22 composition and directs it to the gap between the applicator 26 and the stitch 18. And again towards the primary backing substrate 16. The applicator 26 then provides a vortex or tunnel force acting on the adhesive and fiber mixture in addition to the adjusting force provided by the controller 80.

Separation or slip layer 104 can be made by circulating cold water within fluid chamber 102 to form a layer of condensate along the entire mating surface portion of applicator 26. Alternatively, the lubricant may be delivered through the curved engagement wall of the fluid chamber 102 and along the entire engagement surface portion of the applicator 26 to provide liquid between the applicator 26 and the adhesive 20 and fiber 22 mixture. Can form a sliding path of Separation layer 104 provides a slip path for the mixture of adhesive 20 and fibers 22 away from applicator 26 so that the treated mixture of adhesive 20 and fibers 22 can be more easily moved toward stitch 18. The slip layer 104 can also be made of a layer of non-flowable, slippery material to provide a slip path for the treated mixture of adhesive 20 and fibers 22 away from the applicator 26.

As shown in FIG. 12, a removable tip portion 100 is located at the exit end of the curved engagement surface of the peel applicator 26. The removable tip portion 100 may be planar, as shown in FIG. 12, or depending on the properties desired to move the adhesive 20 and/or fibers 22 away from the applicator 26. , May have other shapes. The tip portion 100 can be angularly adjusted relative to the primary backing substrate 16 by, for example, adjustably rotating or moving the release applicator 26. The combination of the curved engagement surface of the release applicator 26 and the shape and alignment of the tip portion 100 moves the fiber 22 as desired toward the primary backing substrate 16 and the adhesive 20 to the stitch 18. Helps to apply uniform pressure to penetrate into. The removable tip 100 also helps prevent droplets of adhesive 20 from forming.

The moving force and pressure exerted by the controller 80 on the adhesive 20 and the fibers 22 is amplified by providing the slip layer 104. In addition, the vortex or tunnel forces provided by the curved crescent release applicator 26 are also amplified by creating a lubricated sliding path for the mixture of adhesive 20 and fibers 22. The removable tip portion 100 is then placed at the end of the curved applicator engagement surface to facilitate penetration of the adhesive 20 and press the fiber 22 against the end of the stitch 18. The position of the crescent-shaped applicator 26 and the position of the tip portion 100 are adjusted to adjust the penetration amount of the adhesive 20 or the amount of pressing the fiber 22 to the end of the stitch 18. The applicator 26 is movable so that it may be selectively changeable with respect to the pool.

12-16 also show an exemplary method and apparatus for forming a peelable adhesive cover system for a general purpose carpet. In a preferred embodiment, the peelable adhesive cover system is gecko-like, which provides advantages over general purpose carpet, including removable attachment to the support surface of the carpet, and increased strength and stability of the general purpose carpet. It has non-stick properties. It is desirable to have a peelable, gecko-like cover system that is peelable to layers 24 of fibers 22 (see, eg, FIGS. 1, 3B, and 4A) that can be peeled off if desired. Also, by forming a cover on the relatively stiff layer 24 of fibers 22 that engages the reinforcing fiber layer to provide additional strength and stability to the general-purpose carpet and attaches to the reinforcing fiber layer, It is desirable to improve strength and stability in the machine direction.

As disclosed herein, a method of forming a peelable adhesive cover system includes a primary conditioning member 106 to form a conformable layer of adhesive 116 that is applied to a relatively stiff reinforcing fiber layer 24. Is included. Also, the surface contact of the adhesive 116 with the conforming layer is maximized by the secondary conditioning member 112. A coating layer of adhesive 118 is preferably applied to a compatible layer of adhesive 116 after curing. The conforming layer of adhesive 116 and the coating layer of adhesive 118 provide a peelable tacky cover system that also provides additional strength, stability, and breakable bond between a general purpose carpet and a support surface. Also give.

The primary conditioning member 106 is used to conform the backing layer 10 by applying a conforming layer of the aqueous adhesive 116 to the layer 24 of the laminated fiber 22 after forming the universal reinforcing backing layer 10 and before curing. As shown in FIG. 13, the primary adjustment member 106 includes a crest 108 and a valley 110. The crests 108 engage the stiff layer of fibers and the troughs 110 dispense the aqueous adhesive to form a horizontally conforming adhesive layer. The gecko-like properties are provided by the conforming layer provided by the conditioning member 106 and the rigid base provided by the layer 24 of the laminated fiber 22. In addition, the engagement of the top 108 with the fiber layer 24 also improves the lamination of the fibers 22 and the homogeneity of the adhesive layer 116 (see FIG. 15). Then, the surface strength and the tensile strength of the fiber layer 24 are improved by pushing the water-based adhesive 116 into the fiber layer 10 with the adjusting member 106.

Referring again to FIG. 12, a secondary conditioning member 112 is provided to maximize surface contact. As shown in FIG. 14, the secondary adjustment member 112 includes an embossing element 114, which may extend outward relative to the outer surface of the member 112 or may be recessed inward. The secondary adjustment provided by member 112 may occur prior to curing, as shown in FIG. 12, or after curing. The secondary conditioning member 112 can be used to form a coating layer of the water-based adhesive 118, as shown in FIGS. The secondary adjustment member 112 is preferably used before curing and immediately after the primary adjustment member 106 is used. Also, the layer of water-based adhesive 118 is preferably applied by different conditioning members after curing. And, the compatible layer of the aqueous adhesive 116 is preferably thicker than the relatively thin coating layer of the aqueous adhesive 118. Direct embossing of the conforming layer by the secondary conditioning member 112 provides desirable surface contact properties that complement the conforming properties provided by the primary conditioning member 106.

As shown in FIG. 15, the coating layer of aqueous adhesive 118 is applied to the conforming layer of aqueous adhesive 116. The two layers of adhesive 116 and 118 form a peelable or gecko-like cover for the reinforcing backing layer 10. The peelable cover may include both a layer of adhesive 116 and a layer of adhesive 118, or the cover may include only a layer of adhesive 116. By way of example only, and not limitation, both adhesive 116 and adhesive 118 are water-based so that they can be recycled, and adhesive 116 includes a filler such as calcium carbonate, while adhesive 118 is a filler. Does not include. Alternatively, the adhesive 116 or the adhesive 118 may be non-synthetic, a gecko-like pressure sensitive adhesive, or an adhesive having gecko-like synthetic bristles releasably attached to a support surface. It may be. A peelable or non-stick, gecko-like cover is formed to the backing layer 10 using the methods and apparatus described above, which cover enables the disclosed universal carpet to be removably attached to a support surface. To do. As used herein, a peelable adhesive cover system or a gecko-like adhesive cover system each includes at least one adhesive that enables the carpet and reinforcing fiber layers to be removably attached to a support surface. Intended for systems that have.

FIG. 16 discloses an alternative construction of a peelable cover applied to the reinforcing backing layer 10. The foam layer 120 is applied to the layer of adhesive 116 on one side and the layer of adhesive 118 is applied to the other side of the foam layer 120. Alternatively, one side of the foam layer 120 may be applied directly to the reinforcing backing layer 10 and either the layer of adhesive 116 or the layer of adhesive 118 is applied to the other side of the foam layer 120.

FIG. 15 also shows an embodiment of the equipment and technique for cutting and rolling a general purpose carpet having the peelable covers disclosed in FIGS. As shown in FIG. 15, the cutting edge 60 does not penetrate either the adhesive 116 or the cover layer with the adhesive 118. The cutting edge 60 does not cut through the primary backing substrate 16 and the reinforcing backing layer 10. Alternatively, the universal carpet disclosed in FIG. 15 may be completely dissected, or cut according to one or more of the other embodiments of cutting disclosed in FIGS. 7, 8A, 8B. ..

The peelable or gecko-like cover system disclosed in FIGS. 12-16 provides desirable conforming and elastic properties from the primary conditioning member 106, desirable relatively rigid base features from the fiber layer 24, and secondary conditioning member 112. It has a high surface contact property. These properties allow the peelable or gecko-like adhesive cover system of the present invention to provide additional strength and stability in the machine direction to the carpet and allow the carpet to be removably attached to a support surface. In another embodiment, the applicator 26 is close to the stitch 18 so that the fibers 22 and the adhesive 20 are captured and form a relatively stiff layer of fibers and adhesive in the space between the stitched portions 18. The peelable or gecko-like cover system disclosed in FIGS. 12-16, and the method and apparatus described in connection with FIGS. Can be used and made for this alternate embodiment.

The present invention may be embodied in other forms without departing from the spirit and essential characteristics of the invention, and therefore, the scope of the present invention is not limited to the above specification but is attached to the accompanying description. Reference should be made to the claims.

Claims (29)

A method of manufacturing a general purpose floor covering that can be used as either a wide floor covering or a modular floor covering,
A tufted base fabric having a primary backing substrate extending in a first direction and having a surface and a backside opposite the surface; and a plurality of yarns tufted through the primary backing substrate, each of which comprises: A wide floor covering from a group of components including a thread, a portion of the thread forming a stitched portion having an end located on the backside of the primary backing substrate, and a space present between the stitched portions. Or producing either a modular floor covering,
The group of components further comprises a pool of composite comprising a mixture of adhesive and reinforcing fibers,
Moving the tufted backing fabric relative to a release applicator having an engagement surface portion to provide a space between the stitched portion of the thread and the release applicator;
Applying moving pressure to the mixture of reinforcing fibers and adhesive to move the fibers and adhesive to the mating surface portion of the release applicator;
Forming a layer of a sliding path on the engaging surface portion of the applicator to separate the moving fibers and adhesive from frictional engagement with the release applicator;
A controlled pressure is applied to the release applicator in a second direction to align the reinforcing fibers to extend primarily in the first direction to provide a relatively stiff laminated fiber substantially parallel to the first direction. Forming a reinforcing layer, the relatively stiff reinforcing layer of the laminated fibers providing strength and stability to the general purpose floor covering, and for removably attaching the floor covering to a support surface. To form a peelable adhesive cover system,
The method including the steps of. 2. The method further comprising moving the adhesive and fiber mixture along a curved engagement surface portion of the release applicator to move the adhesive and fiber mixture toward the stitched portion. The method for manufacturing a floor covering according to. Of the curved engagement surface portion and one end of the curved engagement surface portion for pressing fibers against the ends of the stitched portion and for directing adhesive to the primary backing substrate. The method of manufacturing a floor covering according to claim 2, further comprising using a tip portion. The method of claim 1, further comprising forming a conformable layer of adhesive with a first adhesive and covering the layer of laminated fibers with the conformable layer of adhesive. Further engaging the layer of laminated fibers with a primary conditioning member to dispense a first adhesive with the primary conditioning member to form a horizontally adapted adhesive layer having desired conforming properties. The method for manufacturing a floor covering according to claim 1. 6. The method of claim 5, further comprising forming a desired surface contact characteristic with a secondary conditioning member, wherein the desired surface contact characteristic complements or forms the matching characteristic provided by the primary conditioning member. Method for manufacturing floor coverings. Forming tops and valleys in the primary adjustment member to engage the fiber layer with the tops and dispense the first adhesive at the valleys to form the horizontally adapted adhesive layer. The method for manufacturing a floor covering according to claim 5, further comprising: Attaching a second adhesive layer to the first adhesive layer, wherein the first adhesive layer and the second adhesive layer form an adhesive cover for the laminated fiber, and the adhesive cover supports the floor covering. The method of manufacturing a floor covering according to claim 5, further comprising: releasably attaching the structure to the structure. The method of claim 5, further comprising embossing the first adhesive layer with a secondary conditioning member after forming the adapted adhesive layer. The method for manufacturing a floor covering according to claim 8, further comprising embossing the second adhesive layer with a secondary adjustment member. The method for producing a floor covering according to claim 4, further comprising: applying the first adhesive layer to one side of the foam layer and applying the second adhesive layer to the other side of the foam layer. Affixing a foam layer to the layer of laminated fibers on one side and forming an adhesive cover on the other side of the foam layer to allow the floor covering to be removably attached to a support surface. The method for manufacturing a floor covering according to claim 1, further comprising: The method of manufacturing a floor covering according to claim 1, further comprising selectively cutting the general-purpose floor covering without cutting the peelable adhesive cover. The method of claim 1, further comprising moving a portion of the adhesive and fiber mixture into the space between the stitched portions simultaneously or simultaneously in forming the relatively stiff layer of reinforcing fibers. A method for manufacturing a bedding as described. The floor covering of claim 1, further comprising: applying a vortex force from the applicator to the fiber-adhesive mixture in addition to the moving pressure applied to the fiber-adhesive mixture. Manufacturing method. A method of manufacturing a general purpose floor covering that can be used as either a wide floor covering or a modular floor covering,
A tufted backing fabric having a primary backing substrate extending in a first direction and having a surface and a backside opposite the surface; and a plurality of yarns tufted through the primary backing substrate, each of which comprises: A wide floor covering from a group of components including a thread, a portion of the thread forming a stitched portion having an end located on the backside of the primary backing substrate, and a space present between the stitched portions. Or producing either a modular floor covering,
The group of components further comprises a pool of composite comprising a mixture of adhesive and reinforcing fibers,
Moving the tufted backing relative to an adjustable release applicator having an engaging surface portion;
Applying moving pressure to the mixture of reinforcing fibers and adhesive to move the fibers and adhesive to the mating surface portion of the release applicator;
Forming a layer of a sliding path on the engaging surface portion of the applicator to disengage the moving fibers and adhesive from frictional engagement with the release applicator;
Applying a controlled pressure to the release applicator in a second direction toward the primary backing substrate to form a relatively stiff reinforcing layer of fibers and adhesive; and removing the floor covering to a support surface. Forming a peelable adhesive cover system for possible attachment,
The method including the steps of. Distributing a first adhesive with a primary conditioning member to form a conforming layer of adhesive having desired conforming properties and covering a relatively stiff reinforcing layer of the fibers and adhesive with the conforming layer of adhesive. The method for manufacturing a floor covering according to claim 16, further comprising: 18. The method of making a floor covering of claim 17, further comprising using a secondary conditioning member to provide the desired surface contact properties. Engaging the fiber and adhesive layer with the top of the primary conditioning member to form a horizontally adapted adhesive layer to dispense the first adhesive in a trough of the primary conditioning member; The method for manufacturing a floor covering according to claim 17, further comprising: 17. The method of claim 16, further comprising pressing a fiber against the end of the stitched portion to direct the adhesive to the primary backing substrate with a curved engagement surface portion having a removable tip portion. Method of manufacturing floor coverings. Applying a second adhesive layer to the first adhesive layer, the first adhesive layer and the second adhesive layer forming an adhesive cover for the relatively hard layer of fibers and adhesive, the cover comprising: The method of manufacturing a floor covering according to claim 17, further comprising: adhering the floor covering so that the floor covering can be removably attached to a support structure. A method of manufacturing a general purpose floor covering that can be used as either a wide floor covering or a modular floor covering,
A tufted base fabric having a primary backing substrate extending in a first direction and having a surface and a backside opposite the surface; and a plurality of yarns tufted through the primary backing substrate, each of which comprises: A wide floor covering from a group of components including a thread, a portion of the thread forming a stitched portion having an end located on the backside of the primary backing substrate, and a space present between the stitched portions. Or producing either a modular floor covering,
The composite puddle contains a mixture of adhesive and reinforcing fibers,
Moving the tufted backing fabric relative to the applicator to provide a space between the stitched portion of the thread and the applicator;
A pressure control device is used to apply pressure to the reinforcing fibers and the adhesive in a second direction, the pressure control device separates and disperses the fibers, and the mixture of the adhesive and the dispersed fibers is applied to the applicator and the applicator. Simultaneously or simultaneously moving into the space between the stitch portions and into the space between the stitch portions, the adhesive and dispersed fibers are moved into the space between the applicator and the stitch portion. Forming a layer of adhesive and fibers in the space between the stitches when
Applying a controlled pressure to the applicator in a third direction to align the fibers to extend predominantly in the first direction to form a fiber reinforcement layer substantially parallel to the first direction; Or moving the applicator to engage the ends of the stitched portion to capture the fiber and adhesive layer in the space between the stitched portions, and to cure the universal floor covering. Letting,
The method including the steps of. Applying a vortex force to the fibers and the adhesive in addition to the pressure from the controller, the vortex force assists in aligning the fibers and forces the adhesive and fibers to the backing substrate. 23. The method of making a floor covering of claim 22, further comprising assisting in adding towards the lumber. Injecting air into the puddle of adhesive and reinforcing fibers, the injecting of air causing the adhesive to foam and the injecting of air to help disperse the fibers as desired The method for manufacturing a floor covering according to claim 22, further comprising: Applying adjustable pressure to the fibers and adhesive in addition to the pressure from the controller, the adjustable pressure assisting in aligning the fibers and removing the adhesive and fibers from each other. 23. The method of making a floor covering of claim 22, further comprising assisting in adding towards the backing substrate. 23. The method of making a floor covering according to claim 22, further comprising separating and dispersing the fibers with at least one rotatable blade having a thickness less than the length of the fibers. 23. The method of making a floor covering of claim 22, further comprising forming a cushioning layer or a friction layer of a material that engages the fiber reinforcement layer. 23. The method of making a floor covering of claim 22, further comprising: forming a cushioning or friction layer of material that engages the layer of adhesive and fibers in the space between the stitched portions. .. 28. The method of claim 27, further comprising pressing a portion of the cushion material or friction material into the fiber reinforcement layer in forming the cushion layer or friction layer of material that engages the fiber reinforcement layer. Method of manufacturing floor coverings.

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